Innovation at the Washington Suburban Sanitary Commission ... · PDF fileInnovation at the Washington Suburban Sanitary Commission (WSSC) ... Washington Suburban Sanitary Commission

Innovation at the Washington Suburban

Sanitary Commission (WSSC)

Keith Tyson, P.E. Technical Services Group Leader

Aloysius Obodoako Principal Materials Engineer

Engineering Construction Team Washington Suburban Sanitary Commission

March 29, 2017

Overview of Innovation WSSC Pipelines Forecast of Breaks Cost of Repairs on Pipeline Criteria for Pipeline Replacement/Rehabilitation Pipe Average Service Life Effect of Corrosion on Pipeline Corrosion Control Methods Ductile Iron Pipe Monitoring Program Effect of Strategic Sourcing Summary

© 2017 WSSC All Rights Reserved. 2

Building new Bio-Energy plant (design ongoing, construction begins in 2018) to capture waste heat and reduce solids

Installed 2 MW of solar panels at Western Branch WWTP

Converted to Zinc coated Ductile Iron Pipe with V-Bio poly-wrap


Water Treatment: • Online dissolved manganese analyzer to detect concentrations

in raw water Wastewater Treatment:

• Chemical Disinfection - Peracetic acid disinfection to replace chlorine disinfection

• Process modeling - IViewOps software pilot for the Parkway WWTP

• Carbon Diversion - Carbon diversion technology that uses Waste Activated Sludge (WAS) to biosorb more carbon from the influent

• Aeration efficiency - GE ZeeLung; membrane-aerated biofilm reactor

• Shortcut nitrogen removal – exploring options


Collection System: ◦ SL-RAT - Acoustic Sewer Line Rapid Assessment Tool -

quickly identify lines that need cleaning or CCTV inspection ◦ EcoTabs - Tablet or granular chemical/microbial applied

in the collection system to oxidize H2S and/or FOG Distribution System: ◦ Advanced Water Main cleaning system – alternative to

Uni-Direction Flushing


2571 miles of DIP

2548 miles of CIP

360 miles of PCCP

38 miles of Steel

7 miles of ACP

7 miles of PVC

15 miles Unknown

DIP

CIP

PCCP

STEEL

ACP

PVC

UNKNOWN

5546 Total Miles


Usually defined as pipes located between two valves ◦ Not a single stick of pipe



0

500

1,000

1,500

2,000

2,500

8" 10-12" 6" <6" 20-24" 16-18" 36-42" 60-96" 24-30" 48-54" 14" Unknown

Tota

l MIle

s

Diameter

Total Miles

Based on literature review and not on WSSC pipe operating experience

Water Distribution System (Pipe Diameters ≤ 14")

Material Cast Iron Pipe (CIP) Ductile Iron Pipe (DIP)

Attribute Pit Cast Spun Cast Non Polywrap Polywrap

min (yr.) 85 45 -- 88

max (yr.) 110 65 65 115



0

100

200

300

400

500

600

700

800

900

1000

1910s 1920s 1930s 1940s 1950s 1960s 1970s 1980s 1990s 2000s 2010s 2016

Leng

th, M

iles

Period, Decades

Miles Installed by Decade

Buried Water Assets

0

20

40

60

80

100

120

2008

2010

2012

2014

2016

2018

2020

2022

2024

2026

2028

2030

2032

2034

2036

2038

2040

2042

Breaks & Leaks per 100 miles of Projected B&Ls/100 mi Historical B&Ls/100 mi


Average repair costs for 8” water main break ◦ Crew costs - $1600

◦ Equipment - $2500

◦ Materials, non-pipe - $2000

◦ Materials, pipe - $250

◦ Overhead - $1200

◦ Total ~ $7,550/break


Criteria used to determine replacement/rehab: 1) Level of Risk Probability of failure, consequence of failure, and mitigation

factor 2) Pipe attribute Material Coating/Lining Diameter/thickness

3) Field inspection result or condition assessment 4) Maintenance History Break rate ≥ 3 within 5 yrs Work orders – customer complaints, other projects


Corrosion Material Deterioration ◦ Distortion ◦ Erosion

Poor Installation Practices ◦ Leaking joints

Manufacturing Defects ◦ Flaws

Operating Conditions ◦ Excessive external/internal loading


Pitting Corrosion – localized deterioration leading to pits

https://picacorp.files.wordpress.com/2013/03/2013-05-sc-verif-pipe.jpg


Galvanic Corrosion - one metal corrodes preferentially to another when both metals are in electrical contact (i.e., copper bolt - steel nut)

http://education.sptech.xyz/galvanic.png


Stray Current Corrosion - caused by the flow of stray currents through pipelines

http://www.techart.rs/english/images/korozija%20pruga.jpg


Microbial Corrosion (MIC) - caused or promoted by microorganisms Ex. Iron corrosion by sulfate reducing bacteria (SRB)

Converts sulfates to hydrogen sulfide (H2S) H2S reacts with metal ions to form metal sulfides

http://www.oilfield-biocides.com/media-oilfield-biocides/Scheme-of-iron-corrosion-by-SRB-2.png


Methods used to prevent corrosion and extend asset service life 1. Protective Coating/Lining

2. Polymer Wrap

3. Cathodic Protection


External Coating • Tape coating • Pritec coating • Epoxy coating • Zinc coating

Internal Coating/Lining • Cement mortar lining • Epoxy coating • Fiber reinforced polymer • Cured-in-place pipe (CIPP)


Unbounded protective film

Limits contact between pipe and soil

Decrease O2 beneath wrap

ANSI/AWWA C105/21.5

https://www.dipra.org/ductile-iron-pipe/dipra-facts-and-figures/v-bio-enhanced-polyethylene-encasement


Technique used to control corrosion of pipe by making it the cathode of an electrochemical cell

Two main types of Cathodic Protection Galvanic Anodes Impressed Current

Currently used only on pipes with high stray current

Neither method used in conjunction with zinc coating and V-Bio polymer wrap


Galvanic Anodes Localized protection for corrosion hot-spots Discrete or distributed anodes No on-going monitoring of electrical components

required Impressed Current

High level of system control and performance Global protection for the entire structure Long service life On-going monitoring of system performance


Zinc coating is effective corrosion prevention product

Zinc is anodic to iron • zinc is consumed in place

of iron • zinc conversion products

formed zinc oxide, zinc

carbonate, zinc chloride, etc.

stable impermeable binding layer

http://www.american-usa.com/


Zinc applied using arc spray process ◦ wire fed into the spray

gun ◦ wire is charged and arc is

generated ◦ wire is melted ◦ molten feedstock is

deposited on the pipe at 200 g/m2

http://www.metal-monster.com/ArcSpray.html


Zinc coating applied per ◦ International standards organization ISO 8179

Coating application evaluated at factory via coupon attached to pipe

Damaged zinc coating is repaired per manufacturer’s recommendation ◦ Metallic zinc spray, or ◦ Zinc-rich paint with 85% zinc, by mass


Zinc is applied as the basecoat Asphalt topcoat applied to reduce exposed zinc V-bio polyethylene encasement used as protective

film

http://www.american-usa.com/


Corrosion inhibitor vapor-like molecule attracted to pipe bonds to pipe prevents the pipe from

oxidizing Anti-microbial additive

Kills and repels microbiological organisms

Prevents microbial corrosion https://www.dipra.org/images/pageimages/

v-bio-brochure.jpg


Overall cost of 1 mile of 8” pipeline replacement


Costs for 8” pipe; the difference is minimal


Cost per foot 1 mile Total Cost $365.40 5280 $96,466 $441.80 5280 $116,635

Difference: $20,170

4 mil Poly wrap $1,235.75 8 mil V-Bio poly wrap $3,821.07

Difference: $2,585

Total Construction Cost per mile $2,879,418 Percent of cost for regular DIP with 4 mil poly 3.39% Percent of cost for zinc coated DIP w/ V-Bio 4.18%

Difference: 0.79%

Verify assumptions used to determine service life

Validate corrosion prevention using Zinc

3 pipe types that will be monitored DIP with no protection (1970-2005) DIP with polymer wrap (2005-2016) Zinc Coated DIP with V-BIO polymer wrap (2016–today)


Direct Measuring Techniques ◦ Corrosion Probe Monitor change in resistance of a metal coupon

◦ Mass-loss Coupon Monitor change in material weight and structure

http://www.cosasco.com/thumb.php?img=images%2Fproducts%2F6200_Corrosion_strip_coupon_holder.png&w=150&h=84 © 2017 WSSC All Rights Reserved. 32

Indirect Measuring Techniques ◦ Ultrasonic Testing Pulse-wave transmitted to detect internal flaws and

thinning ◦ Acoustic Emissions Testing Sound wave used to determine pipe wall condition


WSSC created Strategic Sourcing teams in 2012 Goal was to create better relationships with

Vendors Work with Vendors as Partners on large

purchases



36

November 2013 Official Launch of WSSC’s SCM Transformation implementation

(Phase II)

December 2013

Feb - June 2014 July – Dec 2014

• Cost reduction calculation and reporting

• Risk management seminars

• Pro-active Steering Committee

• Org design fine tuned • TCO emphasis • Speaking with One

Voice

• Launch several Wave 2 SSTs

• Org design finalized, hiring begun

• Initial cost reductions reported

• Intensive internal communications

Classroom Training in Strategic Sourcing, Launch of first two cross-functional SS

Teams under auspices of Steering Committee

© 2017 WSSC All Rights Reserved.

July 2013 Phase I

Assessment, Transformation Roadmap and Business Case

37

• An active and engaged Supply Chain Management Steering Committee will promote the vision, promote positive outcomes, and help identify and remove obstacles.

• Sourcing strategies will be developed with cross-functional representation and robust strategic sourcing and negotiations management processes.

• A Strategic COE (Center of Excellence) will provide leadership, policies and practices, training, and strategic sourcing capabilities serving all of WSSC.

• Cross-functional teaming can improve both the effectiveness and the efficiency of Procurement processes.


Team Name Goal Breakthrough Moment

Results CR / CA Impact

Bio-Solids Handling Award Critical Environmental Contract

Supplier Outreach & RFI can reduce risk and improve competitive results.

Contracts addressed current need and future uncertainty

$$

Bulk Chemicals Team Work with Cooperative to Reduce Pricing

Sole Source and Proprietary product requirements can be negotiated.

Participated in a regional sourcing event, identified alternate suppliers. Negotiated reduced prices.

$$

PCCP Team (Pre-stressed Concrete Cylinder Pipe)

Reduce Costs of Critical Technical Service

Separate critical/urgent from non-critical/Urgent requirements to optimize process and reduce costs.

Improved Competition, Eliminated Costly Markups, can benefit from Intellectual property.

$$$

38 © 2017 WSSC All Rights Reserved.

Team Name

Goal Breakthrough Moment

Results CR / CA Impact

Ductile Iron Pipe

Reduce Costs and Risks for a major component.

Costs include more than just Price. A TCO strategy can bring value and reduced pricing.

Partnering with a Major distributor and manufacturer with multiple manufacturing locations and a sophisticated materials management system. Improved Inventory Controls and reduced materials costs.

$$

Water Main Replacement

Improve the company’s approach to Routine Construction Projects.

Partnering with qualified vendors to reduce lead times and improve quality can still generate competitive pricing.

Qualified Utility Contractors were made part of the design process. Individual task orders were awarded through a competitive low bid process.

$$$

Fleet Develop strategy to compete long-lead equipment with standard and non-standard components.

Successful Procurement cannot exist without clear requirements, consistent standards, and good planning.

Single task evolved into five teams to address critical pre-procurement and post-procurement processes.

TBD

39 © 2017 WSSC All Rights Reserved.

40

What Will Not Change at WSSC The focus on doing what is necessary to maintain safe and reliable water operations The focus on Best Pricing, Supplier Service Performance and Product Quality Commitment to SLMBE

What Will Change at WSSC – Near Term

Focus on improving cycle times More collaboration - increased upfront input into sourcing strategies Need for accurate usage information Improved communications: end users/depots/facilities sourcing suppliers

Greater opportunity to address shortcomings in supplier performance Increased importance of scripted messages to support “Speaking with One Voice” The need to coordinate planned, and unplanned, supplier meetings Some suppliers may change


41

What Will Change at the WSSC – Longer Term Fewer surprises, fewer materials shortages and fewer emergencies Better supplier performance and expanded supplier service levels Increased standardization of products used, resulting in lower Total Cost of Ownership – Total Cost of Operations (TCO) Greater use of supplier KPIs (key performance indicators) and performance targets A reduction in the number of active suppliers, and a lower number of individual transactions Improved and standardized payment terms Lower materials and services costs


Knowledge & Expertise

Operational Activities

Strategic Vision

Apply Expertise • Develop Analytic Capabilities • Utilize Market Awareness • Engage End Users • Manage Contracts

Reduce Transactional Costs • Employ Technology • Enhance Bid Quality • Decrease Cycle Time • Improve Bid Management


Numerous Transformation Initiatives Across Six Key Dimensions are Underway at WSSC

• Aggressive Stretch Objectives • Total Cost of Ownership

Perspective • ROIC / ROE goals • Objectives Shared Across Entire

Organization • Incentives / Consequences • Supplier Performance Metrics

• Spend Analysis & Category Management • Demand Aggregation • Electronic RFIs, RFPs • Reverse Auctions • Optimization & Decision Support • Contract Mgmt & Compliance • Results Tracking & Reporting • Supplier Performance Evaluation • Project Mgmt & Executive Dashboard

• Structure that works in your culture • Cross-functional involvement • Speaking with One Voice • Commitment to Continuous Learning • Professional Career Track • Governance

• Strategic Sourcing • Negotiations Management • All Spend Categories in Scope • Risk Management • Partnerships with Suppliers • Supplier Recognition • Contract Management & Supplier Centric Strategies • Cost Reduction Planning / Tracking • Budget Adjustments to Preserve Cost Reductions • Low-Cost Country Sourcing • Consortium Buying • Asset Recovery • Selective Outsourcing

• Core Part of Corporate Strategy Objectives Best Practices

Optimized Organization Innovation & Technology

Procurement Role

Good Leadership • The Right Leader • Leadership Culture at all Levels • Bias to Action and Results

$

Excerpted from the book “Straight to the Bottom Line®” (Rudzki et al)

Blue = Underway


WSSC implementing innovative techniques to improve service to customers

Experiencing increasing number of pipe breaks Costs of repairing pipe breaks is increasing Developing corrosion controls methods to manage

pipeline degradation Zinc coated DIP and V-Bio are now standard pipe

materials Developing monitoring program to evaluate pipe

performance Created sourcing teams to reduce cost of purchasing

Ductile Iron Pipe



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Innovation at the Washington Suburban Sanitary Commission ... · PDF fileInnovation at the Washington Suburban Sanitary Commission (WSSC) ... Washington Suburban Sanitary Commission