Innovation at the Washington Suburban Sanitary Commission (WSSC) Keith Tyson, P.E. Technical Services Group Leader Aloysius Obodoako Principal Materials Engineer Engineering Construction Team Washington Suburban Sanitary Commission March 29, 2017
Innovation at the Washington Suburban
Sanitary Commission (WSSC)
Keith Tyson, P.E. Technical Services Group Leader
Aloysius Obodoako Principal Materials Engineer
Engineering Construction Team Washington Suburban Sanitary Commission
March 29, 2017
Overview of Innovation WSSC Pipelines Forecast of Breaks Cost of Repairs on Pipeline Criteria for Pipeline Replacement/Rehabilitation Pipe Average Service Life Effect of Corrosion on Pipeline Corrosion Control Methods Ductile Iron Pipe Monitoring Program Effect of Strategic Sourcing Summary
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Building new Bio-Energy plant (design ongoing, construction begins in 2018) to capture waste heat and reduce solids
Installed 2 MW of solar panels at Western Branch WWTP
Converted to Zinc coated Ductile Iron Pipe with V-Bio poly-wrap
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Water Treatment: • Online dissolved manganese analyzer to detect concentrations
in raw water Wastewater Treatment:
• Chemical Disinfection - Peracetic acid disinfection to replace chlorine disinfection
• Process modeling - IViewOps software pilot for the Parkway WWTP
• Carbon Diversion - Carbon diversion technology that uses Waste Activated Sludge (WAS) to biosorb more carbon from the influent
• Aeration efficiency - GE ZeeLung; membrane-aerated biofilm reactor
• Shortcut nitrogen removal – exploring options
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Collection System: ◦ SL-RAT - Acoustic Sewer Line Rapid Assessment Tool -
quickly identify lines that need cleaning or CCTV inspection ◦ EcoTabs - Tablet or granular chemical/microbial applied
in the collection system to oxidize H2S and/or FOG Distribution System: ◦ Advanced Water Main cleaning system – alternative to
Uni-Direction Flushing
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2571 miles of DIP
2548 miles of CIP
360 miles of PCCP
38 miles of Steel
7 miles of ACP
7 miles of PVC
15 miles Unknown
DIP
CIP
PCCP
STEEL
ACP
PVC
UNKNOWN
5546 Total Miles
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Usually defined as pipes located between two valves ◦ Not a single stick of pipe
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0
500
1,000
1,500
2,000
2,500
8" 10-12" 6" <6" 20-24" 16-18" 36-42" 60-96" 24-30" 48-54" 14" Unknown
Tota
l MIle
s
Diameter
Total Miles
Based on literature review and not on WSSC pipe operating experience
Water Distribution System (Pipe Diameters ≤ 14")
Material Cast Iron Pipe (CIP) Ductile Iron Pipe (DIP)
Attribute Pit Cast Spun Cast Non Polywrap Polywrap
min (yr.) 85 45 -- 88
max (yr.) 110 65 65 115
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0
100
200
300
400
500
600
700
800
900
1000
1910s 1920s 1930s 1940s 1950s 1960s 1970s 1980s 1990s 2000s 2010s 2016
Leng
th, M
iles
Period, Decades
Miles Installed by Decade
Buried Water Assets
0
20
40
60
80
100
120
2008
2010
2012
2014
2016
2018
2020
2022
2024
2026
2028
2030
2032
2034
2036
2038
2040
2042
Breaks & Leaks per 100 miles of Projected B&Ls/100 mi Historical B&Ls/100 mi
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Average repair costs for 8” water main break ◦ Crew costs - $1600
◦ Equipment - $2500
◦ Materials, non-pipe - $2000
◦ Materials, pipe - $250
◦ Overhead - $1200
◦ Total ~ $7,550/break
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Criteria used to determine replacement/rehab: 1) Level of Risk Probability of failure, consequence of failure, and mitigation
factor 2) Pipe attribute Material Coating/Lining Diameter/thickness
3) Field inspection result or condition assessment 4) Maintenance History Break rate ≥ 3 within 5 yrs Work orders – customer complaints, other projects
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Corrosion Material Deterioration ◦ Distortion ◦ Erosion
Poor Installation Practices ◦ Leaking joints
Manufacturing Defects ◦ Flaws
Operating Conditions ◦ Excessive external/internal loading
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Pitting Corrosion – localized deterioration leading to pits
https://picacorp.files.wordpress.com/2013/03/2013-05-sc-verif-pipe.jpg
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Galvanic Corrosion - one metal corrodes preferentially to another when both metals are in electrical contact (i.e., copper bolt - steel nut)
http://education.sptech.xyz/galvanic.png
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Stray Current Corrosion - caused by the flow of stray currents through pipelines
http://www.techart.rs/english/images/korozija%20pruga.jpg
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Microbial Corrosion (MIC) - caused or promoted by microorganisms Ex. Iron corrosion by sulfate reducing bacteria (SRB)
Converts sulfates to hydrogen sulfide (H2S) H2S reacts with metal ions to form metal sulfides
http://www.oilfield-biocides.com/media-oilfield-biocides/Scheme-of-iron-corrosion-by-SRB-2.png
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Methods used to prevent corrosion and extend asset service life 1. Protective Coating/Lining
2. Polymer Wrap
3. Cathodic Protection
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External Coating • Tape coating • Pritec coating • Epoxy coating • Zinc coating
Internal Coating/Lining • Cement mortar lining • Epoxy coating • Fiber reinforced polymer • Cured-in-place pipe (CIPP)
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Unbounded protective film
Limits contact between pipe and soil
Decrease O2 beneath wrap
ANSI/AWWA C105/21.5
https://www.dipra.org/ductile-iron-pipe/dipra-facts-and-figures/v-bio-enhanced-polyethylene-encasement
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Technique used to control corrosion of pipe by making it the cathode of an electrochemical cell
Two main types of Cathodic Protection Galvanic Anodes Impressed Current
Currently used only on pipes with high stray current
Neither method used in conjunction with zinc coating and V-Bio polymer wrap
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Galvanic Anodes Localized protection for corrosion hot-spots Discrete or distributed anodes No on-going monitoring of electrical components
required Impressed Current
High level of system control and performance Global protection for the entire structure Long service life On-going monitoring of system performance
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Zinc coating is effective corrosion prevention product
Zinc is anodic to iron • zinc is consumed in place
of iron • zinc conversion products
formed zinc oxide, zinc
carbonate, zinc chloride, etc.
stable impermeable binding layer
http://www.american-usa.com/
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Zinc applied using arc spray process ◦ wire fed into the spray
gun ◦ wire is charged and arc is
generated ◦ wire is melted ◦ molten feedstock is
deposited on the pipe at 200 g/m2
http://www.metal-monster.com/ArcSpray.html
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Zinc coating applied per ◦ International standards organization ISO 8179
Coating application evaluated at factory via coupon attached to pipe
Damaged zinc coating is repaired per manufacturer’s recommendation ◦ Metallic zinc spray, or ◦ Zinc-rich paint with 85% zinc, by mass
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Zinc is applied as the basecoat Asphalt topcoat applied to reduce exposed zinc V-bio polyethylene encasement used as protective
film
http://www.american-usa.com/
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Corrosion inhibitor vapor-like molecule attracted to pipe bonds to pipe prevents the pipe from
oxidizing Anti-microbial additive
Kills and repels microbiological organisms
Prevents microbial corrosion https://www.dipra.org/images/pageimages/
v-bio-brochure.jpg
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Overall cost of 1 mile of 8” pipeline replacement
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Costs for 8” pipe; the difference is minimal
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Cost per foot 1 mile Total Cost $365.40 5280 $96,466 $441.80 5280 $116,635
Difference: $20,170
4 mil Poly wrap $1,235.75 8 mil V-Bio poly wrap $3,821.07
Difference: $2,585
Total Construction Cost per mile $2,879,418 Percent of cost for regular DIP with 4 mil poly 3.39% Percent of cost for zinc coated DIP w/ V-Bio 4.18%
Difference: 0.79%
Verify assumptions used to determine service life
Validate corrosion prevention using Zinc
3 pipe types that will be monitored DIP with no protection (1970-2005) DIP with polymer wrap (2005-2016) Zinc Coated DIP with V-BIO polymer wrap (2016–today)
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Direct Measuring Techniques ◦ Corrosion Probe Monitor change in resistance of a metal coupon
◦ Mass-loss Coupon Monitor change in material weight and structure
http://www.cosasco.com/thumb.php?img=images%2Fproducts%2F6200_Corrosion_strip_coupon_holder.png&w=150&h=84 © 2017 WSSC All Rights Reserved. 32
Indirect Measuring Techniques ◦ Ultrasonic Testing Pulse-wave transmitted to detect internal flaws and
thinning ◦ Acoustic Emissions Testing Sound wave used to determine pipe wall condition
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WSSC created Strategic Sourcing teams in 2012 Goal was to create better relationships with
Vendors Work with Vendors as Partners on large
purchases
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November 2013 Official Launch of WSSC’s SCM Transformation implementation
(Phase II)
December 2013
Feb - June 2014 July – Dec 2014
• Cost reduction calculation and reporting
• Risk management seminars
• Pro-active Steering Committee
• Org design fine tuned • TCO emphasis • Speaking with One
Voice
• Launch several Wave 2 SSTs
• Org design finalized, hiring begun
• Initial cost reductions reported
• Intensive internal communications
Classroom Training in Strategic Sourcing, Launch of first two cross-functional SS
Teams under auspices of Steering Committee
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July 2013 Phase I
Assessment, Transformation Roadmap and Business Case
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• An active and engaged Supply Chain Management Steering Committee will promote the vision, promote positive outcomes, and help identify and remove obstacles.
• Sourcing strategies will be developed with cross-functional representation and robust strategic sourcing and negotiations management processes.
• A Strategic COE (Center of Excellence) will provide leadership, policies and practices, training, and strategic sourcing capabilities serving all of WSSC.
• Cross-functional teaming can improve both the effectiveness and the efficiency of Procurement processes.
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Team Name Goal Breakthrough Moment
Results CR / CA Impact
Bio-Solids Handling Award Critical Environmental Contract
Supplier Outreach & RFI can reduce risk and improve competitive results.
Contracts addressed current need and future uncertainty
$$
Bulk Chemicals Team Work with Cooperative to Reduce Pricing
Sole Source and Proprietary product requirements can be negotiated.
Participated in a regional sourcing event, identified alternate suppliers. Negotiated reduced prices.
$$
PCCP Team (Pre-stressed Concrete Cylinder Pipe)
Reduce Costs of Critical Technical Service
Separate critical/urgent from non-critical/Urgent requirements to optimize process and reduce costs.
Improved Competition, Eliminated Costly Markups, can benefit from Intellectual property.
$$$
38 © 2017 WSSC All Rights Reserved.
Team Name
Goal Breakthrough Moment
Results CR / CA Impact
Ductile Iron Pipe
Reduce Costs and Risks for a major component.
Costs include more than just Price. A TCO strategy can bring value and reduced pricing.
Partnering with a Major distributor and manufacturer with multiple manufacturing locations and a sophisticated materials management system. Improved Inventory Controls and reduced materials costs.
$$
Water Main Replacement
Improve the company’s approach to Routine Construction Projects.
Partnering with qualified vendors to reduce lead times and improve quality can still generate competitive pricing.
Qualified Utility Contractors were made part of the design process. Individual task orders were awarded through a competitive low bid process.
$$$
Fleet Develop strategy to compete long-lead equipment with standard and non-standard components.
Successful Procurement cannot exist without clear requirements, consistent standards, and good planning.
Single task evolved into five teams to address critical pre-procurement and post-procurement processes.
TBD
39 © 2017 WSSC All Rights Reserved.
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What Will Not Change at WSSC The focus on doing what is necessary to maintain safe and reliable water operations The focus on Best Pricing, Supplier Service Performance and Product Quality Commitment to SLMBE
What Will Change at WSSC – Near Term
Focus on improving cycle times More collaboration - increased upfront input into sourcing strategies Need for accurate usage information Improved communications: end users/depots/facilities sourcing suppliers
Greater opportunity to address shortcomings in supplier performance Increased importance of scripted messages to support “Speaking with One Voice” The need to coordinate planned, and unplanned, supplier meetings Some suppliers may change
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What Will Change at the WSSC – Longer Term Fewer surprises, fewer materials shortages and fewer emergencies Better supplier performance and expanded supplier service levels Increased standardization of products used, resulting in lower Total Cost of Ownership – Total Cost of Operations (TCO) Greater use of supplier KPIs (key performance indicators) and performance targets A reduction in the number of active suppliers, and a lower number of individual transactions Improved and standardized payment terms Lower materials and services costs
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Knowledge & Expertise
Operational Activities
Strategic Vision
Apply Expertise • Develop Analytic Capabilities • Utilize Market Awareness • Engage End Users • Manage Contracts
Reduce Transactional Costs • Employ Technology • Enhance Bid Quality • Decrease Cycle Time • Improve Bid Management
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Numerous Transformation Initiatives Across Six Key Dimensions are Underway at WSSC
• Aggressive Stretch Objectives • Total Cost of Ownership
Perspective • ROIC / ROE goals • Objectives Shared Across Entire
Organization • Incentives / Consequences • Supplier Performance Metrics
• Spend Analysis & Category Management • Demand Aggregation • Electronic RFIs, RFPs • Reverse Auctions • Optimization & Decision Support • Contract Mgmt & Compliance • Results Tracking & Reporting • Supplier Performance Evaluation • Project Mgmt & Executive Dashboard
• Structure that works in your culture • Cross-functional involvement • Speaking with One Voice • Commitment to Continuous Learning • Professional Career Track • Governance
• Strategic Sourcing • Negotiations Management • All Spend Categories in Scope • Risk Management • Partnerships with Suppliers • Supplier Recognition • Contract Management & Supplier Centric Strategies • Cost Reduction Planning / Tracking • Budget Adjustments to Preserve Cost Reductions • Low-Cost Country Sourcing • Consortium Buying • Asset Recovery • Selective Outsourcing
• Core Part of Corporate Strategy Objectives Best Practices
Optimized Organization Innovation & Technology
Procurement Role
Good Leadership • The Right Leader • Leadership Culture at all Levels • Bias to Action and Results
$
Excerpted from the book “Straight to the Bottom Line®” (Rudzki et al)
Blue = Underway
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WSSC implementing innovative techniques to improve service to customers
Experiencing increasing number of pipe breaks Costs of repairing pipe breaks is increasing Developing corrosion controls methods to manage
pipeline degradation Zinc coated DIP and V-Bio are now standard pipe
materials Developing monitoring program to evaluate pipe
performance Created sourcing teams to reduce cost of purchasing
Ductile Iron Pipe
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