AWWA 20446-2010 Maintenance Management for Water Utilities (Third Edition).pdf

1、 #MBOL1BHFMaintenanceManagementfor Water UtilitiesThird EditionJames K. JordanThe Authoritative Resource on Safe WaterMaintenance Management for Water Utilities, Third EditionCopyright 2010 American Water Works AssociationAll rights reserved.No part of this publication may be reproduced or transmitt

2、ed in any form or by any means, electronic or mechanical, including photocopy, recording, and online, or in any information or retrieval systems, except in the form of brief excerpts or quotations for review purposes, without the written permission of the publisher.DisclaimerThe authors, contributor

3、s, editors, and publisher do not assume responsibility for the validity of the content or consequences of their use. In no event will AWWA be liable for direct, indirect, special, incidental, or consequential damages arising from the use of information in this book. In particular, AWWA will not be r

4、esponsible for any costs, including, but not limited to, those incurred as a result of lost revenue. In no event shall AWWAs liability exceed the amount paid for the purchase of this book.AWWA Publications Manager: Gay Porter De NileonProduction Services: PerfecType, Nashville, TNCover Design: Chery

5、l ArmstrongCover Photos: Bryan Bechtold, AWWA (left); Philadelphia Water Department (right)Library of Congress Cataloging-in-Publication DataJordan, James K.Maintenance management for water utilities / James K. Jordan. - 3rd ed.p. cm.Includes bibliographical references and index.ISBN 978-1-58321-783

6、-21. Water treatment plants-Equipment and supplies-Maintenance and repair-Man-agement. I. Title. TD434.J67 2010628.10682-dc222010017437ISBN 978-1-58231-783-2Printed in the Unites States of America.American Water Works Association6666 W. Quincy AvenueDenver, Colorado 80235www.awwa.orgvContentsList of

7、 Figures ixPreface .xiChapter 1The Need for Maintenance .1Role of the Maintenance Department 2Responsibilities 2Maintenance Department Management .3Advances in Maintenance Management .4Maintenance Management Information Systems .4Relationship Between Operations and Maintenance 5General Maintenance F

8、unctions 5Balancing Maintenance Requirements 6Summary .9Reference 9Chapter 2Organization of the Utility 11Organization-Wide Involvement in a Maintenance Program 11Effective Organization Models 13Maintenance Personnel . 16Maintenance Personnel Policies . 21Maintenance by Operations Personnel 23vi |MA

9、INTENANCE MANAGEMENT FOR WATER UTILITIESMaintenance by Outside Contractors 25References . 27Chapter 3Planning a Maintenance Management System .29Elements of an Effective MMS . 29Planning the System 42Implementation Steps . 46References . 48Chapter 4Information Management and System Monitoring .49Equ

10、ipment and Structure Records 49Work Order Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Maintenance Work History . 63Management Reporting . 67Maintenance System Monitoring Techniques 71Maintenance Management System Control 73Performance Monitoring . 84References . 87Chapte

11、r 5Inventory Management 91General Concepts . 92Maintenance Group Requirements . 92Determining Quantities in Inventory 95Inventory Information Systems 96Inventory Accountability 102Automated Inventory Systems .104References .110CONTENTS |viiChapter 6Maintenance Costs and Budget .111The Cost of Mainte

12、nance 111Collecting Cost Data 116Management Reporting .124Preparing a Budget 126Estimating Maintenance Costs .129Chapter 7Training .135Responsibility for Training .136Assessing the Need for Training .137Structuring Training Programs .138Maintenance Training Needs Throughout the Organization .147Safe

13、ty Training Programs 151References .152Index 153ixList of FiguresTable4-1 System of classifying priorities for maintenance work, 72Figures2-1 Sample large water utilitygeneral manager/chief engineers office/ technical departments, 152-2 Sample maintenance organizationdivision/section levels, 172-3 E

14、xample job description: Electrical/mechanical journeyman, 223-1 Maintenance procedure for flexible coupling of a motor filtrate pump, 353-2 Preventive maintenance checklistmotor control centers, 363-3 Preventive maintenance checklistmotor with slip-rings, 373-4 Preventive maintenance schedule175-mgd

15、 water filtration plant, 384-1 Equipment data sheetelectric motors, 514-2 System map with maintenance information, 524-3 Corrective maintenance work order flow and work order log-book, 574-4 Equipment maintenance work ordercopy 1, 584-5 Equipment maintenance work ordercopies 2 and 3 (bottom section)

16、, 594-6 Work order flowdistribution system maintenance (emergency work), 614-7 Computer-generated work orderdistribution system mainte-nance, 624-8 Data printout from a maintenance service history file, 644-9 Equipment history for a process unit, 66x |MAINTENANCE MANAGEMENT FOR WATER UTILITIES4-10 S

17、ample management report (partial listing) on work order backlog, 694-11 Monthly PM tracking report (Report format adapted from PSDI MAXIMO CMMS software), 704-12 Work order summary, 744-13 Preventive maintenance work order summary, 754-14 Monthly cost summary, 764-15 Graphnumber of incomplete preven

18、tive maintenance actions vs. time, 774-16 Graphcorrective maintenance work hours, 774-17 System control reports, 824-18 Onscreen exception report, 834-19 Performance by program report for October, 20XX, 885-1 Purchase requisition, 975-2 Receiving ticket, 995-3 Parts history file, 1005-4 Stores requi

19、sition, 1015-5 Guidelines for organizing a storeroom, 1045-6 Sample part report from automated inventory management sys-tem, 1065-7 Stock reorder report, 1075-8 Report on essential parts and supplies, 1085-9 Report on outstanding parts orders, 1096-1 Monthly expense report, 1156-2 Labor time sheet,

20、1186-3 Cost report, 1206-4 Report of nonproductive time, 1216-5 Work order with space for cost-allocation information, 1236-6 Work accomplished summary report, 1266-7 Radio equipment request form, 1286-8 Budget estimate summary, 1306-9 Budget support document, 1316-10 Labor estimate form, 1336-11 Co

21、ntractor/other costs estimate form, 1347-1 Steps for assessing training needs, 1387-2 Types of training, 1407-3 Types of technical training programs for maintenance of pumps, 1437-4 Checklist for selecting training media, 1447-5 Multimedia training aid, 1457-6 Training aid created by computer integr

22、ation, 146xiPrefaceSuccess in any project requires careful planning, design, imple-mentation, and monitoring. Establishing an effective mainte-nance program is no different. Many significant advances have been made in recent years in maintenance management systems, including the introduction of a nu

23、mber of software packages that simplify the task of designing a good maintenance operation and the application of geographic information system and global position-ing system (GIS/GPS) technology to facilitate the location of plant equipment and distribution system components. Still, the fundamental

24、 requirements for establishing an effective program remain the same. A maintenance manager who initiates a project to establish or improve a program must:Develop a clear statement of the scope of the work with cost 1. estimates.Sell the merits of the project to senior management.2. Carefully design

25、the program to include all necessary elements, 3. including planning for future expansion.Solicit the cooperation and recommendations of upper 4. management, operations personnel, and field maintenance technicians.Develop an implementation plan and schedule.5. Plan techniques for monitoring and revi

26、ewing the program 6. after implementation.xii |MAINTENANCE MANAGEMENT FOR WATER UTILITIESThe establishment or improvement of a maintenance program must be a high priority for any maintenance manager. The benefits to a water utility of an effective maintenance program are well established, and senior

27、 managers generally support implementing improved programs for maintenance. The maintenance manager and staff are key members of a utility staff who contribute to the effective operation of a water utility by ensuring that equipment runs smoothly and facilities and grounds are safe and functional wo

28、rkspaces. This book was prepared to provide guidelines to help water utility maintenance managers develop and analyze their maintenance man-agement programs. The text systematically covers the primary com-ponents of effective maintenance management and suggests actions that a maintenance manager can

29、 take to improve the operation of the maintenance section.While this book continues to emphasize the importance of per-forming preventive maintenance and of carefully planning new and modified maintenance systems, this edition introduces newer concepts involving the use of GPS technology and asset m

30、anagement. In par-ticular, the application of computer technology has expanded from generating and tracking work to integrating maintenance data with the utilitys financial and inventory systems. The use of the Internet to pro-vide training for maintenance staff is also introduced as an additional r

31、esource for maintenance managers to consider.The author thanks manuscript reviewers Kenneth C. Morgan, PE, Water Distribution Superintendent, City of Phoenix, Ariz.; and Robert Garcia, City of Peoria, Ariz. The author also wishes to acknowledge the important contribution that maintenance managers an

32、d techni-cians make to the success of their water utility. This acknowledgment extends to those operations staff, particularly in smaller water utilities, who perform many of the maintenance tasks that are essential for the efficient operation of a water utility.1CHAPTER 1The Need for MaintenanceWhe

33、n a piece of equipment is first placed in service, it gener-ally operates near its maximum efficiency. For example, a new automobile, assembled with new parts, is at its operating peak, with the engine running smoothly and according to the specifications of the designers and manufacturers. The shock

34、 absorbers, springs, and tires produce the best ride that the vehicle is capable of delivering.The same principle applies to a water pumpset and its auxiliary equipment. Assuming proper design, construction, and installation, the volume of water pumped immediately after a system has been com-mission

35、ed is at or near its design capacity. This principle holds true whether the equipment for transmitting the water is a hand pump located in a village or farm or a 50-mgd centrifugal pumpset providing water to a large community.Also, of course, all equipment with moving parts eventually wears and must

36、 be replaced. The owner of the car, the farm with the hand pump, and the utility using large-capacity pumping equipment all must recognize this fact and develop plans to correct inevitable equipment wear.A water utility is among the most capital intensive of all utilities. A utility of any size must

37、 allocate sufficient resources to perform those maintenance functions needed to protect its investment in equipment. In larger utilities, a separate maintenance group is usually required; 2 |MAINTENANCE MANAGEMENT FOR WATER UTILITIESfor smaller utilities, staff, for example, plant operators, may per

38、form all duties critical to the operation and maintenance of the system. Only through effective maintenance management can a utility fulfill its responsibility to provide high-quality water to the community it serves.Role of the Maintenance DepartmentA water utilitys primary function is to provide s

39、afe, high-quality water to its customers in sufficient quantities and at a reasonable cost. The performance of the utilitys maintenance department plays a key role in the success of this endeavor. In general, the maintenance group provides support services to other departments within the organiza-ti

40、on. Maintenance is responsible for keeping the equipment, vehicles, and structures of the utility in good operating condition. The services provided by maintenance personnel range from routine tasks such as replacing light bulbs to critical ones such as repairing equipment neces-sary for production

41、of finished water. Whatever the nature of the work, efficient completion of these tasks requires a planned approach.ResponsibilitiesThe specific responsibilities of the maintenance group include the following:Repairs to equipment, vehicles, distribution system scomponents, and buildingsplanning and

42、executing repairs to restore the equipment and structures to acceptable standardsPreventive maintenance (PM)developing and implementing sa program of regularly scheduled work designed to maintain equipment operation and prevent major problems. In addition, predictive maintenance techniques are now s

43、tandard procedure in many water utilitiesCommunicationsdeveloping methods to keep operations spersonnel, upper management, and other departments aware of maintenance activitiesBudgetpreparing realistic budgets detailing labor and smaterial needsTHE NEED FOR MAINTENANCE |3Inventoryensuring that the p

44、arts and material necessary sto perform maintenance tasks are available and can be accounted forSupervisiondeveloping techniques for monitoring the sactivities of maintenance personnelTrainingproviding opportunities for both supervisory and sfield personnel to improve their skills and performanceSaf

45、etydeveloping safety education programs for maintenance spersonnel and implementing techniques to improve the safety of the workplaceContract managementpreparing contract specifications and sinspecting the work of independent contractors to ensure compliance with requirementsConstructionreviewing pl

46、ans for new facilities and sinstallation of new equipmentRecord keepingmaintaining up-to-date information on sequipment and plant services, including files containing operations and maintenance (O availability of practical methods to assess maintenance needs; and the importance of the equipment or s

47、tructure needing maintenance.Balancing Maintenance RequirementsA large utilitys maintenance department is frequently organized into four sections to accommodate different O chemical-feed equipment; flocculation, sedimentation, and filtration units; process instrumentation devices (such as flowmeters

48、 and other telemetry components); and transformers, motor control centers, and protec-tive relays.Since E/M equipment incorporates a multitude of moving parts (e.g., bearings and contacts) subject to wear, it requires effective PM for reliable and economical operation of treatment plants and pumping

49、 stations. However, PM is not cost-effective for all E/M equipmentsome equipment is generally operated until it fails. For example, unless a fractional horsepower motor is driving a critical piece of equipment, PM for it is probably not cost-effective. The motor will be replaced when it fails. Even under a good PM program, other equipment will fail on occasion simply because of faulty components. Thus, pr