SPS optimised maintenance plans

Overview

Barwon Water used Modla’s existing asset library model for Sewage Pump Stations (SPS) to produce optimised maintenance plans for their ~200 Sewage Pump Stations. Various scenarios were ran to validate the value added by their current maintenance plan, as well as optimisations that can be made.

Asset Models: Sewage Pump Stations

Solvers: Current Plan, Optimised Plan

Outputs: PowerBI and Excel

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More information on asset models can be found here.

More information on solvers can be found here.

Project objectives

Primary objective: to develop a risk and context informed maintenance plan for each SPS within the fleet

Secondary objective: to contribute to an open-source asset model knowledge base, to enable organizations share knowledge and learnings.

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What was done

Asset Data

• Compiled by Barwon Water from existing SPS info
• Rolled individual pump data up to a SPS facility level
• Excluded odour control, backup generators, surge protection etc. from analysis.

Costs

• Override the default costs for tasks where unit rates were provided.
• Add specific costs for each pump based on flow rates

Criticality Data

• Used existing criticality assessment results and tied to blockage causing events
• Added in electrical risks to failures that have a safety risk exposure

Scenarios

• Ran the entire SPS fleet to failure, replacing only on failure event, to baseline the risk profile (Dashboard deliverable)
• Ran the current plan of Yearly Electrical, Yearly Mechanical inspections, to determine value add of tasks. (Dashboard deliverable)
• Ran the Optimiser over the Electrical and Mechanical inspections to adjust for operation, condition, environment, cost and consequences. (Dashboard eliverable) This optimisation considered the next 5 years only.
• Reviewed the recommended strategy from the optimiser, and manually adjusted some task intervals where it enabled easier planning, with minimal cost downside(slightly less optimal but easier to schedule/bundle)
• Ran the adjusted strategy and reviewed the results (Dashboard deliverable)
• Exported the SPS to task timing relationships to excel

Results

• The Modla library asset model for SPSs was vetted and improved by Barwon Water SMEs.
• Optimised maintenance plans were produced for ~200 SPSs.
• Identified where the maintenance plans should vary from baseline.
• $250K worth of value added over 5 years.
• Improvement opportunities across Data, Model and Solvers were identified.

Summary

Barwon water and Modla worked together to:

• Implement requested improvements to the underlying SPS model.
• Collect data required to utilise the analytics platform.
• Generate, understand and validate the results.
• Agreed on an improved maintenance plan for the next 5 years, that considers consequence, cost, condition, and environmental factors.

Modla engineers assisted throughout the process to ensure the stated objectives were achieved.

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