Maintenance Program Assessment

Purpose Provide a concise, actionable evaluation of a facility’s maintenance program for water and wastewater treatment systems. Identify gaps, prioritize corrective actions, and recommend measurable improvements to increase equipment reliability, reduce downtime, and optimize operating cost.

Scope

• Mechanical, electrical, instrumentation, and control systems supporting treatment processes

• Preventive, predictive, and corrective maintenance practices

• Spare parts management, vendor support, and contract services

• Maintenance planning, scheduling, and work execution

• Maintenance-related training, competency, and safety practices

• CMMS review and data quality

• Key performance indicators (KPIs) and continuous improvement processes

Assessment Methodology

1. Document review

   • Maintenance SOPs, PM task lists, lubrication and alignment procedures, isolation/lockout guides

   • Equipment OEM manuals, electrical schematics, P&IDs, and past work orders

   • Spare parts inventory records, service contracts, and warranty files

   • CMMS reports (backlog, overdue PMs, work order cycle times), safety incident logs, and training records

2. Site inspection and interviews

   • Walkdown of critical assets (pumps, blowers, mixers, chemical feed, screens, clarifiers, motors, valves)

   • Visual inspection for alignment, vibration, leakage, corrosion, and improper installations

   • Interviews with operations, maintenance technicians, stores, and management to verify practices and constraints

3. Data analysis

   • CMMS data integrity and KPI validation

   • Failure mode analysis for repeat failures and root causes

   • Spare parts lead time vs. stocking strategy

   • Maintenance labor utilization and overtime trends

4. Risk and criticality assessment

   • Assign criticality to assets using consequence-of-failure criteria (safety, environmental, production, cost)

   • Prioritize PMs and predictive tasks based on criticality and failure history

Findings (typical issues)

• Incomplete or obsolete PM task lists; PMs not reflecting OEM guidance or actual field conditions

• CMMS data poor quality: incomplete work order histories, inconsistent coding, and large overdue PM backlogs

• Reactive maintenance culture with high emergency repair rates and excessive overtime

• Spare parts shortages for long-lead items and poor stocking policy for critical spares

• Insufficient predictive maintenance (PdM) coverage: limited vibration,

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Maintenance Service Plan — Baseline

Purpose

• Provide a clear, repeatable baseline maintenance service plan for water and wastewater treatment equipment and systems.

• Can be quoted per piece of equipment or per complete system to match client preference and budgeting.

Scope

• Covers preventive maintenance (PM), predictive maintenance (PdM), corrective maintenance (CM), spare parts recommendation, lubrication, inspection, testing, documentation, and operator training.

• Applicable to pumps, motors, blowers, compressors, valves, clarifiers, filters, chemical feed systems, instrumentation & controls, electrical panels, heat exchangers, and other process equipment.

Service Options (quoteable per piece or system)

• Basic PM Package (recommended minimum)

  • Visual inspection and clean

  • Tightening of accessible fasteners

  • Basic lubrication per OEM spec

  • Filter and strainer checks and cleaning

  • Function test (start/stop, basic controls)

  • Monthly or quarterly frequency (client selectable)

  • Standard report with findings and recommended actions

• Standard PM + PdM Package

  • All Basic PM items

  • Vibration screening for rotating equipment

  • Thermographic scan of electrical panels and major bearings

  • Oil sampling and analysis where applicable

  • Operational performance checks and trend logging

  • Quarterly or bi-monthly frequency

  • Detailed report with priority-coded recommendations and cost-to-fix estimate

• Comprehensive Reliability Package (Best for critical assets)

  • All Standard PM + PdM items

  • Detailed alignment, balancing, and coupling inspection

  • Full electrical testing (megger, motor circuit analysis)

  • Valve diagnostics and actuator calibration

  • Onsite small repairs and adjustments included (up to agreed labor hours)

  • Annual overhaul coordination and shutdown planning

  • Monthly frequency or tailored to risk profile

  • Reliability-focused reporting, lifecycle cost analysis, and spare parts optimization

• Emergency & Corrective Response Add-on

  • 24/7 emergency response option

  • Guaranteed response windows (e.g., 2, 4, or 8 hours) selectable at quote

  • Mobilization and diagnostics charged per event unless covered by service tier

  • Loaner equipment or temporary bypass solutions as needed (quoted separately)

Core Tasks & Frequencies (baseline examples — adjustable per OEM/spec)

• Daily/Shift

  • Visual inspection for leaks, unusual noise, vibration, alarm conditions

  • Check operating parameters (flows, pressures, levels, chemical feed rates)

  • Log key values in operator logbook

• Weekly

  • Clean screens/strain ers and verify alarms

  • Check lubrication reservoirs and refill if needed

  • Quick electrical panel visual check

• Monthly

  • Comprehensive visual and functional inspection of equipment

  • Lubricate bearings and moving parts per schedule

  • Inspect seals, gaskets, and couplings

  • Verify instrumentation calibration status

• Quarterly

  • Vibration screening and trend analysis for rotating assets

  • Thermographic scans on electrical distribution and control panels

  • Basic chemical dosing system checks and feed accuracy tests

  • Replace routine consumables (filters, small seals) as needed

• Semiannual

  • Oil sampling and analysis for critical rotating equipment

  • Valve exercise and seating inspection

  • Motor electrical testing (insulation resistance)

  • Check alignment and belt tension

• Annual

  • Full preventive maintenance overhaul per OEM recommendations

  • Shutdown coordination for major inspections/repairs

  • Review of spare parts inventory and critical spares procurement list

  • Training refresh for operators and maintenance staff

  • Life-cycle cost and reliability review with recommendations

Documentation & Deliverables

• Service schedule and agreed scope for each quoted asset/system

• Daily/weekly/monthly inspection logs (electronic or paper)

• PdM data files (vibration, thermography, oil analysis reports)

• Action lists with prioritized recommendations and cost estimates

• Annual summary with asset health index and improvement roadmap

• Updated spare parts list with criticality ranking and lead-time notes

Spare Parts & Consumables

• Critical spares list developed during baseline assessment

• Option to hold consigned critical spares on-site (quoted separately)

• Consumable replacement program included in higher tiers or available as an add-on

KPIs & Performance Metrics

• Planned maintenance compliance (% of PMs completed on schedule)

• Mean time between failure (MTBF) for critical assets

• Mean time to repair (MTTR)

• Downtime hours and cost tracking

• First-time-fix rate for corrective work

• Cost avoidance and energy efficiency improvements (reported

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We can provide hands-on operator training and operational support focused specifically on helping both new and experienced operators properly run and maintain the equipment.

Our training can include:

Monitoring incoming flow and how changing flow conditions affect equipment operation

Proper startup, shutdown, and draining procedures

Daily and routine equipment inspections

Identifying abnormal operating conditions before they become failures

Proper cleaning and basic preventive maintenance practices

Troubleshooting common operational issues

Reinforcing manufacturer-recommended operating procedures and best practices

The goal would be to give the City more than just equipment—we would help ensure their operators understand how to run it correctly, safely, and consistently.

This could be incorporated into your proposal as an optional operator training and post-startup support package, with CR Environmental Services providing the local hands-on training and field support.

I think this could add significant value to the overall proposal while also reducing operator-related issues, unnecessary service calls, and premature equipment problems.

$250 per student per course. Minimum 4 students to start a class.