Anatomy of an Effective PM Program at United Water Springfield

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Anatomy of an

Effective PM

Program at United

Water Springfield

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Presentation Highlights

¢ PM Basics

¢ Origin of the Springfield Program

¢ Developing the Program

¢ Conclusions

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Effective Preventative Maintenance

What is

Preventative Maintenance?

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The care and servicing by personnel for the

purpose of maintaining equipment and

facilities in satisfactory operating condition by

providing for systematic inspection, detection,

and correction of incipient failures either

before they occur or before they develop into

major defects

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Part 1

“care and servicing by personnel for the

purpose of maintaining equipment”

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Part 2

“inspection, detection, and correction of

incipient failures either before they

occur or before they develop into major

defects”

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RPM Work Order – A Repair Work Order

generated from the performance of a

Preventative Maintenance Work Order

An important metric to track and helps to

prevent Emergency Work Orders

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wear on centrifuge discharge port

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Preventative Maintenance

Program for facility centrifuges

and associated equipment

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2 Centrifuges were installed in 2008

replacing 4 belt filter presses and

became operational in 2009 as part

of a sludge dewatering upgrade

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2 Centrysis 21HC Centrifuges

1 Spare Rotating Assembly

Polymer Storage, Makeup, and Pumping

Systems

Conveying Systems – 5 Conveyors

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Centrifuge Production

40,000 Wet Tons Per Year

@ 25% Solids

Polymer – 14 lbs Active Polymer / DT

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A great opportunity to start a

PM program from scratch on

new equipment

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Where do PM’s come from?

¢  Manufacturers Recommendations*

¢  Staff Recommendations

¢  Experience

* To avoid warranty issues

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Example of Staff Recommendation/Experience:

¢ Metal greased bearings on shafted sludge

conveyors that required monthly maintenance

replaced with nylon bearings that only

required maintenance every six months

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Example of Staff Recommendation/Experience:

¢ Combine multiple short PM’s into one larger

PM

¢ Shorten or lengthen the time between PM’s

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Who does the PM?

The person that can add the

most value to the task

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In general:

Assign 90-day or less PM tasks or

simple PM tasks to your Operators

and free up Mechanics for higher

level functions.

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Today’s operators are smarter and more

capable than ever before, not only in terms of

formal academic achievement, but relative to

interest and desire to be part of the

maintenance solution.

Avoid the “I operate it, you fix it” mentality!

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Components of a PM Task

•  Accurate Task Instructions (SOPs)

•  Job Safety Analysis

•  Equipment Specific LO/TO Procedures

•  CMMS – Computerized Maintenance

Management System

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Effective Preventative Maintenance Equipment Specific LO/TO Procedure

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United Water Springfield Job Hazard Analysis

Job: Monthly Centrifuge Polymer Make Up Units PM

Job Description: Perform monthly PM on centrifuge polymer make up units, LO/TO and test equipment, remove flow sensor and clean tip, take apart polymer check valve and clean components

Job Hazards:

1. Ergonomic – bending, standing lifting, congested area 2. Falls – working on elevated platform 3. Stored Energy – process water line under pressure, equipment must be depressurized,

locked out, tagged, and tested 4. Slips and Trips – work area may be wet, polymer is extremely slippery

Hazard Controls:

1. Test LO/TO before starting work 2. PPE – hard hat, safety glasses, safety shoes, gloves 3. Check floor for polymer spills and clean if needed 4. Use proper lifting and bending technique 5. Clean jobsite after completion

Task Related Safety Information

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Accurate Task Instructions

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Grease fi(ng for bearing – grease un1l fresh grease comes out of plug hole on opposite side of sha9

Grease fi(ng for sha9 seal – three squirts

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Effective Preventative Maintenance CMMS Program

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Effective Preventative Maintenance PM Assignment Board

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PM Assignment Board Value

• A visual tool that clearly establishes performance expectations

• Promotes accountability

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11 PM’s Done by Operators 4 day – 1

7 day – 2 30 day – 3 90 day – 1

180 day – 2 365 day – 2 730 day – 2

~191 PM’s Per Year

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Completion – Failure Rate 2012 to 2014

4 Day PM Conveyors

7 Day PM Centrifuges

30 Day PM Poly Units


30 Day PM Conveyors

90 Day PM Poly Units


180 Day PM Hydraulic Units (2)

365 Day PM Belt

Conveyor

730 Day PM Conveyors

730 Day PM Poly Pumps Total

2012 -‐ Completed 88 52 12 12 10 4 2 4 1 1 186 2012 -‐ Failure 3 2 5

2013 -‐ Completed 91 52 12 12 12 4 3 1 1 188 2013 -‐ Failure 2 1 3

2014 -‐ Completed 92 52 12 12 12 4 2 4 1 1 192 2014 -‐ Failure 0

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Completion – Failure Rate 2012 to 2014

Total PM Work Orders 574 Total -‐ Completed 566 Total -‐ Failed 8 CompleMon Rate 98.6%

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Major Centrifuge Maintenance In House – Every 5,000 Hours Back to Manufacturer – Every 15,000 Hours

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0

10

20

30

40

50

2010 2011 2012 2013 2014

Cent 1 Y Avg

Cent 2 Y Avg

Cent 1 D Avg

Cent 2 D Avg

Shutdown

Alarm

Centrifuge Vibration Levels

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Conclusions •  CMMS System provides strategic value •  Whiteboard provides tactical value •  Our effective preventative maintenance

program is a very important part of our overall maintenance program

•  Use metrics to measure the effectiveness of your program

Anatomy of an Effective PM Program at United Water Springfield

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