Condition Assessment and Rehabilitation of Pumps, …...assessment questions & answers) 3 •Upload...
Transcript of Condition Assessment and Rehabilitation of Pumps, …...assessment questions & answers) 3 •Upload...
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Condition Assessment and Rehabilitation of Pumps, Valves, and Meters
Jeffrey B. Sanford CMRP, CRL
Dan Buonadonna PE
May 4th
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Agenda
•Asset Management Strategies (Risk Based)
•Condition Assessment
–Approaches
–Field Investigation Technologies
•Thermography
•Vibration
•Ultrasonic
•Rehabilitation Approaches
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3 Presentation Title
Safety Moment
Greenwood Neighborhood (Seattle, WA)March 14th Heavy Windstorm
+250K without power
Felled trees and powerlines can start a fire quickly in a windstorm.
Emergency services may be delayed in such a widespread event.
Proper maintenances of urban canopy trees by certified arborists can greatly reduce the likelihood of accidental tree falls.
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Effective Asset Management is:
An integrated set of processes to minimize the
life-cycle costs of owning, operating and
maintaining assets, at an acceptable level of
risk, while continuously delivering established
levels of service
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An integrated set of processes to minimize the lifecycle costs of infrastructure assets, at an acceptable level of risk, while
continuously delivering established levels of service.
Acceptable Risk
Lifecycle Costs Service Levels
Balance conflicting goals by managing risk
Balancing Act…
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Risk is quantified by the classic equation.
Risk = (consequence x likelihood)
How severe are the
consequences of asset failure?
How likely is it for
the asset to fail?
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Top Down Bottom Up Approach
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Understanding the risk of asset failure provides…
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The basis prioritizing capital investments for R&R
The basis for optimizing O&M
The basis for investing in condition assessments
A uniform and rigorous manner that results in defensible decisions
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Risk Based ApproachQuantified by using the classic risk equation
Risk = (consequence x likelihood)
How severe are the consequences of asset failure?
How likely is it for
the asset to fail?
• Health & Safety implications
• Financial impact
• Regulatory compliance
• Public confidence
• Service delivery
Levels of Service
• Condition
• O&M Protocols
• Performance
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Consequence of Failure Matrix
Consequence by Level of Service Category
LOS Category Wt. Negligible = 1 Low = 4 Moderate = 7 Severe = 10
Safety of public and
employees30%
No injuries or adverse health
effects
No lost-time injuries or
medical attention required
Lost-time injury or
medical attention required
Loss of life or widespread
outbreak of illness
Financial impact 15%Can be repaired within Utility
budget (<$2,500)
Can be repaired between
$2500 and $9,999
Can be repaired between
$10,000 to $29,000.
Greater than $30,000.
Sealed bids and City
Council approval required
Public confidence 10%
No social or economic impact
on the community. No reactive
media coverage. Any media
coverage is a result of proactive
announcements by Utility. No
complaints.
Minor disruption (e.g.,
traffic, dust, noise,water
pressure). No adverse
media coverage. Some
complaints.
Substantial but short-term
disruption. Adverse media
coverage due to public
impact. Localized media
coverage.
Long-term impact. Area-
wide disruption. Regional
media coverage.
Regulatory
compliance25%
No State or local permit
violations . No SSO'sPossible technical violation
Probable enforcement
action, but fines or
surcharge unlikely
Enforcement action with
fines or surcharge
Service Delivery 20% No impact
Minor impact to process or
out of service less than 24
hours. No SSO's or loss of
service
Major impact to process,
out of service <24 hours.
Potential SSO or loss of
service
Major impact to process,
out of service >24 hours,
outside services required,
SSO' or loss of service
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Likelihood Matrix
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Example Risk Profile by area
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Example Risk Profile by asset
Relative Risk ScoresAsset Systems at Treatment Plant No. 1
Acceptable Level of Risk
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The Role of Condition Assessment in Asset Management
Inventory
Assess
Prioritize
Optimize
Implement
Update
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Re-score likelihood of failure based on updated field information
Recalculate risk
Use risk levels to prioritize detailed
assessments
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Condition Assessment is step-by-step process
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1• Gather asset data
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• Develop assessment criteria (e.g. Review and verification of condition assessment questions & answers)
3• Upload data into a tracking tool
4• Field investigation
5• Risk results
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Asset Data Gathering
Assets and their characteristics need to be captured
Easiest method is to obtain from EAM/CMMS database
“Walking down” assets is a critical step
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Criteria development
We must ask and answer some predefined questions that relate to the equipment condition.
Questions are grouped by asset type. (e.g. All pumpswill have the same question and answer group.)
Each answer is rated from 1 to 5 with 1 being excellent and 5 being un-serviceable.
Predictive Maintenance (PdM) Technologies
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Asset and Risk Upload
•Data gathered is entered into a tool for tracking.
•Once the data is uploaded, field devices are shipped to the job site.
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Assessment data is captured in the field
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Condition Assessment Technologies
Visual/Audio
• SOP Checklists
Mechanical
• Torque wrench
• Calipers
• Pit-depth gauge, etc.
Electrical
• Multi-meter
• “Meggar”, etc.
Specialty…
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Thermography
•Versatile technology
•Low cost for equipment
•Training is significant
•Most common uses
– Electrical
– Mechanical
– Structural
– Security
– Health
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Vibration
•Most common PdM tool in use
•Significant investment for training/certification
•Must trend data for effective use
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Ultrasonic
•Common uses
– Electrical corona, tracking, arcing
– Compressed gas leaks
– Vessel integrity
– Pipe wall thickness
– Material defects
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Condition Data Updates the Risk Register and is Used to Identify Risk Reduction Measures
Reduce Likelihood
•Rehabilitation
•Replacement
•Operating procedures
•Maintenance procedures
Reduce Consequence
•Demand management
•Reduce LOS & educate
•Improve response & recovery
•Add redundancy
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Approaches to Rehabilitation/Maintenance
• Corrective Rehab/Maintenance
– Repair work conducted after a failure or breakdown.
• Preventive Rehab/Maintenance
– A specified list of inspections, cleaning, testing, and part replacement during a pre-defined, time-based schedule.
• Predictive Rehab/Maintenance
– Schedule based on diagnostic evaluations. Also factors in equipment age, environmental stresses, criticality of equipment, (etc.) in order to decide on schedule.
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Severe 10 20 30 40 50 60 70 80 90 100
9 18 27 36 45 54 63 72 81 90
8 16 24 32 40 48 56 64 72 80
Moderate 7 14 21 28 35 42 49 56 63 70
6 12 18 24 30 36 42 48 54 60
5 10 15 20 25 30 35 40 45 50
Low 4 8 12 16 20 24 28 32 36 40
3 6 9 12 15 18 21 24 27 30
2 4 6 8 10 12 14 16 18 20
Negligible 1 2 3 4 5 6 7 8 9 10
Neg
ligib
le
Po
ssib
le
Lik
ely
Ver
y L
ikel
y
Likelihood
C
on
seq
uen
ce
Options are ranked and optimum is chosen
Assess risk
reduction for
identified
options
Rank options by:
Risk Reduction
Cost
$Risk Reduction
Pro
jec
t L
ife
cyc
le C
os
t
R&R Project 2 R&R Project 6
R&R Project 3
R&R Project 8
R&R Project 7
R&R Project 4
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In a nut shell…..
•Define your levels of service
•Characterize your risk exposure
•Optimize your rehab/maintenance strategy
Low High
Cost
of A
sset O
wners
hip
($)
Levels of Service
Total Cost
Target
Area
Call a certified arborist and trim your trees. Today.