Massachusetts Water Resources Authority Presentation to the Board of Directors MW RA Maint enance and Asset Prot ect ion Prog ogram May 13, 2015
What Does MWRA Own?
Facility Asset Management Program (FAMP) • 2000 – FAMP program started • Industry Best Practices – Building Blocks as shown • Reliability Centered Maintenance (RCM) • Expanded use of Condition Monitoring
Reliability Centered Maintenance (RCM) Approach Craft Hour by Work Orders Type Preventive and • Preventive Maintenance Predictive, 33% • Predictive Maintenance Corrective Maintenance • • Emergency Work Orders Corrective and Project , • Correct and Adequate Spares 67% • Proper Planning and Scheduling Number and Type of Work Orders Emergency Work Coordination Group formation Corrective • , 0.1% and Project, 21.5% • 67,000 work order completed per year • Less than 0.1% are emergency Preventive and Predictive , 78.4%
Condition Monitoring Techniques include: • Electrical Testing • Thermal Imaging • Infrared Temperature • Vibration • Acoustic Ultrasonic Predictive Maintenance • Lubrication analysis 14% • Ultrasonic thickness 12% % of Predictive Work Orders • TV inspection 10% 8% • Acoustical leak detection 6% • Cathodic protection testing 4% 2% • Increased from 2% in 0% FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY 04 to 11.8% in FY14
Condition Assessments • Identified in Master Plan • Budgeted in Capital Program • Components ‒ Roofs, Coatings, Gearboxes, pumps • Assets ‒ Wastewater Interceptor renewal program • Facility ‒ Prison Point Pump and Gearbox replacement ‒ Headworks Upgrades ‒ DI North Main Pump Motor and VFDs ‒ Chemical Feed Pump and Piping Upgrades at JJCWTP
How Does MWRA Track What I t Owns? • Computerized Maintenance Management System – Maximo ‒ 1995 start and fully implemented ‒ 120,000 individual pieces of equipment ‒ Work order management ‒ Maintenance planning and scheduling ‒ Preventive and predictive maintenance ‒ Corrective maintenance • Maximo Upgrade from 5.2 to 7.6 upcoming
Who Performs Maintenance? • In house staff complete majority of maintenance ‒ 491 maintenance staff ‒ 40% of all MWRA • Contracted services ‒ $ 13M per year ‒ Specialized training, experience or tools ‒ Non core business ‒ One time or intermittent
I s Enough Maintenance Being Done? DEER ISLAND EQUIPMENT AVAILABILITY 100 99 98 % Availability Actual 97 96 Target 95 94 -97 -98 -99 2000 -01 -02 -03 -04 Fiscal Year -05 -06 -07 -08 -09 2010 -11 -12 -13 -14 Wastewater and Collections Availability – 99.98% in FY14
I s Enough Maintenance Being Done? • Over 36 maintenance metrics are tracked • Reviewed daily, monthly, quarterly, and yearly • Reported internally and externally For example: • 99.9% of all predictive maintenance work orders completed in FY14 • Light maintenance increased from 2% in FY02 to 7% in FY14 • 10,000 hours of preventive maintenance completed by operations staff
CEB and CI P Spending CEB Maintenance - FY86 to FY14 Actual Spending $30 $25 $20 $s in Millions $15 $10 $5 $0 FY86 FY87 FY88 FY89 FY90 FY91 FY92 FY93 FY 94 FY 95 FY 96 FY 97 FY 98 FY 99 FY 00 FY 01 FY 02 FY 03 FY 04 FY 05 FY 06 FY 07 FY 08 FY 09 FY10 FY11 FY12 FY13 FY14 CEB of $469M from 1985 to today ($29M) CIP of $1.5B from 1985 to today ($54M/year)
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