ocsd predictive maintenance program - cwea
TRANSCRIPT
Santiago Escobar & Adam Newsom
Predictive Maintenance Team Orange County Sanitation District
Fountain Valley, CA
OCSD Predictive Maintenance Program
Orange County Sanitation District Facilities in
Southern California
Reclamation Plant No. 1
Fountain Valley Treatment Plant No. 2
Huntington Beach
Los Angeles
San Diego
OCSD Service Area 471 square miles
221 million gallons per day
2.5 million population
21 cities, 3 special districts
2 treatment plants
15 pump stations
Orange
County
OCSD PdM History
• 2002 – Baseline Vibration Monitoring with
consultant assistance
• October 2006 – Comprehensive Vibration Analysis
Program Implementation
– Both treatment plants and our 15 pump stations
– Predictive Maintenance Team – Engineer, 4 Predictive
Maintenance Technicians
Program Strategy
• Trained Predictive Maintenance personnel on
PM / PdM Best Practices
• OCSD Predictive Maintenance Program self
assessment performed in 2007
• Continuous improvement based on annual
assessment results
Mission Statement
“Effective implementation of Predictive
Maintenance technologies to provide
reliable process equipment by having
the ability to plan maintenance and repair
activities, and by reducing treatment
process interruptions and overall
maintenance costs”
Program Key Elements
• Training Program for Predictive Maintenance Team
• Equipment Criticality and Coverage
• Program Procedures and Standards
• Predictive Maintenance Process
• Root cause analysis
• PM optimization
• Solid Communication Strategy
• PdM reliability metrics and benchmarks
• PdM cost-benefit and return on investment
Personnel Qualifications & Training
In-House Vibration Analysis
• Train qualified technicians in Vibration analysis
• Hands-on training on laser alignment for direct and belt
driven machines without impacting the plant process
• equipment
• Vibration Trending, Analysis and Report Writing
Procedure, OCSD 2008.
• Laser Shaft Alignment Procedure, OCSD 2009
• Condition Monitoring and Diagnostics of Machines –
Requirements for Training and Certification of
Personnel – Part 2: Vibration Condition Monitoring
and Diagnostics – ISO 18436-2, 2003
Procedures and Standards
Predictive Maintenance Process
Root Cause Analysis
• Identifies lasting improvements
• Avoids recurring adverse events
PM Optimization Rotating Machinery
Asset
Type
Current PM
Man-hours
Recommended PM
Man-hours
PdM VA/OA
Man-hours
Annual Impact
Man-hours
Pumps 5127 1578 1734 1815
Fans 2320 662 312 1346
Others 1217 531 392 294
TOTAL 8664 2771 2438 3455
Based on this study 3,455 man-hours can be
reassigned to other needed areas every fiscal year.
Representing savings for $172,750 (man-hour @ $50)
annually.
Solid Communication Strategy
• Monthly Predictive Maintenance reports: Plant 1, Plant 2
and Pump Stations
• Quarterly Update report
• Annual Predictive Maintenance Reports
• Detailed Diagnostic Reports
• Formal internal presentations to promote program
effectiveness (findings, case histories and documented
savings)
Solid Communication Strategy
Program Reliability Metrics & Benchmarks FY07-11
Return on Investment (ROI) FY07-11
Predictive Maintenance Program
Master Plan FY12-15
Comprehensive PdM program Implementation
Projected Return on Investment (ROI) FY12-15
PdM Initiatives – Vibration Analysis
PdM Initiatives – PMT Truck
READY TO GO !!!
Vibration Analyzer
Strobe Light
Ultrasound Kit
Thermal Imager
Accelerometers, Cables, Tachometer, etc.
PdM Initiatives – Oil Analysis
Oil Analysis
Oil Analysis program implemented at OCSD
Oil sampling and analysis of all types of oil shipped to OCSD
Oil Analysis routes for critical equipments at Plant 1 and 2
Oil Sampling Techniques
Gas Compressors
Turblex Blowers
100% of High critical assets with oil sample ports
Machines running under normal operating
conditions
Sampling on return line zone
Safe to conduct oil sampling up to 50 psi
PdM Initiatives – Lubrication Program
Storage / Handling
Containers are properly labeled
Lubricant facility well organized
and clean
Lubrication Practices
Ultrasound grease guns
Clear grease container
PdM Initiatives – Lubrication Program
Lubricant storage facility is well
designed and organized
New oil pre-filtration system
using 10 micron filters
Oil containers and drums labeled
(numbers) based on type of
lubricant
Installed desiccant breathers on
oil containers and drums
Reference oil samples are taken
before each tote is replenished to
ensure the additive packages are
still within the specified range
and to avoid mislabeling of
vender supplied oil.
PdM Initiatives – Thermography
• Acquisition of several thermal imagers for reliability and
maintenance personnel
• Thermal images support vibration readings for machinery
troubleshooting
Precision Maintenance Initiatives – Laser Alignment
• Acquisition of two laser alignment systems for Plant 1 and 2
• Laser alignment procedure in place
• The primary objective of accurate alignment is to increase the operating
life span of rotating machinery.
Questions???
Santiago Escobar
Adam Newsom