Condition Assessment beyond the Pipes: Tools for Facility ......• Condition assessment information gathered in the field, • Interviews with the owner’s personnel • Review of

Condition Assessment beyond the Pipes: Tools for Facility

Condition Assessment and CIP Prioritization

Topics of Discussion

o Purpose of Assessment o Assessment Drivers o Assessment Methodology o Asset Criticality o Prioritization of Asset

Rehabilitation

What is Condition Assessment?

o Defined as the art and science of determining and documenting the physical state of infrastructure at a point in time.

What is Condition Assessment?

o The goal is to identify the root cause, if any, of the observed state of the infrastructure and to develop model renewal options for the continued, cost-effective operation of the infrastructure.

Why Conduct a Condition Assessment?

o Condition assessment investigations often form the basis for prioritization of improvements in a capital improvement plan and for more efficient operations and maintenance of the structures.

Facility Assessment Drivers


o Capital Improvement Planning •  What •  When •  How

o  Identifying Replacement Timing Strategically with Capital Projects


o Extending the Operating Life of a Component or System

o Forecasting Equipment Replacement

Facility Assessment Methodology

Defining the Scope of the Assessment

Establish Asset Classes and

Create/Update Asset Database

Inspection and

Condition Criticality Analysis Forecast

Replacement, Rehabilitation and

Repair

Establish Asset Designations Designation Description Typical Values

Facility Location or system Water Treatment Plant Remote Sites

Process Area Distinct processes that make up the Facility

Raw Water System Permanganate Building Pre-Sedimentation

Asset Class A broad term used to describe the type of equipment or structure located within a process area.

Pump Motor – Electrical Structural PLC

Asset The specific equipment or structure.

Finished Water Pump 1 Sedimentation Basin 6

Establish Asset Classes and Create/Update Asset Database

Inspection and Condition Criticality Analysis Forecast Replacement, Rehabilitation and Repair

Document Review

o As-Built Drawings o O&M Manuals o Maintenance Records o Operating Records and Standard Operating

Procedures o Equipment Submittals

Create and/or Update Asset Database

o Existing Utility Database o Project-specific Asset Database o Define Asset Designations and/or IDs



Facility Assessment Methodology for Treatment Facilities

o Facility Assessment of major equipment focused on: •  Process/Mechanical •  Structural •  Heating, Ventilation and Air Conditioning (HVAC) •  Electrical •  Instrumentation and Controls and SCADA



Facility Assessment Methodology for Treatment Facilities

o Can Also Include: •  Wells and ASR •  Pumping Facilities •  Storage Facilities •  Blending Stations •  Other Remote Infrastructure



Inspection and Condition o Level 1: Age Only/Desktop Analysis o Level 2: Visual Field Inspection by Discipline

Specific Professionals (Observation Only) and Staff Interviews

o Level 3: Performance Testing o Level 4: Non-Destructive Testing o Level 5: Forensic Testing



Typical Inspection Form


o Each Asset Evaluated For: •  Condition •  Reliability •  Capacity •  Remaining Useful Life Analysis

•  0 – 5 Years •  6 – 10 Years •  11 – 20 Years •  20 + Years



Condition

o Condition Rating is a subjective measure of the state of deterioration. A basic rating is based on “Best valued judgment.”



Condition

Condition

Rating

Description Percent of Original Life

Maintenance

1 New or Excellent condition

100% Normal preventive maintenance

2 Minor defects only 75% Normal preventive maintenance, Minor corrective maintenance

3 Moderate deterioration

50% Normal preventive maintenance, Major corrective maintenance

4 Significant deterioration

25% Rehabilitation, if possible

5 Virtually unserviceable

1% Replace

U Unknown

Reliability

o Provides an assessment of each asset to allow the physical effective lives to be adjusted for poor or unreliable performance.



Reliability

Reliability

Rating

Description Failure Timing Probability of

Failure

1 As specified by manufacturer

Never <1%

2 Random breakdown Every 20 years 10%

3 Occasional breakdown Every 5 years 50%

4 Periodic breakdown Every 2 years 75%

5 Continuous breakdown ≤ 1 year 100%

Capacity

o Captures whether an asset is not delivering the required capacity, the required functionality, or is financially inefficient.



Capacity/Performance

Capacity/ Performance Rating

Description

1 Exceeds/Meets all Performance Targets

2 Minor Performance Deficiencies

3 Considerably Performance Deficiencies

4 Major Performance Deficiencies

5 Does not meet any Performance Targets

Useful Remaining Life

o  Industry Recommendations and/or Engineer’s Judgment

o Baseline that may be adjusted up or down depending on maintenance and equipment operating environment




o Useful Remaining Life Methodology Asset Class Useful Life (Years) Useful Life Source Structural/ Architectural 50 IRS Pub946 Table B HVAC 15 CIBSE, ASHRAE Boiler 25 Manufacturer’s Estimate Power Generation 30 Engineer’s Judgment Power Distribution 30 Engineer’s Judgment Power Distribution – VFDs 15 Engineer’s Judgment Instrumentation 15 Manufacturer’s Estimate SCADA (HMI) 2 - 5 Manufacturer’s Estimate Large PLCs 15 Manufacturer’s Estimate Medium PLCs 10 Manufacturer’s Estimate Communication 10 Manufacturer’s Estimate Civil/Sitework 50 IRS Pub946 Table B

Useful Remaining Life

Asset Class Useful Life (Years) Useful Life Source Process/Mechanical

Pump 30 Engineer’s Judgment Motor – Electrical 30 Engineer’s Judgment Valve (incl. Actuator) 25 Engineer’s Judgment Pump – Chemical 15 Engineer’s Judgment Tank – Chemical* 10 -15 Engineer’s Judgment Chemical Systems 15 Engineer’s Judgment Piping – Buried 75 Engineer’s Judgment Piping – Aboveground 40 Engineer’s Judgment Rotating Equipment (Mixers, Blowers)

25 Engineer’s Judgment

Filtration – Media 15 - 25 Engineer’s Judgment

Engineering Analysis

o Uses information from previous efforts including: •  Condition assessment information gathered in the field, •  Interviews with the owner’s personnel •  Review of maintenance logs and history to estimate the

remaining service lives of the components or systems o Develop planning level opinions of cost, o Develop maintenance procedures to extend the life of

the asset, and o Establish the priority of the rehabilitation projects.

Planning Level Opinions of Cost o  Process/Mechanical

•  Manufacturers quotes o  Structural/Architectural

•  Estimating guides, •  Materials quotes and •  Judgment by the engineer/architect

o  Piping and valves •  Materials quotes and installation cost estimates

o  Electrical and instrumentation and controls •  Manufacturer’s quotes and estimating guides

o  Civil and Site Costs •  Estimating guides

Facility Assessment Criticality Analysis

Criticality o  Impact on Plant Function or Safety Consideration

•  1 – Non-Critical •  2 – Minor •  3 – Moderate •  4 – High

o  If evaluated during asset database development, can be used to determine if Level 3 – 5 Testing is required

o  Used to further define asset ranking and priority for CIP development



Criticality Analysis

Facility Assessment Prioritization Ranking

Forecast Replacement, Rehabilitation and Repair Develop Prioritization Methodology comprised of: o  Condition, Reliability and Capacity Score o  Useful Remaining Life o  Criticality o  Timeframe for Prioritized Schedule

•  0-5 Years •  6-10 Years •  11-20 Years •  Greater than 20 Years


Inspection and Condition Criticality Analysis Forecast Replacement,

Rehabilitation and Repair

Typical Summary Table

Facility Assessment Summary and Conclusion

Recap of Discussion

o Purpose of Assessment o Assessment Drivers o Assessment Methodology o Asset Criticality o Prioritization of Asset Rehabilitation

Condition assessment investigations often form the basis for prioritization of improvements in a capital improvement plan and for more efficient operations and maintenance of the structures.

Condition Assessment beyond the Pipes: Tools for Facility ......• Condition assessment information gathered in the field, • Interviews with the owner’s personnel • Review of

Documents