Transcript Rand Water
ASSET MANAGEMENT CHALLENGES IN RAND WATER FAROUK KHAN Maintenance Support Services Manager Rand Water Gauteng, South Africa RAND WATER OVERVIEW Bulk water supplier to Gauteng and adjacent areas 3 SOURCES OF WATER Lesotho Highlands Vaal Dam Purification Lesotho Highlands Scheme augments Vaal River System Raw water from Vaal Dam purified and pumped to foothills of Witwatersrand ridge 4 SOURCES OF WATER Pumping Distribution Storage Water is boosted to high lying storage reservoirs Large parts of the area of supply can be fed under gravity 5 Primary Pumping and Distribution Elevations RESERVOIRS Klipriviersberg Meyer's Hill Meredale Johannesburg Tunnel from Lesotho + 300m Daleside Vereeniging Zuikerbosch Zwartkopjes Palmiet Eikenhof Klipriver VaalVaalriver River + 60 km Pretoria Focus 6 Potable Water Pumps – 25 to 300 Ml/d Raw Water Pumps – up to 450 Ml/d Motors – 200kw to 6230kw Pipelines – 400mm to 3.5m diameter RAND WATER OVERVIEW Bulk water supplier to 11.7 million people Current average demand – 3700 Ml/d 3500 km of pipeline – mostly > 600 mm 54 reservoirs – average size 100 Ml 8 FORECAST DEMAND GROWTH Population growth • Estimated in 2010 – 11.7 million for Rand Water • Projected for 2030 – 14.7 million area of service Components of demand Growth in demand • Domestic usage – 70% • Balance is mining, industry, commercial and government • Maximum day in 2010 – 4500 Ml/d • Projected for 2030 – 6900 Ml/d 9 Asset management Framework Asset Management “ The optimum way of managing assets to achieve a desired and sustainable outcome”. Phase1 Planning Phase 6 Phase 2 Disposal Design Phase 5 Phase 3 Operate & Maintain Acquire Phase 4 Install & Commission GM: SAM Senior Manager: Senior Manager: Senior Manager: Senior Manager: Assets Projects Project Controls Strategic Projects Programme Asset Planning Asset Manager Manager Design Office Managers Construction Services Project Manager (X8) Manager Support Emhlangeni Fabrication (X7) Project Engineering Engineering Managers Managers (X40) (X8) Maintenance Asset Design Planning Assessors Disciplines Land and Rights Research Asset Knowledge Systems Maintenance Support And Engineers (X40) Energy Management Project Execution Business Assurance Document SHREQ Management Manager Water Cycle Management Development QC Special Supervisors Projects Integration Planning Construction Crews Life Cycle Asset Management •Design ,Eng ,Diagnostics and Maintenance Project Execution Divisional Support ADDRESSING ASSET MANAGEMENT STRATEGIES FOR EFFECTIVE INFRASTRUCTURE • TAR/FAR • Alignment with Systems SAP/Maximo/GIS/Linear Assets • Plant criticality analysis • Infra Structure Asset management Plan • Life Cycle Maintenance Plan 14 Importance of Assets • Assets are acquired for their ability to produce the product on which an organisation base its existence. • Maintenance must focus on preserving our assets. • Maintenance is an insurance against Risks. Pro-active Maintenance (Planned) Maintenance Strategy Maximo/SAP Reactive Maintenance (Unplanned) Continuous Improvement Assess Asset LCC & TCO Monitoring Reporting Technical Asset Register Plant & Equipment Formal PCA Reliability Engineering Process to be used High Criticality Medium Criticality RCM PMO RCA RCA Low Criticality Proactive RCA Reactive AVAILABILITY IMPROVEMENT AVAILABILITY IMPROVEMENT MODEL Running time + Standby time) / total time x 100 AVAILABILITY Per pump set Ability of the asset to be used by operations during a specified time Actual running hours ……………………. No of Failures + 1 TRIP STATS Per pump set RELIABILITY 10 – TEMP 6 – VIBRATION 2 -EXT. POWER Per pump set The capability of an asset to continue to perform its intended functions.. MTBF. RCA POLICY & PROCEDURE No of callouts CONTINUOUS IMPROVEMENT RCA ROOT CAUSE ANALYSIS Monthly Reliability / weekly report to include a spreadsheet that displays the following info: No of trips on all main pumps Trip stats of all main pumps Temperature Vibration Low Suction Eskom Trips, etc If a main pump trips more than 2 times for the same reason within 30 days. If reliability for the pump set drops below the 12 month average as per internal target ALL MAJOR FAILURES Reliability Report to highlight conditions that may require further Investigation using Root Cause Analysis. CONTINUOUS IMPROVEMENT Weekly/ Monthly Print out reliability/availability reports from Maximo > 85% 1.1 Further investigation not required 1 Availability 2 Reliability < 85% 1.2 Investigate reasons Use criteria as per policy (RW SAM 00030 P) 1.2.1 Does not meet criteria for RCA 2.1 Same as 1.1 1.2.2 Meets criteria for RCA > 40 days < 40 days 2.2 Same as 1.2.1 or 1.2.2 to 1.2.5 should criteria for RCA be met 1.2.3 Arrange RCA session with site Note: Where failure of a system or equipment has severe safety, environmental or financial consequences, RCA’S must be done to eliminate recurrence or manage the situation. 1.2.4 Implement solution 1.2.5 Follow up to ensure that all solutions have been implemented A LIFETIME OF HIGHLY RELIABLE PRODUCTION PLANT AND EQUIPMENT. THANK YOU