Asset Renewal Case Studies For Pump Station Condition Assessment

Asset Renewal Case Studies for Pump
Station Condition Assessment

Earl Schneider, PE
Hatch Mott MacDonald

Asset Management
 What do you have?

 What condition are your assets in? The most fundamental
question that is needed to
 What risks do your assets pose to you? answer all other questions
 It is being operated and maintained
properly?
 When will it need to be renewed
(rehabilitated or replaced)?
 What are the results of the Business Case
Evaluation (BCE)?
AWWA NJ 2015 Annual Conference | March 17-19, 2015 | Atlantic City, New Jersey
Pump Stations Come in All Shapes and Sizes
What approach is best for you?
 A medium sized pump station (Case Study 1)
 1 to 5 MGD pump station supplying a
gradient zone in a system for a medium sized
town
 Numerous small/medium sized pump stations spread
out over a very large geographic area (Case Study 2)
 Hilly terrain with numerous
“lift” zones (vertically)
 Large geographic areas spread out from the
source of supply (radially)
 A large and complex pump station (Case Study 3)
 Responsible for major source of supply
transmissions (100+ MGD)
How to Perform a Condition Assessment- How to
“Attack” the Problem
 Break Assessment into Broad Categories
• There is a “function” of the asset as a whole
• “Performance” of the whole and component parts
• There is the “condition” of the assets component parts
• There is the potential over or under “utilization” of the asset as a
whole (which needs to consider present and the future)
 Category Summary
 FUNCTION
 PERFORMANCE
 CONDITION
 UTILIZATION
Case Study 1 – Cedar Grove, NJ
Francisco Avenue Pump Station
 General Description
• Standard issue brick and block building, slab
on grade
• Two (2) 3 MGD horizontal, centrifugal, split
case pumps with 250 hp motors
• One pump is for “firm” capacity
• Diesel generator
• Built 1987
 Function
• Wholesale interconnection with NJDWSC
• Primary source of supply
• “Critical” asset
• Condition assessment will provide “probability of failure (PofF)” for
this asset, and combined with “consequence of failure (CofF) will
yield current “risk”
 Performance
• Pump Station has been very reliable for 28 years
• Firm capacity allows station to function in event of
normal issues (e.g., coupling failure, etc.)
• Recently “ball-type” pump control valves have been a
problem (surges in system when opening and
closing)
• One pump control valve replaced with “diaphragm-
type” control valve
• Pump motors have previously been reconditioned
• More maintenance required on pumps
 Performance
• Electric bill is approximately $100,000/year (efficient?)
• Wire-to-water efficiency test
• http://energyexperts.org/CalculatorsTools/PumpingSystemEffi
ciencyCalculator.aspx#resultPanel
• Need:
• Total Dynamic Head
• Flowrate
• Motor Data
• Measure Amperage and Voltage
• Our Result – 61% Wire to Water (Fair)
 Performance
• Our Result – 63.4% pump efficiency
• 61% Wire to Water (Fair)
• Note: Original pump curve at 80%
efficiency at design point
• Estimated that new pump and
motor could achieve 71% wire to
water efficiency, and save $10K/yr
• Ancillary ROI benefit for replacing
old pump and motor
 Present Utilization
• 3 MGD pump station is conservatively sized
compared to maximum day demands
 Future Utilization
• Very small amount of development anticipated
in the Township in the future
• No substantial increase in water demand
forecasted
 Condition Assessment Components
o Process
o Electrical
o Structural
o Site
o Security/Safety
o Instrumentation/SCADA
o Mechanical (HVAC and Plumbing)
o Architectural
 Condition Assessment Codes, Standards, and
Regulations
o Process – Hydraulic Institute, AWWA, NJDEP,
10 State
o Electrical – NEC, IEEE, UL, Arc-Flash, PPE
o Structural – IBC
o Site - Local
o Security/Safety – OSHA, NFPA You need to know your codes
o Instrumentation/SCADA - NEC to perform these assessments.
o Mechanical (HVAC and Plumbing) - ASTM Besides safety issues, you will
end up paying for it later
o Architectural - IBC anyways.
 Comprehensive Checklists
o As much “granularity” as possible
o Photo documentation
o Identify any code violations
o Grading system
Sample Checklist
Sample Checklist
Operator Interview
Operator Interview
Good time to review past work

orders, log books, CMMS entries,
etc.
IIMM, 2006
Looking for patterns/clues

AMSA, 2002
Condition Grading System
Simple
AMSA, 2002
Condition Grading System
Sophisticated
Case Study 1 Results
Case Study 1 – Results
 Remaining Useful Life

o Pumps – nearly 30 years old, reduced efficiency, increased
maintenance
o Motors – original equipment, have previously been reconditioned,
significant run hours
o Electrical Equipment – original equipment, difficult to get parts, parts
wearing out, increasing maintenance
o Diesel Generator – original equipment, fair condition, increasing
maintenance, some operational issues, ATS in fair condition
 Business Case Evaluation (BCE)

 A BCE evaluates all feasible alternative approaches to arrive at the
lowest “lifecycle” cost (not capital) cost while reducing risk
 Final Approach
o Perform Upgrade Project in Two Phases
o Pumps, Valves, and Motors
o Electrical, Generator, Site, Structural, Architectural, SCADA
o Select new pumps with 80% plus efficiency
o Potentially size pumps smaller based on future demands
o No need/benefit for VFDs
Case Study 2 – Eastern State Utility
• 58 booster stations (124 pumps)
• 5 to 125 HP
• 20 to 3,100 gpm
 Project Need
• High level assessment for master
planning purposes
• Detailed assessment of “high risk” assets
• Determine short-term and long-term
funding needs through an annual
program
 Project Approach
• Don’t have the budget to perform 58
detailed assessments
• Which ones should we evaluate first?
• Answer: Business Risk Exposure (BRE)
evaluation
• Criticality (High CofF)
• Failure Probability (High PofF)
• Risk = f (CofF, PofF)
WERF
 Criticality (High CofF Assets)

• Total Customers Served
• Critical Customers Served (e.g., schools,
hospitals, wholesale supply, etc.)
• Existing redundancy/contingency
measures
• Water storage
• Redundant pump stations
• Feed by gravity at reduced
pressures
• Estimated Length of Service Disruption
• Difficult to Obtain Spare Parts
• Difficult to Access
 Failure Probability (High PofF Assets)

• Past Maintenance History
• Past Failure History
• Age of equipment
• Safety concerns
• Operator Knowledge
• Seasonal Issues
 High Risk Assets

 10 Pump Stations Identified
 Assessments very similar to Case
Study 1 performed
 Desktop Approach for Remaining Assets

 Pump Service Life
 Pump Station Service Life
 Pump Efficiency
 Hydraulic Capacity
 Power Outage Reliability
Above / Latest
Pump Station Pump Age Storage/Hy RATED CAPACITY RATED TDH Motor Age
Service Area Gradient Booster Station Below PUMP NO. VFD? HP Efficiency Test
Age (years) (Years) dro/Slip (GPM) (FEET) (Years)
Ground (Test Year)
2 13 Y 3 22 180 13 None
Buering 3 13 Y 3 22 180 13 None

Buering Drive 13 Above Hydro
Drive/Kannon Ln
4 13 N 40 600 250 13 None
1 0 Y 15 35 269 0 None
Clark Estates Clark Estates 0 Above Slip
2 0 Y 15 35 269 0 None
3 28 Y 5 100 154 8 None
Edgewood Drive Edgewood Drive 8 Above Hydro
4 28 Y 5 100 154 8 None
4 2 Y 20 240 200 2 None
Garden Farms Garden Farms 45 Above Storage
Main 5 2 N 20 240 200 2 None
3 6 Y 5 100 200 6 None

Green Valley Hgts Green Valley Hgts 6 Above 4 6 Y Slip 5 100 200 6 None
5 6 Y 40 400 200 6 None
3 3 N 40 500 212 3 None
Hapgood Hill Hapgood Hill 3 Above 4 3 Y Slip 15 150 200 3 None
5 3 Y 15 150 200 3 None
3 9 Y 7.5 100 180 9 None

Hillview Road Hillview Road 43 Below Slip
4 9 Y 7.5 100 180 9 None
 Final Prioritization of
Investment
 Business Case Evaluation (BCE)

 Final Approach
o Develop Annual Program for Booster Station Renewal
o Fund at $1 Million Per Year for 5 Years
o Includes Renewal at 17 Pump Stations over 5 Years
o Set schedule for additional field assessments
o Perform pump efficiency tests
o Add additional flow meters to track non-revenue water
Case Study 3 – NJ Water Supply Authority
South Branch Pump Station
• Ten (10), 40 MGD horizontal centrifugal pumps
• 2,000 HP motors
• Pump Up to 350 MGD from South Branch of Raritan
River to Round Valley Reservoir
• Built in 1966
• Low “run hours” on pumps
 Project Need
• Asset Management Plan for entire facility
• Significant process and electrical concerns
• Sophisticated approach since one pump and motor
replacement costs about $1.5 million
• Determine short-term and long-term funding needs
 Concerns with Pumps and Motors
• Vibration
• Pump and Motor Misalignment
• Baseplate deterioration
Anchor bolt rusted out
 Vibration Analysis Approaches
• Modal Impact Testing
• Better understand condition of
baseplates and entire system
• Identify natural frequencies and
mode shapes
• Develop animation of exaggerated
movement
• Identified design requirements for
new baseplates (stiffness, grouting,
anchoring, etc.)
• Follow up dynamic tests will be
performed when construction
complete
 Motor Condition Assessment
• Motor Circuit Evaluation Test
• To assess stator winding health,
faulty or broken rotor
components, eccentricity,
insulation condition,
deteriorating connections
• Revealed potential core problem with
several motors
• Assisted in developing motor rehab
specification
 Summary
• Pump and motor rehab in lieu of
replacement
• Based on low run hours
• Based on detailed CA testing results
• Plan to rehabilitate 2 pump/motor sets
every two years
Summary of Case Studies
 The General Approach to Pump Station Condition
Assessment is the same for any facility
 Function
 Performance
 Condition
 Utilization
 Start at the desktop and move to the field
 Arm yourself with detailed checklists, perform code
evaluation, and develop grading systems
 The level of CA investment and effort is a function of
overall asset value and criticality
 Always perform a formal business case evaluation (BCE)
to evaluate alternative solutions in a holistic manner
 Establish short-term prioritization and estimates of
long-term funding requirements
 Update O&M practices based on CA outcomes
 Repeat CA’s on a periodic basis
Making Infrastructure Sexy!
I leave you with this…….
https://www.youtube.com/watch?v=Wpzvaqypav8
Questions During the Panel Discussion
Earl.schneider@hatchmott.com
(973) 912-2574

Asset Renewal Case Studies For Pump Station Condition Assessment

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Asset Renewal Case Studies for Pump

Station Condition Assessment

Hatch Mott MacDonald

 What do you have?

Good time to review past work

Looking for patterns/clues

 Remaining Useful Life

 Business Case Evaluation (BCE)

 Criticality (High CofF Assets)

 Failure Probability (High PofF Assets)

 High Risk Assets

 Desktop Approach for Remaining Assets

Buering 3 13 Y 3 22 180 13 None

3 6 Y 5 100 200 6 None

3 9 Y 7.5 100 180 9 None

 Business Case Evaluation (BCE)

Anchor bolt rusted out

I leave you with this…….

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