Best Maintenance Reliability Programs 2014

he goal of the Metropolitan Sewer District of Greater Cincinnati (MSDGC) was to build a sustainable low cost in-house Asset Condition Monitoring (ACM) Program keeping in line with the overall business goal of “Providing reliable sustainable

infrastructure and high-quality, cost-effective utility services for collection and treatment of wastewater and storm water”.

With this in mind MSDGC built a two-tiered ACM program consisting of a Centralized predictive maintenance (PdM) team

with sophisticated tools and decentralized teams with affordable technologies. A PdM vendor and a subject matter expert

provided training and support to get the program up and running.

The centralized ACM team employs ACM hardware and computer software for Vibration, IR, Ultrasound and MCA\

MCE that is fully functional and capable of detailed diagnostic analysis leading to accurate identification of

defects, affected parts and evolving conditions. This allows more precise repair planning which in turn

reduces life cycle repair costs, decreases downtime for operations and shortens active repair time for

maintenance, and ultimately minimizes required capital investments by deferring expansion

projects by increasing asset useful life. ACM Team members are trained and certified to collection data and perform advanced. This capability provides MSDGC WWT with ability to anticipate critical repairs with a high level of confidence, minimizing expensive plant outages or permit violations. This allows the scheduling and completion of economically efficient repairs at times determined by personnel - not the equipment.

The decentralized portion of the ACM program employs maintenance crew members at WWT plants equipped with low cost, easy-to-learn and easy-to-use Vibration, Ultrasonic and Infrared thermography instruments. These

instruments have proven useful in a wide variety of applications in confirming the

presence or absence of defects and are relied upon to quickly confirm whether or not a repair has been completed satisfactorily, allowing for timely return of equipment to service

The ACM Program is sustained through a five year master plan that establishes the training, communication, budgets and processes used by the two-tiered approach. The plan is a living document used to sustain performance throughout each fiscal year and make further progress using an annual auditing/planning exercise. One key communication item contained in the plan, the Find of the Week email, supports a culture of proactive effort and focus on value by sharing maintenance successes and cost avoidance on a monthly basis. The ACM program also tracks and communicates the overall return on investment of asset condition monitoring activities. To date, MSDGC has seen a total cost avoidance of $961,131. This significant savings provides a compelling business case to upper management for continued program support.

In two years, MSDGC has moved from external ACM services to an effective internal ACM program that delivers results. With the two-tiered approach, a sustainable master planning process and consistent demonstration of added value, the ACM program is a key element of MSDGC’s success and an opportunity to continue achieving increased benefits in the future.Best

Asset

Condition

Management

Program

Metropolitan Sewer District of Greater Cincinnati

T

CMMS Software and Predictive Maintenance

Instruments/SoftwareEmerson CSI 2130 Data Collectors• Emerson AMS Machinery Health

Manager• UltraTrend DMS5 and UE

Spectralyzer• UE Grease Caddy• SKF Surveyor Explorer AC 3.02.1• MCEGold 2.5.1• Flir Tools• BICycle for reliability analysis and

KPI Measures• 24/7 Tango software for PDMMS

Routes\Data Correlation• Maximo 7.5• ThinkReliability for RCA

PdM Equipment is as follows:

1. Vibration, Csi 21302. Online Motor Testing, SKF Baker

Explorer 30003. Offline Motor Testing, PdMA MCE

Max4. Infrared, Flir E40 and the Fluke Ti 605. Ludeca Optalign Smart6. UE 10,000 Ultrasonic