Fundamentals of Asset Management
Step 10. Build Asset Management Plan
A Hands-On Approach
Toms bad day
Fundamentals of Asset Management
AM plan 10-step process
Develop
Asset
Registry
Assess
Condition,
Failure Modes
Determine
Residual
Life
Determine
Live Cycle &
Replacement
Costs
Set Target
Levels of
Service (LOS)
Determine
Business Risk
(Criticality)
Optimize
O&M
Investment
Optimize
Capital
Investment
Determine
Funding
Strategy
Build AM
Plan
Asset Mgmt Plan;
Policies and
Strategy;
Annual Budget
Fundamentals of Asset Management
Recall View 4: Management framework
Asset Management
Business Processes
Asset Management
Plans
Strategic Initiatives
Annual Budgets
Operating Budget
Fundamentals of Asset Management
Capital Budget
Asset decision framework
Big picture
z Whole portfolio
perspective
Trends
Macro forces
z
z
Micro view
z Event based
z Specific asset focus
z Case-by-case decision
points
Policy framework
Budget arena
Repair? Refurbish? Replace? Augment?
Fundamentals of Asset Management
Toms Jones Street asset management plan: Key
points
z
State of the facility
Required LOS
Facility is well into mature stage of life cycle
Most imminent major failure modecapacity
Assume two years before peak design flow is
exceededgrowth
Additional capacity can not be feasibly added
Stop SSOs
Meet Whispering Oaks flow requirements
O&M/CIP investment strategies
Keep lift station running for two years, then decommission
All replacement equipment sized for reuse in new lift station
Move to predictive maintenance (monitor intervals) for dynamic
(mechanical/electrical) equipment based on root cause
Run to failure with effective reactive response plan for rest
Assure that reactive response plan provides for continuous functioning
(bypass/supplemental power/supplemental pump)
Fundamentals of Asset Management
Steps in developing your AMP
1. Existing levels of service (LOS)
2.
Assess existing assets
3.
Physical details
Condition/remaining life
Performance
Capacity (current, ultimate)
Predict demand, LOS
4.
Regulatory
Customer-related
Internal operations
Capacity, demands
Levels of service
Performance risk
Predict failure mode
Capacity (due to growth)
LOS
Mortality
Efficiency
Fundamentals of Asset Management
Steps in developing your AMP, cont.
5.
Predict capital program
6.
Predict O&M
7.
Growth (additional flows)
New assets LOS
Age of overall portfolio
Predict future expend. model
8.
Growth, augmentation
Renewal, reliability
New LOS
Business efficiency
Capital, debt service
Operations
Maintenance
Administration
Predict future income model
Rates
Charges
Other sources
Total
Fundamentals of Asset Management
Steps in developing your AMP, cont.
9.
Ask: Are customers
willing to pay?
Yes
10. Execute
No
11. Review program options (reduce cost)
Reduce LOS
Dispose of under-utilized and under-performing assets
Manage demand for service (pricing, regulation)
Alter maintenance or operations
Accept higher residual risk
Rationalize project work in order of risk
Fundamentals of Asset Management
12. Return to 1;
revise AMP
items as
necessary
The Enterprise Asset Management Plan
Executive
Summary
State of the Assets
Section - 1
Levels of Service
Section - 2
Growth & Demand
Section - 3
Lifecycle Management
Section - 4
Renewal
O&M
Management
Strategies
Section - 6
Risk Profile
Section - 5
Augmentation
Financial Planning
Section - 7
Business Improvement Plan
Section - 8
Fundamentals of Asset Management
10
The Enterprise Asset Management Plan
Fundamentals of Asset Management
11
The Enterprise Asset Management Planasset
system summary
2. Demand Profile and Performance
A total of six influent trunk lines bring influent into the metering and diversion
structure at Plant No. 1. This structure contains magnetic flow meters, pH
meters and electro-conductivity meters along with gates that can be raised or
lowered to move flows from one trunk-line to another as necessary. A portion
of the influent can also be diverted to Plant No. 2 through an interplant pipeline
to regulate flow into Plant No. 1.
Hydrogen Peroxide
Max. Pressure 150 psi
Sunflower Pump Station
30 MGD duty
30 MGD standby?
Headworks No. 1
30 MGD duty
Main Sewage Pumps
Screening Station (Bar screens)
Flow from the Metering and Diversion Structure is routed to the influent
channel for the mechanically-cleaned bar screens at Headworks #2. There are
four individual bar screen channels containing automatically cleaned screens.
Two of the screens are operated and the other two are standby. The structure
contains space to accommodate two additional screens in the future.
Grit System (Grit Removal)
There are five aerated grit removal chambers at Headworks #2 and two at
Headworks #1 that are standby. The purpose of these is to remove inorganic
solids that are present in the wastewater. The removal of this grit helps
prevent clogging in pipes, protects mechanical equipment, and reduces the
amount of material that collects in the sludge digesters. Each grit chamber
contains four grit collection hoppers. Grit is removed from the chambers using
telescoping valves that continuously discharge grit slurry by gravity to
classifiers. Grit from the classifiers discharged to the conveyor belt carrying
screens normally or to a separate grit bin for off-site disposal. Flow from the
Headworks #2 grit removal chambers is collected in an effluent channel that
discharges to the Primary Influent Distribution Structure (Splitter Box).
30 MGD duty
30 MGD standby
Headworks #1
10B
Grit Removal
2 chambers
Headworks #2
10C
Headworks No. 2
210 MGD duty
Main Sewage Pumps
280 MGD duty
70 MGD standby
4. Key Issues for Further Investigation
Bar Screens
4 units (+allowance for 2
units to be constructed)
234 MGD max
1 unit standby
General
Grit System
Grit Chambers
Grit Washers
Grit Storage Capacity
Odor Control Facilities
(Bleach)
3 @ 24000 cfm duty
1 @ 24,000 cfm standby
Feed Pumps
3 @ 11.3 gph duty
1 @ 20 gph standby
Recirculation Pumps
4 @ 600-700 gpm duty
4 @ 600-700 gpm
standby
Muriatic Acid Scrubbing
Cleaning Pumps
1 @ 30 gpm duty
1 @ 30 gpm standby
Trunk Line Scrubbers
1 * Caustic
1 * Biotower
24,000 CFM duty
24,000 CFM standby
Ferric Chloride
Feed Pump
3 @ 200 gph duty
1 @ 200 gph standby
Splitter Box
4 duty (See 10H-120,
Pump information)
4 standby pumps
Flowrate Capacity 85
gpm
Pressure 116 psi
Max. Flowrate Capacity
325 gpd
Max. Pressure 150 psi
Support Generators
Power Rating 1000 KW
Scrubbers Headworks
2 on trunk lines
Fundamentals of Asset Management
P1-105 - Headworks Rehabilitation and Expansion at Plant No. 1
identified for repair and upgrade. The bulk of the project includes
upgrades to existing bar screens, an additional bar screen, a screenings
compressor, improvements to the grit removal facilities, improvements to
the power distribution system including three new larger emergency
generators, and miscellaneous process, mechanical, structural and I&C
upgrades.
This project is in keeping with industry practices as required for reliable
and dependable plant operations. The capital budget identified on this
sheet is based on the non-critical items necessary to ensure the facility
failures. Proper operation of the meters is important because treatment
costs are allocated to the various revenue areas based on influent meter
readings.
Headworks No. 1
2 days
Design & Construction
infrastructure within the Plant 1 Headworks facility, to ensure that the
facility continues to be operational. Several studies have been conducted
on the Headworks facility and a number of non-critical items have been
Concerns about the reliability and accuracy of meters exist due to meter
Hydraulic 1800 gpm
Overflow Rate 12,000
gpd/ft2
1 duty and 1 standby
TBA
This project rehabilitates and refurbishes process equipment and
Project I-10 to increase flow to Plant 1 by 40 MG/D
87 MGD duty
25 MGD standby
5 tanks
2 tanks standby
325 MGD
Hydrogen Peroxide
Headworks
Planning
Metering & Diversion Structure
Splitter Box
Splitter Box
The splitter structure discharges to the Primary Clarifier Basin # 1 to 5 through
a 72 inch-diameter pipeline and/or to the rectangular PCB # 6 to 15 through
two 90 inch-diameter pipelines. Splitting is accomplished using the sluice
gates.
Rating
10A
Main Sewage Pumps
After passing through the Headworks #2 bar screens, wastewater flows into the
Influent Pump Station wet well. The Influent Pump Station lifts screened
wastewater to the influent channel serving the grit removal chambers. There
are four 70 mgd variable speed pumps at Headworks #2 and two 30 mgd
constant speed pump at Headworks #1, which services as stand by pumps. A
sluice gate in this wet well can be opened to allow screened wastewater to flow
to the Headworks #1 Influent Pump Station wet well if required allowing the wet
wells at Headworks #2 and Headworks #1 to act as one large wet well under
extreme wet weather conditions.
TBA
Area
Metering & Diversion
Structure
Headworks #1 & #2
There are two Headworks at Plant 1, which have a total rated pump capacity of
210 mgd with 130 mgd of stand by. Headworks #2 can be increased by
another 70 mgd in the future by addition of another pump. It has two support
generation units with a power rating of 1000 KW. Headworks #2 is the newest
and is the operated system and Headworks #1 is the standby system. Three
key processes for Headworks are bar screens, influent pumps, and grit
removal.
Process
Efficiency
Max. Flowrate 490 MGD
Study
Reliability
Metering & Diversion Structure
Actual
Performance
5. Current Program
Failure Summary
Function
Sub System(s)
Design Capacity
(Min, max, peak and/or
average)
Table 2
Capacity
System
Metering & Diversion Structure
3. Failure Mode
Peak, Average and Standby Design Capacities
Table 1
Condition
1. Asset Profile
continues to function and conforms to the ultimate layout of the facility.
The FY 2004/05 budgets for P1-71 and P1-105 have been reallocated
after further evaluation of critical and non-critical work. P1-105 will
address increases in the facilities capacity to meet expected increases in
wastewater flow projected in the 2001 Interim Strategic Plan Update.
P1-71 - Headworks Rehabilitation/Refurbishment
Questions have been raised as to the ability of the headworks to operate
The scope of work consists of rehabilitating and refurbishing the VFDs for
properly under emergency conditions.
the main sewage pumps and the cable trays and wiring from the VFDs to
the pumps. An evaluation of the pumping capacity of Headworks No. 2 at
Headworks No. 2
Plant 1 conducted in 2001. Capacity issues will not be addressed through
this project as capacity upgrades are being handled through a separate
project (Ellis Avenue). There are other potential tasks items for this project
Grit Chamber No. 2 is out of service.
which includes: a grit characterization study based on a computer model,
gate operators, and installation of ventilation in Headworks 1 to meet
NFPA 820. Other tasks that were previously part of this project have been
6. Investment Program
moved to Job No. P1-105.
Table 3
Insufficient
performance
5-Year Summary
Investment
(thous.)
Total
Projected
Budget
Cost
to
date
200506
200607
200708
2008
-09
P1-105
4,920
240
393
320
3,430
537
Total
4,920
240
393
320
3,430
537
This project is in keeping with industry practices as required for reliable
and dependable plant operations. These reliability of these VFDs must be
restored by late 2008 such that Plant 1 may reliably accept diverted flow
from Plant 2 during Plant 2 Headworks changeover.
P1-104 Regional FOG Control Collection at Plant 1
J71-8 Headwork Scrubbing Replacement
Table 4
O&M Cost Summary
Management Strategies
Cost (thous.)
200203
2003
-04
2004
-05
Maintenance
208
Operations
1108
2005
-06
2006
-07
TBA
12
Detail, left page
1. Asset Profile
2. Demand Profile and Performance
Peak, Average and Standby D
Table 1
System
Metering & Diversion Structure
A total of six influent trunk lines bring influent into the metering and diversion
structure at Plant No. 1. This structure contains magnetic flow meters, pH
meters and electro-conductivity meters along with gates that can be raised or
lowered to move flows from one trunk-line to another as necessary. A portion
of the influent can also be diverted to Plant No. 2 through an interplant pipeline
to regulate flow into Plant No. 1.
Fundamentals of Asset Management
Sub System(s)
Design Capac
(Min, max, pe
average)
Metering & Diversion Structure
Max. Flowrate
Hydrogen Peroxide
Max. Pressure
Sunflower Pump Station
30 MGD duty
30 MGD stand
Headworks No. 1
30 MGD duty
Main Sewage Pumps
30 MGD duty
30 MGD stand
Grit Removal
2 chambers
Headworks No. 2
210 MGD duty
Main Sewage Pumps
280 MGD duty
70 MGD stand
Bar Screens
4 units (+allow
units to be con
234 MGD max
1 unit standby
Grit System
Grit Chambers
Grit Washers
87 MGD duty
25 MGD stand
5 tanks
2 tanks standb
Hydraulic 1800
Overflow Rate
13
Detail, right page
3. Failure Mode
Study
Failure Summary
Rating
Metering & Diversion
Structure
10A
Headworks #1
10B
Headworks #2
10C
Efficiency
Reliability
Planning
Function
Area
Condition
Process
TBA
Capacity
Table 2
5. Current Program
4. Key Issues for Further Investigation
General
Project I-10 to increase flow to Plant 1 by 40 MG/D
Metering & Diversion Structure
Concerns about the reliability and accuracy of meters exist due to meter
failures. Proper operation of the meters is important because treatment
costs are allocated to the various revenue areas based on influent meter
Fundamentals of Asset Management
TBA
Design & Construction
P1-105 - Headworks Rehabilitation and Expansion at P
This project rehabilitates and refurbishes process equipme
infrastructure within the Plant 1 Headworks facility, to ensu
facility continues to be operational. Several studies have b
on the Headworks facility and a number of non-critical item
identified for repair and upgrade. The bulk of the project in
upgrades to existing bar screens, an additional bar screen
compressor, improvements to the grit removal facilities, im
the power distribution system including three new larger em
generators, and miscellaneous process, mechanical, struc
upgrades.
This project is in keeping with industry practices as require
and dependable plant operations. The capital budget ident
sheet is based on the non-critical items necessary to ensu
continues to function and conforms to the ultimate layout o
The FY 2004/05 budgets for P1-71 and P1-105 have been
after further evaluation of critical and non-critical work. P1
address increases in the facilities capacity to meet expecte
14
The asset management improvement plan section
OCSD Asset Management Improvement Program
Staff Lead Program 2005/06 Budget - Overall Timeline
Project No.
Project Name
June
July
Aug
Sept
Oct
11 & 12
Data Standards Asset Registers
AMIS Function Applications and
Strategy
13
Condition Assessment Guidelines
CIP Validation Stage 4
BRE Collections
BRE Plant
LOS Stage 2
(JH)
4 Box Model
(DS)
Asset Management
Plan 2
10
ORDM / LLCCA
Risk Policy
14
Organizational Alignment
Reliability Centered Management
(GHD)
Nov
Dec
Jan
Feb
Mar
April
May
CMMS
(GHD)
(GHD)
(JB)
(NA)
Fundamentals of Asset Management
(JB)
(AMT-DS)
(AMT-DS)
(AMT-DS)
(AMT-DS)
(
15
Example: Organizational AM strategies
No.
Description
Remarks /Deliverables
Asset Management
Plan 2006
Increase confidence level rating with
better accurate data on condition and
performance, more defined
management strategies, improve
future predictions on changed levels
of service overall results / outputs etc
including rate modeling. Complete
updated asset management plan
analysis and assess improvements
made. Links and inputs from most
projects.
Benefits
Asset Management
Plan output
improvements.
Improved Confidence
Level Rating.
Improved Business
Risk Exposure
assessments, funding
and rate models,
operations and
maintenance budgets.
Expenditure prediction
Tool enhancements
and improved Business
Risk Exposure
modeling.
2/10
Capital
Improvement
Program Validation
Stage 4 (2005/06)
Add life cycle costs, Business case
analysis methodology, including
improved maintenance budgets
/options and improve risk model to full
economic cost and Triple Bottom
Fundamentals of Asset Management
Significant benefits
derived for 2004
program ($25M in
capital) and over $50M
in life cycle costs.
16
The AM charter
Fundamentals of Asset Management
17
The AM charter, cont.
Fundamentals of Asset Management
18
The AM charter
Asset Inventory We will know the assets that we own,
or for which we have legal responsibility, and will
maintain an accurate computerized asset register
developed around an asset hierarchy that supports
advanced asset management functions.
Fundamentals of Asset Management
19
Telling the storyinstitutionalization
Annual budget process
Annual report
Fundamentals of Asset Management
20
Key points from this session
What does my asset management plan look like?
Key Points:
z AM focuses relentlessly on
providing sustained
performance at the lowest
life-cycle cost to the
organization
z AM is both a way of thinking
and a set of specific practices
z The more we understand
about our assets, the better
we can mange them
z Understanding our assets
starts with asking the right
questions
Fundamentals of Asset Management
Associated Techniques:
z The Enterprise Asset
Management Plan
z The Total Enterprise Asset
Management Improvement
Program
z Best AM Practices; Best
Appropriate Practices
z The Five Core AM Questions
z The 10 Step Process to an
asset management plan
21
Fundamentals of Asset Management
22
