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FAROUK KHAN Maintenance Support Services Manager Rand Water Gauteng, South Africa

Asset Management challenges in Rand Water. FAROUK KHAN Maintenance Support Services Manager Rand Water Gauteng, South Africa. RAND WATER OVERVIEW. SOURCES OF WATER. Lesotho Highlands. Vaal Dam. Purification. SOURCES OF WATER. Pumping. Distribution. Storage.

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FAROUK KHAN Maintenance Support Services Manager Rand Water Gauteng, South Africa

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  1. Asset Management challenges in Rand Water FAROUK KHAN Maintenance Support Services Manager Rand Water Gauteng, South Africa

  2. RAND WATER OVERVIEW

  3. SOURCES OF WATER Lesotho Highlands Vaal Dam Purification

  4. SOURCES OF WATER Pumping Distribution Storage

  5. Primary Pumping and Distribution Elevations Vaal River Focus

  6. Potable Water Pumps – 25 to 300 Ml/d • Raw Water Pumps – up to 450 Ml/d • Motors – 200kw to 6230kw • Pipelines – 400mm to 3.5m diameter

  7. RAND WATER OVERVIEW

  8. FORECAST DEMAND GROWTH

  9. Asset management Framework Asset Management “ The optimum way of managing assets to achieve a desired and sustainable outcome”.

  10. Life Cycle Asset Management • Design ,Eng ,Diagnostics and Maintenance Divisional Support Project Execution

  11. ADDRESSING ASSET MANAGEMENT STRATEGIES FOR EFFECTIVE INFRASTRUCTURE • TAR/FAR • Alignment with Systems SAP/Maximo/GIS/Linear Assets • Plant criticality analysis • Infra Structure Asset management Plan • Life Cycle Maintenance Plan

  12. Importance of Assets Assets are acquired for their ability to produce the product on which an organisation base its existence. Maintenance must focus on preserving our assets. Maintenance is an insurance against Risks.

  13. Maintenance Management Process Pro-active Maintenance (Planned) Assess Asset LCC & TCO Maintenance Strategy Monitoring Reporting Maximo/SAP Reactive Maintenance (Unplanned) Continuous Improvement

  14. Maintenance Strategy Technical Asset Register Plant & Equipment Formal PCA Reliability Engineering Process to be used High Criticality Medium Criticality Low Criticality RCM PMO Proactive RCA Reactive RCA RCA

  15. AVAILABILITY IMPROVEMENT • Reliability improvement methods and metrics are being utilized to meet the increasing demands placed on utilities to achieve optimum levels of Plant availability • A key aspect of any Availability improvement program is the comprehensive capture and analysis of actionable, accurate, performance data.

  16. Actual running hours ……………………. No of Failures + 1 Running time + Standby time) / total time x 100 RCA POLICY & PROCEDURE TRIP STATS Per pump set AVAILABILITY IMPROVEMENT MODEL RCA CONTINUOUS IMPROVEMENT AVAILABILITY Per pump set RELIABILITY Per pump set 10 – TEMP 6 – VIBRATION 2 -EXT. POWER The capability of an asset to continue to perform its intended functions.. MTBF. Ability of the asset to be used by operations during a specified time No of callouts

  17. ROOT CAUSE ANALYSIS • Monthly Reliability / weekly report to include a spreadsheet that displays the following info: • No of trips on all main pumps • Trip stats of all main pumps • Temperature • Vibration • Low Suction • Eskom Trips, etc Reliability Report to highlight conditions that may require further Investigation using Root Cause Analysis. • If a main pump trips more than 2 times for the • same reason within 30 days. • If reliability for the pump set drops below the 12 • month average as per internal target • ALL MAJOR FAILURES

  18. CONTINUOUS IMPROVEMENT Weekly/ Monthly Print out reliability/availability reports from Maximo 2.1 Same as1.1 1 Availability 2 Reliability < 85% > 85% > 40 days 1.2 Investigate reasons Use criteria as per policy (RW SAM 00030 P) < 40 days 1.1 Further investigation not required 2.2 Same as1.2.1 or1.2.2to1.2.5 should criteria for RCA be met 1.2.2 Meets criteria for RCA 1.2.1 Does not meet criteria for RCA 1.2.3 Arrange RCA session with site Note: Where failure of a system or equipment has severe safety, environmental or financial consequences, RCA’S must be done to eliminate recurrence or manage the situation. 1.2.4 Implement solution 1.2.5 Follow up to ensure that all solutions have been implemented

  19. RELIABILITY IMPROVEMENT GOAL A LIFETIME OF HIGHLY RELIABLE PRODUCTION PLANT AND EQUIPMENT. THANK YOU

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