reporting - Metropolitan Water Reclamation District of Greater Chicago
reporting - Metropolitan Water Reclamation District of Greater Chicago
reporting - Metropolitan Water Reclamation District of Greater Chicago
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Maintenance at the<br />
Stickney <strong>Water</strong><br />
<strong>Reclamation</strong> Plant
Public Image <strong>of</strong> Maintenance
Increase Productivity
Latest iPod Product
Maintenance<br />
More than just firefighting
ASSET MANAGEMENT CYCLE<br />
BUILD<br />
Engineering Construction<br />
DESIGN<br />
Engineering Design<br />
MAINTAIN /<br />
OPERATE<br />
Maintenance & Operations<br />
END OF<br />
USEFULL LIFE<br />
Collaborative Effort
Maintenance Mission<br />
To ensure reliable plant<br />
operation in the most<br />
economically sustainable manner<br />
possible.
Over 11,000 Stickney Asset<br />
Records<br />
• The Stickney WRP<br />
– Main Sewage Pumps up to 3500HP<br />
– Blowers up to 10,000HP<br />
– 37 Centrifuges<br />
– 96 Final Clarifiers<br />
– 6 Boiler, 4 capably <strong>of</strong> 80,000lbs/hr steam<br />
– Miles and miles <strong>of</strong> piping
Over 11,000 Stickney Asset<br />
Records<br />
• 6 Pumping Stations<br />
– Mainstream 550MGD, 8 pumps 3,600 – 17,500HP<br />
– Racine Ave 3.9BGD, 14 pumps 1,000 - 1,750HP<br />
• 103 TARP Control Structures<br />
• 4 Reservoirs
SWRP M&O Org Chart<br />
Plant Manager<br />
Plant Services<br />
Maintenance Manager<br />
Operations Manager<br />
Plant<br />
Engineering<br />
•Electrical<br />
•Mechanical<br />
Skilled<br />
Trades<br />
•Master Mechanics<br />
•Multiple Union Crafts<br />
Operators<br />
Electrical<br />
Operators
SWRP M&O Org Chart<br />
Maintenance Manager (ETPO)<br />
Steve Carmody<br />
Supervising Mechanical Engineer<br />
Farsheed Hafezi<br />
Principal Mechanical Engineers<br />
Bob Regan<br />
Pete Kane<br />
Supervising Electrical Engineer<br />
Lionel Gomberg<br />
Master Mechanic II:<br />
Tom Butler<br />
Assistant Master Mechanics:<br />
Bob Henry<br />
Jim McNamara<br />
Mike Pijanowski<br />
Christine Vollmer<br />
Principal Electrical Engineers<br />
Mike Cavarretta<br />
Sam Evans
M&O Engineer Responsibilities<br />
• Work order approval and planning<br />
• Manage $20M+ in spare parts<br />
• Budget and administer contract services<br />
• Preventive maintenance administration<br />
• M&O Liaisons on Engineering projects<br />
• Technical knowledge and libraries<br />
• Root-cause analysis<br />
• Betterments
M&O Master Mechanics and<br />
Skilled Trades<br />
Over 160 skilled trades<br />
13 Unions<br />
Work order planning and scheduling<br />
Tools and equipment<br />
Work execution
Computerized Maintenance<br />
Management System<br />
aka CMMS<br />
or<br />
Mainsaver
Pre-Computerized Maintenance<br />
System (Pre-1990)<br />
Pencil, paper, and the TUBE.<br />
• No asset inventory for maintenance purposes<br />
• Work orders on paper<br />
• No time-<strong>reporting</strong><br />
• Squeaky-wheel scheduling<br />
• Few PM’s, mostly lubrication<br />
• Service history not recorded<br />
• Spare parts not inventoried
Computerized Maintenance System<br />
(Post1990)<br />
• Complete asset inventory<br />
• Electronic work orders<br />
• Time-<strong>reporting</strong>/contract capturing<br />
• Formalized scheduling based on priority<br />
• Automated preventive maintenance<br />
• Service history captured<br />
• Spare parts inventoried and interfaced
WORK ORDER BASICS<br />
Corrective<br />
Preventive<br />
Predictive
Corrective Work Request Flow<br />
Operations Supervisors<br />
Maintenance Engineering<br />
Master Mechanics<br />
Operators<br />
Skilled Trades<br />
Contractor
Preventive/Predictive<br />
Maintenance<br />
Plant Engineering<br />
CMMS<br />
Skilled Trades
Preventive/Predictive<br />
Maintenance Examples<br />
• Blower overhauls based on vibration<br />
• Chain & flight overhauls<br />
• Cleaning and testing <strong>of</strong> electrical distribution<br />
• Cleaning and painting <strong>of</strong> large motors<br />
• Filter changes<br />
• Instrumentation calibrations<br />
• Lubrication
Work Volume<br />
• 1,300 – 1,500 Work orders per month<br />
• 50% Corrective 40% Preventive/Predictive<br />
10% Emergency<br />
Labor Costs( 70/20/10)
10/3/2011<br />
20.0<br />
18.0<br />
16.0<br />
14.0<br />
12.0<br />
10.0<br />
8.0<br />
6.0<br />
4.0<br />
2.0<br />
0.0<br />
Backlog<br />
11/26/2007<br />
2/1/2008<br />
4/1/2008<br />
6/3/2008<br />
8/1/2008<br />
10/1/2008<br />
12/1/2008<br />
2/3/2009<br />
5/1/2009<br />
7/1/2009<br />
9/3/2009<br />
11/2/2009<br />
1/5/2010<br />
3/1/2010<br />
5/3/2010<br />
7/7/2010<br />
9/7/2010<br />
1/3/2011<br />
3/7/2011<br />
53/3/11<br />
6/30/2011<br />
Average Backlog in Weeks for Primary Trades<br />
C2 E2 F2 I2 M2 P2 S2 T2 G2<br />
Total Backlog Average Ready Backlog Average
Contract Maintenance
Outsourcing Examples<br />
• Tank Rehabs<br />
• Steam Boilers<br />
• Centrifuges<br />
• HVAC<br />
• Rotating Assemblies<br />
• Final Clarifier Painting<br />
• 13.2kV Switchgear<br />
• Motor Cleaning
Budget
$70,000,000<br />
Maint Budget<br />
$63,186,316<br />
$60,000,000<br />
$58,521,167 $58,117,313<br />
$50,000,000<br />
$40,000,000<br />
$44,617,504<br />
$30,000,000<br />
$20,000,000<br />
$10,000,000<br />
$-<br />
2009 2010 2011 2012
SWRP Maintenance Budget<br />
2009-2012<br />
• 9% Reduction in staff<br />
• 50% Reduction in Service Contract<br />
Expenditures ($13.2M – $6.8M)
Maintenance Photos
10,000 HP
3000 HP
Emergencies
MSPS Dewatering Chamber
RAPS 2008
Questions
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