Annual Report 2001

4.0
Maintenance Services

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Annual Report 2001

4.0 Maintenance Services

Maintenance Services is responsible for maintaining and optimizing the more than 10,000 pieces of process equipment at the Gold Bar Plant and related sites, specifically the Clover Bar Biosolids Recycling Facility, Poundmaker Wastewater Transfer Station, and the sludge and supernatant distribution system. They also provide support services for the flare stations and landfill wet wells owned by the Waste Management Branch. Custodial services at the Gold Bar Wastewater Treatment Plant, provided by four custodians of the Land and Buildings Branch, report to the General Supervisor of Maintenance Services.

Installed new shear pin sprockets on all collector drives of secondaries 1 8. Inspected and repaired all mixers in secondaries 9 and 10. Inspected and repaired chains, sprockets as required in #9 secondary. Broken cross collector chains and flights in secondary #8 repaired and replaced. Installed a gate operator at the main gate, and control system in main control room. Replaced oil pump for #6 aeration blower, and the shear pin on vane control of #5 aeration blower. Cleaned and inspected #2 boiler, replacing one bad tube, and installed new front door kit on #3 boiler. Cleaned, inspected, overhauled Fermenter Odour blower. Overhauled motor and gearbox on Fermenter drive.

4.1 Maintenance Highlights 2001

In addition to the regular preventive and demand maintenance, the Maintenance sub-section was heavily involved in the upgrade of the secondary bioreactors to BNR, which was wrapped up in late December. A number of additional projects are listed below. Overhauling heat exchangers for digesters #1 3, which included replacing circulating pumps and installing sonic level measuring instrumentation. Radar Level monitor installed in Digester #2. Installed Mag-Meter and low flow protection at the sludge transfer pumps, for sludge transfer to Clover Bar Biosolids Recycling Facility. Replaced Rotork actuators on grit tanks #1, 2, 3, and 5, and replaced #5 grit gate inlet actuator with new unit. Replaced chains and repaired sprockets on #4 bar screen. Completed replacement of all chains and sprockets in primaries 7 and 8. The second tier flights (which were overloading the chains) on the secondary clarifier collector chains were removed from all but # 2 clarifier, which will be removed in 2002. Inspected, shortened and replaced broken chain links and flights in secondary #9.

4.2 Equipment Inventory

Electrical and mechanical foremen schedule equipment servicing and inspection checks using a Maintenance Management Program (MMP). Equipment type, priority (A, B, C), repair /response guidelines and limits for failure downtime are recorded. Equipment, which excludes laboratory equipment, refers to any pump, motor, or instrument for process control. Equipment is classified as A, B or C, with A being the most critical from an operational and safety standpoint.

4.2.1 Priority A Equipment

A piece of equipment that when non-operational due to an electrical, mechanical or instrumentation malfunction will cause: 1. A safety hazard; 2. A significant detrimental effect upon the wastewater treatment process. Priority A equipment requires an immediate trouble response, with prompt repair or replacement. Priority A equipment, totaling 10,200 pieces in 2001, receives frequent scheduled inspections.

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4.2.2 Priority B Equipment

A piece of equipment that when non-operational due to an electrical, mechanical or instrumentation malfunction will cause: 1. A detrimental effect upon the wastewater treatment process. This equipment, which totaled 3,150 pieces in 2001, requires a trouble response within 24 hours and will normally have a downtime tolerance of up to 30 days. Scheduled inspections are required on all such equipment.

4.3 Scheduled Preventive Maintenance

Scheduled preventive maintenance on electrical, instrumentation, and mechanical equipment in 2001 was performed according to the following inspection frequencies.

Electrical and Instrumentation Inspection Frequency

2001 Daily Weekly Monthly Yearly Sub total 21,460 27,690 25,305 2,510 76,965 2000 21,862 27,144 25,092 2,462 76,560 1999 22,100 25,792 24,180 2,344 74,416 1998 21,840 25,740 23,280 2,375 73,235 1997 16,380 26,468 27,900 2,069 72,817

4.2.3 Priority C Equipment

A piece of equipment that when unserviceable will not cause a safety hazard or a detrimental effect upon the wastewater treatment process. Priority C equipment requires a response within four days, with a downtime tolerance exceeding 30 days. In 2001, there were 200 such items, or 1.5% of the total.
Equipment Type Priority A Priority B Priority C Total Equipment Listed 2001 10,200 3,150 200 13,550 2000 8,615 2,280 158 11,053 1999 8501 2257 158 10,916 1998 8,215 2,244 158 10,617 1997 6,621 734 143 7,498

Mechanical Inspection Frequency

2001 Daily Twice Weekly 3 times Weekly Weekly Bi-Weekly 153,843 1982 1735 30,510 830 9480 250 14106 6 120 198,756 2000 155,662 1,860 1,674 29,486 843 8,936 284 1,048 6 104 199,903 1999 143,290 1,692 1,712 29,182 863 8,875 297 1,056 6 104 187,077 1998 134,677 1,900 1,260 42,767 1,063 9,043 663 1,510 6 46 192,935 1997 189,020 624 2,070 81,048 1,930 5,551 1,008 1,024 144 60 282,479

Work Orders
In 2001, 1,055 work orders were issued for maintenance action, an increase of 172 from the 883 in the previous year. They are listed below by equipment priority rating.
Work Orders Issued Priority A Priority B Priority C Total W.O.s 2001 920 115 20 1,055 2000 819 55 9 883 1999 794 93 16 903 1998 713 273 49 1,035 1997 950 150 28 1,128

Monthly Bi-Monthly Quarterly Semi-Annually Yearly Sub Total Annual Total (Elect. and Mech.)

275,721

276,463

261,493

266,170

355,296

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Annual Report 2001

4.4 Equipment Downtime

Failure downtime of Priority A equipment is measured in hours from the time that the malfunction was reported to when the repair (or replacement) was completed. Maintenance downtime hours are those resulting from Priority A equipment failure prior to any preventive maintenance being taken, whereas non-maintenance refers to all other failures. A monthly breakdown of hours for these two categories appears in the following table; they apply to the Gold Bar Wastewater Treatment Plant only.

4.5 Utility Usage Gold Bar Wastewater Treatment Plant

Yearly totals for the three utilities at the Gold Bar Wastewater Treatment Plant power, water and natural gas appear in the following tables for 1997 2001. Utility charges for the Clover Bar Biosolids Recycling Facility, which do not appear here, were mostly for power used in supernatant pumping. (See Operations chapter for supernatant pumping volumes.)

Table 10: Summary of Downtime Hours GBWWTP

Month January February March April May June July August September October November December Monthly Avg. 2001 Total 2000 Total 1999 Total 1998 Total Maintenance Downtime (Hours) 1 11 1 14 3 21 12.5 5 3 1 6.04 72.5 40.5 13.0 17.0 Non-Maintenance Downtime (Hours) 2 12 1 4 4.5 21 3.71 44.5 22.5 12.5 65.5 Total (Hours) 1 11 1 14 5 33 13.5 5 7 4.5 22 9.75 117.0 63 25.5 82.5

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Table 11: Power Usage 2001, Gold Bar WWTP

Power (kWh) Month Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Total KWh Cost 2001 3,393,634 3,115,224 3,376,468 3,218,183 3,412,441 3,163,847 3,203,542 3,282,359 3,089,008 3,062,485 2,722,591 2,968,694 38,008,475 $2,155,150 2000 3,417,416 3,137,151 3,445,648 3,455,516 3,825,551 3,841,509 3,963,090 4,114,107 4,040,916 4,023,412 3,493,769 3,553,696 44,311,781 $2,185,293 1999 3,295,917 2,957,327 3,431,153 3,518,551 3,583,432 3,750,209 4,034,946 4,285,170 3,842,357 3,829,142 3,480,467 3,736,834 43,745,505 $1,817,833 1998 3,125,341 2,764,213 3,158,362 3,138,454 3,379,236 3,246,164 3,686,159 3,858,053 3,429,972 3,735,944 3,293,621 3,270,236 40,085,755 $1,632,478 1997 2,671,096 2,718,459 2,929,486 3,015,339 2,890,815 1,786,915 2,495,679 2,795,909 2,795,726 3,082,984 3,364,376 2,900,083 33,446,867 $1,435,914

a) Power
Gold Bars power usage in 2001 was noticeably lower in fact, 14.2% lower than in 2000. The Plant used 38,008,475 kWh, or 6,303,306 kWh under the 2000 figure, with maximum peak demand reaching 5628 kW in January. On the cost side, the resulting annual power bill was $2,155,150; that is $30,143 below the 2000 cost, or a 1.4% decrease in power expenditures over 2000. Power for supplying process air to the secondary aeration bioreactors represents the largest portion of power used at the plant. The significant decrease (14.2%) in power usage can be attributed to the BNR retrofit and the installation of fine bubble diffusers in the secondary bioreactors. Since the last two of the ten bioreactors were retrofitted in late December of 2001, it will be the end of 2002 before it is known what affect fine bubble aeration and BNR has had on overall power usage.

Graph 13: Power Usage: 1997 2001, Gold Bar WWTP

4,500,000 4,250,000 4,000,000 3,750,000 3,500,000 3,250,000 3,000,000
kWh

2,750,000 2,500,000 2,250,000 2,000,000 1,750,000 1,500,000 1,250,000

Sept May Nov Aug Mar Dec Oct

1,000,000
Feb Jan

Apr

Jun

1997 2000

1998 2001

1999

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Jul

Annual Report 2001

Power Consumed/Treated Flow

Gold Bar handled 93,310ML in total flows in 2001, down 390ML from the previous years 93,700ML. As a result of this modest decrease in flows, combined with the drop in power consumed, the ratio of power per megalitre of treated flow declined from 473 kWh/ML in 2000 to 408 kWh/ML in 2001. By comparison, power costs in relation to treated flow declined modestly, as power charges remained high. Whereas the 2000 per megalitre power cost was $23.32, the 2001 figure was $23.09, a $.23/ML (or approximately 1%) decrease.

Graph 14: Monthly Water Usage (M3): 1997 2001, GBWWTP

35,000 30,000 25,000 20,000
M3

15,000 10,000 5,000

Sept May Nov Aug Mar Dec

0
Feb Jan

1997 2000

1998 2001

1999

b) Water
In 2001, the Gold Bar plant consumed 189,501 m3 of potable water at a cost of $115,785. That is a 14% increase over the 2000 level.

c) Natural Gas
Biogas supplies the bulk of the Gold Bar Plants heating needs, with natural gas used only on a limited basis, such as for potable water heating (i.e. washroom sinks and showers), and for heating two structures the Training Centre (trailer) and the Wetwell Building. Small amounts of natural gas are used in laboratory analyses and in the biogas flare pilots.

Table 12: Water Usage: 1997 2001, Gold Bar WWTP

Water (M3) Month Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Total 2001 14,702 13,832 12,214 16,571 18,469 16,863 18,530 19,098 18,562 14,203 13,526 12,931 189,501 $115,785 2000 12,331 10,800 11,451 12,042 11,535 13,904 15,196 18,028 16,095 14,115 15,365 15,152 166,012 $84,782 1999 13,834 11,735 7,487 18,872 16,185 15,984 19,608 10,417 9,505 16,153 13,918 14,516 168,214 $86,181 1998 9,760 8,941 14,919 10,377 13,310 18,228 16,181 30,571 24,241 20,430 14,748 10,992 192,698 $107,200 1997 14,410 13,069 11,730 11,638 11,391* 11,391* 15,342 19,293 15,487 14,615 11,602 9,036 159,004 $118,222

Table 13: Natural Gas Usage: 1997 2001, Gold Bar WWTP
Natural Gas (GJ) Month Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Total 2001 472 404 227 71 47 35 36 38 64 222 428 608 2,652 $16,990 2000 446 358 230 208 53 45 33 33 49 99 268 602 2,424 $14,482 1999 277 247 260 180 60 41 34 36 45 67 187 333 1,767 $7,926 1998 710 447 482 341 89 74 35 45 95 144 284 378 3,124 $8,984 1997 465 363 514 268 101 46 30 228 58 234 580 656 3,543 $10,518

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Apr

Jun

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Protecting the Environment Today and Tomorrow

Graph 15: Natural Gas Usage: 1997 2001, GBWWTP

1000 900 800 700 600 500 400 300 200 100
Sept May Nov

GJ

0
Mar Feb Apr Jan

Aug

1997 2000

1998 2001

1999

Dec

Oct

Jun

Jul

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