CENTRAL SAN S APPROACH O ASSET MANAGEMENT · 2020. 7. 14. · CENTRAL SAN’S APPROACH TO ASSET MANAGEMENT Nitin Goel, P.E. Senior Engineer, Special Projects and Asset Management/GIS
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CENTRAL SAN’S APPROACH T O ASSET MANAGEMENT Nitin Goel, P.E. Senior Engineer, Special Projects and Asset Management/GIS Group Baywork Training A La Carte April 23, 2019
Nitin Goel, P.E.Senior Engineer, Special Projects and Asset
Management/GIS Group
Baywork Training A La Carte
April 23, 2019
WHERE IS CENTRAL SAN?
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450 Miles NW of here
CENTRAL CONTRA COSTA SANITARYDISTRICT
• Serves over 480,000 residents and 3,000 businesses
• Dry weather season flows currently average around 34 mgd
• During the wet season, peak hourly flows can exceed 200 mgd
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Central San provides wastewater collection and treatment services
LIQUID TREATMENT PROCESS
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Preliminary Treatment: Used to remove large debris and grit prior to primary treatment Headworks (Bar Screens and Screenings Grinders) Pre-aeration aerated grit removal system Primary Treatment: Removes scum and settleable solids from the raw influent downstream of the pre-aeration tanks. Primary sedimentation tanks (PSTs) Primary effluent pumps. Secondary Treatment: Activated sludge process removes the remaining biochemical oxygen demand (BOD) and suspended solids that pass through primary treatment. Aeration/Nitrification Tanks – carbonaceous BOD removal mode Secondary Clarifiers – mixed liquor from the A/N tanks settle RAS/WAS Systems UV Disinfection – provides rapid, effective inactivation of microorganisms
SOLIDS HANDLING PROCESS
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Solids are byproducts of the primary and secondary treatment processes. Dissolved Air Flotation Thickener System (DAFTs) – concentrate WAS produced by the activated sludge process Sludge Blending Tanks Lime is added to the blended sludge Primary sludge and TWAS are blended in the Sludge Blending Tank Prior to dewatering Dewatering Centrifuge System Polymer solution is injected to flocculate the sludge solids for efficient separation in the centrifuge Flocculated sludge separates into cake and centrate due to centrifugal force imparted by the rotation of the bowl Scum Thickening System: Scum (light oils and grease and floatable plastic materials) produced from the primary sedimentation basins is thickened and conveyed to the incinerators in a daily batch operation. Incineration Process: two multiple hearth furnaces (MHFs) Only one furnace is operated while the other is available in cold-standby Each MHF system includes 11 hearths Ash Handling System: Ash is collected from Hearth 11 (bottom of furnace)
SPECIAL PROJECTS AND ASSETMANAGEMENT GROUP
Central San
Engineering Department
Planning & Development
Services Division
Special Projects & Asset Management Group
Senior Engineer (1)
Maintenance Planner (1)
Asset Management Coordinator
GIS Analyst (2)
Engineering Technician (1)
Capital Projects Division
Reg & Env Compliance
Division
ASSET MANAGEMENT OBJECTIVE & FRAMEWORK
Objective• Optimize lifecycle of
Central San’s assets • Deliver high quality &
reliable services in a sustainable manner
FrameworkAsset management is a broad strategic framework that encompasses many disciplines
WE ALL MANAGE ASSETS IN OUR PERSONAL LIVES
Know your Asset Inventory (Tires, Timing Belt, etc.)
Calculate Vulnerability, Criticality, Risk (Risk associated with long distance travel)
Determine Asset Life Cycle Costs (Cost of repairs)
Communicate Need for Funding
Implement Repair, Replace, Decisions (Buy a new car or repair existing)
ASSET MANAGEMENT IS A JOURNEY, NOT A DESTINATION. MANYTASKS, IMPLEMENTED OVER TIME, ARE REQUIRED FOR A
SUCCESSFUL PROGRAM
Know your Asset Inventory
Calculate Vulnerability, Criticality, Risk
Determine Asset Life Cycle Costs
Communicate Need for Funding
Implement Repair, Replace, Decisions
BOARD POLICY FORMED IN 2014 ON ASSET MANAGEMENT WASINSTRUMENTAL IN IMPLEMENTING A FORMAL ASSET MANAGEMENT
PROGRAM
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HISTORY OF MAPPING AND GIS AT CENTRAL SAN
’70s to Mid’90s• 669 maps
Mid’90s to 2005• 739 maps
2005 to 2016• 766 maps
2016 Onward• No printed map
books!
Pen and ink drafting on mylar film
Moved to MicroStation + MGE
Intergraph GeoMediaand AutoDeskMapGuide web maps
Esri ArcGIS and Geocortex
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70’s-90’s: Everybody had hardcopies, even in field vehicles 90s thru 2005: Still all about hardcopy maps, just the method for producing them changed First GIS asset registry Operations departments maintained separate (duplicate) asset registries as part of their Computerized Maintenance Management Systems 2005 thru 2016: WIN! First time we had a tile-less mapping environment However: Field crews still relying on paper maps – attempts made to create self-contained web map application on laptops Still have competing asset registries, although efforts made to reconcile them 2016: Started deploying our GIS-Centric applications
FOR THE FOLLOWING REASONS CENTRAL SANNEEDED A NEW GIS CENTRIC COMPUTERIZED
MAINTENANCE MANAGEMENT SYSTEM
• To avoid duplication of assets among different databases
• To have repeatable, flexible, trendabledatabase
• Consistency• Generate Condition Scores
Mainsaver (Treatment Plant)
• Asset maintenance history persistence
• One asset class• Old version• Process habits
Accela AMS/Fleet (Collection Systems and Fleet)
• Asset edits were made in three places• Difficult/Inefficient user interface• Inflexible data fields for searching• Office staff responsible for all data
entry/no field access• Version lock
• One CMMS. One Asset Registry.• Robust Asset Registry• Empower field users engagement• No custom code (expect for SCADA and ERP integration)• Flexible and configurable• Continual version updates• Opportunity to develop improved workflows• Not perfect, but a huge huge step forward in CMMS technology for Central San.
We are active partner in its development
Cityworks
HISTORY OF CMMS
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Mainsaver: 1: Asset maintenance history persistence: Maintenance history (Work orders and Inspections) is associated to an Asset by its Asset Number. Asset numbers in Mainsaver were reused because they represented that position on the plant site and that point in SCADA. If an asset was disposed, a new asset would inherit that number. This meant when looking at asset maintenance history, the user would see work completed on the now disposed asset. Sometimes the number was given to a new asset not in the same position as the previously disposed asset or even a different type of asset (pump vs. fan). 2: One Asset Class: All plant equipment assets were in one table and were distinguished by an attribute. All equipment types shared the same fields and all specs for those assets were stored in a separate table. Each spec was a separate line in the table so you might have, for example, 20 lines for a single asset’s specs. 3: Old Version: The Mainsaver version Central San was using was several years old and some of the customizations in use made it difficult to upgrade to a contemporary version 4: Process Habits: The processes followed were not always the most effective or efficient. It was not inherently due to the software, but they became repeated practice (habits) which can be difficult to change. Implementing new software system allow for examination of current practices and allow for process improvements because no habits have been formed yet Accela: 1: Asset edits made in three places: Because the Central San was maintaining multiple asset registries and databases, if CSO made an update to an asset, they might need to make the change in Accela, the database for the web mapping system, the construction database, and/or tracking spreadsheets 2: Difficult/Inefficient user interface: Not intuitive. Lots to remember to use system well. Lots of clicks to make edits to work orders and other forms. Difficult to search and input info into work orders and other forms. Took years to feel comfortable as a power-user. Difficult to teach others due to its complexity. Running monthly schedules was difficult, took three days, and multiple programs to accomplish. 3: Inflexible data fields for searching: Searching in system was difficult because search values had to be perfect. No fuzzy search. Had to use system’s abbreviated codes. 4: Office staff responsible for all data entry/no field access: Field staff completed paper work orders and office staff entered them into the system. Significant staff time required to do this. 5: Version lock: Former staff significantly modified this version of Accela and any upgrade would break these customizations. Customizations were significant enough that vendor support was limited or restricted. Cityworks: 1: One CMMS. One Asset Registry: One centralized database to maintain asset data and draw from. Shift much of its development and maintenance to GIS/Asset Management staff, who are adept database administrators. Improved data quality control. Increased reliability. Streamlined reporting and data sharing. 2: Robust Asset Registry: Utilizes the power of a GIS relational database. More robust database with huge increase in flexibility and power. Designed to be adaptable, flexible, expandable, and sustainable. Asset Registry outside of the CMMS system, so CMMS software can focus on being a strong maintenance management system. All assets have a unique Asset Id that is never duplicated or used for another other asset, so maintenance history is retained as part of only the discrete asset the maintenance was actually associated with. For the treatment plant, we now have over 70 asset classes to group and store asset class specific information and specs. 3: Empower field users engagement: Field staff can complete work orders, create new work orders, access asset maintenance history and all asset attributes, and identify (in some cases, correct) data issues all while in the field. Staff have access to dynamic digital maps to help them in their work. Office staff have significantly more time to focus on maintenance operations optimizations and other responsibilities other than data entry 4: No Custom code: We want to avoid the risks associated with custom code in the CMMS. As a team policy, we do not insert custom code into the core functionality of Cityworks. If Cityworks has room to improve, we work with the Cityworks team to incorporate improved functionality in future software versions. We do not want custom functionality that our staff rely on to break after a software upgrade. Custom code is difficult to maintain or manage if the staff with those skills leaves the organization. 5: Flexible and Configurable: Modern CMMS systems prioritize configurability rather than limiting administrators by hardcoding software components such as fields or templates. Good example is work orders templates, inspection templates, and custom fields. Strong search and reporting functionality. 6: Continual version updates: Allows us to take advantage of all new functionality released by Cityworks. 7: Opportunity to develop improved workflows: New system allows us to assess our existing practices, build improvements, and establish best practices from the start. 8: Not perfect, but a huge step forward in CMMS technology for Central San: Robust program for our linear asset management and strong for our treatment plant. We are active in working with Cityworks to continue its functional and mythological improvements for our organization and others like ours.
GIS-CENTRIC ASSET MANAGEMENT
Hydraulic Capacity Model
ArcGISGeodatabases and Map Services
Portal for ArcGIS, Geocortex
• Record Drawings• Completed Permits• Easement
Documents• Asset Management
Documents
• Permitting• Accounting• Land Use
Enterprise Resource Planning
DocumentManagement
CCTV Inspection/Condition
Assessment
Asset Management
Risk ModelPrioritized Capital Plan
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The GIS is the foundation on which we’ve built the Asset Management Program since it stores the asset inventory for Central San. Central San’s geoportal (Web Portal) To find and access Geographic Information and associated Attributes (Permits, CCTV Inspections, Past Cleaning, etc.) GeoPortal, which has also been programmed to display data and documents related to assets and parcels from Laserfiche, Sungard, and the Stormwater and Pre-Treatment Program. CITYWORKS provides a robust platform which is utilized to manage maintenance work orders of treatment plant and collection system. Replace static model for the CS with a commercially available, supported, dynamic model that leverages with GIS. What are the hydraulic limitations of collection system? If we have to temperory close a sewer main for repair, what is the effect on the overall system. Infomaster is collection system only. Takes information ArcGIS, Infoworks, and Condition Scores from IT Pipes and determines which pipes needs to replaced in coming years. Capital improvement prioritization system for CS renovation planning that integrates with GIS, CMMS, CCTV, and the Hydraulic Model.
HOW IS CENTRAL SAN MANAGING ITSASSETS?
16 CHALLENGE: 1500 MILES OF COLLECTION SYSTEM REQUIRES AROBUST MAPPING & CLEANING PROGRAM TO MINIMIZE CLOGGING &
OVERFLOWS
Resolution: Asset Management Softwares (ArcGIS, Geoportal, Cityworks, IT Pipes) assist Central San staff in determining which pipe to clean it and when to clean it.
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Our community relies on over 1500 miles of underground pipes that carry from 32 MGD to over 200 MGD to the treatment plant in Martinez.
CHALLENGE: DUE TO LARGE NUMBER OF TREATMENT PLANTASSETS (MORE THAN 6,000) REQUIRES A ROBUST WORKORDERSYSTEM
Resolution: Asset Management Software (Treatment Plant Portal and Cityworks) assist Central San staff to refer to past maintenance record & perform maintenance of assets.
Sub 33
Sub 34
Sub 73
Sub 52
CHALLENGE: SOME IMPORTANT EQUIPMENT REQUIRESMORE IN-DEPTH CONDITION INSPECTION
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Resolution: Central San retained services of subject matter expert for condition assessment of these assets.
CHALLENGE: CONTINUOUS OPERATION OF ASSETS REDUCESDOWNTIME & BRINGS A CHALLENGE OF PERFORMING CONDITIONASSESSMENT OF ASSETS
Resolution: Apart from using CMMS, strong coordination among various groups helps in performing condition assessment
CHALLENGE: DUE TO SOME SPECIALTY EQUIPMENT ATCENTRAL SAN, WHICH CAN HAVE A LONG LEAD TIME, A ROBUST SPARE PARTS MANAGEMENT TOOL WAS REQUIRED
Resolution: Spare Parts Management Tool developed by Asset Management Group informs maintenance staff if spare parts are available before beginning any maintenance work
CHALLENGE: PERFORMING PREVENTIVE MAINTENANCE ON ASSETSAT TIMES REQUIRES MULTI DIVISIONS COORDINATION
Resolution: Computerized Maintenance Management System such as Cityworks assists in coordination b/w various groups
ASSET MANAGEMENT APPLICATIONSDEMONSTRATION
SCADA => CMMS
How we integrated our treatment plant’s SCADA system with our CMMS to enhance our reliability centered maintenance program
SCADA (DYNAC) representation of turbin/blower.
SCADA & CMMS INTEGRATION
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Picture 1: Aeration turbines and blower in the Pump and Blower building have instruments on them collecting various information 2: This information is sent to the PLC. For example, one bit of data the PLC collects is if the equipment is running or not, which is important for calculating an equipment’s runtime, or number of hours a piece of equipment has been operating. 3: The information is passed from the PLC to the plant SCADA system where it is used by plant operations, maintenance, and engineering staff, as well as, stored in the SCADA’s historian. The CMMS integration uses the historian tables outside the secured SCADA network, and in this example, specifically the runtime hours 4: In the Cityworks integration SQL database, a custom script runs each night accessing the runtime table in the historian tables to populate runtime hour values in our intermediate SQL table. This intermediate table has both the SCADA equipment number and the corresponding CMMS unique ID. Once the updated value is populated in the link table, the Cityworks Metrics API allows for this value to be moved into the Cityworks Asset Readings table. 5: With the new runtime hour value, the Cityworks Asset Reading module takes over. Based on a configured set of rules, Cityworks will look at the difference between the new runtime hour value and the last value for which a runtime hour work order was generated. If the difference between the two values meets or exceeds the configured value, the Asset Readings module will generate a new runtime hour Preventative Maintenance (PM) work order for our plant maintenance team. In the example shown here, we have this asset configured so that every 1000 hours that this blower is running, this specific PM is generated. 6: Here is an example of a work order generated from this process for our maintenance staff. So why is this process important? It allows us to focus our maintenance of assets based on there actual use. It reduces the potential of preforming work on an asset when it may not actually need it. Maintenance work to address wear and tear should only be done is wear and tear actually occurs, which likely does not occur when an asset is not in use. This allows our maintenance planners to focus maintenance efforts based on data and helps reduce the potential of over-maintaining and by automating this process, it saves our maintenance planner time since they are no longer charged with manually monitoring the runtime hours of our assets.
maintenance work, maintenance staff have access to all spare parts.
Secondary Benefit• Enables Warehouse
Supervisor effectively manage spare parts
• Reduces maintenance staff inquiring about parts needed for maintenance work
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TREATMENT PLANT SPARE PARTS TOOL
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Background: the Plant’s previous CMMS system (Mainsaver) had a module for associating/tracking spare parts for the assets it managed. Cityworks (our new CMMS for Plant and Collection System) does not have this vital functionality. The Asset Management group developed a tool to provide this missing functionality. We cleaned up and imported the previous spare parts information from Mainsaver, and have been working with the Warehouse and Maintenance Planners to refine the existing lists and add additional lists for newer assets.
