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MAINTENANCE AUDIT:ASSESSING THE PERFORMANCE OF CMMSAT A WRRFJOINT EXPO 2018TIM SULLIVAN, P.E.2/20/20182018 JOINT EXPO MAINTENANCE AUDIT1
PRESENTATION SUMMARY Background (How it came to be) Audit Scope (Basic Questions) Findings Recommendations What does all this mean to you?2/20/20182018 JOINT EXPO MAINTENANCE AUDIT2
BACKGROUND “Somewhere at a WRRF, far, far away .”2/20/20182018 JOINT EXPO MAINTENANCE AUDIT3
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SOMETHINGS WRONG But NPDES Permit conditions were met (No red flags) New Authority Manager2/20/20182018 JOINT EXPO MAINTENANCE AUDIT10
SUM TING WONG But NPDES Permit conditions were met (No red flags) New Authority Manager2/20/20182018 JOINT EXPO MAINTENANCE AUDIT11
STARTED WITH BASIC QUESTIONS: What is considered an Asset? Are all assets in the CMMS? Are the PM Steps in the CMMS adequate? Are the PM measures being properly performed on a timely basis? How are calendar and run times squared away? What are Critical Assets and should Predictive or Proactive Maintenanceprocedures be in place?2/20/20182018 JOINT EXPO MAINTENANCE AUDIT12
WHAT IS CONSIDERED AN ASSET?(What is the definition of an Asset?) No formal definition Q: “How do you handle valves?” Left to “Wing it”2/20/20182018 JOINT EXPO MAINTENANCE AUDIT13
ARE THE ASSETS IN THE CMMS? Vast majority of assets were in the CMMS 1050 assets in 109 (?!) process areas Valves lumped together in process areas Gates and Actuators not included Electrical equipment not included or lumped together in process areas Emergency Generators not included Building envelope assets not included New / replacement assets not changed in a timely manner2/20/20182018 JOINT EXPO MAINTENANCE AUDIT14
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Electrical pictures2/20/20182018 JOINT EXPO MAINTENANCE AUDIT17
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ARE THE MAINTENANCE STEPS IN THECMMS ADEQUATE? No New CMMS Software purchased O&M procedures were not migrated into new CMMS Software O&M Manuals not considered with re-writing maintenance steps,But many maintenance step were VERY detailed. Some assets did not identify any PM instructions 20% of collection system inspected annually2/20/20182018 JOINT EXPO MAINTENANCE AUDIT21
ARE THE MAINTENANCE STEPS IN THECMMS ADEQUATE? No New CMMS Software purchased O&M procedures were not migrated into new CMMS Software O&M Manuals not considered with re-writing maintenance stepsBut many maintenance step were VERY detailed. Some assets did not identify any PM instructions 20% of collection system inspected annually2/20/20182018 JOINT EXPO MAINTENANCE AUDIT22
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O&M MANUALS Need to be annotated, customized, specific Ex. “ if applicable” Manual not always consistent with training Obtain calendar days if you don’t haveeETM or run times2/20/20182018 JOINT EXPO MAINTENANCE AUDIT31
ARE THE PM MEASURES BEING PROPERLYPERFORMED ON A TIMELY BASIS? Generally yes, when CMMS instructions were sufficient Lubrication very inconsistent Leaking oil obvious Lack of Electrical Maintenance Slide Gate Maintenance Actuator Maintenance2/20/20182018 JOINT EXPO MAINTENANCE AUDIT32
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ARE THE CORRECTIVE MAINTENANCE MEASURESBEING PROPERLY PERFORMED ON A TIMELY BASIS? No 7 of 8 Odor Control Chemical pumps off-line Aerated Grit tanks off-line for 15 – 20 years Aerated Channel diffusers off (blower failures) Numerous exhaust fans off-line (impacting safety and creating corrosionissues) All SFE automatic backflush strainers failed (no manual backflush initiated) On-line analyzers not functional Essential zero redundant equipment CMMS could not list off-line equipment2/20/20182018 JOINT EXPO MAINTENANCE AUDIT45
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ASSESS MAINTENANCE OPERATIONS Assessed NO. of Work Ordersopen, No. of Staff, Time tocomplete WOs, etc. Staff: 1 1 Technician 3, 1 Technician 2,1 Technician 1 Approx. 1,000 WO /yr. (20 / week) Average Time WO Open: 2 to 3weeks Very little corrective work ordersgenerated2/20/20182018 JOINT EXPO MAINTENANCE AUDIT73
HOW ARE CALENDAR AND RUN TIMESSQUARED AWAY? Disabled eETM run times due to security concerns (?) Calendar time only, but no consideration for redundancy or actual runtimes2/20/20182018 JOINT EXPO MAINTENANCE AUDIT74
RECOMMENDATIONS: List of 100 Recommendations Fully Align CMMS with Assets Identify and Perform Corrective Maintenance Critical Assets / Condition Assessment / Predictive Maintenance Implementation Plan Staff: Maintenance Manager to focus on Maintenance Add 2 additional Staff Members until caught up Shift in PM tasks to Operators Aerated Grit and Process Renovations CIP2/20/20182018 JOINT EXPO MAINTENANCE AUDIT75
HOW DOES THIS RELATE TO YOU? You have some of these issues Yes you do Define and Identify All Assets including Critical Assets (if you don’t have aformal definition) Take another look at CMMS procedures Update CMMS procedure with new(er) measures/technologies Consider predictive maintenance Be cognizant of unintended consequences Are you using your CMMS to make decisions? (Are you able to?)2/20/20182018 JOINT EXPO MAINTENANCE AUDIT76
PRIVATIZED OPERATIONS:ISSUES AND QUESTIONS What are their financial incentives? Know your contract, they do Their incentives may not align with your incentives Who pays for consumables, energy, etc. Did they commit to a set number of operators, mechanics, electriciansinstrument techs? Are they handling capital improvement projects? Meeting MPDES Permit conditions is NOT an indication that all is well2/20/20182018 JOINT EXPO MAINTENANCE AUDIT77
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THANK YOUIf you have questions about the presentation, please contact me:Tim Sullivantsullivan@hrcengr.com2/20/20182018 JOINT EXPO MAINTENANCE AUDIT83
2/20/2018 2018 JOINT EXPO MAINTENANCE AUDIT 73 ASSESS MAINTENANCE OPERATIONS Assessed NO. of Work Orders open, No. of Staff, Time to complete WOs, etc. Staff: 1 1 Technician 3, 1 Technician 2, 1 Technician 1 Approx. 1,000 WO /yr. (20 / week) Average Time WO Open: 2 to 3 weeks Very little corrective work orders generated
