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| 75.01 | General Overview |
| 75.02 | Maintenance Methodology |
| 75.03 | Equipment Information |
| 75.04 | Parts Inventory |
| 75.05 | Documentation / Records |
| 75.06 | Figures |
Maintenance Management is the comprehensive organization of tasks, expenditures, data recording and client services required to maintain or improve the Marine Park Water Reclamation Facility (MPWRF). The primary purpose of the Maintenance Management strategies at MPWRF is to support and assure that all equipment and systems required for processes are operating at as close to optimum conditions as possible. This ensures that process control personnel have the maximum complement of tools at their disposal.
The maintenance procedures utilized at the MPWRF include Corrective Maintenance (CM), Preventive Maintenance (PM), and Predictive Maintenance (PdM). Each method requires skilled individuals to perform tasks that are scheduled through the use of a Computerized Maintenance Management System (CMMS). Each task is associated with scheduling regardless of the method, with the only exception being emergency repairs, which are made on an unscheduled basis and then documented after process conditions are stabilized or restored.
Corrective Maintenance is sometimes referred to as "Unscheduled Maintenance". Corrective Maintenance procedures are defined as any needed repair that requires:
Through these criteria, the CMMS is provided with the necessary data to create accurate material histories. All corrective maintenance is prioritized to assure that maintenance management schedules available man-hours towards accomplishing critical repairs. Supervisory personnel always confirm the evaluation of priority.
Priorities are assessed under the following criteria:
Level 1 - Emergency Repair - Documentation follows.
Preventive Maintenance (PM) is an applied program, which assures that equipment is serviced on a regular, and scheduled basis for the replacement of wear parts, lubricants, cleaning, and other repeated tasks that are designed to extend the serviceable life of equipment. The performance of PM is organized to reduce the effects of constant wear and exposure of equipment through normal operating conditions by optimizing the physical environment in which it exists.
Preventive Maintenance tasks are defined by determining the following:
These tasks are created through analysis of the manufacturer's recommendations and requirements as the minimum performance criteria. These tasks are the basic beginning of any properly constructed program. It is essential for new equipment to be maintained by application of these tasks to assure that warranty issues are supported to the benefit of the owner of the equipment or system. Supervisory personnel should enhance the minimum manufacturers required tasks by adding tasks or scope to the basic complement of activities. In this way, the PM program maintains a dynamic evolution, which provides an opportunity for all persons associated with the program to learn from the experience of maintaining similar equipment. PM tasks are also combined for dissimilar Crafts and Frequencies into coherent combinations referred to as "GROUPS".
These PM groups then can be assigned to multiple pieces of equipment. Through the assigning of a group, the CMMS will produce an instruction for maintenance personnel to perform the predetermined tasks (See PM Schedule).
PM tasks are scheduled by the evaluation of the SCHEDULE parameter. The schedule is an identification to the system of a unique code, which determines when the various frequencies are applied to the calendar. This evaluation determines when the tasks are evaluated by the CMMS as "DUE" which in turns provides a hard copy printout of the tasks with this status. In this manner, equipment that has the same group, tasks, and even crafts, can be scheduled individually. This provides management personnel with a versatile manpower-balancing tool.
Predictive Maintenance (PdM) is an extension, and at times a parallel program to Preventive Maintenance. Unlike PM programs, PdM requires the performance of many different analytical procedures where the condition of the equipment is specified as accurately as possible. The procedures are repeated periodically through scheduling (see 75.02.b.1.) and compared with previous conditional values. The goal for PdM programs is not to eliminate wear on the equipment, as this is not possible, but to determine how well the PM procedures are working, and to pre-alarm a potential for failure or breakdown of equipment. The detection of deterioration is a powerful tool for maintenance management decisions regarding equipment repair and replacement when the procedure will affect process routines and capabilities. Key technologies for PdM program include, but are not limited to:
Through these and other techniques, and as scheduled by CMMS, the maintenance program is enhanced.
Maintenance management at Vancouver is based upon the creation of relational databases and files that are primarily structured around equipment numbers. The assignment of equipment numbers is based upon the Location Code that is an arbitrary value for each major process area. The Location Code that is used is related to an Influent to Effluent ascending order where each major area is assigned a contiguous group of numbers. The use of this system does not preclude the assigning of specific Location Codes, but does provide a specific value by which plant personnel can readily assess the general area of any piece of equipment when the equipment number is known. The other key data points for each piece of equipment:
Each piece of equipment is considered a single number and associated equipment and peripherals are normally not specifically identified. Major pieces of equipment that effects other equipment with specific maintenance needs are uniquely identified. A typical example is an Adjustable Speed Pump:
With this identifier, inventory, critical spare parts, nameplate information, vendor references, and all maintenance activities are referenced back to the equipment number. This also applies to hard copy filing structures for the permanent recording of the performance of Corrective, Preventive, and Predictive Maintenance. Although some files are arranged by Location, files are immediately sub-sorted by the value of the equipment number.
Equipment and system components that are critical to process permit compliance, or are potentially prohibitively expensive to the City of Vancouver, are assessed "CRITICAL" status. This is denoted in the CMMS as "CRIT" in the Equipment Code field. Critical status is granted to equipment for the following reasons:
If the equipment is granted Critical status, the equipment will require inventory of spare parts, as well as not greater than 24 hour replacement with equivalent equipment should equipment be deemed unrepairable.
Nameplate information is a very critical to the proper maintenance of equipment. Nameplate information references the following information, as a minimum:
Manufacturers and Vendors are also added to miscellaneous information not found on the nameplate. This information is specifically recorded to provide all the information necessary for expeditious repairs.
Historical data is the accumulated and summarized values and specifics for the work that has been performed on this equipment. The most significant history is the Corrective Maintenance records for a piece of equipment. The accumulation of data relevant to past expenditures and repairs is used to project budget values for the next fiscal period, evaluation of repair versus purchase costs. Additional analysis can be used to provide various engineering entities operational cost data when considering similar equipment for new construction or upgrades. Minimum requirements for CMMS are for the retention of all CM on hard copy, and the previous two years and the current year on the active CMMS platform.
PM data is also recorded for the purpose of documenting the maintenance of the equipment to a predefined schedule. This is used to cross- reference to the historical records for corrective procedures. Cross-reference analysis can provide valuable information in determining the cause of prohibitive or questionable accumulations of cost. The retention of PM performance data is usually not kept in the active system past two years. Requirements for CMMS are for the retention of all PM on hard copy, and the previous and current year on the active CMMS platform.
PDM data is also stored whenever possible in database, spreadsheet, or vendor provided predictive software. The data contained for the PdM procedures can be accessed whenever detail of the running or operating condition is relevant. The capability of accessing PdM data in graphical formats or other forms of visual presentations, can be an advantage when the data needs to be explained to persons who may not have knowledge of the instrument that acquired the data.
Historical data can be accessed by the CMMS by various sort orders and can be used to isolate specific equipment or globally list equipment that fulfills a specific set of criteria. The significance of the use of the CMMS is the speed and organization of a preponderance of data. The use of the hard copy as the primary record is for back up to electronic storage, where the electronic media is for data retrieval speed and organization of the requested data.
Parts inventory have been establish using a standardized coding / tagging protocol that allows for ease of reference while searching using the CMMS inventory control module. Grouping spare parts into common types also enhances physical location. Electrical, plumbing, bearings, belts, etc. are generally grouped together and are tagged with the CMMS inventory part number. Included in the CMMS is a location reference that tells what site, build, storage room, storage shelf, and specific shelf location where the item is located. When needed spare parts are shared between the two WWRF sites. Each site currently has it's own copy of the CMMS, a recent purchase of networked software will allow both sites to view the spare part inventory at all sites. Though the sharing of spares at both sites is not uncommon, the software will allow us to expedite locating of spares through the networked software between the two sites. Upon the completion of a job the spare parts used are entered into the CMMS. Inventory levels are compared and if they fall below a predetermined set point a requisition is generated to order the additional parts to bring inventory levels back to proper levels.
The following records and files are maintained and located at the Westside Facility. This information should be addressed for specific needs at the MPWRF. Additional listings for various equipment codes are provided for all facilities and are located in the maintenance and/or operations area for ease of reference.
Documents maintained and available include:
Figures 75.01 and 75.02 provide samples of the Preventive Maintenance Task Listing and the Preventive Maintenance Schedule. The full listings are maintained on site and in the plant maintenance files.
75.02. Maintenance Methodology
75.02.a. Corrective Maintenance
Level 2 - Repair as soon as possible. Scheduled ahead of PM Tasks.
Level 3 - Routine Repair - Scheduled as resources allow. PM tasks take precedent.
Level 4 - Long term or schedule when convenient repair.
Level P- Project Work Order. Work may continue for undetermined period.
75.02.b. Preventive Maintenance
75.02.b.1. PM Schedule
75.02.c. Predictive Maintenance
75.03. Equipment Information
75.03.a. Critical Equipment
75.03.b. Nameplate Information
75.03.c. Historical Conditions
75.04. Parts Inventory
75.05. Documentation / Records
75.06 Figures
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