How Proactive or Reactive to Be? Getting Ahead of the Curve on Preventive Maintenance

Transcription

1 How Proactive or Reactive to Be? Getting Ahead of the Curve on Preventive Maintenance JESSICA BROWN, P.E., FREESE AND NICHOLS, INC. SALLY MILLS-WRIGHT, CITY OF ARLINGTON BILL GASE, CITY OF ARLINGTON MAZEN KAWASMI, P.E., CFM GISP FREESE AND NICHOLS, INC.

2 Agenda Background on Arlington s Water System Preventive Maintenance Survey Background Preventive Maintenance Survey Results Preventive Maintenance Best Practices and Recommendations PMs for Pumps, Valves and Pipelines Testing Frequencies for Pumps, Motors, and Meters Types of Pump and Meter Testing Water lines and Valves 2

3 Agenda Background on Arlington s Water System Preventive Maintenance Survey Background Preventive Maintenance Survey Results Preventive Maintenance Best Practices and Recommendations PMs for Pumps, Valves and Pipelines Testing Frequencies for Pumps, Motors, and Meters Types of Pump and Meter Testing Water lines and Valves 3

4 Background on City of Arlington s Water System 1,565 miles of Treated Water Piping, from 1 to 54 2 Water Treatment Plants Pierce-Burch WTP (75 MGD) John F. Kubala WTP (97.5 MGD) 4 Pressure Planes Served population of 378,000 Entertainment Capital of Texas: Home of Dallas Cowboys, Texas Rangers & Six Flags over Texas 4

5 Agenda Background on Arlington s Water System Preventive Maintenance Survey Background Preventive Maintenance Survey Results Preventive Maintenance Best Practices and Recommendations PMs for Pumps, Valves and Pipelines Testing Frequencies for Pumps, Motors, and Meters Types of Pump and Meter Testing Water lines and Valves 5

6 Preventive Maintenance Survey Background Survey consisted of 57 questions targeting specific topics based on input from Treatment staff. Utility Background Staffing CMMS Pump Station PMs Electrical PMs Established PM schedules for clearwell, waterlines, and valves Valve exercise program within WTP Hosted on SurveyMonkey.com Invited 15 water utilities to take survey 11 utilities completed survey 6

7 Preventive Maintenance Survey Background Received responses from: Denver Water Department Seattle Public Utilities Tacoma Water Portland Water Bureau Metropolitan Sewer District of Greater Cincinnati Lincoln Water System Columbus Department of Public Utilities Las Vegas Valley Water District St. Johns County Utilities Department Raleigh Public Utilities Department Tulsa Water 7

8 Agenda Background on Arlington s Water System Preventive Maintenance Survey Background Preventive Maintenance Survey Results Preventive Maintenance Best Practices and Recommendations PMs for Pumps, Valves and Pipelines Testing Frequencies for Pumps, Motors, and Meters Types of Pump and Meter Testing Water Lines and Valves 8

9 Preventive Maintenance Survey Results: Utility Background Retail Only Wholesale & Retail 9

10 Preventive Maintenance Survey Results: Pumps 25% do Vibration, Thermal, and Efficiency Test on pumps 50% don t have a PM to restore pumps to Original Equipment Manufacturer (OEM) condition 10

11 Preventive Maintenance Survey Results: Pumps (Continued) 50% have a PM to inspect pump components. Of those, 2 have annual inspections, and 3 inspect as needed. Criticality Historical Performance Manufacturer Specs 11

12 Preventive Maintenance Survey Results: Electrical Staff Large Pump Repair HVAC 12

13 Preventive Maintenance Survey Results: Electrical 75% have a PM to inspect electrical components. Of those, 6 have annual inspections, and 3 inspect as needed. Majority of Electrical PMs are done by Utility Staff Every 2 years Manufacturer Specs Varies based on Criticality 13

14 Preventive Maintenance Survey Results: Electrical (Continued) Majority have a PM to inspect pump station electrical components. Of those, the majority have annual inspections. Manufacturer Specs 14

15 Preventive Maintenance Survey Results: Water Lines & Valves Majority have a water line rehabilitation program. Survey group was split on taking coupons to assess the condition of water lines. 15

16 Preventive Maintenance Survey Results: Water Lines & Valves Majority don t have a valve rehabilitation program. 50% have a valve exercising program at water treatment plant 16

17 Agenda Background on Arlington s Water System Preventive Maintenance Survey Background Preventive Maintenance Survey Results Preventive Maintenance Best Practices and Recommendations PMs for Pumps, Valves and Pipelines Testing Frequencies for Pumps, Motors, and Meters Types of Pump and Meter Testing Water Lines and Valves 17

18 Three Categories of Maintenance Activities Reactive Maintenance Higher risk for near term savings Appropriate for less critical assets Preventive Maintenance (PM) Regularly scheduled activities to extend asset life Predictive Maintenance (PdM) Detecting problems before affecting performance Maintenance activity based on need vs. schedule 18

19 Maintenance for Pump Stations Regular daily operational checks Flow and pressure in normal range Valve functionality Leaks Abnormal noise, vibration, heat, etc. Clear dust and dirt Other simple visual checks 19

20 Preventive Maintenance Best Practices: Pumps Activity Check bearing lubrication meets OEM specification Recommended Frequency* Monthly Arlington s Implementation Monthly Check packing for wear Monthly Monthly Start up and run every pump Monthly Monthly Inspect bearings and impellers Perform field and vibration tests Every 3 Years Every 4 Years after initial PM service Perform oil analysis Conduct performance trending based on historical field, vibration, and oil test * Service at calendar time or OEM specified run time interval, whichever comes first 20

21 Preventive Maintenance Best Practices: Motors Activity Check bearing lubrication meets OEM specification Recommended Frequency Monthly Arlington s Implementation Monthly Check alignment and mounting Monthly Monthly Check electrical connection terminals Monthly Monthly Clean motor Monthly - Visually inspect bearings - Perform temperature and vibration tests Check power supply condition Perform infrared (IR) thermography analysis Conduct performance trending based on historical temperature, vibration, and IR test 21

22 Preventive Maintenance Best Practices: Pipelines and Valves Activity Pipeline leak detection Recommended Frequency Every 5 years or based on performance trends Arlington s Implementation Every 5 years Pipeline condition analysis Prioritized based on the RBA Every 5 years based on condition analysis (Pure Technologies) Inspect isolation valves: verify location, accessibility, operational status* Inspect pump control valve and actuator system (motor operators, gearboxes, hydraulic accumulators, etc) Inspect critical air valves on raw water pipelines and high service pipelines 22

23 Preventive Maintenance Best Practices: Electrical & Instrumentation Activity Visual inspection of low and medium voltage electrical equipment Recommended Frequency Arlington s Implementation 3 months Quarterly Exercise circuit breakers, switches, etc. 6 months N/A Infrared inspection on all major electrical equipment. Perform dissolved gas analysis on liquid filled transformers Calibrate pressure, level, and temperature transmitters Perform testing/ maintenance of low and medium voltage electrical equipment Test solid state protective relays 3 Years 3 Years Analyzing recommendation Calibrate as needed if problems arise. Every 2 years per NETA standard Test major transformers 3 Years Inspect for Oncor Update Arc Flash Study 5 Years/after major modifications As needed 23

24 Preventive Maintenance Best Practices: Meters Activity Recommended Frequency Arlington s Implementation Check instrument settings regularly Monthly As needed Calibrate pressure instruments on venturi meters Calibrate ultra-sonic and magnetic meters (limited) Inspect meter vaults for standing water or structural issues Certified annually 3 months Quarterly 24

25 Implementation of Recommendations from Asset Management Plan Completed Projects Electrical upgrade on High Service pumps Electrical upgrade at the Raw Water Pump Station Performance of a comprehensive condition assessment for various water lines Replacement of Raw Water High Service Pump #4 Short Term Projects Rehabilitation/replacement of Raw Water High Service Pump #5 Clearwells #1, 2 and 3 rehabilitation High Service Pump #1 (PED) under evaluation for rehabilitation 25

26 Additional Benefits Realized by the City Condition assessment of PB North WTP determined it needed to be decommissioned. Experience less incidents of mistakes utilizing GIS maps developed through the project. This effort highlighted the need for dedicated maintenance staff and placed higher urgency on filling vacancies. This effort highlighted some skill sets and helped identify training needed for the City to incorporate some of these practices inhouse. This effort provided justification for developing on-going service agreements to ensure this work was provided in a timely fashion. 26

27 Questions? Contact Information: Jessica Brown, P.E. (817) International Plaza, Suite 200 Fort Worth, TX Sally U. Mills-Wright (817) John F. Kubala Water Treatment Plant 7001 US Hwy. 287 Arlington, TX 76001