Maintenance Presented by: John J. Jackman, P .E. Associate - - - PowerPoint PPT Presentation

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”
• Data collection during maintenance forms the foundation
• Individual asset data collected is analyzed on system-wide scale

Asset

Maintenance Condition Value Criticality

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

Tag No. Description Location Redundancy Health & Safety Permit Violation Difficulty to 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

34% 4% 3% 48% 6% 5%

10 Year Life Cycle Cost

Capital Cost Preventive cost Repair cost Operational cost Energy cost Other cost

Capital Cost $ 32,000.00 Preventive cost $ 4,000.00 Repair cost $ 3,000.00 Operational cost $ 45,000.00 Energy cost $ 5,000.00 Other cost $ 5,000.00

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

• Acquisition
• Operation
• Maintenance
• Renewal
• Reparation
• Rehabilitation
• Replacement
• Disposal and decommissioning

Economic Costs

• Financial costs
• Direct costs to the governmental
• rganization
• Direct customer costs
• Community costs
• Triple bottom line
• Financial and economic
• Social
• Environmental

Direct Life Cycle Cost

• Cash Requirement and Cumulative Costs over Asset Life

Direct Life Cycle Cost

• O&M cost continue to increase
• ver 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

Average of to repair a break $5,500.00 LOS/Resisdent/Day $150.00 LOS/Store/Day $1,000.00 LOS/Business/Day $5,000.00

• What is the social cost of water

break

• Resident can not prepare food, wash,

flush, etc.

• Store will vary based on type

(restaurant may close)

• Business/Industry can very but can be

up to $1,000,000/hr

• Traffic
• Diverting or slowing traffic
• Rough road wear on vehicles

Development Life Cycle Cost

• Determining life cycle cost requires work flow with goal in mind
• Cost Tracking
• Integrating CMMS to financial system
• Setting up activity-based accounting
• Exporting data that has value
• Cost Allocation
• Direct pay
• Overhead or administrative
• Benefit burden
• Material cost
• Expense cost

Equipment

Task

Cost

Development of Life Cycle Cost

• Determining replacement cost
• Level 1
• Original cost X general cost index
• Cost Performance Index (CPI)
• Level 2
• Original cost X sector-based cost index
• Engineering News-Record (ENR)
• Means Building Construction Cost Data (Means)
• Consumer Confidence Index (CCI)
• Level 3
• Modern Equivalent Engineered Replacement Asset (MEERA)
• Detailed site-based cost analysis

What is the Value of My Asset?

• Associated Techniques
• Valuation and costing
• Straight-line depreciation
• Condition-based depreciation
• Renewal/Replacement costing
• Depreciated replacement cost
• Deprival cost

Wastewater Treatment Facility

• Understanding the data

Everyone at the plant needs to understand value of tracking data and the software they are using

Invoice

Q & A