Instrumentation, Control & Automation Staffing. Maintenance Benchmarking Study

Transcription

1 Electronic Document Instrumentation, Control & Automation Staffing Prepared by ITA Technical Committee, Maintenance Subcommittee, Task Force on IC&A Staffing John Petito, Chair Richard Haugh, Vice-Chair Prepared under the Direction of ITA s Maintenance Subcommittee Charles K. Aycock, Chair ITA s Technical Committee Peter Craan, Chair John Grey, Vice-Chair and the ITA Board Joseph Murray, President James E. Patterson, Vice-President Robert Werner, Treasurer Carl A. Neumayer, Past President Lewis Debevec, Past Treasurer William J. Borlase John Guidolin Donna Hautz William H. Hendrix, Jr. Tom Pukenis Donald Wunderlich 1999 Instrumentation Testing Association 631 North Stephanie Street, 279 Henderson, NV USA

2 Electronic Document Abstract This maintenance benchmarking study presents data on reported instrumentation, control, and automation (IC&A) data received from surveyed water, wastewater, and industrial treatment facilities. Data on plant staffing profiles, salary ranges, education, experience, and training requirements are provided. In addition, data on IC&A staff management and staff time allocation for performing maintenance are provided. A discussion of the development and utilization of computer maintenance management systems (CMMS) is also provided. ii Preface

3 Electronic Document Library of Congress Cataloging-in-Publication Data Instrumentation, Control and Automation Staffing: prepared by the ITA Technical Committee, Maintenance Subcommittee, Task Force on IC&A Staffing under the direction of the ITA Board. Includes bibliographical references and index. ISBN Instrumentation, Control & Automation (IC&A) Staffing 2. Maintenance Benchmarking Study 3. Instrumentation Testing Association MBS99IS Copyright 1999 by the. USA All rights reserved. Printed in the United States of America. No part of this publication may be reproduced or distributed in any form or by any means or stored in a database or retrieval system without the prior written permission of ITA. Printed in the USA 1999 Information contained in this work has been obtained by ITA believed to be reliable. However, neither ITA nor its officers and authors guarantees the accuracy or completeness of any information published herein and neither ITA nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that ITA and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. Preface iii

4 Electronic Document of the Instrumentation Testing Association The was established on March 1, The primary function of ITA is to conduct charitable, educational, and scientific testing for public safety. ITA's mission is to advance the theory and practice of instrumentation and automation for water and wastewater treatment and other public works facilities by promoting the reliability and performance of environmental instrumentation and automation technologies. ITA's mission is designed to advance these services order to provide better public water service and enhance public health. ITA carries out its mission by developing and disseminating information on instrumentation and automation technologies and conducting educational programs in the field of instrumentation and automation. ITA's Maintenance Subcommittee of the ITA Technical Committee was developed by the ITA Board to originate and produce maintenance benchmarking studies to address the needs of ITA membership. These reports are intended to provide a basic understanding of maintenance practices and procedures and include reported maintenance requirements, cleaning, calibrating, and cost analysis of surveyed treatment facilities. IMPORTANT NOTICE The contents of this publication are for general information only and are not intended to be a standard of the. No reference made in this publication to any specific method, product, process, or service constitutes or implies an endorsement, recommendation, or warranty thereof by ITA. ITA makes no representation or warranty of any kind, whether expressed or implied, concerning the accuracy, product, or process discussed in this publication and assumes no liability. Anyone using this information assumes all liability arising from such use, including but not limited to infringement of any patent or patents. Instrumentation Testing Association Technical Committee Authorized for Publication by the Board of Directors Instrumentation Testing Association The Instrumentation Testing Association is an international nonprofit technical and educational organization dedicated to promoting the understanding, selection, improvement, and cost-effective use of instrumentation and automation applications for monitoring and controlling water, wastewater, and industrial systems. Since 1984, ITA has provided educational and technical services to environmental specialists, including civil, mechanical, electrical, and environmental engineers; scientists; local, state, and government officials; treatment plant operators, technicians, and collection systems personnel; laboratory personnel; chemists; industrial technologists; students; academics; and equipment manufacturers and distributors. For information on membership, publications, and workshops, contact USA Tel: (702) Fax: (702) Internet: iv Preface

5 Electronic Document Preface The purpose of this publication is to report instrumentation, control, and automation (IC&A) maintenance staffing practices and procedures for water, wastewater, and industrial treatment facilities. The reader of this report is responsible for determining which parameters are of most importance to their application to implement the most suitable IC&A staff practices and procedures for their respective needs. It is also emphasized that a complete assessment of the information presented herein requires that the report be read in its entirety. This publication was prepared by the ITA Technical Committee, Maintenance Subcommittee, Task Force on IC&A Staffing under the direction of the ITA Technical Committee, Maintenance Subcommittee, and Board. Report authors and reviewers include Charles K. Aycock Lynn Campbell Peter Craan John Grey Richard Haugh William H. Hendrix, Jr. Gauher Kahn Joseph A. Murray John Petito Reddwari S. Reddy Robert Werner Authors' and reviewers' efforts were supported by the following organizations: Carollo Engineers, Sacramento, California, USA Columbus Water Works, Columbus, Georgia, USA City of Houston, Houston, Texas, USA City of Roseville, Roseville, California, USA Grey Engineering, Inc., Mocksville, North Carolina, USA Hazen & Sawyer, New York, New York, USA New York City, Department of Environmental Protection, Elm Hurst, New York, USA Sacramento Regional Wastewater Treatment Plant, Elk Grove, California, USA Washington Suburban Sanitary Commission, Laurel, Maryland, USA Survey planning, development and review includes participation from William J. Borlase Peter Craan Lewis Debevec M. Truett Garrett, Jr. John Grey John Guidolin Donna A. Hautz William H. Hendrix, Jr. Robert D. Hill Thomas J. McBride Joseph A. Murray Carl A. Neumayer James E. Patterson Tom Pukenis Robert C. Steidel Michael W. Sweeney Robert Werner Preface v

6 Electronic Document Harry Wilkinson Michael Woolsey Donald Wunderlich as supported by the following organizations: City of Fort Worth, Water Pollution Control Group, Fort Worth, Texas, USA City of Houston, Department of Public Works and Engineering, Houston, Texas, USA City of Winnipeg, Water & Waste Department, Winnipeg, Manitoba, Canada Columbus Water Works, Columbus, Georgia, USA Corporation of the City of Windsor, Windsor, Ontario, Canada EMA, Inc., The Woodlands, Texas, USA Grey Engineering, Inc., Mocksville, North Carolina, USA Hazen and Sawyer, New York, New York, USA Hopewell Regional Wastewater Treatment Facility, Technical Services, Hopewell, Virginia, USA Louisville and Jefferson County, Metropolitan Sewer District, Louisville, Kentucky, USA New York City, Department of Environmental Protection, Elm Hurst, New York, USA Newport News Waterworks, Newport News, Virginia, USA Northeast Ohio Regional Sewer District, Cleveland, Ohio, USA PBS&J, Houston, Texas, USA Royce Instrument Corporation, Parkesburg, Pennsylvania, USA Sacramento Regional Wastewater Treatment Plant, Elk Grove, California, USA Washington Suburban Sanitary Commission, Laurel, Maryland, USA Water Reclamation District of Greater Chicago, Cicero, Illinois, USA Review and support was also provided by ITA s Manufacturer Committee Harry Wilkinson, Chair James N. Radney, Vice-Chair ITA technical staff project management and development was provided by Tony M. Palmer, Executive Director, and Maureen C. Ross, Technical Programs Director. Technical editing was provided by Lorna Johnson. This publication was made possible through special project funding contributions and inkind services provided by Louisville and Jefferson County Metropolitan Sewer District, Louisville, Kentucky, USA Sacramento Regional Wastewater Treatment Plant, Elk Grove, California, USA Washington Suburban Sanitary Commission, Laurel, Maryland, USA vi Preface

7 Electronic Document Contents Chapter 1 Introduction Background Survey Procedures Distribution Response Rate Survey Participants Report Format 1-2 Chapter 2 Organization of IC&A Staff Typical Plant Staffing Profiles Organizational Charts Small Treatment Facilities Medium Treatment Facilities Large Treatment Facilities Position Descriptions Instrumentation Specialist/Technician Electrician Automation Specialist Information Systems Specialist General Operations and Maintenance Staff Laboratory Personnel Engineer Supervisor Foreman 2-4 Chapter 3 Computerized Maintenance Management Systems Construction Capabilities Development Addressing Treatment Plant Needs Defining System Components and Developing Database Modules Prioritizing Module Design Identifying Input and Output Formats Programming Use and Maintenance Utilizing a CMMS Maintaining a CMMS Summary 3-5 Chapter 4 General Facility and Treatment Process Information Existing Plant Conditions General Facility and Treatment Process Information General Facility Information Type of Treatment Facility Ownership Plant Staffing Plant-Attended Operation General Flow and Treatment Characteristics Average Flow Water Treatment Influent Flow Characteristics Wastewater Treatment Influent Flow Characteristics Secondary Treatment Disinfection Advanced Treatment General Instrumentation, Control, and Automation Plant Control and Automation System Plant Staff and Control and Automation Systems Attended Hours of Operation and Control and Automation Systems Average Flow and Control and Automation Systems Documentation of Instrumentation Maintenance 4-20 Contents vii

8 Electronic Document Chapter 5 Staff Comparisons Examining Comparisons Average Plant Flow Versus Total Plant Staff Total Number of Operations and Maintenance Staff Versus Total Number of Electricians and Instrumentation Staff 5-2 Chapter 6 Instrumentation Maintenance Staffing Benchmarking Survey Results Staff and Management Staff and Management Responsible for Instrumentation Maintenance Staff Management Number of Staff Performing Instrumentation Maintenance Percent Time Maintaining Instrumentation Staff Qualifications Minimum Staff Education and Training Requirements Minimum Required Staff Experience Annual Training Hours Required Staff Compensation Skilled-Based Compensation Contract Maintenance Minimum Hourly Pay Electrician Minimum Hourly Pay Instrumentation Specialist/Technician Minimum Hourly Pay Laboratory Personnel Minimum Hourly Pay General Operations and Maintenance Minimum Hourly Pay 6-16 Chapter 7 Control and Automation Maintenance Staffing Benchmarking Survey Results Staff and Management Staff and Management Responsible for Control and Automation Maintenance Staff Management Number of Staff Performing Overall Facility Control and Automation Maintenance Percent Time Maintaining Control and Automation Staff Qualifications Minimum Staff Education and Training Requirements Minimum Required Staff Experience Annual Training Hours Required Staff Compensation Skilled-Based Compensation Control and Automation Specialist Minimum Hourly Pay Contract Maintenance Minimum Hourly Pay Electrician Minimum Hourly Pay Instrumentation Specialist/Technician Minimum Hourly Pay General Operations and Maintenance Minimum Hourly Pay 7-19 Chapter 8 Summary Summary of Survey Results General Facility and Treatment Process Information Survey Distribution and Response Rate General Facility Information General Flow and Treatment Characteristics General Instrumentation, Control, and Automation Instrumentation Maintenance Staffing Staff and Management Responsible for Instrumentation Maintenance Staff Qualifications Staff Compensation Control and Automation Maintenance Staffing Staff and Management Responsible for Control and Automation Maintenance Staff Qualifications Staff Compensation 8-3 viii Contents

9 Electronic Document Appendix A Survey Form A-1 Appendix B Survey Participant Listing B-1 Appendix C IC&A Consultant Resource Listing C-1 Contents ix

10 Electronic Document List of Tables Chapter 1 Table Survey Distribution and Response Rates 1-2 Chapter 4 Table General Facility Information 4-4 Table General Facility Comments 4-7 Table General Flow and Treatment Characteristics 4-12 Table General Flow and Treatment Comments 4-16 Table General IC&A Information 4-22 Chapter 5 Table Plant Staffing Comparisons 5-4 Chapter 6 Table Staff and Management for General Instrumentation Maintenance 6-4 Table Staff Qualifications for General Instrumentation Maintenance 6-9 Table Staff Compensation for General Instrumentation Maintenance 6-17 Chapter 7 Table Staff and Management for General Control and Automation Maintenance 7-4 Table Staff Qualifications for General Control and Automation Maintenance 7-12 Table Staff Compensation for General Control and Automation Maintenance 7-20 x List of Tables

11 Electronic Document List of Figures Chapter 2 Figure Typical Small Treatment Facility Staff Organizational Chart 2-1 Figure Typical Medium Treatment Facility Staff Organizational Chart 2-2 Figure Typical Large Treatment Facility Staff Organizational Chart 2-2 Chapter 3 Figure Common CMMS Functions 3-1 Figure Sample CMMS Components and Modules 3-2 Figure Step-By-Step CMMS Development 3-4 Chapter 4 Figure Type of Treatment 4-2 Figure Ownership 4-2 Figure Total Plant Staffing 4-3 Figure Plant Hours of Attended Operation 4-3 Figure Plant Days of Attended Operation 4-4 Figure Average Flow 4-8 Figure Water Treatment Influent Flow 4-9 Figure Wastewater Treatment Influent Flow 4-9 Figure Secondary Treatment 4-10 Figure Disinfection 4-10 Figure Advanced Treatment 4-11 Figure Plant Control and Automation System 4-16 Figure Staff Size with Control and Automation Systems 4-17 Figure Staff Size without a Control and Automation System 4-18 Figure Operation Hours with a Control and Automation System 4-18 Figure Hours of Operation without a Control and Automation System 4-19 Figure Average Flow with a Control and Automation System 4-19 Figure Average Flow without a Control and Automation System 4-20 Figure Instrumentation Maintenance Documentation 4-20 Figure Staff Size Utilizing a CMMS 4-21 Figure Staff Size Utilizing Manual Documentation 4-21 Figure Staff Size Utilizing Other Methods of Instrumentation Documentation 4-22 Chapter 5 Figure Comparison of Average Plant Flow to Total Plant Staff 5-2 Figure Comparison of Total O&M Staff to Electricians and Instrumentation Staff 5-3 Chapter 6 Figure Personnel Performing Instrumentation Maintenance 6-1 Figure Instrumentation Maintenance Staff Management 6-2 Figure Number of Staff Performing Instrumentation Maintenance 6-3 Figure Percent Time Spent Performing Instrumentation Maintenance 6-3 Figure Minimum Education and Training Requirements 6-8 Figure Minimum Required Experience 6-8 Figure Required Annual Training 6-9 Figure Skilled-Based Compensation 6-13 Figure Contract Maintenance Pay 6-14 Figure Electrician Pay 6-14 List of Figures xi

12 Electronic Document Figure Instrumentation Specialist/Technician Pay 6-15 Figure Laboratory Personnel Pay 6-16 Figure General Operations and Maintenance Staff Pay 6-16 Chapter 7 Figure Personnel Performing Control and Automation Maintenance 7-2 Figure Control and Automation Maintenance Staff Management 7-2 Figure Number of Staff Performing Control and Automation Maintenance 7-3 Figure Percent Time Spent Performing Control and Automation Maintenance 7-4 Figure Minimum Education and Training Requirements 7-10 Figure Minimum Required Experience 7-10 Figure Required Annual Training 7-11 Figure Skilled-Based Compensation 7-16 Figure Control and Automation Specialist Pay 7-17 Figure Contract Maintenance Pay 7-17 Figure Electrician Pay 7-18 Figure Instrumentation Specialist/Technician Pay 7-19 Figure General Operations and Maintenance Staff Pay 7-19 xii List of Figures