Operations Developing Equipment Hierarchy
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Transcript of Operations Developing Equipment Hierarchy
Rich Ludlow
Oak Lodge Sanitary District
Taxonomy of Hierarchy from ISO 14224, International Standard for the Petroleum, petrochemical and natural gas industries.
A Little About Oak Lodge SD Approximately 8,600 sewer connections
100 miles of sewer pipe 2273 sewer manholes
5 wastewater pump stations
Surface Water Management: 2,500 catch basins
53 miles of storm lines
100 sedimentation manholes
50 private detention systems.
Water Reclamation Facility, 10 MGD, Cannibal Plant
A Little More about Me 5 year veteran, USN, Steam propulsion plant operator
5 year supply chain specialist, private sector
20 years in municipal wastewater collections/treatment professional 12.5 years Bureau of Environmental Services, City of Portland,
OR
4.5 years Veolia Water, Gresham, OR
1 year HDR Inc., Portland, OR/Honolulu, HI
2 years Oak Lodge Sanitary District, Oak Grove, OR
Grade 4 certified Collections and Treatment Plant Operator
Practicing and Implementing Asset Management principals for 8 years
Why Build Hierarchies? Organization
Communication Cost rollup (Financial)
Budgeting
Repair/replace decisions
Capital versus Operational expenses
Location based rollup (Geographic) Inventory of equipment in specific locations
Process based rollup (Functional) Systematic inter-relationships
Preemptive failure analysis
WERF Simple Hierarchy Tool Step 1 1) Identify Hierarchy Components
Organizational groupings
Start/stop criteria for various hierarchy types
2) Determine Hierarchical Rollup Needs (what questions need answers?)
Financial
Geographical
Functional
Rich’s pointer: Allow room to grow
WERF Simple Hierarchy Tool Step 1 3) Define Lowest Data Recording Levels Across the
Hierarchy (Definition of an Asset) How granular is too granular?
When does tracking data go beyond the point of diminishing returns?
Is the item serviceable?
Repair/replace criteria
Business decisions considering:
Labor cost
Impact of downtime
Available redundancy
Available skillsets
Don’t go too deep…
Drilling in to find Assets may be cumbersome
The harder it is to find, the less likely people will look
WERF Simple Hierarchy Tool Step 1 4) Build the Hierarchy
Could have multiple elements depending on organizational needs
5) Test the Hierarchy
Ensure the level divisions make sense
Ensure the hierarchy groupings meet needs
6) Make Adjustments as Needed
Testing reveals the need for adjustments
WERF Simple Hierarchy Tool Step 2 7) Develop Asset ID Numbering/Naming Convention
Universally Applied to all Assets
Consistent Convention throughout Organization
100% Coverage of Everything Defined as an Asset
WERF Simple Hierarchy Tool Step 2 8) Identify Data Attributes, Sources and Purposes
This one is bigger than a breadbox
Attributes depend on characteristics of Assets
Sources can include: O&M manuals
As-built drawings
Equipment nameplate data
Design specifications
Maintenance tech napkin notes
Purposes related to data implies being sure it’s meaningful
WERF Simple Hierarchy Tool Step 2 9) Document
Capturing the rationale for decisions can:
Remind decision makers what they were thinking
Articulate decisions to those not making them
Reference material for people who want to understand “why?”
Thorough documentation requires discipline
WERF Simple Hierarchy Tool Step 3 10) Develop Data Collection, Maintenance and Update
Procedures Collection: Information must be gathered to get it all in one
place Sources are:
Equipment Nameplates
O&M Manuals
P&IDs
As-Built drawings
Institutional knowledge
Maintenance and Update: a change management plan and practice to keep information current with equipment/process/organizational evolution
WERF Simple Hierarchy Tool Step 3 11) Collect, Load and Test Data Structure
Loading and testing should be done with samples to ensure structure and grouping work well
Functional testing of the Hierarchy and data detail structure
Successful Testing is Notice to Proceed
Populate the rest of the Hierarchy, you’re off to the races!
WERF Simple Hierarchy Tool Step 3 12) Activate Registry
The Asset Registry is now complete
Begin the continuous improvement
Data change management
Information retrieval stages
Diagram of OLSD Asset Hierarchy
Plant Field
Sewer Storm
OLSD
Fleet
Fleet Assets
Collections Facilities Process
Pump Stations
Pump Station Assets
Buildings/Systems
Building/System Assets
Process Systems
Process Equipment Assets
Sewer Assets
Storm Assets