Case Study: Eraring Power Station

Transcription

1 Case Study: Eraring Power Station Evidence based asset planning Background: The Eraring Power Station (EPS) was constructed in the late 1970s and is located on the western shore of Lake Macquarie. While the asset management planning for the operational plant has been very good over time, the asset planning for the civil supporting assets needed to improve. SPM Assets was engaged by EPS in early 2012 to assist with the project of improving the civil infrastructure asset management using the IPWEA/NAMS planning principles. This was enabled by the SPM Assets software linking to the current asset management system, Ellipse. The goal has been to move from a reactive maintenance approach to a planned programme based on component level evidence and using the science to forecast a programme of works over the next 20 years. The Eraring Power Station has numerous civil and building related assets that includes 24 bridges - pedestrian, services and vehicular 178 buildings large industrial plant housing, workshops and administration 136 culverts and 126 km of roads - sealed, unsealed, paved areas and fire trails 6 km of high volume cannels, 1500 drainage pits, 5 dams, a tunnel and caissons Two chimney stack 200m high and Four conveyors - total about 9kms

2 Page 2 Requirements To develop a strategic plan for their program of works, EPS needed to understand the condition of those assets, when they should be renewed or replaced, how they should be maintained, and an accurate financial forecast of what is needed to maintain the assets at EPS s specific standards. SPM Assets was to: 1. Design and implement an asset management planning process for all civil assets that is aligned with the IPWEA/NAMS Practice Note #3 for Building Condition & Performance. 2. Provide the tools and process for EPS to continue the asset information management and analytical planning process with scarce internal resources. 3. Implement the SPM Assets software as the primary asset management planning tool for civil assets 4. Conduct building condition assessments across the building portfolio and implement the assessment approach across all other civil assets. 5. Implement a web services linkage to the Ellipse asset management system to provide a complete asset management system, i.e. planning is undertaken in SPM Assets software, works are managed in Ellipse, and the completed works information is feed back into the software to update the asset information. Process SPM Assets used its sevenpoint framework (based on NAMS IIMM principles) to ensure that the asset information collected would enable both current and future condition shortfalls to be determined against the building Quality Standards. Condition Assessment of Buildings The process started with a condition survey of buildings to collect data so that EPS better understood the condition of the assets. The SPM Assets software was configured using templates and asset references from SPM Assets knowledge library and as a result, the software was fully available for the surveys within days of the design being signed off.

3 Page 3 The screen image below shows the Mobile module of the SPM Assets software that was accessed through ipads in the field. It shows how the data was structured for the survey of building assets: Each building is separately identified to a room or location level where components are assessed. Components are categorised in a three tier hierarchical structure (group, type, and component) using the default names from the SPM Assets libraries and then localised to EPS s specific naming conventions where needed. Each component is identified, described and assessed (condition grades 1 to 5) by a Generalist Surveyor. Where needed, component age, capacity, make and model of component is also recorded. Each component is measured based on a predefined unit of measure so that unit replacement costs can be assigned for the works programming. Once the surveyor identifies the component, the Asset Reference library within the SPM Assets software automatically assigns other parameters such as base life range, unit rates, level of service and criticality. The surveyor also identified any defects and immediate repairs. Condition Assessment of Bridges SPM Assets software was also configured to allow for the specialist assessment of bridges and progressively all other structures using the same ipads. The PQS module was used to record the commentaries provided by the bridge surveyors aligned with the standard proforma required by the local and state authorities such as Roads and Maritime Services (RMS, formerly RTA).

4 Page 4 These RMS reports are embedded alongside the bridge condition assessments, and are completed on a regular basis following specific criteria. The RMS report was compiled and reviewed in the SPM Assets software so that each bridge report is stored with the assessments. Condition of bridges and buildings The evidence from the condition surveys confirmed that the bridges were mainly in a good to very good condition. Only 0.5% of the bridge components assessed were in a poor to very poor condition, which is being addressed based on risk rating. Due to their critical nature, it was expected that the bridges have been well maintained. The process has now provided a tool that will minimise the ongoing inspection effort and in many ways, automate the reporting requirements. As expected, the buildings were assessed to be in a poorer condition compared to bridges. About 24.7% of the total assessed building components are in a poor to very poor condition. However, about 45% were assessed to be in a very good to good condition.

5 Page 5 EPS s planning process now has the evidence to determine the immediate works-programme. It s likely that the programme will focus on high risk building components associated with the more important operational buildings and this may only need to be a fraction of the identified costs EPS s Quality Standards are currently being considered by management. Results from the Predictive Model The collected data was analysed to produce the profile of forecasted expenditure for both the bridges and buildings using the condition, condition-age, and age based risk analysis predictive models embedded within SPM Assets software. The following figure illustrates how the remaining life is determined based on condition grading, a deterioration model and the expected useful life. As shown by the grey curve (depending on the component), it is possible that the expenditure required to continually maintain and operate can be more costly than replacing with a modern equivalent asset. Applying this model to the data, the forecasted expenditure over the next 20 years can be assessed in terms of an approximate total expected outlay and an annualised average. Where this model determines longer term needs, the immediate backlog can also be determined. Adopting an assumed quality standard (still to be approved by EPS), a slightly higher works expenditure program may be needed than the annualised average within the next 2 years to address the risks associated with critical assets that are in either a poor or very poor condition. EPS budget forecasts have taken the backlog into account.

6 Page 6 Web Services Linkage with Ellipse One of the key requirements of the project was to develop an interface between SPM Assets software and Ellipse. The interface allows SPM Assets to capture, analyse and report on the assessed components. SPM Assets software is then used to create works-programmes for cyclic maintenance schedules and renewal or replacement projects. The Ellipse application is used to manage the resulting programme of works through the generation of work orders. The following flow diagram shows how this interface is working for the work-order and planning functions. Within SPM Assets software the Project Planning module is used to generate projects from assessed components as either renewal or cyclic maintenance programmes. Upon the generation of a project, the relevant information is transferred to the Ellipse system as a work order. Once the work has been completed, the information in Ellipse is updated prior to the transfer of the information to SPM Assets, where the associated assets are updated for both condition and age. The web interface design allows asset information to be transferred between applications as planned projects, completed work orders and ongoing maintenance, maintains up-to-date asset information and enables a transition from a reactive renewal/maintenance program to a planned approach.

7 Page 7 Recognised Benefits The noticeable benefits resulting from the project so far include: An increased knowledge of EPS s building and bridge assets. This means decisions associated with future work are based on evidence rather than judgment. Decisions are generally better informed; Data improvement activities are now targeted and data are being updated progressively; Ongoing alignment and expansion of the database to include other asset categories such as roads, culverts, canals, conveyor structures, chimney stacks etc., increasing knowledge of the assets; The risk of any unexpected future expenditure requirements is reduced, and allows funding applications to be developed well in advance; Interface between SPM Assets and Ellipse applications allows for the production of works within SPM to be undertaken within EPS s works programme (Ellipse), and relevant information to be updated in SPM Assets software upon completion; Boosted reporting capabilities and process, with further reporting requirements to be scoped for system generation. Future outlook: Eraring Power Station EPS delivered a half hour presentation to the Sydney user group meeting in March 2013 and summarised the future outlook for the project as follows: Continued use of SPM Assets software for inspections, lifecycle analysis, planning projects, maintenance and reporting. Inclusion of chimney stacks, roads, drainage, canals, dams and miscellaneous civil assets into SPM Assets software through future timetabled inspections. Further application of condition assessments in conjunction with measuring performance and quality criteria against all civil assets. Continual development of the Asset Management Strategy, Asset Management Plan and Asset Management Policy for civil assets at Eraring Power Station.