Read Chapt12 Fac Maint.doc text version

Chapter 12 Facilities Maintenance

Introduction

Within the Process Control Division, the Facilities Maintenance Section=s main responsibility lies in the proper care and maintenance of mechanical equipment, piped utilities, structures, buildings and grounds within the department=s eight wastewater treatment plants and chemical feed systems at several sewage pump stations. The section=s maintenance personnel perform many building trades such as machine repair, welding, machine shop services, plumbing, heating/ventilating/air conditioning service, locksmith service, roofing and masonry work. Regulatory requirements have resulted in having our air conditioning system technicians E.P.A. certified for refrigerant transition and recovery, and also for chemical water treatment of equipment cooling towers. The staff maintains over 5,000 pieces of mechanical equipment, 180 tanks, 20 miscellaneous structures, and 54 buildings, mows 20 acres of lawn and snowplows the parking lots and several miles of service roads at seven facilities.

In addition to the plant maintenance programs, this section is also responsible for the department=s Inventory Control and Stockroom Operation, Archive Records Control, Materials Management/Surplus Equipment Disposal, Office Waste Paper and Scrap Metal Recycling. For several plants, the section also handles Custodial Services and Pest Control. It is also heavily 113

involved in construction design review for any plant upgrades and capital improvement projects. Besides using the traditional techniques of standard preventive and corrective maintenance, the Plant Maintenance Management System takes a Aproactive [email protected] by utilizing specialized programs that include Predictive Maintenance (PdM) through machine monitoring and vibration analysis, laser shaft and sheave alignment and lubricant wear-metal analysis. System re-design and small new construction/equipment installations are also performed on a limited basis. Five of the eight plants are staffed full time with maintenance personnel, with the remainder being serviced weekdays on a part time basis. Plant Assistance Crews (P.A.C.) are utilized to relieve the smaller plant crews from the burden of doing time-consuming major repairs and/or in-house new construction projects, thereby reducing the disruption in daily maintenance programs. The program has smoothed out the maintenance management effort and the special team approach is a tremendous success. During 2002, Plant Maintenance Supervisors set up in-house training sessions on many of the different trades utilized within Plant Maintenance. This insures the quality of work performed is kept at the highest level and that employees are not apprehensive about tackling the more difficult jobs. The training also serves to improve their self-esteem and degree of professionalism. The in-house training program has taken a positive move in that the concept of on-the-job-training continued all year, and the utilization of the knowledge gained in the classroom has been passed on to several new and long term employees alike. This process has encouraged a sense of total cooperation within the Maintenance section. Formal informational sessions were held for several affected plants for proper handling and safety of Liquid Oxygen and Aluminum Sulfate chemicals.

114

For 2002, all of the Maintenance crews were involved with mandatory training programs also, such as fork truck operation and safety, the ARight To [email protected] Law and chemical emergency response training. The Predictive Maintenance Program, although understaffed and not able to monitor equipment as frequently as we would have liked to through the year, has continued to be a substantial cost saving asset. Through machine monitoring by vibration analysis, the program has proven it=s worth by detecting machinery mechanical faults in their infancy and preventing unscheduled downtime. By finding a problem earlier and preventing collateral damage to other equipment parts, the program has been a huge cost saving effort. The expanded use of laser alignment between motor and equipment drive-shafts and laser drive belt pulley alignment continues to provide savings in equipment parts and labor expenses, to reduce equipment downtime and electrical power costs. C.M.M.S. Project Working with the consulting firm of Stearns & Wheler, L.L.C., the department continued building a new information management system by way of implementing a Computerized Maintenance Management System (CMMS) to manage the operation and maintenance of six (6) major wastewater treatment plants, over 100 pump stations, eight (8) Combined Sewer Overflow (CSO) treatment facilities and approximately 3,000 miles of sewer piping. Every division of the department was involved in the project with the Plant Maintenance sections Superintendent being Project Manager. The new information management system includes the following features: * A Computerized Maintenance Management System (CMMS) to manage maintenance work orders, provide equipment history, supply and parts inventory management and maintenance cost tracking. * A geographical Information System (GIS) interface with the CMMS to allow on-line viewing of the entire collection system, rapid assignment of work orders to any sewer line or manhole in the system, easy retrieval of maintenance history on any element of the sewer system, rollup capabilities to analyze and summarize maintenance data by work type and geographical area, and ability to generate billing reports for maintenance services. * A department-wide [email protected] providing rapid access to reports, documents and O&M information on all treatment facilities and pump stations and other data and information required for operation, maintenance and administration. * A drawing database for on-line retrieval of sewer, plant and pump station design drawings. The project impacts most every division in the department. Several department core teams were formed to work specifically on Maintenance, Operations and Information Technology areas of the system. The project began in March of 2001, has progressed from site assessment and business process analysis, core team training, through strategic planning and design document development, equipment nameplate data collection; storeroom parts and material identification, pricing, data collection; and end user training, Facilities began to go on-line in a staggered sequence from February through December of 2002. This transformation from a manual record 115

keeping system to electronic automation includes materials ordering, receiving, issuance and conducting inventory physical counts. Benefits for the department include: * Wireless Bar Code Scanning for receiving, issuing and physical count updating * Improved accuracy of records * Speed up parts receiving, locating, issuing * Improved/faster customer service * More timely ordering/ less stock outages * Standardize stockroom operations, labeling of materials * More efficient issuing of stock * Allow instant, automatic, complete and accurate reporting * Improved cost center accounting and budget forecasting * Electronic Purchase Requisitioning * Electronic Work Requests with helpful attachments such as work plans, diagrams, precautions and status viewability * Equipment parts reserved to Work Orders * Improved allocation of maintenance resources to decrease overall cost of maintenance and improved maintenance efficiency * Enhanced ability for supervisors to review and upgrade Preventative Maintenance Schedules * Ability for anyone to look up equipment parts, parts availability in Storerooms, diagrams, maintenance procedures * Improved interaction between Operations and Maintenance staff for coordinating equipment or system outages for maintenance * A resource database providing rapid access to on-line Operations & Maintenance Manuals, Standard Operating Procedures, thousands of treatment plant, pump station and sewer drawings as well as selected manufacturers drawings and photographs * Hyper-Links to other internet sites * Ready availability of system maps for maintenance planning, scheduling and work order implementation * Sophisticated reporting capabilities for billing, maintenance cost analysis, inventory management *Work Requests tied to G.I.S. Interface allow faster service, recording maintenance, reporting, and billing. The Department is in the process of developing an AOwnership [email protected] to take over the administration responsibilities of the CMMS from the consultant. The team will provide oversight and monitor and guide the usage, maintenance and growth of the O&M Information Management System by utilizing representatives from the departments various divisions and user types.

116

Long Range Planning and Facilities Upgrade

The challenge of operating and maintaining aging wastewater treatment facilities, while being faced with shrinking budgets, grows larger each and every day. It has been estimated that today=s replacement cost for our seven treatment plants would be over A BILLION dollars. Many of our plants are approaching, or have exceeded, their design life. Some of the equipment dates back to 1959, with some parts having to be manufactured in-house due to their obsolescence. The Department must stay on course with the long-term improvement plan. Besides capital improvement funding, annual operating budget money must be made available for new equipment, upgrade projects conducted in-house and out-sourced upgrades in order to protect our investment and meet regulatory mandates. In addition, adequate training and staffing levels need to be maintained to provide the manpower necessary to conduct the required maintenance of Department facilities. The Maintenance section was involved in the following projects during 2002: * HVAC Improvements at Metro and Oak Orchard (initiate and review design, monitor construction) * Metro Digester #2 Roof Repair (bid specification, monitor project) * New Screen and Grit Bldg. Dry Well Cover (design review, monitor construction) * Metro Ammonia/ Phosphorous Removal Project (design review, monitor construction) * CMMS Project (initiate and manage project) * Metro Primary Effluent Bypass Structure Weir Replacement (initiate and review design, monitor construction) * Metro Secondary Clarifier Improvements (design review, monitor construction) * Oak Orchard Odor Control System Project (design review, monitor construction) * Brewerton Sludge Thickening and Miscellaneous Improvements (design review, monitor construction) * Variable Speed Drive Upgrades (design review, monitor construction) * Baldwinsville Odor Control System (design review, monitor construction) * Jamesville Penitentiary Plant Conversion to Pump Station (facilities study, design review) * Harbor Heights Conversion to Pump Station (initiate project) * Roadway Repair (initiate and maintain ongoing project) * Roof Replacements (initiate and maintain ongoing project) These facility upgrade projects require the maintenance staffs support in the design process and during construction, interfacing with the contractors to accomplish major building construction/modification, equipment repair and replacement to keep the multiple projects on schedule, ensure quality equipment is purchased, properly installed and that process remains uninterrupted. Many staff hours are dedicated to de-watering and cleaning tanks, opening and closing valves and coordinating plant maintenance activities with construction efforts.

117

Operations Review

The plant maintenance section staff numbers have been reduced over the past several years due to budgetary constraints. At the same time, three new Odor Control Systems and a new Chemical Feed Facility have been placed on-line in the department, with a fourth Odor Control facility on the drawing boards. Maintenance has also taken on the chemical feed portion of two remote pump stations. All of these came with no additional staff. The Section is working under conditions similar to other departments, whereby facilities are aging at the same time they are expanding, requiring the staffs to perform with an increased level of efficiency. In some cases, major repair work must be contracted to outside firms, where there is insufficient staff and it is cost effective to do so. With the addition of a Mechanical Engineer to the staff in 2000, this division continues to get caught up on a backlog of projects that has existed for many years, many of which involved investigating problems and finding solutions that take many hours of research. This position is also utilized to review preliminary construction design to ensure that we get the best possible equipment, building, structure and process systems design and assist other sections in the department.

Plant Maintenance

Preventive Maintenance tasks represent approximately 50 % of the total workload with Corrective Maintenance and new construction tasks compiling the remaining 50 %. The numbers are expected to shift to a higher percentage of preventive maintenance through the use of the new Computerized Maintenance Management System. In addition to the routine daily care of existing equipment, buildings and grounds, a large and growing number of major repairs, rebuilds, equipment replacements and building repairs have taken place. An abundance of pumps, doors, large valves, compressors, pipelines, lawn hydrants and roof fan/exhausters have being replaced. Extensive roadway and roof repairs/replacements and the number of construction projects mentioned previously are indicative of the amount of repair/maintenance work done to the existing facilities that were built between 1959 and 1980. The 2002 accomplishments listed below include several process and money-saving improvements. They also show an increasing amount of modification work being completed in-house to keep up with the needs of other sections within the department. The ever-increasing workload will require careful review of staffing and funding considerations to keep pace with it.

South Maintenance Accomplishments

Metropolitan Waste Water Treatment Plant Harbor Brook Pump Station, New Screen & Grit, Existing Screen and Grit, Odor Control Building, Low Lift Pump Station, Plant Maintenance Building, and Administration Building. 118

* * * * * * * * * * * * *

Modifications to Stockroom Mezzanine Project Install a wind curtain on the stockroom overhead door to conserve energy when the door is required to be open to transport materials Install a new noise reduction curtain enclosure around the compressors in the large truck repair garage Engineered, fabricated and installed a guard rail system to protect the fire suppression equipment in the small vehicle repair garage Annual inspections on all three (3) Harbor Brook screw pumps, scrape, prime and paint rusted metal, cleaned and greased the pump main shaft bearings Fabricate and install new motor adjusting screws for #1 Harbor Brook screw pump De-water, clean and inspect all three (3) channels in Existing Screen & Grit Building. Replaced several hangers on the grit conveyor Rebuild the main screw conveyor drive gear box for number one (#1) Grit Channel, New Screen and Grit De-water, clean and inspect two (2) grit removal channels in the New Screen and Grit Building Begin seal modifications on the New and Existing Screen and Grit, grit collection system main screw conveyor drive right angle gear boxes to reduce failures Replace #2 influent screen rake carriage assembly Replace #1 effluent screen rake carriage assembly Replace all rubber pipe connector seals on the odor control piping

Primary Clarifiers, Aeration Tanks, Secondary Clarifiers, Tertiary Clarifiers, Bypass Chlorination, Plant Operations and Sewer Maintenance Buildings. * Replace the all thread hangers on all four of the secondary clarifier tanks ducking skimmer troughs and lower the troughs to coordinate with new effluent weir elevations. * Repair and reattach sludge draft tubes on #3 secondary tank. * Repair the skimmer trough for #4 secondary clarifier tank. * Replace a failed 12= section of the air header in H-tank aeration. * Drain, clean and inspect six (6) tertiary clarifier tanks. * Repair number one (#1) Tertiary main pump. Replace the main shaft bearings and seals. * Replaced the rotor and stator for the tertiary sludge pumps (2A & 4A). * Rebuild twenty-four (24) primary sludge pump suction side ball valve stems. * Rebuild 1A waste activated sludge pump, replace the bearing casing, impeller and suction volute casing. * Rebuild #7a Wemco primary sludge pump, replace the main shaft bearings, suction volute casing, impeller, wear sleeve, and packing box. * Remove motor on #8 primary scum pump and fabricate new motor base. * Remove failed mechanical seal on 3b Wemco primary sludge pump and replace with packing and new packing gland. * Drain, clean and inspect all four (4) secondary clarifier tanks. * Rebuild extra bearing box (rotating assembly) for waste activated sludge pump. * Replace the primary gear drive unit on #3 secondary clarifier tank. * Drain and clean #1 primary tank, remove pipe sections to check for restricted flow to 119

* * * * * * * * * * * *

pump. Modify valve handle access holes on top of Primary Scum Houses #8 and #2 to eliminate water infiltration. Repair or replace suction and discharge valves in Secondary Scum Houses - #7 and #2. Fabricate and install new belt guards on #8 and #5 Primary Scum Pumps. Remove, repair and replace number fifty-three (#53) power roof exhauster on the Plant Operations Building Roof. Rebuild six (6) automatic seal water panels used to support the return activated, waste activated and primary sludge pumps. Fabricate and install a new support bracket for the primary gallery steam line. Re-seal the roof joints on A North, F. North, and D. South aeration blower enclosures. Remove and repair all ventilation louvers on Primary Scum Houses. Custom fabricate and install blower vibration sensor brackets. Scrape and repaint five (5) aeration blowers. Repair the hand railing on the chlorine bypass tank. Replace the broken sample line on #1A return activated sludge pump.

Solids Handing

Digester Control House, Thickener Control House, Sludge Process Building and Sludge Dewatering Facility * Isolation, cleaning and inspection of main biogas lines. * Changed out three (3) gas separator tanks and auto drip traps. * Rebuilt two (2) biogas compressors. * Replaced fiberglass reinforced piping (FRP) on #2 sludge heat exchanger. * Refastened siding on #2 digester, repaired spots on roof and resealed siding to parapet wall. * Installed new heat trace and insulation on tanker off load piping. * Disassembled three (3) heat exchangers for cleaning * Rebuilt two (2) sludge hose pumps. * Cleaned and inspected three (3) sludge thickener tanks and replaced wiper arm material. * Removal and replacement of two (2) pumps for sanitary pump station * Cleaned sludge holding tank (3 times). * Cleaned centrate channel (3 times). * Rebuilt Serpentix conveyor and changed twenty-eight (28) conveyor pans. * Rebuilt belt wash booster pump number two (#2). * Installed pump-lifting gantry for booster pumps. * Filter press repairs- consisted of replacing ten (10) rollers, twenty-five (25) filter belts, thirty-two (32) bearings, three (3) mixing valves, twenty-two (22) cams and twelve (12) doctor blades. * Rebuilt two (2) sludge pumps. * Rebuilt Stranco Gen-2 polymer pump 120

HVAC/Chemical Buildings/Odor Control * Removed and replaced a/c unit compressor and condenser for Oak Orchard battery room. * Removed and replaced fifty-feet (50=) of one an one half inch (1-1/[email protected]) black iron steam pipe. * Removed and replaced (2) two drinking fountains. * Inspected the Plant Operation Building (POB) chimneys. * Installed manual bleeders on perimeter heaters on 3rd floor Administration building. * Relocated the ice machine in the Plant Operations Building. * Started up the heating system in Henry Clay Facility (HCF). * Repaired #1 boiler at HCF. * Drained and winterized cooling tower at HCF. * Cleaned and inspected the boiler for Sludge Process Building (SPB). * Remove and repair of Loop Pump for HCF. * Installed a new drip trap and drain line for the fourteen inch ([email protected]) Biogas Feed line in Chemical Gallery basement of POB. Chemical Handling * Drained, flushed and inspected five (5) chemical tanks. * Removed all sight glasses from sodium Hypochlorite tanks for safety reasons. * Removed and replacing five hundred-twenty feet (520=) of six inch ([email protected]) sodium hypochlorite solution feed piping. Odor Control Building: * Removed and replaced the belts and sheaves on main blower for Odor Control Building (OCB) air scrubber. Contracted out the following services: * Garage door inspection services and repairs. * Carpet cleaning of the Administration building third floor carpet (steam extract, rake and set pile). * Window washing of POB and Plant Maintenance Buildings. * Elevator maintenance. * Coverall and shop coat washing and rug rental. * Overhead crane inspections and repairs. Contractor Interface: Coordinated maintenance staff work activities with private contractor to accomplish the following tasks: * Ongoing interface with contractors involving the Ammonia and Phosphorous Removal project. * Secondary clarifier modifications. * Modification to primary effluent by-pass structures. * New screen and grit dry well enclosure project. * #2 Sludge Digester Tank roof replacement. 121

* * * * *

Hydro Laser services to clean three (3) water to sludge heat exchangers and fire tubes on three (3) 250 hp Cleaver Brooks Boilers. Inspection and repair of three (3) Plant Operations Building boilers and necessary fire tube replacements. Drained and cleaned two (2) sodium hydpochlorite tanks for repairs. Drained and flushed chemical lines and assisted in unplugging six-inch ([email protected]) PVC lines underground. Modifying reaction chamber at (OCB) with contractor for better odor removal.

Equipment Vibration and Alignment Services * Obtain oil samples from selected equipment and send out for professional oil analysis, review results and schedule required maintenance services to repair minor problems before they are allowed to escalate into more costly equipment repairs. * Equipment Vibration Monitoring and Laser Shaft Alignments were completed on an as needed basis. Building, Grounds and Utilities * Completed over twenty (20) U.F.P.O. Projects. (Locating underground utilities prior to excavation to prevent damage) * Re-organize the steel storage shed and fabricate a new steel storage rack that more efficiently uses the available storage space. * Flush, inspect and make necessary repairs to all lawn and fire hydrants. * Organize material and transport to County auction location. * Modify Metro Crew Leaders office. * Construct an interior wall for the 1st floor of pole barn. * Re-roof the carpenter shop wood storage shed. * Inspect and caulk all Administration Building windows. * Mobilize and operate a special gantry on the Plant Operations Building 5th floor roof to support a video camera used to inspect the inside of the boiler chimneys. * Painted Administration Building offices as required. * Repair or replace twenty-two (22) different department locksets. * Professionally fabricated metal and wooden signs as needed for the entire department.

North Maintenance Accomplishments

1. Baldwinsville B Seneca Knolls Waste Water Treatment Facilities * Raw Sewage Screen Rake B Replaced lifting cables and guide blocks on #1 screen rake. Adjusted #2 screen rake cables and guide blocks. Removed the obsolete level control (bubbler) system and built up grit in screen rake channel. * Raw Sewage Grit System B Installed chain wheel valve operators to grit blower valves to allow easier and safer valve control. Rebuilt and modified #2 blower base to allow laser alignment crew more accuracy with their alignment procedures necessary for extended equipment life. 122

* * * * * *

* * * *

*

* * * * *

Raw Sewage Pumping System B Verified the proper function of all related equipment in preparation for contractor replacement of drive units. Primary Clarifiers B Replaced wear shoes on all flight boards in primary tank #2. Completed minor adjustments to maximize operational efficiency. Primary Sludge System B Replaced damaged oil seal on #1 pump. Aeration Tanks B Removed aerator #1 from stage #1- train #2 and move to shop area for rebuilding. Process demands required the replacement of the aerator with aerator #1 from stage #2 - train #3. Replaced two 2= x 2= weir slide gates. Union Carbide Oxygen Generation System - Replaced an [email protected] butterfly valve, several control valves and actuators with replacements that have been rebuilt and tested in house by qualified personnel. Process Air Compressors B Assisted the electrical section with #2 Penn compressor motor replacement by removing and replacing the three-belt drive pulley on the damaged motor. Realigned the new motor with the compressor to ensure maximum pulley and belt life. Perform additional inspections and adjustments on all compressors to extend service life, minimize unscheduled equipment outages and maximize efficiency. Cooling Towers B Replaced the thermostats on both cooling towers and heating and ventilation unit #2. Instrument Air Compressors B Completed the installation of new compressors, piping, valves, holding tank and related equipment. Plant Air System B Rebuilt and installed one of the used instrument air compressors in the plant air system. (The plant air system is only used for a back up to the new instrument air system). Secondary Tank Systems B Removed old slide valves and resealed and caulked weirs on secondary tank #1 - stage #2. Replaced several collector chain sprockets including the drive sprockets on tank #1 and #2 - stage #1 and tank #2 - stage #2. Replaced all the flight boards on tank #3 - stage #2. Secondary Sludge System B Installed new pipe fittings to allow for piping access required to clean out obstructions with out pipe line disassembly on the return activated sludge pumps (RAS) #1 and #3. Rebuilt #1 RAS pump including new main shaft sleeve, bearings, and oil seals. Rebuilt #3 waste activated sludge pump (WAS) including main shaft wear sleeve, bearings, and oil seal. Tested all WAS and RAS pumps utilizing gauge readings to determine efficiency. Sludge Thickener Tank B Changed oil on drive units and evaluated wear on the concrete and steel structures on pre-thickener tanks #1 and #2, and post-thickener tanks #1 and #2. Sludge Handling Digesters B Coordinated work activities with the contractor during installation of a new valve and piping for connecting digester air with stage 1 aeration system to reduce odors. Digester Aspirator System B Repaired discharge/mixing piping on #5 and #6 aspirator pumps. Digested Sludge Pumps B Rebuilt #1 pre-thickener pump including oil seal and main shaft bearings. Modified the lubrication devices on the positive displacement piston pumps by installing automatic oilers. Sludge Disposal System (belt presses) B Rebuilt # 1 spray water booster pump and 123

*

* * * *

replaced filtering belts. Adjusted belt alignment on both units. Ferric Sulfate Chemical Feed System B Repaired ladders and removed sight tubes on both chemical tanks. Repaired or replace several valves, fittings, and chemical system related equipment. All repairs were completed and recorded to comply with state mandated regulations. Sodium Hypochlorite Feed System B Repaired or replace several valves, fittings, and chemical system related equipment. All repairs were completed and recorded to comply with state mandated regulations. Overhead Cranes B Completed minor repairs that were necessary for safety compliance. Yard Hydrants B Coordinate work activities with a contractor to replace one hydrant on the mulch bed associated with the new odor control system. Buildings, Grounds, Utilities, and Miscellaneous B The plant staff assisted the water back flow preventer technician with the yearly testing of back flow prevention devices necessary to verify proper function of all units to ensure that the facility drinking water remains isolated from process water and is of acceptable quality. Minor adjustments on doors and window units and various seasonal duties were completed.

2. Harbor Heights Waste Water Treatment Facility. The existing wastewater treatment facility is scheduled to be replaced with a new pumping station. The maintenance staff has repaired the aging, unreliable equipment at the facility to maintain process during the transition. 3. Brewerton Waste Water Treatment Facility * Raw Sewage Screen Rake B Reposition the sweep arm dampers as per manufactures recommendations. * Raw Sewage Grit System B Complete annual maintenance on the clamshell hoist. * Raw Sewage Pump System B Coordinate work activities with the contractor that is replacing the pumps. Rebuild the discharge check valve for #2 pump. * Clarifiers B Assisted operations personnel cleaning both tanks. Inspect and replace rubber on skimmer arms and adjust to achieve maximum skimming capabilities. * Sludge System B Recondition the old positive displacement pumps that are now being utilized to transfer sludge to the new drum thickener holding tank. Drain and clean the sludge holding tank and air diffusers to prepare for the manufacture inspection. * Digester Aeration System B Replaced old style ceramic air diffusers with new rubber more efficient style that will minimize plugging problems. * Blower System B Replace the obsolete air filtration system with new frame type filters, enabling the use of replaceable filter elements. * Ferrous Sulfate Chemical Feed System B Replaced several valves, fittings, and related chemical feed devices. All work and documentation was completed to comply with state regulations. * Sodium Hypochlorite (bleach) Chemical Feed System B Replaced several valves, fittings, and related chemical feed devices. All work and documentation was completed to comply with state regulations. * Plant Effluent Feed Water System B Disconnect the pumps from the motors to allow the motors to be removed and repaired. 124

*

*

Plant Air and Instrument Air System B Remove the obsolete instrument air compressor system and install a new refrigerant air dryer connected to the plant air system to meet instrument air demand and quality. Combining the systems will reduce associated operation and maintenance costs. Buildings, Grounds, Utilities, and Miscellaneous B The maintenance personnel are also responsible for Sawmill Pump Station and South Bay Pump Station. Complete the yard work, snow removal and other small projects with the assistance of the operational staff.

4. Jamesville Penitentiary Waste Water Facility * Blower System - Replaced the blower drive belt and laser aligned blower and motor to ensure maximum belt life and operating efficiency. * Chemical Feed System - Reconditioned the bleach feed pumps. All work and documentation was completed to comply with state regulations. * Digester System B Unplugged piping several times. Drain, clean and inspect the digester tank. * Buildings and Grounds B Extensive brush, snow removal and salting was required to keep the entrance road clear to enable tanker trucks to enter the facility safely. 5. Meadowbrook-Limestone Waste Water Treatment Facility * Raw Sewage Screen Rake B Replaced the complete carriage rake assembly during low flow conditions to allow for maximum working time. Repaired the slack cable alarm, changed turnbuckles, rewound and adjusted cable. The old carriage assembly will be repaired with existing parts and materials in stock and utilized as a spare unit. * Raw Sewage Grit Collection System B Installed new drive sprockets and chain. Fabricated a lifting device and anchored it to the ceiling to enable workers to work under safer conditions. * Heating Ventilation and Air Conditioning B Replaced the main shaft bearings and related mechanicals on #1 air handling unit and the Power Roof Exhauster located in raw sewage dry well. Replaced the shaft bearings on #1 and #2 Power Centrifugal Turbine Exhauster. * Aeration System B Remove grit from #2 aeration tank and make minor repairs on air monitoring tubing. * Aeration Blowers B Modified all blower base plates by installing jacking bolt assembles to allow accurate adjustments during laser alignment procedures. * Secondary Clarifiers B Installed a second layer of rubber to stiffen skimming function of sweep arm. Changed clamps on draw-off tubes in both tanks. Repaired scum discharge line on #1 tank. * Recycle Activated Sludge (RAS) Pumps B Assisted the operations staff with a system test to determine the maximum amount of time flow can be backed up in plant to accommodate valve replacements. * Waste Activated Sludge (WAS) Pumps B replaced the main shaft bearings on #1 WAS pump. * Digester Tanks B Installed new scum baffle in decanting tank #2. Removed weeds/small trees, and buildup of debris. * Rotary Drum Sludge Thickener B Modify [email protected] pipe to install a new flow meter. Switched the guide wheels and realigned the drum to ensure even wear and extended equipment

125

* *

*

* *

service life. Thickener Tank B Removed damaged aspirator pump and transported to the shop for rebuild (in progress). Cleaned and inspected the tank. Made temporary repairs on the tanker loading platform flexible joint. Sodium Hypochlorite (bleach) System B Replaced the majority of PVC pipe on the entire feed system and tested with city water pressure. Several valves, fittings, and related chemical feed equipment were replaced to keep system operational. All work was completed and documented to comply with state requirements. Ferrous Chloride System B Changed the fill port strainer element, strainer element deteriorates in a short period due to the characteristics of the product. Several other valves, fittings, and related chemical feed equipment were replaced through out the year. All corrective maintenance was completed and documented to comply with state requirements. Garage Upgrade B Since the garage project was completed it has become evident that the building has continued to sink/settle. The plant staff has been responsible for conducting a test to determine how much and how fast it is settling. Buildings and Grounds. B The entire staff at this facility has contributed many man-hours of lawn care, landscaping, and snow removal.

6. Oak Orchard Waste Water Facility * Raw Sewage Screen Rake System B Installed a new gearbox on #1 screen rake. Steam cleaned both units and area surrounding machines to promote a safe work environment and extend equipment life. * Raw Sewage Grit Collection System B Assisted the operations staff with cleaning grit from system that collects in a dead zone of the tank where the clam bucket will not effectively remove it mechanically. * Primary Tanks B Replaced the cross collector chain in #2 tank. Repaired four cog bridge wheels and adjusted and realigned them as needed. * Primary Sludge Pumps B Rebuilt #1 and #2 piston pumps, including new pistons, cylinders, packing, and check balls. Installed a third piston pump as a backup to the primary system utilizing spare parts. * Aeration System B Routine monitoring on mixing units. Winterized mixer seals with food grade antifreeze. * Oxygen Production and Storage Equipment B Replace two valve actuators with rebuilt units that routinely in stock. The liquid oxygen evaporators were thawed out with water several times. * Process Air System B #1 and #2 Penn compressors were partially rebuilt. Complete inspections (internal/external) and minor adjustments were conducted to maintain peak operation and prevent unscheduled outages of the compressors because of their age. * Instrument Air B routine inspections and adjustments made as needed. * Secondary Tanks B Replace the main chain in #1 and #4 tanks and install new bottom rails. Clean, inspect and adjust the chain in the remaining four tanks. * Secondary Sludge System B Both the WAS and RAS pumps have been thoroughly evaluated and all have had the impeller clearances checked and adjusted. * Plant Water Pump B Replace the shaft bearings and mechanical seals. Instrumentation

126

*

*

*

* * *

adjusted drive settings to give operations better water flow when needed. Phosphorous Removal Chemical Feed System B Both chemical pumps were rebuilt and tested on Oak Orchards metering pump test bench. Several leaking valves, piping, fittings have been repaired or replaced. All work and documentation has been completed and recorded to comply with state chemical regulations. Sodium Hypochlorite (bleach) System B There are two separate bleach systems each consisting of two metering pumps, controls, monitoring equipment, spill containment=s, and delivery points and containment=s. One system located in [email protected] building utilized for the new odor control equipment. The second is located in the disinfection building formally the Chlorine building and is used for the final treatment of the wastewater before it is discharged into the river and is a seasonal application. Both systems have had yearly pump rebuilding and several piping modifications, in all cases modifications have been performed to allow more convenient access for maintenance or operations. All repairs for both systems have been completed and recorded to comply with state regulations regarding chemicals. Odor Control Chemical Feed System B The system incorporates two chemicals. One, Sodium Hypochlorite (bleach) was addressed in the previous section. The second chemical utilized in the systems is Sodium Hydroxide (caustic). Both feed pumps were rebuilt, tested, and returned to service. Numerous CPVC valves, fittings, and related chemical feed equipment were replaced or repaired. This is the only chemical we use that requires CPVC valves, fitting, and other apparatus because the chemical has the characteristic of producing heat, CPVC will handle up to 150 degrees. Polymer Chemical Feed System (sludge settling aid)B Rebuilt both Polyblend units and two polymer solution transfer pumps. Heating, Ventilation, and Air Conditioning System B Several condensate lines were repaired. Numerous steam traps were repaired and bench tested. Three heating units, #7, #8, and #9, were repaired. Buildings, Grounds and Utilities - Performed landscaping, lawn care and snow removal at this facility and Davis Road Pump Station. To enhance the lighting around the front gate so that the video security monitoring equipment function properly the staff relocated one light pole and installed a second light pole.

7. Davis Road Pump Station * Raw Sewage Pumps B #4 main pump was removed and transported to the Ley Creek shop for repairs and returned to service. The wet well and dry well was thoroughly cleaned after the spring high flows and flooding. * Sodium Hypochlorite (bleach) Chemical Feed System B #2 bleach pump was rebuilt and returned to service. Numerous valves, fittings, and related chemical feed system equipment were repaired. All repairs were completed and recorded in order to comply with state chemical storage regulations. · Buildings and Grounds B Several locks and doors were repaired with assistance from our carpenter shop. The Oak Orchard staff is responsible for lawn care, snow removal, and fence repairs. Completed extensive landscape repairs that the recent construction created the need to perform.

127

8. Gaskin Road Pump Station Chemical Feed System Sodium Hypochlorite (bleach) Chemical Feed System B Rebuilt both chemical feed pumps. Numerous valves, fittings, and related chemical feed equipment were repaired or replaced. All work on the facility chemical feed system was completed and documented in order to comply with state mandated regulations 9. Wetzel Road Waste Water Treatment Facility * Raw Sewage Screen Rake System B The aging screen rake system has been completely rebuilt, including new main shafts, sprockets, chain, ware shoes, structural steel, and rakes. * Raw Sewage Grit Collection System B The sump pump was replaced in grit pump area. The grit classifier and related equipment required only minor adjustments. * Raw Sewage Pump System B Test the [email protected] potable pump periodically. Bee/wasp control around the pump was required during the warm weather. Flow matcher drive units were flushed, cleaned and filled with new solution. * Primary Clarifier Tanks B #1 and #2 tanks were drained and cleaned to perform inspections and necessary repairs. Several chain sections were replaced. A malfunctioning safety/shear device caused the need for extensive emergency repair, the mechanism was repaired and all other shear devices were checked and repaired as needed. * Primary Sludge Pumps B The pumps are routinely rebuilt and stored to allow for a quick switch minimizing down time for process. * Trickling Filter System B Several times a year during warm weather the filtering media is saturated with a bleach solution to disinfect tanks. The process piping was cleaned to maximize flow to the system. * Effluent Pump System B Flow matcher drive units were flushed and filled with new solution. Performed minor pump adjustments necessary to maintain efficiency. * Filter Re-circulation Pumps B Performed minor adjustments. * Secondary Clarifier Tanks B Safety shut off devices were checked and calibrated. Tanks were cleaned and inspected. * Secondary Return Sludge Pumps B Replaced pump, rebuilt pumps are available for a switch to minimize process down time. * Sludge Digesters - #2 digester developed a gas leak in the cover that was repaired with the assistance of the operational staff and sludge-hauling group. The leak was located and a patch was welded in and tested. * Sludge Distribution System B Change the pulley size on the newer pump to slow down the flow to extend the retention time of sludge in the heat exchanger to increase the heat transfer. One valve was replaced on system and new seal water regulators were installed. * Sodium Hypochlorite Chemical Feed System (bleach) B Sight glasses were removed on both chemical storage tanks and are not necessary because the tanks are transparent and the liquid level is visible. Plugging chemical feed pumps were a problem and they required frequent cleaning and flushing. The pump plugging was caused by contamination in one of the tanks that was drained and flushed eliminating the problem. Several valves, fittings, and chemical related equipment was replaced or repaired. All required work was completed and recorded in order to comply with state regulations.

128

*

*

Ferric Chloride Chemical Feed System B Several valves, fittings, and chemical related feed devices were replaced or repaired. All required work was completed and recorded in order to comply with state regulations. Replace the stairway anchors and repair the heating and ventilation system. Buildings and Grounds B The maintenance staff is responsible for snow removal, landscaping, lawn mowing, painting, and record keeping.

10. Sawmill and South Bay Pump Station Chemical Feed Systems B The maintenance staff is responsible to maintain the chemical feed systems. C A common occurrence with both systems is pipe and fitting leaks and numerous repairs have been made. Repaired the truck unloading containment area several times because of damage caused by the chemical delivery truck. C All work was completed and recorded in order to comply with state regulations. C Two new different style chemical feed pumps were installed at Sawmill. The cost to replace the existing pumps (non-repairable) in kind was much more then the cost to purchase two new repairable pumps. C Replaced approximately 350 feet of discharge polyethylene tubing at both facilities. INVENTORY CONTROL AND STOCKROOM OPERATIONS The inventory control sections mission is to strive to provide the highest level of quality customer service possible, while continuing to seek and implement ways to improve the overall efficiency of the inventory control operation. Improvement is continuously being sought through enhancement of policies, procedures, and departmental standards that streamlines the inventory control functions and supports the customer service needs employees of the department, so that in turn they can more rapidly serve the taxpayers of Onondaga County. The following report details the numerous accomplishments that the inventory control staff has achieved while operating the Departments four main storeroom facilities at the following locations, Metropolitan Syracuse B (Main Storeroom), and (Fleet Storeroom), Oak Orchard, and Ley Creek storerooms.

129

1. General Accomplishments

(A) CMMS B Maximo inventory control automation project During 2002, this project has been a primary focus of the inventory control section, and has been implemented in the Metropolitan Syracuse B (Main), Oak Orchard, and Ley Creek Storerooms. The inventory control staffs involvement has been with the continued preparation for, the implementation of, and the beginning of the actual usage of the CMMS B Maximo inventory control automation software. This includes the following related aspects of the project. * Assisted the Stearns & Wheler consulting staff with the data collection phase of the project. * Began the actual usage of the Maximo inventory control automation software, for the materials issuance, materials receiving, materials ordering, and the conducting of physical inventories phases of the inventory control functions. * Performing of the related AQA B [email protected] (Quality assurance and quality control) review and correction of the data collected, phase of this important project. * Attend the necessary training to ensure the proper usage of the Maximo software. * Began to recommend the development of Maximo generated inventory control custom reports. * Continued to adapt and modify certain inventory control storeroom operational procedures, to ensure a [email protected] and proper transition to the new Maximo inventory control automation software. * The continuous evaluation of the overall performance of the Maximo software, and any related inventory control or general business functions.

130

(B) Inventory Valuation Project The inventory control section took the lead in determining the value of all inventories throughout the department for the dual purpose of preparing to create the Asatellite [email protected] in the Maximo software where parts, supplies and materials are stored at facilities outside of the normal stockrooms and to comply with a requirement to report the overall year-end department inventory value for the County=s financial statement. Completing the work for the stockrooms already using Maximo software, the following work was performed: Metropolitan, Oak Orchard and Ley Creek Stockrooms* Running reports to list inventory line items in Maximo that need pricing information entered into the system. * Work in cooperation with field supervisory staffs to obtain pricing information for specialized materials, for entry into Maximo where needed. * Obtain and enter pricing information into Maximo for standard stock materials. Satellite Stockrooms: * Work in cooperation with field supervisory staffs to assist with the coordination and review of inventory and materials pricing information that was collected. * Forward inventory information collected and reviewed to designated clerical staff member for data entry into Microsoft Excel database. Provide informational or instructional assistance as needed. Fleet Maintenance (Metropolitan, Liverpool, and Burnet Ave) facilities. * Conducted physical inventories of parts and materials, resulting in 3,536 inventory line items being inventoried at the three facilities. * Work in cooperation with fleet maintenance field and supervisory staffs to identify the parts or materials, or to obtain pricing information as needed. * Entered the information collected into a Microsoft Excel database for inventory value calculation, and potential future use for the creation of an automated inventory control database. (C) Storeroom reorganization project This project has involved the entire inventory control group. The primary goal of this continuous reorganization project is to utilize the available storeroom and materials storage areas in the most efficient manner. Individual storeroom accomplishments are detailed later in this report. (D) Collection of Hazardous Materials for disposal During 2002 the inventory control staff continued to collect used lighting lamps containing mercury and dry cell batteries for proper disposal. These items were collected at the four primary storerooms, Metropolitan, Fleet, Oak Orchard & Ley Creek. (E) Space Utilization study & design Members of the inventory control team have been working in cooperation with other Departmental groups to participate in a space utilization study & design for specific areas within

131

the Department that will be vacated when the new Henry Clay Facility opens in 2003. This project also includes participating in the design of the new Henry Clay storeroom facility. The overall goal of this project is to utilize all available space in the most efficient manner. (F) Asset, property identification and bar code labeling project. The Inventory Control Supervisor worked in cooperation with the Onondaga County Materials Management Coordinator on this project to identify and bar-code label a total of 110 assets.

2. Individual Storeroom accomplishments

Although each of the four individual storerooms within the inventory control section is part of the inventory control team, each storeroom made the following individual accomplishments, that were in addition to the above listed group accomplishments. (A) Metropolitan (Main) Storeroom Storeroom reorganization project Progress continued with the reorganization of the Metro storeroom facility, and related materials storage areas, resulting in the following accomplishments:

Number of New Shelf Bins Created 460

Number of Line Items Reorganized 830

Number of Shelves Reorganized 170

Number of New Shelves Added Or Changed 20

Number of Bar Code Labels Created 85

This project also included the reorganization of two first floor primary materials storage areas B (bays) of the Metro pole barn. This allowed for the fabrication of a new pipe storage rack and a new steel storage rack that were placed in one of the bays of these reorganized areas. This resulted in 70 line items being reorganized within these areas. In addition a portion of the second floor storage area of the pole barn was cleaned and reorganized, allowing for obsolete materials to be identified, and were being prepared for auction. Shipment and materials staging and receiving area Progress continued with the creation of a shipment and materials staging and receiving area. This area is being created to accommodate the need for an area within the Metro storeroom facility that would be dedicated specifically to receiving shipments and materials. This area will allow for an efficient flow of shipments or materials throughout the Metro storeroom facility. This area will include; * A materials receiving and sorting counter for conducting Quality Assurance and Quality Control (QA-QC). * QA-QC inspections of materials that have been received.

132

* * *

A materials staging area for materials to be staged the will either be placed into stock, have vendor discrepancies, or are awaiting other status. A shipment staging area, for the shipments that are either for the storeroom or other departmental sections and are awaiting pick up by the designated ordering party. A clerical work station or desk area that has a computer that is designated for materials receiving information data entry into Maximo.

Installation of new HVAC B (Heating, Ventilation, and Air conditioning system) During 2002 a new HVAC system was installed in the Metro storeroom. This will accomplish the following: * Provide an climate controlled environment that will allow for materials to achieve their maximum shelf life potential. * Provide a climate controlled work environment that is conducive to employee productivity, and is relatively free of harsh environmental employee stress factors such as heat, humidity or cold. * Frequent moving of materials to accommodate ductwork installation and the cleanup of incidental dust and debris from shelving units and materials was completed by the inventory control staff. Employee apparel B (coveralls & shop coats) A group [email protected] pilot [email protected] During 2002 the Metro storeroom staff was involved with a test B pilot program that would issue employee apparel to a specific work group in quantity, instead of issuing individual apparel to employees at the service counter. This pilot program has resulted in the following initial findings: * Decreasing service counter traffic, shortening the waiting line for parts pick-ups. * Allowed the employees within the monitored work group to focus more on their specific work activities, by having the apparel more readily available in their designated work area. * Allowed for the Metro storeroom staff to concentrate more on their specific inventory control activities, initially resulting in an improvement of operational efficiency. Obsolete materials identification program The Metro storeroom staff continued with the process of identifying obsolete materials. This has resulted in 165 inventory line items being identified as obsolete. This material will be prepared for auction, and the auctioning process will be coordinated through the Onondaga County Materials Management Coordinator. (B) Metropolitan (Fleet) Storeroom & Satellite Storeroom Areas During 2002 the inventory control staff continued to evaluate and improve the various services and functions provided by the Fleet storeroom facilities. The Fleet Storeroom consists of three primary storeroom areas located at the Metro, Liverpool Garage, and Burnet Ave facilities and is staffed by a Storekeeper. These storeroom facilities supply the fleet section with the necessary automotive related parts for vehicles and ground

133

equipment at several Onondaga County Departments including: * Department Of Water Environment Protection. * Sheriff=s Department. * Parks Department, including facilities located at: (Beaver Lake Nature Center, Carpenter=s Brook Fish Hatchery, Veteran=s Cemetery, Highland Forest, Hopkins Road Park, Jamesville Beach, Onondaga lake Park, Oneida Shores, P&C Stadium, and the Rosamond Gifford Zoo. Accomplishments: * Completed initial facilities assessment of the fleet storeroom facilities. * Began evaluation of services provided. Examples: Customer service volume and parts & materials ordering volume. The evaluation results will be used to increase the overall efficiency of operation of the fleet storeroom facilities. * Storeroom reorganization project: The fleet storeroom facilities were continuing to be reorganized, resulting in 1,600 total line items reorganized, 54 total shelves reorganized and the fabrication of 2 new wooden shelving units, resulting 10 new shelves being available for parts storage. (C) Oak Orchard Storeroom Reorganization Accomplishments: Total number of new shelf bins created with labels 57 Total number of line items reorganized 225 Total number of shelves reorganized 162 Total number of new shelving units added 2 Total number of new shelves added 14

(D) Bldg. Cage Area: Installed second access door for more efficient access. Added additional roof bracing and repaired the floor and continued reorganization of the upstairs auxiliary storage and tool crib area. During 2002 a new Heating, Ventilation, and Air conditioning system was installed in the Oak Orchard storeroom. This provided a climate controlled environment that will allow for materials to achieve their maximum shelf life potential and provide a work environment that is conducive to better employee productivity. This also involved the frequent moving of shelving units and materials to accommodate ductwork installation and the routine cleanup of dust and debris from the construction. (E) Ley Creek Storeroom Reorganization accomplishments * Total line items reorganized - 2,045 * Completely reorganized the tool room, front customer service area, bolt room and the Downstairs auxiliary cage area.

134

* * *

Reorganized books containing Onondaga County purchasing contracts. Reorganized vendor information file Completed reorganizing of MSDS information listing

General accomplishments: * Continued to archive old documents * Instituted storeroom opening and closing procedures. * Inspected first aid kits for out of date B expired items * Instituted weekly storeroom cleaning schedule.

Customer Service

The primary function of three of the primary storerooms located at Metro Oak Orchard and Ley Creek facilities is to provide as high a level of quality customer service as possible. The tables below represent the customer service volume that was handled by each respective storeroom. Customer Service (Transactions) STOREROOM Metro Oak Orchard Ley Creek Grand Totals General Materials 15,937 5,115 5,291 26,343 Tools 6,097 4,376 914 11,387 Apparel 1,613 387 379 2,379 Total Transactions 26,343 11,387 2,379 40,109 Totals 23,647 9,878 6,584 40,109

SERVICE TRANSACTION TYPE General Materials Tools Apparel Grand Totals

The table below indicates the types of customer service transactions that were provided by each storeroom during 2002. The number of customer service transactions is followed by the estimated percentage of that type of service provided. STOREROOM Facility Metro Oak Orchard Ley Creek Grand Totals General Equipment Materials Issued Tools On Loan (Tool Crib) 15,937 = 67% 5,115 = 52% 5,291 = 80% 26,343 6,097 = 26% 4,376 = 44% 914 = 14% 11,387 Apparel Issue & Return 1,613 = 7% 387 = 4% 379 = 6% 2,379 Total Annual Transaction s 23,647 9,878 6,584 40,109

135

Customer Service B (Customers Serviced) Storeroom Total 2002 Customers Serviced Metro Oak Orchard Ley Creek Grand Totals 16,951 9,605 5,438 31,994

Difference In Total Customers Serviced Between 2001 & 2002 -3,043 -1,145 -159 -4,347 = (-8.8%)

Metro (Main Storeroom) Customer Service Percentage The following table represents the approximate percentage of employees serviced by Departmental Section. This percentage is based on the 16,951 customers serviced by this facility.

Departmental Section Metro Plant Maintenance Instrumentation & Electrical B (South) Fleet Maintenance Administration B (Including L.I.P.O.) Engineering & Laboratory Services Outlying Plants Metro Plant Operations Flood Control

Annual Percentage 56% 15% 9% 6% 5% 4% 3% 2%

Oak Orchard Storeroom - Customer Service Percentage The following table represents the approximate percentage of employees serviced by Departmental Section. This percentage is based on the 9,605 customers serviced by this facility. Departmental Section Oak Orchard Plant Maintenance I&E B North Oak Orchard Plant Operations Sewer Maintenance Wetzel Road Oak Orchard Laboratory Baldwinsville Plant Meadowbrook Limestone Plant Metro B Plant Annual Percentage 63% 13% 9% 9% 2% 1% 1% 1% 1%

Ley Creek Storeroom - Customer Service Percentage The Ley Creek Storeroom primarily services the employee of the Flood Control & Flow Control sections. This customer service volume accounts for approximately 90% of annual 5,438 annual customer service volume at this facility. The remaining 10% of the annual 5,438 customers

136

serviced are divided amongst the other Department sections.

Materials Ordering

During 2002 the inventory control staff at the Metro, Oak Orchard, and Ley Creek Storerooms submitted and processed as total of 386 orders. The table below represents the number of orders that were submitted and processed by the inventory control staffs at these facilities. Also shown are the estimated annual encumbrances for the same respective Storeroom staffs.

Storeroom Facility

Metro & Oak Orchard Ley Creek Grand Totals

Total Orders Processed

188 198 386

Estimated Encumbrances

$185,848 $354,840 $540,688

M.O.S. - (Mutual Ordering System)

During 2002 the Inventory Control Section continued utilizing the Mutual Ordering System (M.O.S.), that was originally implemented in the year 2000. The M.O.S. is a mutually cooperative system of combining orders for general commodities between the facility Storekeepers of the individual storerooms at Metro, Oak Orchard, and Ley Creek. Prior to the implementation of the M.O.S. the three facility Storekeepers at different time of the year would each write an individual order for the same type of general commodities, resulting in excessive paperwork and labor costs. Now anytime that an individual Storekeeper needs to order more general commodities the other two Storekeepers are consulted and one Amutual (M.O.S.) order is submitted. During 2002 a total of 79 M.O.S. orders were written, resulting in an estimated order processing cost savings of $7,900. The table below represents the accomplishments of the M.O.S. for the first three years of the programs existence.

Year 2000 2001 2002 Grand Totals

Total M.O.S. Orders Written 56 73 79 208

As a result of the three-year existence of the M.O.S. there has been an estimated total order processing cost savings of $20,800. This estimate is based on an estimated order processing cost of $100 per order written.

137

Shipments & Parcels Received During 2002 the Inventory Control staffs at the Metro, Oak Orchard & Ley Creek Storerooms received shipments and parcels designated for virtually every section of the Department. For each shipment that is received the receiving process includes, all documentation involved, the notification of the employee that ordered the material, temporary storage until the shipment is picked up by the employee that ordered the material and in some cases the arrangement for and the actual delivery of shipments to the designated ordering section or employee. The following table indicates the number of shipments and parcels that were received by each storeroom during 2002. Storeroom Facility Shipments Received Parcels received Metro 1,460 4,093 Oak Orchard 247 1,176 Ley Creek 221 1,066 Grand Totals 1,928 6,335

6. Goal of the Inventory Control Section

The goal of the Inventory Control Section continues to be to improve the overall efficiency of operation, utilizing the following methods: * * * * Continue with the storeroom reorganization effort Continue to utilize and develop operational methods allowing for the new CMMS B Maximo system to perform to it=s fullest potential. Continue to seek develop, and implement operational policies and procedures. Continue to seek, develop, and implement ways to save money, through the monitoring of materials issued, thereby reducing the volume of materials being ordered.

Conclusion

It is the belief and commitment of the Inventory Control Section that there are always to improve the overall efficiency, and to always continue to seek, develop and implement ways to achieve their goal of continuously seeking to improve the overall efficiency of operation of their respective Inventory Control facilities, while continuing to strive to provide the highest possible level of customer service possible. The Inventory Control Section remains committed to make every effort possible to service the taxpayers of Onondaga County in the most efficient manner possible.

138

12.6 Engineering and Technical Services

This service provides engineering and technical support for a wide variety of programs and projects for several sections and divisions of the department. Typically, the Mechanical Engineer provides assistance in construction design review; troubleshooting operating, mechanical and structural problems; evaluation of equipment and structures for upgrade or repairs and preparing specifications and drawings for contracting out minor work projects.

Highlights of this year= s work include the following: = * Review and update the department=s new construction design criteria. * Trouble shoot and recommend repair procedures for Syracuse Metropolitan WWTP (Metro) #1 main tertiary lift pump. (The pump was experiencing low performance and high vibration operating conditions caused by a failed main shaft bearing and a partially plugged suction pipe.) * Review design documents and drawings for the new Metro secondary pump station wet well and comment on possible omissions, design changes and improvements. * Draft Metro=s sodium hypochorite (disinfectant) header configuration and supply to the sanitary engineering section to assist in cleaning activities. The pipe header is frequently fouled by calcium carbonate build up that reduces the inside diameter of the pipe header restricting flow and eventually completely plugging the pipe if not removed. * Investigate, recommend and supply required information to purchase a calcium carbonate

139

* * * * * * * * * *

* * * * * * * * * * *

electronic pipeline descaler unit for Metro=s disinfectant supply header. Review Metro=s Sludge Process Building six-inch ([email protected]) potable (drinking water) pipe header section replacement contract documents, drawings, material submittals and shut down/start up procedures and comment on omissions, changes or improvements. Review design documents and drawings for Metro=s New Screen and Grit Building fiberglass dry well cover and heating and ventilation system and comment on omissions, changes or improvements. Assist the Metro Maintenance staff in testing more cost-effective odor control mist generator nozzles. Review Metro and Oak Orchards heating, ventilation and air conditioning upgrade design documents and drawings and comment on omissions, changes or improvements. Investigate Meadow Brook Limestone WWTP digester tank #2 aeration system condition and performance. Supply improvement options and construction budget estimate. Review material submittals for the department=s variable speed drive and pump upgrade. Assist the Metro maintenance staff in trouble shooting and correcting low speed cavaiton/performance issues on the plants main influent pumps. Design, purchase and coordinate installation of a noise reduction curtain enclosure for the air compressors located in the automotive large vehicle repair garage. Originate design documents, drawings and construction budget estimate for Metro=s fenceline security improvements. Originate design documents, drawings and construction budget estimate for Baldwinsville WWTP liquid oxygen hot water bath vaporizer replacement with an ambient air vaporizer system. The proposed new system will eliminate the heavy electrical power demand required by the existing non-efficient hot water bath system. Review Metro=s fire suppression improvement design documents and drawings and comment on omissions, changes or improvements. Design, supply shop drawings and coordinate construction of a fire protection riser guardrail system that was installed in Metro=s automotive small vehicle repair garage. Review Baldwinsville WWTP odor control project design documents and drawings and comment on omissions, changes or improvements. Review Metro=s primary effluent by-pass structure replacement design documents and drawings and comment on omissions, changes or improvements. Assist the construction section with technical specifications and project coordination for the repair and recoating of the roof on Metro=s #2 Digester Tank. Review preliminary design documents for Wetzel Road WWTP and Saw Mill Creek Pump station upgrade project and comment on omissions, changes or improvements. Review Metro=s contract drawings, edit and prepare for scanning in the computerized maintenance management system. Assist the maintenance staff with the scheduled shut down, cleaning and video inspection of the inside of the Metro Plant Operation Building boiler exhaust stacks. Review and prepare Metro=s Sludge Dewatering Facility operation and maintenance manuals for scanning in the computerized maintenance management system. Review replacement necessity of Metro=s thickened sludge pumps inlet pulse accumulators and supply material identification information and cost estimate. Review Metro=s cellular communication sites design drawings and comment on omissions,

140

* *

*

changes or improvements. Evaluate the application and performance of the Metro chlorine by-pass tank dewatering pumps and recommend upgrade. Order new more corrosion resistant pumps with improved performance, review equipment submittals and recommend bid award. Originate a draft for a request for proposal to select a consultant to supply contract documents, drawings and construction phase services to replace several of the departments obsolete or worn out mechanical screen rake machines with new climber screen machines at multiple locations. Identify services required to evaluate the existing performance and condition of Oak Orchard and Baldwinsville WWTP - Union Carbide oxygen production equipment and contact a profession service contractor to provide project options and budget estimate.

141

Information

Chapt12 Fac Maint.doc

30 pages

Report File (DMCA)

Our content is added by our users. We aim to remove reported files within 1 working day. Please use this link to notify us:

Report this file as copyright or inappropriate

687330


You might also be interested in

BETA
บทความ
Brochure-Pamav-Substation-2010.cdr
untitled