Maintenance Presented by: John J. Jackman, P .E. Associate - Asset Management Specialist David Wheeler, E.I.T. Environmental Engineer
Agenda • What is Maintenance? • Develop & Implement Maintenance Management System • Maintenance Management System Activities • Using Maintenance Management • Existing Asset Decisions Based On Risk • Fundamental Asset Management Elements
What is Maintenance? • Asset “Centric” Maintenance • Data collection during maintenance forms the foundation • Individual asset data collected is analyzed on system-wide scale Asset Criticality Condition Value
What is Maintenance? • Maintenance Program • Scheduled • Generated through routine work orders • Advanced planning of labor and parts needed • Updated condition assessment during maintenance • Collect associated cost data • Both operations and maintenance are part of this system
What is Maintenance? • Maintenance Goals • Maximize asset life and reliability • Minimize asset failure • Increase asset efficiency • Increase labor efficiency
What is Maintenance? • Benefits • Asset performance is optimized • Provide data on the state of the system • Minimize costs from unplanned maintenance • Reduced service disruptions from asset failure • Assist in determining rehabilitation and replacement decisions • Establish labor requirements • Budgeting for asset maintenance activities • Prepare SOPs
What is Maintenance? • Three General Types • Reactive • Predictive • Preventative • Ideal Maintenance Balance • Generally accepted to be about • 75% Planned • 25% Reactive or Unplanned Reactive Predictive Preventative
Develop & Implement Maintenance System • Reactive Maintenance • Work performed after a breakdown • Emergency (High Risk) • Non-emergency (Low Risk) • Unplanned (resources, manpower, loss of service) • Expensive (unbudgeted, no optimization of purchasing, overtime)
Develop & Implement Maintenance System • Predictive Maintenance • Monitoring and analyzing asset condition to anticipate failures • Delay or prevent failure • Reduces operating costs • Reduces emergency repairs • Provides data on effectiveness of preventive maintenance program
Develop & Implement Maintenance System • Preventive Maintenance • Schedule maintenance based on manufacture recommendation • Performance and safety inspections • Provides data on effectiveness of preventive maintenance program • Testing equipment • House cleaning • Protect surface from corrosion
Maintenance Management System Activities • Preventative Maintenance • Activities and Frequencies • Manufacturer Recommendations • Historical data • Breakdown analysis • Staff experience • Determine material and labor requirements
Maintenance Management System Activities • Predictive Maintenance • Determine testing methods • Determine whether internal or external forces are needed • Evaluate the data and what it tells you • Determine labor and funding requirements
Using Maintenance Management • Establishing Levels of Service • Desired outcomes from customers and other stakeholders perspective • Vary between organizations (size, region) • Can change within organizations over time
Wastewater Treatment Facility – JobCAL • Brattleboro, VT • South Burlington, VT Everyone at the plant needs to understand functionality of the software
Develop & Implement Maintenance System • Computerized Maintenance & Management System (CMMS) • Reactive, Predictive & Preventative Maintenance • Defines asset relationships • Incorporates asset criticality • Enhances planning for future capital projects • Minimizes reactive/unplanned maintenance • Tracks costs to an asset
Using Maintenance Management • Understanding Asset Failures • We tend to over-maintain mechanical assets • We do the “wrong” maintenance • Most failures are not traditional “wear and tear” failures • We identify the wrong critical assets • We measure failures instead of measuring and understanding if we could have prevented failures
Develop & Implement Maintenance System • Develop a priority asset list based on risk • Prioritize the preventative maintenance tasks • Implement the maintenance program Permit Difficulty to Tag No. Description Location Redundancy Health & Safety Violation Repair Cost of Priority PMP-1A Raw Sludge Rotary Lobe Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-1B Raw Sludge Rotary Lobe Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-2A Feed Sequencing Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-2B Feed Sequencing Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-3A Thermophilic Sludge Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-3B Thermophilic Sludge Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-4A Hot Water Recirculation Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-4B Hot Water Recirculation Pump Digester Complex - Lower Level 2 1 3 2 2 3 PMP-5A Mesophilic Sludge Pump Digester Complex - Lower Level 2 1 3 2 2 3
Equipment
Task
Task
Work Order
Sludge Pump • Task Entry : Check pump oil levels • Fill to level as required • • Results of Work Order : Oil level of one pump was lower than others • Topped off oil • • Closing Work Order : Recorded actions taken and inventory used • Increased frequency of labor • Probability of Failure has Increased
Corrective Maintenance
Life Cycle Cost Presented by: John J. Jackman, P .E. Associate - Asset Management Specialist David Wheeler, EIT
Agenda • Life Cycle Cost of a Boat • Cost Perspectives • Direct Life Cycle Cost • Financial Life Cycle Cost • Social Life Cycle Cost • Development Life Cycle Cost • What is the Value of My Asset?
Life Cycle Cost of a Boat • Over 10 years spent • Used the boat total of 150 hours
Life Cycle Cost of a Boat • Initial Costs — Purchase, Acquisition, Construction Costs • Fuel Costs • Operation, Maintenance, and Repair Costs • Replacement Costs • Residual Values — Resale or Salvage Values or Disposal Costs • Finance Charges — Loan Interest Payments • Non-Monetary Benefits or Costs
Life Cycle Cost of a Boat • Buy the 22 ft boat $32,000 • A slip for the boat $ 2,500/yr $25,000/10yrs • Registration/insurance $ 350/yr $ 3,500/10yrs • Winter storage $ 2,000/yr $20,000/10yrs • Getting ready spring $ 400/yr $ 4,000/10yrs • Fill up fuel $ 250/each $ 5,000/10yrs • Life jacket/skies/etc $ 5,000 • Repairs to rear-end $ 3,000 $ 3,000
Life Cycle Cost of a Boat 10 Year Life Cycle Cost Capital Cost $ 32,000.00 Preventive cost $ 4,000.00 Capital Cost Repair cost $ 3,000.00 Operational cost $ 45,000.00 Preventive cost 6% 5% Energy cost $ 5,000.00 34% Repair cost Other cost $ 5,000.00 Operational cost 48% 4% 3% Energy cost Other cost
Life Cycle Cost of a Boat • Options • You want a bigger boat • Your wife wants you to get rid of the boat • You can not afford to keep the boat • You rent a boat when you need one
Cost Perspectives Direct Life Cycle Costs Economic Costs • Acquisition • Financial costs • Operation • Direct costs to the governmental organization • Maintenance • Direct customer costs • Renewal • Community costs • Reparation • Triple bottom line • Rehabilitation • Financial and economic • Replacement • Social • Disposal and decommissioning • Environmental
Direct Life Cycle Cost • Cash Requirement and Cumulative Costs over Asset Life
Direct Life Cycle Cost • O&M cost continue to increase over time. • When do you know when to repair, rehabilitate or replace
Direct Life Cycle Cost • Run to failure • Maximizing the life cycle cost by maximizing the life • Always? • When the cost of maintenance is greater then replacement • What else should you consider? • When the energy cost out weighs the replacement • How do you know this? • When it no longer provide level of service • Have you set a minimal Level of Service?
Financial Life Cycle Cost • Direct costs to the local government • Repair and return to service costs • Service outage mitigation costs • Utility emergency response costs • Public safety costs • Administrative and legal costs of damage settlements • Lost product costs
Social Life Cycle Cost Direct customer costs • Property damage costs, including restoration of business • Service outage costs • Service outage mitigation and substitution costs • Access impairment and travel delay costs • Health damages
Social Life Cycle Cost • What is the social cost of water break • Resident can not prepare food, wash, Average of to repair a $5,500.00 flush, etc. break • Store will vary based on type LOS/Resisdent/Day $150.00 (restaurant may close) • Business/Industry can very but can be LOS/Store/Day $1,000.00 up to $1,000,000/hr LOS/Business/Day $5,000.00 • Traffic • Diverting or slowing traffic • Rough road wear on vehicles
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