ASSET MANAGEMENT CHALLENGES IN
RAND WATER
FAROUK KHAN
Maintenance Support Services Manager
Rand Water
Gauteng,
South Africa
RAND WATER OVERVIEW
Bulk water supplier to
Gauteng and adjacent areas
3
SOURCES OF WATER
Lesotho Highlands
Vaal Dam
Purification
Lesotho Highlands Scheme augments
Vaal River System
Raw water from Vaal Dam purified and
pumped to foothills of Witwatersrand
ridge
4
SOURCES OF WATER
Pumping
Distribution
Storage
Water is boosted to high lying
storage reservoirs
Large parts of the area of supply
can be fed under gravity
5
Primary Pumping and Distribution Elevations
RESERVOIRS
Klipriviersberg
Meyer's Hill
Meredale
Johannesburg
Tunnel from Lesotho
+ 300m
Daleside
Vereeniging
Zuikerbosch
Zwartkopjes
Palmiet
Eikenhof
Klipriver
VaalVaalriver
River
+ 60 km
Pretoria
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
RAND WATER OVERVIEW
Bulk water supplier to 11.7 million people
Current average demand – 3700 Ml/d
3500 km of pipeline – mostly > 600 mm
54 reservoirs – average size 100 Ml
8
FORECAST DEMAND GROWTH
Population growth • Estimated in 2010 – 11.7 million
for Rand Water
• Projected for 2030 – 14.7 million
area of service
Components of
demand
Growth in
demand
• Domestic usage – 70%
• Balance is mining, industry, commercial and
government
• Maximum day in 2010 – 4500 Ml/d
• Projected for 2030 – 6900 Ml/d
9
Asset management Framework
Asset Management
“ The optimum way of managing assets to achieve a
desired and sustainable outcome”.
Phase1
Planning
Phase 6
Phase 2
Disposal
Design
Phase 5
Phase 3
Operate & Maintain
Acquire
Phase 4
Install & Commission
GM: SAM
Senior Manager:
Senior Manager:
Senior Manager:
Senior Manager:
Assets
Projects
Project Controls
Strategic Projects
Programme
Asset Planning
Asset
Manager
Manager
Design Office
Managers
Construction Services
Project
Manager
(X8)
Manager
Support
Emhlangeni
Fabrication
(X7)
Project
Engineering
Engineering
Managers
Managers
(X40)
(X8)
Maintenance
Asset
Design
Planning
Assessors
Disciplines
Land and Rights
Research
Asset
Knowledge
Systems
Maintenance
Support
And
Engineers
(X40)
Energy
Management
Project
Execution
Business
Assurance
Document
SHREQ
Management
Manager
Water Cycle
Management
Development
QC
Special
Supervisors
Projects
Integration
Planning
Construction
Crews
Life Cycle Asset
Management
•Design ,Eng ,Diagnostics
and Maintenance
Project Execution
Divisional
Support
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
14
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.
Pro-active Maintenance
(Planned)
Maintenance
Strategy
Maximo/SAP
Reactive Maintenance
(Unplanned)
Continuous
Improvement
Assess Asset
LCC & TCO
Monitoring
Reporting
Technical Asset
Register
Plant & Equipment
Formal PCA
Reliability Engineering Process to be used
High Criticality
Medium Criticality
RCM
PMO
RCA
RCA
Low Criticality
Proactive
RCA
Reactive
AVAILABILITY IMPROVEMENT
AVAILABILITY IMPROVEMENT MODEL
Running time +
Standby time) /
total time x 100
AVAILABILITY
Per pump set
Ability of the asset to
be used by
operations during a
specified time
Actual running hours
…………………….
No of Failures + 1
TRIP STATS
Per pump set
RELIABILITY
10 – TEMP
6 – VIBRATION
2 -EXT. POWER
Per pump set
The capability of an
asset to continue to
perform its intended
functions..
MTBF.
RCA POLICY & PROCEDURE
No of callouts
CONTINUOUS IMPROVEMENT
RCA
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
 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
Reliability Report to
highlight conditions that
may require further
Investigation using Root
Cause Analysis.
CONTINUOUS IMPROVEMENT
Weekly/ Monthly
Print out reliability/availability
reports from Maximo
> 85%
1.1
Further investigation
not required
1
Availability
2
Reliability
< 85%
1.2
Investigate reasons
Use criteria as per policy
(RW SAM 00030 P)
1.2.1
Does not meet
criteria for RCA
2.1
Same as 1.1
1.2.2
Meets criteria
for RCA
> 40 days
< 40 days
2.2
Same as 1.2.1
or 1.2.2 to 1.2.5
should criteria
for RCA be met
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
A LIFETIME OF HIGHLY RELIABLE
PRODUCTION PLANT AND EQUIPMENT.
THANK YOU