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How Proactive or Reactive to Be?Getting Ahead of the Curve on Preventive MaintenanceJESSICA BROWN, P.E., FREESE AND NICHOLS, INC.SALLY MILLS-WRIGHT, CITY OF ARLINGTON
BILL GASE, CITY OF ARLINGTON
MAZEN KAWASMI, P.E., CFM GISP FREESE AND NICHOLS, INC.
Agenda
• Background on Arlington’s Water System• Preventive Maintenance Survey Background• Preventive Maintenance Survey Results• Preventive Maintenance Best Practices and
Recommendations– PMs for Pumps, Valves and Pipelines– Testing Frequencies for Pumps, Motors, and Meters– Types of Pump and Meter Testing– Water lines and Valves
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Agenda
• Background on Arlington’s Water System• Preventive Maintenance Survey Background• Preventive Maintenance Survey Results• Preventive Maintenance Best Practices and
Recommendations– PMs for Pumps, Valves and Pipelines– Testing Frequencies for Pumps, Motors, and Meters– Types of Pump and Meter Testing– Water lines and Valves
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Background on City of Arlington’s Water System
• 1,565 miles of Treated Water Piping, from 1” to 54”
• 2 Water Treatment Plants• Pierce-Burch WTP (75 MGD)
• John F. Kubala WTP (97.5 MGD)
• 4 Pressure Planes
• Served population of 378,000
Entertainment Capital of Texas:Home of Dallas Cowboys,
Texas Rangers & Six Flags over Texas
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Agenda
• Background on Arlington’s Water System• Preventive Maintenance Survey Background• Preventive Maintenance Survey Results• Preventive Maintenance Best Practices and
Recommendations– PMs for Pumps, Valves and Pipelines– Testing Frequencies for Pumps, Motors, and Meters– Types of Pump and Meter Testing– Water lines and Valves
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Preventive MaintenanceSurvey Background
• Survey consisted of 57 questions targeting specific topics based on input from Treatment staff. – Utility Background– Staffing– CMMS– Pump Station PMs– Electrical PMs– Established PM schedules for clearwell, waterlines, and valves– Valve exercise program within WTP
• Hosted on SurveyMonkey.com • Invited 15 water utilities to take survey• 11 utilities completed survey
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Preventive MaintenanceSurvey Background
• Received responses from:– Denver Water Department– Seattle Public Utilities– Tacoma Water– Portland Water Bureau– Metropolitan Sewer District of Greater Cincinnati– Lincoln Water System– Columbus Department of Public Utilities– Las Vegas Valley Water District– St. Johns County Utilities Department– Raleigh Public Utilities Department – Tulsa Water
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Agenda
• Background on Arlington’s Water System• Preventive Maintenance Survey Background• Preventive Maintenance Survey Results• Preventive Maintenance Best Practices and
Recommendations– PMs for Pumps, Valves and Pipelines– Testing Frequencies for Pumps, Motors, and Meters– Types of Pump and Meter Testing– Water Lines and Valves
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Preventive Maintenance Survey Results:Utility Background
Wholesale& Retail
Retail Only
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• 25% do Vibration, Thermal, and Efficiency Test on pumps
• 50% don’t have a PM to restore pumps to Original Equipment Manufacturer (OEM) condition
Preventive Maintenance Survey Results:Pumps
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Preventive Maintenance Survey Results:Pumps (Continued)
• 50% have a PM to inspect pump components.
• Of those, 2 have annual inspections, and 3 inspect as needed.
• Criticality• Historical Performance• Manufacturer Specs 11
Preventive Maintenance Survey Results:Electrical Staff
• Large Pump Repair• HVAC 12
Preventive Maintenance Survey Results:Electrical• 75% have a PM to inspect
electrical components.• Of those, 6 have annual
inspections, and 3 inspect as needed.
• Majority of Electrical PMs are done by Utility Staff
• Every 2 years• Manufacturer Specs• Varies based on Criticality
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• Majority have a PM to inspect pump station electrical components.
• Of those, the majority have annual inspections.
• Manufacturer Specs
Preventive Maintenance Survey Results:Electrical (Continued)
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Preventive Maintenance Survey Results:Water Lines & Valves
• Majority have a water line rehabilitation program.• Survey group was split on taking coupons to
assess the condition of water lines.
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Preventive Maintenance Survey Results:Water Lines & Valves
• Majority don’t have a valve rehabilitation program.
• 50% have a valve exercising program at water treatment plant
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Agenda
• Background on Arlington’s Water System• Preventive Maintenance Survey Background• Preventive Maintenance Survey Results• Preventive Maintenance Best Practices and
Recommendations– PMs for Pumps, Valves and Pipelines– Testing Frequencies for Pumps, Motors, and Meters– Types of Pump and Meter Testing– Water Lines and Valves
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Three Categories of Maintenance Activities
• Reactive Maintenance– Higher risk for near term savings– Appropriate for less critical assets
• Preventive Maintenance (PM)– Regularly scheduled activities to extend asset life
• Predictive Maintenance (PdM)– Detecting problems before affecting performance– Maintenance activity based on need vs. schedule
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Maintenance for Pump Stations
Regular daily operational checks• Flow and pressure in “normal” range• Valve functionality• Leaks• Abnormal noise, vibration, heat, etc.• Clear dust and dirt• Other simple visual checks
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Preventive Maintenance Best Practices: Pumps
ActivityRecommended
Frequency*Arlington’s
ImplementationCheck bearing lubrication meets OEM specification Monthly Monthly
Check packing for wear Monthly Monthly
Start up and run every pump Monthly Monthly
Inspect bearings and impellers Every 3 Years Every 4 Years after initial PM
service
Perform field and vibration tests Yearly Yearly
Perform oil analysis Yearly Yearly
Conduct performance trending based on historical field, vibration, and oil test
Yearly Yearly
* Service at calendar time or OEM specified run time interval, whichever comes first20
Preventive Maintenance Best Practices: Motors
ActivityRecommended
FrequencyArlington’s
ImplementationCheck bearing lubrication meets OEM
specification Monthly Monthly
Check alignment and mounting Monthly Monthly
Check electrical connection terminals Monthly Monthly
Clean motor Monthly -
Visually inspect bearings Yearly -
Perform temperature and vibration tests Yearly Yearly
Check power supply condition Yearly Yearly
Perform infrared (IR) thermography analysis Yearly Yearly
Conduct performance trending based on historical temperature, vibration, and IR test Yearly Yearly
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Preventive Maintenance Best Practices: Pipelines and Valves
ActivityRecommended
FrequencyArlington’s
ImplementationPipeline leak detection Every 5 years or based on
performance trendsEvery 5 years
Pipeline condition analysis Prioritized based on the RBA Every 5 years based on condition analysis (Pure
Technologies)
Inspect isolation valves: verify location, accessibility,
operational status*
Yearly Yearly
Inspect pump control valveand actuator system (motor
operators, gearboxes, hydraulic accumulators, etc)
Yearly Yearly
Inspect critical air valves on raw water pipelines and high
service pipelines
Yearly Yearly
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Preventive Maintenance Best Practices:Electrical & Instrumentation
ActivityRecommended
FrequencyArlington’s
ImplementationVisual inspection of low and medium voltage
electrical equipment3 months Quarterly
Exercise circuit breakers, switches, etc. 6 months N/A
Infrared inspection on all major electrical equipment.
Yearly Yearly
Perform dissolved gas analysis on liquid filled transformers
Yearly Analyzingrecommendation
Calibrate pressure, level, and temperature transmitters
Yearly Calibrate as needed if problems arise.
Perform testing/ maintenance of low and medium voltage electrical equipment
3 YearsEvery 2 years per
NETA standardTest solid state protective relays 3 Years
Test major transformers 3 Years Inspect for Oncor
Update Arc Flash Study 5 Years/after major modifications
As needed
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Preventive Maintenance Best Practices:Meters
ActivityRecommended
FrequencyArlington’s
ImplementationCheck instrument settings regularly Monthly As needed
Calibrate pressure instruments on venturi meters
Yearly Yearly
Calibrate ultra-sonic and magnetic meters (limited)
Yearly Certified annually
Inspect meter vaults for standing water or structural issues
3 months Quarterly
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Implementation of Recommendations from Asset Management Plan
Completed Projects• Electrical upgrade on High Service pumps• Electrical upgrade at the Raw Water Pump Station• Performance of a comprehensive condition assessment for various
water lines• Replacement of Raw Water High Service Pump #4
Short Term Projects• Rehabilitation/replacement of Raw Water High Service Pump #5• Clearwells #1, 2 and 3 rehabilitation• High Service Pump #1 (PED) under evaluation for rehabilitation
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Additional Benefits Realized by the City
• Condition assessment of PB North WTP determined it needed to be decommissioned.
• Experience less incidents of mistakes utilizing GIS maps developed through the project.
• This effort highlighted the need for dedicated maintenance staff and placed higher urgency on filling vacancies.
• This effort highlighted some skill sets and helped identify training needed for the City to incorporate some of these practices in-house.
• This effort provided justification for developing on-going service agreements to ensure this work was provided in a timely fashion.
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Questions?
Contact Information:
Jessica Brown, [email protected](817) 735-7406
4055 International Plaza, Suite 200Fort Worth, TX 76109
Sally U. [email protected]
(817) 575-5972John F. Kubala Water Treatment
Plant7001 US Hwy. 287
Arlington, TX 76001