Maintenance management of the infrastructure of wastewater sanitation and purification of Canal Isabel II (Madrid – Spain)
Canal de Isabel II is the public body responsible for managing the comprehensive water cycle in the Community of Madrid. Its origin is inextricably linked to the history of the region. The company was created in 1851 when the project was completed thanks to which the water could be supplied to the capital. The domestic distribution of the water marked the entrance of the city of Madrid in modernity, with all that it meant: an increase of population as well as the industrial and commercial activities.
It currently operates in 14 reservoirs, 70 groundwater abstractions; 24 large and 271 small regulation tanks, 130 lift stations, 13 drinking water treatment plants; 16,200 kilometers of adduction and distribution network, 125 waste water pumping stations, 11,148 kilometers of sewage system, 64 storm tanks, 751 kilometers of sewers and outfalls, 200 wastewater treatment plants, 23 recycling plants and 214 kilometers recycled water network. Canal de Isabel II Gestión has 1.4 million customers, homes as well as industries and business.
In reference to sanitation facilities Canal de Isabel II manages more than 200 wastewater treatment plants that allow treating all water in the region thanks to infrastructure investments plans, One Hundred Percent Treatment Plan (1995-2002), and Madrid Purifies Plan (2005-2010), with the objective to treat the entire sewage and benefiting from this plan over 50 municipalities from Madrid and 2,500,000 inhabitants.
ROSMIMAN® WATER manages the maintenance tasks of most of the infrastructures that deal with the execution of the One Hundred Percent Treatment Plan and Madrid Purifies Plan, for the ones managed directly by the Canal de Isabel II (Direct exploitation), as well as the ones awarded to various contractors awarded with the operation and maintenance of these infrastructures such as; Hispanagua, Acciona Agua, Aquagest, OHL Medio Ambiente, Drace Medio Ambiente, etc … in indirect exploitation.
After defining the standardization and codification criteria of all the assets from each one of the infrastructures, in relation to asset inventory of direct execution, the application handles around 50,000 assets managed by external contractors and around 10,000 equipments managed by Canal de Isabel II.
The outsourcing model in terms of the criteria for operation and maintenance of more than 200 treatment plants and ancillary facilities designed by the Technical Department of CYII raised the problem of moving the technical criteria for the classification of assets and inventory, maintenance and operational procedures and application of standards required in the tender operation awards, to the maintenance and daily operation of sewage treatment plants, pumping stations and sludge treatment plants, so the CYII could subsequently make a comparative and unified analysis of the maintenance of each of them, being the operators/maintainers different companies.
The main objective was to move from a paperbased system with pre-designed forms that were sent from each Station or Plant periodically to the operational CYII headquarters with the corresponding inefficiency, loss of data and time, to a fully automated system and a realtime information server, with application of both
quality and operations control, accessible from any device through internet, easy to learn and maintain.
The solution provided by ROSMIMAN® WATER to the maintenance management model required by the Canal de Isabel II consists of two main systems.
A web application where all operators / maintainers enter and complete notifications, incidents and service requests on a simple manner focused to users with basic operative profile. This application is fully customized according to the requirements of the Canal de Isabel II in two versions, one for own asset management and the other one for the externalized ones. ROSMIMAN® WATER CORE CMMS is found behind this web application, it is also an application 100% web enabled, which performs the integrated maintenance management required by the Canal de Isabel II and where are fixed and defined the coding criteria, functional groupings, failures tree, execution and maintenance procedures, preventive plans, revisions and legal-technical certifications, indicators, etc.
Currently, both applications allow a comprehensive management of the corrective as well as the preventive maintenance, which is automatically generated on a daily basis by the system. This way, the staff in charge always has available the incidents occurred and the required repairs such as the preventive work to be performed every day for the correct operation of their equipments and the compliance with the technical requirements and the legal standards required by their activity to maintain the facilities in the highest terms of availability, productivity and quality.
- Equipment technical data sheet
- List of exploded drawings, maintenance instructions, greasing and lubrication.
- Historical records of preventive maintenance.
- Historical records of regulation maintenance.
- Historical records of corrective maintenance.
- Historical records of predictive maintenance and metrology.
- Historical records of maintenance inspections by OCA regulations.
In addition, the data exploitation tools ROSMIMAN® WATER offers, such as reporting, dashboards and various indicators in real time, allow them to follow-up accurately the compliance with all the repair and prevention work, as committed in the exploitation awarding contracts; allowing them to know the reliability of their equipments and maintenance needs. ROSMIMAN® WATER as management corporate solution is included in the ISO certification processes that are carried out and passed annually by the Canal de Isabel II in terms of improvement of objectives and correct functioning.
Year after year we have been including in the system new installations that have enabled our client to effectively meet the maintenance and repair tasks of their equipments, saving in replacement costs or major repairs of expensive and large equipments used in their water cycle management in the Community of Madrid.
Conclusion – Benefits
ROSMIMAN® WATER has defined approxima- tely 5,000 different maintenance procedures, with approximately 20,000 operations defined for all these procedures. It generates around 15,000 work orders per month and around 200,000 per year.
One of the main objectives was to unify the definition of procedures and automate as much as possible the ISO audit and certification processes the Canal de Isabel II has established and that must be audited annually. For this purpose, a series of reports, queries and indicators have been established that are required during audit processes. ROSMIMAN® WATER allows controlling the annual evolution of the standard indicators to prevent deviations and to analyze trends to correct these deviations so the end of a period will not be reached with variables outside the range. This process, of great importance to our customer, requires that each year is kept in constant improvement and successful performance.