Condition Assessment Building Out Your Own CMMS

Transcription

1 (Based upon MOP FD-7) Today's presentations will cover: Condition Assessment: Building Out Your Own Computerized Maintenance Management Systems (CMMS) Condition Assessment Building Out Your Own CMMS Tina Wolf Principal Environmental Eng. Malcolm Pirnie, Inc. Ft. Wayne, IN James Paluch Assistant Superintendent Collection System Operations Joint Meeting of Essex & Union Counties - Elizabeth, NJ Abraham Araya Water Quality Planner/ Project Manager King County DNRP, WTD Seattle, Washington 1

2 Condition Assessment Building Out Your Own CMMS Webcast Sub-Committee Members Abraham Araya Seattle, Washington Samantha Bartow Taylor, South Carolina Thomas Curl The Woodlands, Texas Mattie A. Engels Dallas, Texas Wes Frye Nashville, Tennessee Chris Johnston Burnaby, British Columbia Stephen A. Lipinski Duluth, Minnesota James J. Paluch Elizabeth, New Jersey Tina Wolff Fort Wayne, Indiana Today s Moderator John Nelson Visu-Sewer, Inc. NASSCO President Wastewater Collection Systems Management Water Environment Federation (WEF) Manual of Practice No , Sixth Edition 2

3 The Wastewater Collection Systems Management Series Continues February 2012: Computerized Maintenance Management Systems (CMMS) / Planning & Implementation June 2012: Condition Assessment / Building Out Your CMMS November 2012: Asset Management / Translating Your Data To Information February 2013: Business Case For Action / Replacement or Rehabilitation June 2013: Optimize Your System Operations / Concepts & Benefits November 2013: Asset Management Design / Cost Minimization & Safety Considerations In todays digital age, there is a strong need to effectively manage a massive volume of collection system data. A programmatic approach to collecting, evaluating and managing collection system assets is critical. When implementing new programs, it is critical to gain support from your entire organization. 3

4 How to implement a Condition Assessment Program using CMMS The importance of capturing accurate standardized field data. Pro s and Con s of current inspection technologies. Real life lessons learned when developing and refining your CMMS. Bill DiTullio InfraMetrix, LLC Condition Assessment Inspection Prioritization Implementation 4

5 Hugh Kelso RJN Group, Inc. Assessment Technologies Data Collection CCTV Systems Advanced Inspections Karen Morris City of Fort Wayne Procedures for choosing a CMMS Needs Assessment Shopping for a system Benefits & Lessons Learned 5

6 Presenter : Bill DiTullio President and CEO of InfraMetrix, LLC Professional Engineer with more than 35 years of water and sewer engineering, operations and construction experience. InfraMetrix provides innovative solutions for water and sewer asset management including inventory, mapping, inspection and condition assessment of gravity and pressure pipelines. Our services help our clients make informed maintenance and capital improvement decisions that improve performance and reliability for the lowest overall cost. Bill DiTullio, President Wastewater Collection System Condition Assessment Using CMMS Inspect and asses the condition of assets Target maintenance and capital improvements where greatest needs exist first ID and Assess Risk of blockages and failures to prioritize less critical needs Store inventory, condition videos and photographs in Asset Management, CMMS, GIS, and modeling database Manage performance, level of service and sustainability by considering service level, risk, condition and budgets 6

7 Collection System Condition Assessments Guides the Efforts of Asset Management Asset Management (AM) is: A process that minimizes the total cost of owning and operating a collection system while Delivering service levels that protect public health and the environment and Ensures reliable and sustainable operation for the long-term. Why Develop a Condition Assessment Program? All Assets Deteriorate and Eventually Fail Structural defects may interrupt service and cause roadway subsidence and failure Roots and debris cause backups and overflows Condition Assessment establishes the timing of maintenance and renewal investments. Infiltration and Inflow reduce conveyance capacity and increase transportation and treatment costs 7

8 Wastewater Collection System Condition Assessment (CA) WW Collection System CA Programs Provide Insight into the nature of possible failures Root cause Pattern deterioration curve Timing of possible failures Basis for scheduling maintenance and capital improvements Justification for annual O&M and Capital Budgets What Do We Need to Know? The desired level of service? What assets do we own? Where are they located? What is their condition? What is their remaining useful life? What is the economic value of my assets? Maintenance and capital improvement priorities 8

9 5 Step Collection System CA Process Review Inspect Assess Prioritize Implement Review data ID Data Gaps Develop Attribute Database Locate assets (GPS) Maps, records and reports ID Critical Assets Inspect manholes and pipelines Measure flows Populate AM, CMMS, GIS and modeling database Evaluate asset condition Identify immediate needs Assess Maintenance and Physical Condition of Assets Perform risk-based analysis for maintenance and capital planning Address immediate needs and implement maintenance and capital plans to achieve service level goals Level of Service? What I know? Identify the condition of the assets? What are the maintenance and capital needs? What are the priorities? Make improvements Review Review Available Information Maintenance & Break History I& I and Capacity Issues Develop Attribute Database Identify Data Gaps Design Field Program Locate and Update Mapping GPS Survey Connectivity Physical Attributes Knowledge Update Maintenance, Capacity & Structural Identify Access Issues Buried MH covers Easement locations 9

10 Inspection Reasons for Inspection: Identify blockages and failures and condition of assets for planning routine maintenance and repairs Monitor changes in condition Investigate failures to determine the cause and remedial action Support repair/rehabilitation design Comply with mandates Update AM, CMMS, GIS and modeling database Inspection Levels Inspection Options Level 1: Manhole Inspections and prioritize segments for maintenance and more detailed inspection Pole Cameras Truck Mounted Zoom Cameras Rapid CCTV ft/min Level 2: Detailed inspection of pipelines and laterals Analog and Digital in-line CCTV Level 3: Multi-purpose Systems Acoustic Sonar Electromagnetic Laser Pipe Penetrated Radar 10

11 Inspection Options O&M Observation/Defect Current Investigation Method Non Man-entry Comment Roots CCTV, Zoom Qualitative Identify but not Quantify Infiltration CCTV, Zoom Identify but not Quantify Exfiltration CCTV Only as Infiltration Encrustation Debris, including silt and grease Obstruction Leaks CCTV, Zoom Sonar Laser Profiler CCTV, Zoom Sonar Laser Profiler CCTV, Zoom CCTV Electro Scan (FELL 41) Operator judgment; Identify but not Quantify Identify and Quantify Quantify above water level Identify but not Quantify Identify and Quantify hard/soft deposits Quantify major but not minor deposits above water line Identify but not Quantify; May impede or stop equipment progress during investigation Possibly identify significant leaks above water line Identify but not Quantify leakage Inspection Options Structural Observation/Defect Cracks Fractures Broken Holes Current Investigation Method CCTV, Zoom Sonar Laser Profiler Multi purpose Systems CCTV, Zoom Sonar Laser Profiler Multi purpose Systems CCTV, Zoom Sonar Laser Profiler Multi purpose Systems CCTV, Zoom Sonar Laser Profiler Multi purpose Systems Comment Identify significant cracks with difficulty; no information below water line Collect data above and below water line; resolution may not identify cracks Possibly identify significant cracks above water line Identify and Quantify cracks by analysis Identify but not Quantify above water line Identify large fractures Identifies displacements above water line Identify and Quantify by analysis Identify but not quantify above water line Identify and possibly Quantify Identify and Quantify above water line Identify and Quantify by analysis Identify but not Quantify above water line Identify and limited Quantification above water line Identify and Quantify above water line Identify and Quantify by analysis 11

12 Inspection Options Structural continued Observation/Defect Deformed Displaced or Separated Joint Spalling, Abrasion, and Corrosion Current Investigation Method CCTV, Zoom Sonar Laser Profiler Multi purpose Systems CCTV Sonar Laser Profiler Multi purpose Systems CCTV Sonar Laser Profiler Multi purpose Systems Comment Unlikely to Identify small deformations Identify and Quantify above and below water line Identify and Quantify above water line Identify and Quantify by analysis Possibly identify but not quantify Identify and Quantify Significant displacement Identify and limited Quantification above water line Identify and Quantify by analysis Possibly Identify significant areas of loss Identification and Quantification of even small material loss Identification and Quantification of even small material loss above water line Identify but limited Quantification External Condition Wave Impedance (WIP) Identify but not Quantify voids or impingements outside the pipe (>12") Ground penetrating radar Identify but not quantify voids or impingements outside the pipe depending on (GPR) soil and water table Assess Condition of Assets 12

13 InfraMetrix Provides Vital Information That Will Improve Assess Performance Condition and and Update Reliability Knowledge Update inventory, maps and knowledge of maintenance and structural conditions Evaluate condition using standard coding NASSCO MACP, PACP and LACP Link inventory and condition data back into records (database, maps/gis) Data Management Best Practices Support Success Existing Data GIS CMMS Other Condition Assessment Data GIS Updates Inspection Data Cost Data Priorities Analyses QA Existing data is reviewed to identify gaps CA provides critical information for optimizing maintenance and capital projects CA data must undergo a full QA audit Maintenance and capital priorities are established CMMS, GIS & other databases are updated 13

14 Evaluate Condition Data and Information Catalogue condition data according to various failure modes Maintenance Infiltration and inflow Capacity Structural Corrosion Remaining Useful Life Prioritize Evaluate Risk of Failure for each asset Risk of Failure = Consequence of Failure x Probability of Failure Prioritize O&M, Inspection and Rehabilitation Prioritization based on risk (consequences of failure and various failure modes: maintenance, structural, capacity, I/I, corrosion, and service life Identify Annual Program Components and Capital Needs Level 1 inspection, cleaning, Level 2 and 3 as needed Repair, rehabilitation or replacement 14

15 Calculation of Risk of Failure For Maintenance and Capital Improvements Probability Scores Consequence of Failure Factor Risk Scores 3.00 x 0.15 Risk of Failure = Consequence of Failure x Probability of Failure Implement Perform Level 1 inspections to monitor changes in condition Clean pipelines to avoid blockages and overflows Perform Level 2 and 3 inspections of defective pipelines Repair, rehabilitation or replacement of manholes and defective pipelines 15

16 Benefits of Collection System Condition Assessment using CMMS Understand Condition, Useful Life and Financial Needs Helps in Understanding the Long-Term Financial Needs Guard Against Unexpected Rate Increases Guards Against Rate and Tax volatility. Improves the Ability to Improve and Maintain Reliable Service Reduce Risk of Failures Reduces Expensive Reactive Maintenance and Construction Fixes Improve Performance and Reliability Know Conditions of Each Asset. Know Where & When to Perform Maintenance, Repair and Replacement Activities Questions? 16

17 February 23, 2011 Building Your CMMS Know The Condition Of Your Assets Hugh M. Kelso Vice President RJN Group Inc. Importance Of Condition Assessment For Your CMMS Provides Accurate Inventory Data For Your CMMS Determines Condition/Value of Assets Provides Data For Effective Maintenance Planning Routine Scheduled Maintenance Work Orders Timing Of Repairs/Replacement 17

18 Why Perform Condition Assessment Consequences of Failure 18

19 PIPELINE Condition Assessment Technologies Small Diameter Pipeline Inspection Technologies (6-30 ) Large Diameter Pipeline Inspection Technologies (>30 ) Pre-Cleaning To Do Or Not To Do Small Diameter Pipelines Traditional CCTV Zoom Camera Manhole Entry Visual Pipe Inspection Other Electrode leak detection Smoke test 19

20 Conventional CCTV Inspection Pro s Widely utilized Identifies structural defects Develop condition rating (P.A.C.P) Low cost - $ Con s Inability to see below waterline Cannot quantify level of corrosion May require dewatering Length limitations Operator interpretation of defects Other CCTV Inspection Tools Push Cam Tractors CCTV Camera & Nozzle Technology Small Diameter Steerable Crawlers 20

21 Pro s Zoom Camera Inspection Provides quick assessment of pipes Does not require Man Entry Assists with determining cleaning requirements Costs-$ Con s Limited visibility (deflections/length) Access Limited Does not provide location of defects Manhole / Visual Pipe Inspection Pro s Provides quick assessment of pipes Assists with determining cleaning requirement Cost-$ Con s Limited visibility Requires confined space entry 21

22 Other Pipeline Assessment Tools Smoke Testing Electrode Leak Detection Large Diameter Pipelines Traditional CCTV Zoom Camera Sonar Man Entry Laser Combination CCTV / Sonar / Laser Other Emerging Technologies 22

23 Pro s Sonar Inspection Doesn t require dewatering Quantifies sediment and pipe condition below water line Con s Resolution Length limitation Cost-$$ Advanced Sonar Inspection Pro s Use in siphons, high flow mains, force mains Longer deployments No video cables Improved resolution Quantifies diameter corrosion detection, ovality, sediment volume Con s Lower resolution than laser No data above water line Cost -$$ Debris 23

24 Pro s Up close view Can probe walls Can collect samples Locates defects Con s Man Entry Confined space entry requirements May require dewatering Cost $ - $$ Pro s Laser Profiling Provides accurate 3D model of pipe Quantifies diameter, erosion, deflection, ovality, radius of curvature Con s May require bypass pumping Length limitations Cost-$$ 24

25 Advanced Multi Platform Technologies Laser, HDCCTV, and Sonar in a Single Inspection Laser / Sonar / HDCCTV Pro s High Definition Digital Video Define Pipe Cleaning Methodology Forecast Disposal Costs Provide Accurate Data for Rehabilitation Methodology Predict Life Expectancy of Existing Pipe Quantitative Data for Proactive Decision Making Con s Pipes Must Be Larger Than 30 Cost - $$$ 25

26 Other Advanced Technologies Acoustic Technology Measures vibrations or sound waves to detect signals emitted by defects, stressed wires or leaks Electrical / Electromagnetic Utilized by surcharging non-ferrous pipe for leak and defect detection Innovative Emerging Technologies Include Gamma ray, Ground Penetrating Radar, Infrared Thermography, Micro- Deflection, Impact Echo and Spectral Analysis To Clean Or Not To Clean Inspect-to-Clean Versus Clean-to-Inspect Expensive in Large Diameter Pipes Cost Savings 25 to 50 Percent 26

27 Condition Assessment Determine Ovality 27

28 Comprehensive Laser Profiling Measurable Corrosion Loss to 5+ 28

29 Sonar Condition Assessment Debris reports can assist in the selection for Pipe Cleaning Equipment needs, debris handling expectation, and disposal cost Condition Assessment Assists in Implementation of CMMS Provides Accurate Data for Implementation, Evaluation and Improvement of CMMS Allows for Efficient Work Order Planning Plan Effective Use of Limited Resources Proactive Scheduling of Repairs/ Replacement Maximizes Available Funds and Minimizes Unnecessary Spending 29

30 Questions? Condition Assessment: Building Your Computerized Maintenance Management System Planning for the Long Run Karen Morris Program Manager Operations & Maintenance Water Pollution Control Maintenance City of Fort Wayne, IN 30

31 What s Your Method? Is it Working? 31

32 Time for a Change? Identify motivating factors Regulatory requirements Pressure to do more with less CMOM Condition Assessments Limitations with current technology Before You Begin Needs Assessment What does your current system do well? What is your current system lacking? And of that, what do you truly need it to do? What are your current workflows? Employee skill sets? 32

33 Before You Begin cont d Needs Assessment (cont d) IT support / resources Current Hardware Looking forward, where do you see your organization in 5+ years? Gauge Support No project of this magnitude can move forward without significant support from above Upper management Customers Governing units 33

34 CMMS Shopping Windows Shopping Utilize your WEF network Site visits Talk to vendors Surf the Web Send out Request for Proposal (RFP) Fort Wayne s Journey 2 nd Largest City in Indiana 1,330 miles of existing sanitary/combination/relief sewer mains Sewer service area population approx. 240,000 34

35 Fort Wayne s Journey cont d Green-screen, non-proprietary IMS system started in 1980 s Fort Wayne s Journey cont d Around 2000, started search for new CMMS Departments involved: Sewer Maintenance Water Maintenance Street Maintenance Street Light Maintenance GIS 35

36 Fort Wayne s Journey cont d Project delays Administrative turn over Budgetary restraints Election year Project Restart 2004 RFP, narrowed down to two vendors Selection by Committee (score card) CMMS Scorecard - Criterion 36

37 Fort Wayne s Journey cont d Vendor Selected Finalized Scope of Project Consultant hired for Workflow Analysis Core users identified in each department Intensive hands-on training for core users Went live 11/15/2006 Benefits of the New System GUI (graphic user interface), more usefriendly 37

38 Benefits of the New System cont d Can record more in-depth field notes Benefits of the New System cont d Reports available on demand 38

39 Benefits of the New System cont d Preventative (Scheduled) Maintenance Benefits of the New System cont d Interface Capabilities GIS 311 Call Center Mobile applications Better cost tracking Customizable 39

40 Lessons Learned You will need a Database Administrator (aka Project Leader) Lessons Learned cont d Handle budgetary scissors with care Too much cutting can be bad for your project s health 40

41 Lessons Learned cont d Implementation is not a one and done deal May be broken into phases, or steps Lessons Learned cont d Track queriable information properly Example: Tracking plugged sewer lines Memo field type vs. checkboxes Memo Field Checkboxes 41

42 Lessons Learned cont d Garbage In, Garbage Out Work to minimize misinformation Work to minimize data entry errors Training, feedback, buy-in, encouragement Lessons Learned cont d Don t rush through the process 42

43 Lessons Learned cont d Keep looking for new ways to improve User Groups Newsletters Conferences Trainings Most Important Piece Your Employees / Co-workers Without them, you can t collect your data Upset them, you will get bad data Ignore them, you ll miss their input Exclude them, you ll struggle for buy-in later 43

44 Most Important Piece cont d Your Employees / Co-workers With them the possibilities are endless. Planning for the Long Run For more information on utilizing data stored within your CMMS, check out Mining Data from your Collection System in the Winter edition of the Indiana WEA Digester magazine at: /IWEA/digesterwinter2011/index.html 44

45 Questions? Round cover Discussion / Audience Participation Bill DiTullio, InfraMetrix Hugh Kelso, RJN Group Karen Morris, City of Fort Wayne John Nelson, Visu-Sewer / NASSCO President Webcast Attendees 45

46 A Condition Assessment Program can be greatly improved by using a solid CMMS. Capturing accurate data is critical, no computer system ever fixed a poor field inspection. Make the most of your data by preserving your agency's corporate memory. The biggest cost of a CMMS is data collection, input and upkeep (not software/hardware). The Wastewater Collection Systems Management Series Continues February 2012: Computerized Maintenance Management Systems (CMMS) / Planning & Implementation June 2012: Condition Assessment / Building Out Your CMMS November 2012: Asset Management / Translating Your Data To Information February 2013: Business Case For Action / Replacement or Rehabilitation June 2013: Optimize Your System Operations / Concepts & Benefits November 2013: Asset Management Design / Cost Minimization & Safety Considerations 46

47 (Based upon MOP FD-7) Thank you for joining us today! Condition Assessment: Building Out Your Own Computerized Maintenance Management Systems (CMMS) 47