Selection, Implementation, Growth and Maturation of a Computerized Maintenance Management System in the Biosolids Industry

Transcription

1 Selection, Implementation, Growth and Maturation of a Computerized Maintenance Management System in the Biosolids Industry Ohio Water Environment Association Biosolids Workshop December 7, 2017

2 Meet Your Presenters: Bill Hollman, PMP Certified Project Management Professional, Project Management Institute member 35+ years of experience in leading technical and managerial organizations, B.S. and M.B.A. Captain, United States Navy (Ret.); experienced corporate project and operations manager Extensive experience in industrial product manufacturing, engineering and development Bill is the Assistant to NEFCOs Vice Presidents of Operations and Safety, working with and monitoring all NEFCO plants nationwide, ensuring safe and reliable operations. Duties include Plant Management, major project management, process optimization, vendor relations, plant staffing and plant commissioning. Particular focus has been on new plant commissioning and optimizing legacy facilities to include procuring and implementing the corporate wide computerized maintenance management system.

3 Meet Your Presenters: Raymond M. Zdonkiewicz, PE Professional Engineer in the State of Michigan BSEE from Wayne State University Extensive experience in electrical maintenance at a local steel mill and over 20 years experience in construction management and maintenance at the Detroit Water & Sewerage Department. Ray is Team Leader for the Water Resource Recovery Facility (WRRF) Asset Management Group for the Great Lakes Water Authority. Duties include working with Enterprise Asset Management Group, maintaining assets in Oracle Work & Asset Management (WAM) software, and conducting WAM work management meetings with Operation & Maintenance Team personnel.

4 Agenda The overall drivers stimulating the upgrade of the CMMS system in NEFCO GLWA Background, History of Biosolids Dryer Facility (BDF) Selection Biosolids Thermal Drying Process The process of selection for the new CMMS, including the identification of systems, analysis of alternatives and actual final selection process used in NEFCO. Implementation procedure and overcoming organizational friction. Developing an effective partnership with CMMS vendor and municipalities to include familiarization and training. Growth and maturation of the system beyond traditional scheduling tracking

5 The overall drivers / Quick GLWA Wastewater Facts Service area: 1,079 square miles. Serves 35% of MI population - Encompasses Detroit and 77 neighboring communities ~ 3 million people One WRRF in the system. Average Daily Flow 650 MGD Wet Weather Capacity 1.7 BGD Average Biosolids Production 450 DTPD Peak Biosolids Production 850 DTPD Great Lakes Water Authority officially began operation January 1, 2016

6 The overall drivers / Solids Generation and Disposal Prior to BDF 22% 11% 67% Incineration Land Application Landfill Total Solids Generation: 450 dtpd Multiple Hearth Incineration: 301 dtpd Class B Land Application: 50 dtpd Landfill: 99 dtpd Approx. 51% of the WRRF O&M costs for solids processing & disposal.

7 Selected Technology Option Thermal Drying Primary Sludge Gravity Thickening Secondary Sludge Gravity Thickening New Biosolids Drying Facility Thickened Sludge Storage Dewatering Centrifuges/BFPs Dewatering + Thermal Drying Complex II MHIs Incineration MHI Complex I MHI Complex II Off-Load Facility Lime Stabilization Land Application Landfill

8 Biosolids Drying Facility Located across the street from the WRRF. Four dryer trains 316 dtpd firm capacity (440 dtpd peak). Dewatering included in the facility.

9 Solids O&M Savings Using Dryers Incineration Dewatering COF & Total Solids Residuals Handling Labor $(7.16) $(7.15) $(0.38) $(14.69) Natural Gas $(7.88) $ - $ - $ (7.88) Electricity $(1.55) $(0.33) $ - $ (1.88) Polymer $ - $(3.85) $ - $ (3.85) Lime $ - $ - $(0.91) $ (0.91) Hauling/Disposal $(0.65) $ - $(5.10) $ (5.75) Parts, Services & Other $(2.32) $(3.11) $ - $ (5.43) Subtotal WRRF O&M $ (19.56) $ (14.44) $(6.39) $(40.39) Dryer Facility O&M Cost $ Natural Gas For Dryers $ 5.47 Electricity For Dryers $ 2.16 Subtotal Dryers O&M $ Total $(16.87) Annual O&M savings: $16.9 million 20 year O&M savings: $337.3 million (in 2013 dollars) Payback period on $143 million capital cost: 8.5 years

10 Pollutant Air Emissions Reduction Emissions aggregated from all GLWA facilities. Start-up of BDF requires permanent shut-down of incinerators in Incineration Complex I. Reduction in emissions with thermal drying. Reduction in Emissions Compared to Complex I MHIs BDF Emissions as a % of Total 1 NOx 90.4% 11.9% CO 95.9% 4.7% PM % PM % 1 Includes Complex II MHIs with pollution control upgrades

11 End Uses for Dried Biosolids Bulk land application Fertilizer blending Land Reclamation Alternative Fuels Cement kilns Power generation Renewable fuel

12 BDF Construction

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14 Biosolids Thermal Drying Process

15 Thermal Drying Technology Class A EQ Product with multiple outlets. Proven Technology Nutrients in biosolids remain available after drying product suitable for beneficial use. Nutrients in biosolids not water soluble No runoff No additional need for bulk chemical addition to stabilize cake

16 The Drying Process Solids System Components Air Handling & Emission Controls

17 Contract Operations of Biosolids Dryer Facility Design-build with 20-year operation/maintenance by contractor. Fixed monthly price up to 73,000 DTPY with incremental unit costs per excess dry ton beneficially reused up to 140,000 DTPY (escalated at CPI). GLWA owns the facility and pays utilities to guaranteed caps. Allows contractor to manage energy cost risk, while holding it responsible for excess consumption. NEFCO responsible for marketing and disposal of biosolids.

18 Contract Operations of Biosolids Dryer Facility Brings specialized expertise to the complex operating environment e.g.: Sophisticated mechanical expertise required for dryer drums and centrifuges High degree of automation requires specific instrumentation skills Shifts risk of meeting environmental standards to the private sector. Long-term cost certainty - Offers predictable operations budgeting process. Commodities electricity, fuel chemicals Escalation tied to Indices Pass-throughs with guarantees Mutual trust between NEFCO and GLWA

19 NEFCO is a trusted partner and steward of the GLWA [rate payers] BDF assets So.

20 NEFCO managed CMMS selection process Determine Criteria Identification of systems Analysis of alternatives Final selection process used by NEFCO Contractual Specifications [initial criteria factors] : The Contractor s chosen maintenance CMMS software shall be compatible with GLWA Computerized Maintenance Management System. GLWA is currently transitioning to Oracle s Work and Asset Management (WAM) program. The CMMS shall include preventive maintenance scheduling and tracking functions. In addition, the computerized maintenance management software shall include corrective and emergency maintenance tracking functions.the CMMS shall incorporate a coded identification system for every loose or packaged inventory item..the CMMS shall be installed and fully functional 30 days prior to Substantial Completion of the First Three Dryer Trains..

21 Analysis of the legacy CMMS / Asset Management system showed several shortcomings Compatibility Barcoding Ease of use Condition Monitoring Remote Access Open architecture

22 Needed to improve from the legacy CMMS Search and narrow down the field Selection Board Objective Criteria ranking system best =5, middle =3, worst =1 Factor Weight Vendor A Vendor B Vendor C Vendor A Vendor B Vendor C Cost 14.3% Meets / Exceeds Requirements 11.4% Portal interface 11.4% Data import 5.7% Responsiveness 5.7% Customer Support 8.6% User interface 8.6% Training 5.7% Customization 8.6% Reports 5.7% Oracle Interface 5.7% Purchasing 5.7% KPI Dashboard 2.9% Final Score Sum Total 100.0% = perfect score

23 The selection: emaint

24 Implementation strategy and overcoming organizational friction. Spiral Development with legacy plants Concentrated Green Field Focus - Assets - Procedures - Requirements - State of the Practice

25 Key CMMS Implementation Plan Steps: 1. Establish the Implementation Team 2. Core Team Familiarization 3. Workflow Process Development 4. Establish Standard Equipment Maintenance Procedures 5. Establish Implementation Process 6. Configuration data fields and forms 7. Data Population & Validation 8. Training Main Users 9. Go Live Strategy 10. Process Auditing

26 Implementation strategy and overcoming organizational friction in Legacy Plants. Involve Legacy Plants early Approach the most old school Stressed Commonality vice Standardization One size does not fit all: different technologies, requirements, work forces Answer What s in it for me?

27 Develop an effective partnership with CMMS vendor and municipalities including initial familiarization Constant and open communication Transparency Planning Walk the Talk Initial and evolving customer Needs Training on the CMMS

28 Growth and maturation of the system beyond traditional scheduling tracking Old Dogs..New Tricks

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30 Asset Management Projects Safety Audit tracking Purchasing Custom Reports Condition and online monitoring SCADA integration Analytics More to come..

31 Asset Management > CMMS Asset Management Plan Pillars 1. Asset Registration 2. Asset Inventory Management 3. Asset Condition Assessment 4. Asset Failure Mode Analysis 5. Determination of Asset Residual Life 6. Determination of Asset Life Cycle & Replacement Costs 7. Determination of Levels of Service (LOS) 8. Determination of Business Risk ( Criticality ) 9. Optimize O&M Investment in Assets 10. Optimize Capital Investment in Assets 11. Leverage CMMS for Asset Management

32 Questions

33 Raymond M. Zdonkiewicz, PE Team Leader Great Lakes Water Authority Water Resource Recovery Facility 9300 W. Jefferson Detroit, MI P: E: Bill Hollman, MBA, PMP Corporate Operations and Safety Manager NEFCO 97 East Howard Street Quincy, MA P: E: