EVALUATION OF MAINTENANCE
MANAGEMENT SYSTEM
AT LOWER POTOMAC WASTEWATER
TREATMENT PLANT
FAIRFAX COUNTY
VIRGINIA
by
Lilia A. Abron-Robinson, Ph.D.
Leon W. Weinberger, Sc.D., P.E.
68-01-6222
Walter DeRieux
U.S. Environmental Protection Agency
Washington, D.C. 20460
OFFICE OF WATER AND WASTE MANAGEMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
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DISCLAIMER
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FOREWORD
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ABSTRACT
The Planned Maintenance Management System (PMMS) installed at Lower
Potomac Wastewater Treatment Plant of Fairfax County, Virginia was evaluated.
Descriptions are presented of the-original manual system and the current
computerized version. Although the current system is computerized, senior
personnel are still required to make key decisions if the system is to work.
The system, to work effectively, requires the cooperation and participation
of all plant personnel.
The system is easy to use and only one person is required to code data
for computer interface. The system can be enlarged to accommodate plant
expansion, other plants within the County's jurisdiction, other utilities and
other facilities.
The data collected are enumerated and the benefits of the PMMS are
described. Data are analyzed to demonstrate some of the benefits of the
system. Valuable data could be supplied to designers, equipment manu-
facturers, and purchasing agents.
This report was submitted in fulfillment of Contract No. 68-01-6222 by
PEER Consultants, Inc. under the sponsorship of the U.S. Environmental Pro-
tection Agency. This report covers a period from September 29, 1980 to May
29, 1981, and was completed as of May 29, 1981.
IV
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CONTENTS
Foreword i i i
Abstract iy
Fi gures - vi
Tables v11
Exhibits i*
Executi ve Summary .x
1. Introduction 1
2. Conclusions 2
3. Recommendations 3
4. Description of the Manual System 4
5. Description of the Existing System 16
6. Methodology for Assessing Benefits of "a
Mai ntenance System 28
7. Data Analysis 35
Appendices
A. Forms for PMMS as Originally Installed 71
B. Imput Documents for PMMS Now in Use 84
References 122
v
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FIGURES
Number Page
1 Equipment configuration list 7
2 Average flow in MGD vs. time 36
3 Influent and effluent of BOD and SS vs. time (1970-1980) 33
4 Corrective maintenance history function no. 141.
1976 to date 47
5 Corrective maintenance history cost for selected
function no. 1976 to date 48
VI
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TABLES
Number Page
1 Input Data Documents for Existing PMMS 23
2 Guidelines for Evaluating a Maintenance Management System 32
3 PM and CM Hours at LPWTP - Year 1976 40
4 Monthly Average Maintenance Manpower (Man-Hours) 44
5 Analysis of Corrective Maintenance History 1976-1980
Incinerators 50
6 Analysis of Corrective Maintenance History 1976-1980
Incinerators 51
7 Analysis of Corrective Maintenance History 1976-1980
Sludge Plunger Pumps 52
8 Analysis of Corrective Maintenance History 1976-1980
Sludge Plunger Pumps 53
9 Analysis of Corrective Maintenance History 1976-1980
Air Blowers 54
10 Analysis of Corrective Maintenance History 1976-1980
Air Blowers 55
11 Analysis of Corrective Maintenance History 1976-1980
Vacuum Pump Motors 56
12 Analysis of Corrective Maintenance History 1976-1980
Vacuum Pump Motors 57
13 Analysis of Corrective Maintenance History 1976-1980
Chlorinators 58
14 Analysis of Corrective Maintenance History 1976-1980
Chlorinators 59
15 Analysis of Corrective Maintenance History 1976-1980
Low Lift Pumps 60
16 Analysis of Corrective Maintenance History 1976-1980
Low Lift Pumps 61
vii
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Number Page
17 Analysis of Corrective Maintenance History 1976-1980
Sludge Conveyors 62
18 Analysis of Corrective Maintenance History 1976-1980
Sludge Conveyors 63
19 Analysis of Corrective Maintenance History 1976-1980
Secondary Clarifiers 64
20 Analysis of Corrective Maintenance History 1976-1980
Secondary Clarif iers 65
21 Summary of Analyses of Corrective Maintenance Histories 66
22 Summary of Analyses of Corrective Maintenance Histories 67
vm
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EXHIBITS
Number Page
1 Summary of steps for PMMS for preventive maintenance
and corrective maintenance applications 13
2 Preventive maintenance flow diagram 18
3 Summary of steps for the computerized PMMS 19
4 Flowchart for PMMS corrective maintenance 22
5 Organization for organization and maintenance staff 27
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EXECUTIVE SUMMARY
A planned maintenance management system is one that makes use of a sys-
tematic approach to preventive and corrective maintenance. The system re-
duces the maintenance of a large number of equipment items, many of which are
complex, to a set of explicit, simple tasks that can be easily scheduled,
managed, performed and recorded. In addition, recordkeeping and feedback
features provide for complete accounting of maintenance labor, material and
contractor costs for management use in cost control and budget preparation.
The Planned Maintenance Management System (PMMS) installed at the Lower
Potomac Wastewater Treatment Plant, Fairfax County, Virginia is such a sys-
tem.
Descriptions are presented of the original manual system and the current
computerized version. Although the current system is computerized, senior
personnel are still required to make key decisions if the system is to work.
The system, to work effectively, requires the cooperation and participation
of all plant personnel.
The system is easy to use and only one person is required to code data
for computer interface. The system can be enlarged to accommodate plant
expansion, other plants within the County's jurisdiction, other utilities and
other facilities.
The data collected are enumerated and the benefits of the PMMS are de-
scribed. Data are analyzed to demonstrate some of the benefits of the system.
Valuable data could be supplied to designers, equipment manufacturers, and
purchasing agents.
Preventive maintenance and corrective maintenance have been improved as
a result of the PMMS. Senior plant personnel report that since the was
installed in 1972, critical corrective maintenance has been diminished as
evidenced by a reduction in emergency situations. The attitude of maintenance
personnel has improved. More elective maintenance, which improves the ap-
pearance of the plant, is now carried out.
A number of deficiencies has been noted. There have been gaps in data
input and there has been input of inaccurate data as a result of organiza-
tional difficulties. There is no computer terminal at the treatment plant,
which causes an interface problem between maintenance staff and the computing
center. The parts inventory component has not been implemented and the full
manpower management component of the system is not utilized. Full use of the
PMMS for cost control and budget preparation has not taken place. Thus the
full potential of the installed PMMS has not been utilized as yet.
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SECTION 1
INTRODUCTION
A planned maintenance management system was installed at the Lower
Potomac Wastewater Treatment Plant in 1972. Two reports, (1) A Planned
Maintenance Management System for Wastewater Treatment Plants by Sargent and
Rudich - EPA-600/2-73-004, November 1973 and (2) Evaluation of a Preventive
Maintenance Management System for Wastewater Treatment Plants - Prepared for
U.S. Environmental Protection Agency, Contract No. 68-01-4164 by Enviro Plan,
Incorporated, April 1977, have been prepared in this system and its effective-
ness. The first report describes the PMMS in technical detail; discusses the
installation- of the PMMS, at the Lower Potomac Wastewater Treatment Plant,
including acceptance by the mechanics and coordination with plant operations;
and outlines the application of the PMMS to other wastewater systems. The
second report provides an evaluation of the effectiveness of the PMMS at the
LPWTP from its installation in 1972 through 1975. The name of the system is
Planned maintenance Management System and is hereinafter referred to as the
PMMS, although in the second report, the system was referred to as a Preven-
tive Maintenance Management System.
The purpose of this report is to describe the system that was installed
in 1972 and to describe the manner in which the system is presently being
operated. When the system was installed in 1972 it was operated manually.
The system was computerized in 1976. Documentation has been lacking as to how
the system is being operated, the use to which the system is being put, and
the cost-effectiveness of the installed system.
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SECTION 2
CONCLUSIONS
The following conclusions are made for the evaluation of the PMMS in-
stalled at the Lower Potomac Wastewater Treatment Plant.
1. The PMMS as installed at the Lower Potomac Wastewater Treatment
Plant has all of the components of an exemplary maintenance manage-
ment system.
2. Both planned and corrective maintenance programs are being carried
out in a satisfactory manner.
3. The feedback features of the PMMS, which could be useful to manage-
ment in cost control and budget preparation, are being used only to
a limited extent.
4. An organizational deficiency has existed that resulted in in-
complete and inaccurate data entering the system.
5. The interface between plant maintenance personnel and the computing
center needs improving, including the need for a computer terminal
at the plant.
6. The information that can be derived from the PMMS is considerably
greater than that required to carry out the physical and mechanical
aspects of an effective preventive and corrective maintenance pro-
gram.
7. Although the system is computerized, senior personnel are still re-
quired to make key decisions if the system is to work.
8. Quantification of the benefits of the PMMS such as cost-effective-
ness is difficult although semi-quantitative and qualitative as-
sessment, including subjective analysis of benefits, can be pre-
sented.
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SECTION 3
RECOMMENDATIONS
The U.S. Environmental Protection Agency in cooperation with Fair-
fax County, Virginia should report to the wastewater treatment com-
munity-designers, plant operation and maintenance personnel, plant
managers and executives, plant builders, educators and trainers,
regulatory authorities, and governmental officials - on the suc-
cessful and effective maintenance management system at the Lower
Potomac Wastewater Treatment Plant.
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SECTION 4
DESCRIPTION OF THE MANUAL SYSTEM
Based on a review of the two reports (see page 1) prepared on the PMMS
and on interviews with the Fairfax WasteWater Treatment Plant (WWTP) person-
nel, the following describes the manual PMMS.
CAPABILITIES OF THE PMMS
The PMMS as installed in 1972 was capable of handling two types of main-
tenance procedures. These were:
1. Preventive Maintenance-- those regularly scheduled procedures nec-
essary for routine care and inspection of the equipment to prevent
possible breakdowns and to insure proper operation and efficiency.
2. Corrective Maintenance - those procedures necessary to restore op-
eration of the equipment after a breakdown or when a possible break-
down is anticipated.
The system is also capable of handling overhaul maintenance and elective main-
tenance.
The PMMS as installed consisted of five parts. These were:
1. The Equipment Configuration List
2. The Maintenance Procedures
3. The Preventive Maintenance Cycle Schedule
4. The Recordkeeping System
5. The Maintenance Data Feedback System
The Equipment Configuration List
This list was essential to the successful implementation of the PMMS and
represented the complete inventory of all of the WWTP's equipment. This list
displayed all of the electrical and mechanical equipment used in the treatment
works, the utilities and services (laboratory).
Each item in the plant that could require maintenance was given a dis-
crete five (5) digit number. The numbering system was developed in the
following manner.
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1. The first digit identified the major systems in the plant. An
example of this is as follows:
!_ XXXX - Raw Wastewater Station
2_ XXXX - Primary Treatment
3 XXXX - Secondary Treatment
4 XXXX - Chlorination and Effluent Flow
5 XXXX - Sludge and Scum Processing
6 XXXX - Incineration
7 XXXX - Utilities and Services
2. The second digit identified the subsystems within the major
systems. Examples of this for the major system Sludge and Scum
Processing (5XXXX) are as follows:
51XXX - auxiliary services
5IXXX - sludge thickening
53XXX - sludge storage and handling
57XXX - scum handling
5FXXX - lime treatment
5^XXX - ferric chloride treatment
57XXX - polymer treatment
5jj[XXX - sludge conditioning
59XXX - vacuum filtration
3. The third digit identified the functional unit within the sub-
system described in item 2 above. Examples using the sludge
thickening (52XXX) subsystem are as follows:
521XX - thickeners
527XX - pumping
52"3~XX - flow measurement
527XX - Chlorination
525XX - compressed air
4. The fourth digit identified a piece of electrical or mechani-
cal equipment within the functional unit described in item 3
above. Examples for the thickeners (521XX) are as follows:
5211X - sludge thickeners
521?X - gear motors
5213X - chain drives
52!4~X - gear reducers
521"5"X - ventilators
521j[X - controls
5. The fifth digit identified which parallel units were being
specified. Thus, for the electrical and mechanical equipment
itemized in item 4 above, the numbering system continued as
described below:
52111 - sludge thickener No. 1
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52112 - sludge thickener No. 2
5212T - gear motor No. 1
5212? - gear motor No. 2
5213T - chain drive No. 1
52132 - chain drive No. 2
5214T - gear reducer No. 1
5214? - gear reducer No. 2
In addition to the five-digit identification numbering system described
above, the equipment configuration list also contained a two-digit number
that indicated what that specific piece of equipment was used on or for. Some
examples of this "type" numbering system are shown below.
Type Number Equipment
10 Tanks and Equipment
ll Tanks, Channels, Bins
12 Slide gates, sluice gates
13 Sludge and scum collectors
14 Weirs
20 Pumps, Compressors, Blowers
21 Centrifugal pumps
22 Piston pumps
23 Gear, vane, screw, diaphragm
pumps
30 Electrical equipment
31 Motors, motor and drive
assemblies
32 Supply panels and boxes
33 Controls
40 Mechanical equipment
An example of the equipment configuration list is given in Figure 1. list was
used for the assignment of identification numbers to each piece of electrical
and mechanical equipment at the plant. This list was supplemented with an
equipment data list, equipment reference data forms and other more detailed
forms as necessary.
Information on Equipment Configuration List, Equipment Data List and Equip-
ment Reference Data Forms—
These lists contained the following information:
Identification number
Common name
Equipment type number
Location
Manufacturer's name
Part or model number
Serial number
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ID
Equipment Name
Type
Location
520 SLUDGE. THICKENING
521 Thickener!
52111
52112
52121
52122
52131
52132
52141
52142
52151
52152
52161
52162
Sludge Thickener No. I
Sludge Thickener No. 2
Gear Motor No. 1
Gear Motor No. 2
Chain Drive No. 1
Chain Drive No. 2
Gear Reducer, No. 1
Gear Reducer. No. 2
Ventilator. No. 1 Thickener
Ventilator. No. 2 Thickener
Control. No. 1
Control. No. 2
11
11
31
31
41
41
41
41
72
72
33
33
J N
J .S
J N
J S
J N
J S
J N
J S
J N
J S
J N
J S
522 Pumping
52211
52212
52213
52214
52221
52222
52223.
52224
52231
52232
52233
52234
52241
52242
52243
52244
52251
52252
52253
52254
52261
52262
52263
52264
Duplex Plunger Pump No. 1
Duplex Plunger Pump No. 2
Duplex Plunger Pump No. 3
Duplex Plunger Pump No. 4
Motor, Pump No. I
Motor. Pump No. 2
Motor. Pump No. 3
Motor. Pump No. 4
Variable Speed Reducer, No. I
Variable Speed Reducer, No. 2
Variable Speed Reducer. No. 3
Variable Speed Reducer. No. 4
Gear ~>rive. No. 1
Gear Drive, No. 2
Gear Drive. No. 3
Gear Drive, No. 4
Reduction Gear No. 1
Reduction Gear No. 2
Reduction Gear No. 3
Reduction Gear No. 4
Control, No. 1
Control. No. 2
Control, No. 3
Control. No. 4
22
22
22
22
31
31
31
31
41
41
41
41
41
41
41
41
41
41
41
41
33
33
33
33
J L NW
J L ME
J L SW
J L SE
J L NW
J L NE
J L SW
J L SE
J L NW
J L NE
J L SW
J L SE
J L NW
J L NE
J L SW
J L SE
J L NW
J L NE
J L. SW
J L SE
J L NW
J L NE
J L SW
J L SE
S231I
S2321
52331
Thickened Sludge Magnetic f lowmeter
Flow Transmitter
Influent Sludge Channel Level Recorder
61
bl
63
J L
J L
JO W
Location areas (refer to pages 5 and 6):
J » sludge thickening
L » plant shop and service building
O = outside
Figure 1. Equipment configuration list.
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ID
Manufacturer
Part Number
Serial Number
21 Centrifugal Pumps
13112
13113
13114
22113
22114
22115
23111
23112
35111
35112
35113
35411
36113
36114
42211
42212
42213
42311
42312
42313
43311
Fairbanks Morse
Fairbanks Morse
Fairbanks Morse
Wemco Torque Flow
Wemco Torque Flow
Wemco Torque Flow
Wemco Torque Flow
Wemco Torque Flow
Fairbanks Mors
Fairbanks Mors
Fairbanks Mors
Fairbanks Mors
Fairbanks Mors
Fairbanks Mors
Eastern
Eastern
Eastern
Eastern
Eastern
Eastern
Fairbanks Morse
5710
5710
5710
Mode C
Mode C
Mode C
Mode E
Mode E
Mode 5720
' Mode 5720
Model 5720
5423 B-28
5424D
5424D
U-34-C. 107-3
U-34-C. 107-3
U-34-C. 107-3
U-34-C. 107-3
U-34-C. 107-3
U-34-C. 107-3
5414E
K2N1 044068
K2N1 044069
K2N1 044070
6895610-3
(895610-2
6895610-1
6895610-4
6895610-5
K2N1 044071
K2N1044071-1
K2N 104407 1-2
K2N1044073
K2N1044072
K2N1 044072-1
CJ8-0802
CJ8-0801
CJ9-1305
CJ8-0797
CJ8-0800
CJ8-0798
K2N1044075-1
31 Motors, Motor and Drive Assemblies
32621
32622
33321
33322
34221
34241
3S121
35122
35123
35131
35132
35133
35421
36123
36124
36133
36134
Westinghouse
Westinghouse
Sterling
Sterling
Fairbanks Morse
Westinghouse
US Varidrive'
US Varidrive
US Varidrive
US Electrical
US Electrical
US Electrical
Fairbanks Morse
US Varidrive
US Varidrive
US Electrical
US Electrical
TBDP
TBDP
FBNF-l
FBNF-l
KZK. T1004-2
M
VEU
VEU
VEU
ERHB
ERHB
ERHB
KZK. T1007-2
VLUHVCS
VLUHVCS
ERHP
ERHP
680B101C27-6807
680BI01C27-6807
8A2528-2
8A2528-1
F291080
311P178-A
J1421251
Jl 42 1249
J1421250
BI21781
B121781
B121781
F -457875
P4177843
P4177842
121781
121781
Figure 1. (continued)
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Additionally, pumps were listed separately with their head, capacity, size,
impeller and RPM.
The equipment data list was grouped by equipment type (centrifugal
pumps; motor; motor and drive assemblies; etc.) and specified for each piece
of equipment, using the five-digit identification number, the manufacturer's
name, the part or model number and the serial number.
The equipment reference data forms, prepared for each five-digit number-
ed item, contained all descriptive information on that piece of equipment
taken from the manufacturer's catalogs, drawings, reference data, etc. The
back of the reference data forms detailed the parts that would be needed for
operation of that equipment. This information was used for the development of
preventive maintenance (PM) and corrective maintenance (CM) procedures and
for the development of a spare parts inventory. Additional forms that were
developed, based on the five-digit identification number, gave other informa-
tion such as the head-capacity-power data for pumps and the frame type,
horsepower and current information for electric motors.
Thus, the- equipment configuration list was used to group the equipment
and assign identification numbers. The identification numbers were then used
as catalog numbers to order other information necessary to facilitate a logi-
cal and systematic file on each piece of equipment.
The Maintenance Procedures (MPs)
The maintenance procedures (MP) for each item of equipment were detailed
individually on a sheet called the maintenance procedure sheet. While each
equipment item was identified by a five-digit identification number, the MP
sheet carried the first four digits only and thus those maintenance procedures
were applicable to all equipment items with those first four digits, A two-
character, alpha-numeric code was added to the four-digit number. The first
alpha character specified the frequency of the PM procedure (i.e., D=daily;
W=weekly; M=monthly, etc.) and the second numeric character specified the
num ber of MPs required for that piece of equipment at the specified fre-
quency. For example, using the major sub-function number 520, sludge thicken-
ing, the MPs for the pumping equipment, 522, associated with sludge thicken-
ing, were numbered 5221 01, 5221 Wl, 5221 Rl, 5221 Ml and 5221 M2. The first
four digits identified the particular piece of equipment, in .this case the
duplex plunger pumps. The alpha-numeric codes 01, Wl, Rl and Ml specified
that those particular MPs were to be performed on a daily, weekly, as required
and monthly basis, respectively, and that number one of a series of procedures
is to be performed. The alpha-numeric code M2 specified that number two of a
series of MPs were required for that piece of equipment on a monthly basis.
The maintenance procedure sheet specified in detail all of the tasks
(steps) required for the successful completion of that MP. Additionally, the
sheet detailed (a) the labor skill required (Si-electrician, S2-mechanic and
53-utility man); (b) the labor time required; (c) the name, identification
number, nameplate data and location of that piece of equipment; (d) safety
precautions to be observed; and (e) all parts, tools, materials and test
equipment needed to accomplish that MP.
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A summary MPs list was also prepared that displayed the MP number, a
brief description of the PM task, the labor skill and labor time required and
the week number that the PMMS was initiated for that MP. That initial week
number was then updated based on the specified frequency of the MP. The week
numbering system was used for scheduling the PM tasks. The PM tasks were
scheduled for each of the 52 weeks in a year. All MPs with the alpha codes D
and W were scheduled for daily and weekly assignments; those MPs with the
alpha codes M, Q, S, and A were scheduled according to the week number for
which the PMMS was implemented for that unit; and the MPs with the alpha code
R were scheduled as required. For example, the summary sheet might have
shown the following:
MP NO. TASK DESCRIPTION SKILL/MIN. WEEK NO.
1111 Dl 1
1111 D2 1
1111 Ml 1
1122 Ml 3
1122 Ql 3
1122 Al - - - - 3
1311 Wl 1
1311 Rl - (as required)
1311 SI 9
1311 S2 9
By using the initial week number MPs 1111 Dl and 1111 D2 would have been
scheduled for daily attention; MP 1311 Wl would have been scheduled for each
week; MP 1111 Ml would have been scheduled for weeks 1, 5, 9, 14, 18, 22, 27,
31, 35, 40, 44, and 48 and week 1 of the next year; MP 1122 Ml would have been
scheduled for weeks 3, 7, 11, 16, 20, 24, 29, 33, 37, 42, 46, 50 and week 3 of
the next year; MP 1122 Ql would have been scheduled for weeks 3, 16. 29, 42 and
week 3 of the next year; MPs 1311 SI and 1311 S2 would have been scheduled for
weeks 9, 35 and week 9 of the following year. This summary list was thus used
to prepare the PM cycle schedule.
The Preventive Maintenance (PM) Cycle Schedule
The PM cycle schedule was prepared using the MPs summary list. PM
actions were scheduled for each week and the list was ordered so that all PM
tasks on a particular unit could be assigned to one team. Additionally, the
MPs on the same unit, but different frequencies, were scheduled so that they
could be accomplished during the same weeks that the unit was being worked on.
Thus, MPs 1122 Ml, 1122 Ql and 1122 Al were included on the PM cycle schedule
for weeks 3 of the PMMS year and MPs 1122 Ml and 1122 Ql were included on the
PM cycle schedule for week 3, 16, 29 and 42 of the PMMS year. These items were
scheduled in addition to all daily and weekly PMs required for MP 1122.
However, the daily and weekly PM tasks were listed separately. The PM cycle
schedule was generated on a weekly basis and the actual daily assignments were
left to the foreman and plant management. As a means of facilitating with the
daily assignments, the plant was sectioned into different areas and each area
was scheduled for preventive maintenance on a particular day of the week. For
example:
10
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Monday - PM schedule for The Incinerator Building.
Tuesday - PM schedule for The Blower Building
Wednesday - PM schedule for The Chlorine Building
Thursday - PM schedule for The Chlorine Building
Friday - PM schedule for The Chlorine Building
A master PM schedule was prepared that displayed each PM task and fre-
quency for each piece of equipment for the entire year. The master schedule
assisted plant management in determining staffing requirements and also in
making decisions concerning which PM tasks could be delayed in order to free
personnel to attend to those PM tasks that had to be accomplished during that
week without incurring overtime or having to add additional personnel. Re-
scheduling of PM tasks was done by plant management. This decision was based
on the availability of personnel and the immediacy of the task.
The PM cycle schedule displayed on a weekly basis the PM procedures that
should be accomplished during that week. The schedule listed by MP numbers
all required MPs. The maintenance foreman made the decision as to which MPs
would be performed each day. Upon completion of the task, the date, name and
time were recorded on the back of the MP sheet. This information was used to
adjust the time on the MP sheet for performing that task and to update the
recordkeeping system.
The Recordkeeping System
The recordkeeping system of the PMMS was designed to maintain a permanent
record for each item of equipment. This system included all records on the PM
and CM work performed. In order to develop this system it was necessary to
utilize six forms. These forms were:
1. Equipment Reference Data Form Ml
2. The Equipment Maintenance Record Form M2
3. The Preventive Maintenance Work Record Form M3
4. The Report of Trouble Form M3X (this form was a variation of form
M3)
5. Equipment Malfunction Report Form M4
6. Corrective Maintenance Work Order Form M5
7. Corrective Maintenance Work Order and Work Record Form M6.
These forms, including their reverse sides, are shown in Figures A1-A9 in
Appendix A. The use and description of these forms have been previously
described (1)'.
The recordkeeping system was designed to eliminate unnecessary paperwork
from the maintenance personnel, yet maintain an updated maintenance record on
each item of equipment. It was also used for generating weekly maintenance
summary reports by providing information to update the Maintenance Data Feed-
back System.
The Maintenance Data Feedback System
The Maintenance Data Feedback System was developed to provide plant man-
agement with a weekly maintenance summary report. To accomplish this, the
11
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Weekly Maintenance Summary Report Form M7 was completed by the maintenance
technician using information from the recordkeeping system. The Weekly Main-
tenance Summary Report Form was comprised of three parts: a Work Load Summary
and a Work Accomplished Summary on the front of the form, and a Corrective
Maintenance Summary on the back.
The Work Load Summary included the maintenance workload that should have
been accomplished during the week, what is actually accomplished and what the
carryover (backlog) was for the following week. The maintenance actions were
broken down into Preventive Maintenance and Corrective Maintenance and the
man-hours by skill were also recorded. Management used the Work Load Summary
to determine the number of preventive and corrective maintenance actions
completed and the number of actions that were back logged.
The Work Accomplished Summary summarized the total maintenance costs for
the plant for each week. The Work Accomplished Summary was also broken down
into Preventive and Corrective Maintenance, the number of actions completed,
the actual man-hours expended per skill, the cost for labor, the cost for
outside contractors, the cost of parts and materials, and the total costs.
The Corrective Maintenance Summary listed all CM work that was out-
standing at the beginning of the week and that was initiated during the week.
For each task the job number; the equipment name; the equipment identification
number and the status code were recorded. The equipment status code indicated
whether the equipment was operational, nonoperational or in a reduced cap-
ability mode. The Corrective Maintenance Summary also gave a description of
the work to be done on each action, the work order date, and the completion
date. Additional information was also provided, if necessary. Using this
information a Priority Code was also established for each job. This code was
as follows:
U - Urgent repairs to correct conditions that prevent the plant
from operating or which involve the health and safety of per-
sonnel
N - Needed repairs to correct conditions that seriously impair
plant efficiency or plant reliability
R - Routine repairs, tests and inspections
C - Convenience items.
This coding helped management with the scheduling of corrective maintenance
jobs.
SUMMARY
The manual operation of the PMMS included both PM and CM procedures.
Corrective maintenance was not, of course, planned, but occurred as a result
of a breakdown or a noticed impending failure. Exhibit 1 summarizes the
manual PMMS for PM and CM applications.
12
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EXHIBIT 1
SUMMARY OF STEPS FOR PMMS FOR PREVENTIVE
MAINTENANCE AND CORRECTIVE MAINTENANCE APPLICATIONS
PREVENTIVE MAINTENANCE
1. The functional numbering system and equipment type numbering system
were developed. This was a one-time accomplishment of the complete
inventory of the plant's mechanical and electrical equipment. The
equipment nameplate data was put on Form Ml.
2. "The inventory was restructured into the Equipment Configuration
List by sorting into appropriate groupings the equipment related to
each of the various plant unit treatment works, utilities and ser-
vices.
3. The Equipment Data List was prepared. This list augmented the
Equip ment Configuration List and was grouped by equipment type.
Even more detailed data could have been tabulated if desired.
4. Maintenance Procedures (MP) for each piece of equipment included in
the inventory, using manufacturer's information and drawings, and
the expertise of personnel familiar with the equipment maintenance
procedures were prepared.
5. A numbered (functional numbering system used) Maintenance Procedure
Sheet (MPS) for each individual Maintenance Procedure (MP) was pre-
pared.
6. A summary list of Maintenance Procedures was prepared.
7. Based on the summary list of Maintenance Procedures and the judg-
ment of senior plant staff, PM actions were scheduled for each of
the 52 weeks of the year. The actual work assignments on a daily
basis were left to the discretion of the foreman and plant manage-
ment.
8. When the PM task was completed, the maintenance personnel docu-
mented the task performed on Form M3 or M3X.
9. The PMMS technician used the data on Form M3 or M3X to prepare the
permanent Form M2.
13
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10. If the "trouble" box on Form M3 or M3X was not checked, the Form was
discarded.
11. If the "trouble" box on Form M3 or M3X was checked, the form (after
filling out Form M2) was returned to the Maintenance Department and
Forms M5, CM work order, and M6 were filled out. Form M5 initiated
the CM action.
12. Form M7, Weekly Maintenance Summary Report, was also .completed.
CORRECTIVE MAINTENANCE
1. Corrective maintenance was initiated by the maintenance personnel
that indicated trouble on the back of Form M3 or M3X. Additionally,
CM could have also been initiated by the plant operators or anyone
else that observed an equipment malfunction. In that situation,
Form M4 was completed and returned to the Maintenance Department.
2. The Maintenance Department, after receipt of Form M3 or M3X, com-
pleted Form M5 and the top half of Form M6. Form M6 was given to the
maintenance personnel.
3. The maintenance personnel completed the lower half of Form M6 when
the CM task was completed.
4. The PMMS technician filled out Form M2 and discarded Form M5. Form
M6 was kept as a permanent equipment file.
5. The PMMS technician then completed Form M7.
14
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STAFFING
The PMMS is not a substitute for maintenance staff but rather a tool to
be utilized by the staff. To be effective, the PMMS should be designed to
meet the staff's needs to carry out a maintenance program. The staff must
receive training and it is important that each of the staff's responsibilities
be defined to assure a successful running system. One of the key personnel is
the individual who, at the Lower Potomac Wastewater Treatment Plant, had the
title Maintenance Technician.
The Maintenance Technician was responsible for the running of the
system. This position was essential to the successful implementation and
development of the system. The duties of the Maintenance Technician required
that he maintain and update equipment files; that he prepare working copies of
the maintenance procedure sheets on a weekly basis; that he produce reports on
equipment history, equipment conditions, maintenance history, maintenance
cost and manpower requirements, when necessary to identify and implement
improvements to the maintenance system. This position was usually given to a
person that was quite familiar with the operational and maintenance history of
the plant.
At the Lower Potomac Wastewater Treatment Plant three labor/skill cate-
gories were used for performance of the maintenance tasks. These were:
Skill 1 - Electrician
Skill 2 - Mechanic
Skill 3 - Utility Man
The duties of the electricians and the mechanics are self-explanatory.
The utility man category required some familiarity with the repair and opera-
tion of electrical and mechanical equipment. This person assisted the elec-
trician and mechanic as necessary.
15
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SECTION 5
DESCRIPTION OF THE EXISTING SYSTEM
The maintenance management system presently installed at the Lower
Potomac WWTP is a computerized version of the manual system that was described
previously. The system was computerized in 1976 and has the capability of
handling a comprehensive planned maintenance management program. However,
the system has not been implemented to its complete extent. The five basic
parts of the system as described in Section 1 have been computerized, but some
of the operations are still manual.
Transition from Manual System to Computerized System
The transition from the manual system to the computerized system took
place during a of 2 - to - 3 month period. This was possible because of two
significant factors. One, the complete and detailed manner in which the
manual PMMS had been prepared. Two, the computer software programs developed
by personnel of the Fairfax County Government was prepared with full consulta-
tion with the LPWTP maintenance staff who were very knowledgeable about the
PMMS.
The data and information obtained and stored in the present computerized
system are essentially the same as those which were obtained and stored in the
manual system.
The computer generates both PM and CM work orders, cyclical preventive,
maintenance procedures, a monthly corrective maintenance summary and a work
accomplished summary (summarizes PM and CM actions completed during the
month). The computerized version of the PMMS requires 19 input documents,
whereas the manual system required only 6 (Forms M1-M6). Of those 19 input
documents, the maintenance staff only came in contact with 3 of them.
PREVENTIVE MAINTENANCE (PM)
To carry out the preventive maintenance program a number of files is
necessary. These are the daily, weekly and cyclical Preventive Maintenance
Files.
The Daily and Weekly Preventive Maintenance File, which is a non-com-
puterized file consisting of all the Maintenance Procedure Sheets for the
equipment requiring daily or weekly PMs, is maintained at the plant. This
file is composed of five folders, one for each day of the week. The MPs are
distributed among the five folders using the PM Cycle Schedule described in
16
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Section 2 of this report and on a balanced work load. This file is developed
using the Equipment File Maintenance and Maintenance Procedure File Main-
tenance Documents. Scheduling of the PM tasks is handled by the senior
maintenance, operations, and PMMS personnel. This file is not maintained in
the computer, but a ledger is kept for recording all daily and weekly preven-
tive maintenance actions carried out on each item of equipment. The PMMS
Technician summarizes these weekly PM actions and transmits them to the com-
puting center. The daily and weekly PM actions are recorded by the computer
and are printed out in one of the two monthly reports generated.
The Cyclical Preventive Maintenance File is designed to schedule only
those items of equipment that require maintenance on a monthly, quarterly,
semi-annual or annual basis or on the basis of hours of run-time of equipment.
The file is developed using the Equipment File Maintenance, Maintenance Pro-
cedure File Maintenance and Meter Reading Card Documents. The scheduling of
these actions is prepared by the senior maintenance, operations and PMMS
personnel.
Preventive Maintenance Implementation
Each week, the computer prints out a list of all the PM actions scheduled
for the following week. Exhibit 2 is a PM flow diagram. Since Maintenance
Procedure Sheets are on file in the noncomputerized files for all items
requiring weekly or daily maintenance, the computer only prints out "PM Work
Orders" for equipment requiring cyclical maintenance. The "PM Work Orders"
are delivered to the PMMS Technician for distribution, along with the cor-
responding Maintenance Procedure Sheets, to the appropriate daily folder de-
scribed above. Completed PMs are reported back to the Computing Center via
the PMMS Technician using the "PM Work Orders" for cyclical maintenance.
Uncompleted PMs can be tracked by flagging the unreturned "PM Work Orders" and
Maintenance Procedure Sheets that have not been filled out. Exhibit 3 sum-
marizes the computerized version of the PMMS for the implementation of PM
actions.
For the PM actions, the plant maintenance staff routinely use only two
forms - the Maintenance Procedure Sheets and the "PM Work Orders". However,
the following documents have to be utilized (prepared by senior maintenance,
operations and PMMS personnel) in order to provide for file updating, main-
tenance scheduling and management reporting.
1. Equipment File Maintenance
2. Maintenance Procedure File Maintenance
3. Parts File Maintenance
4. Personnel File Maintenance
5. Meter Reading Card
The above forms are Figures 81, B2, B3, B6, and B15 of Appendix B.
17
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PREVENTIVE MAINTENANCE FLOW DIAGRAM
00
NON-COMPUTERIZED
FILE
DAILY & WEEKLY PM
MAINTENANCE PROCEDURE
SHEETS
CYCLICAL PM ACTIONS
FROM COMPUTER
PM
WORK ORDER
MAINTENANCE PROCEDURE
SHEETS FOR CYCLICAL
PM
FROM PMMS TECHNICIAN
TO
..MAINTENANCE DEPT.
MAINTENANCE
SUPERVISOR
ASSIGNS
TO
DIVISIONS
TO
MAINTENANCE DIVS.
TO
MAINTENANCE STAFF
DIVISION HEAD
SCHEDULES
DAILY PM
AND
ASSIGNS STAFF
CM
COMPLETED
BY
MAINTENANCE
STAFF
I
MAINTENANCE PROCEDURE
SHEETS AND PM WORK ORDERS
COMPLETED
I
TO DEPARTMENT/DIVISION
REVIEW BY
DIV./
DEPARTMENT
TO PMMS TECHNICIAN
PM WORK ORDERS
TO
COMPUTING CENTER
SUMMARIZES ACTUAL
DAILY AND WEEKLY
PM AND FORWARDS
TO
COMPUTING CENTER
Exhibit 2. Preventive maintenance flow diagram.
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EXHIBIT 3
SUMMARY OF STEPS FOR THE COMPUTERIZED PMMS FOR
PREVENTIVE MAINTENANCE
1. A noncomputerized file of daily and weekly PMs is prepared by dis-
tributing the work among the 5 weekdays on the basis of the PM
cycle schedule, a balanced work load and the judgment of the senior
staff. This file consists of the daily and weekly Maintenance Pro-
cedure Sheets.
2. Cyclical PM actions are obtained from the computer center in the form
of "PM Work Orders".
3. The Maintenance Procedure Sheets corresponding to the "PM Work
Orders" generated are obtained by the PMMS Technician.
4. The weekly, daily and cyclical PM requirements are then sent to the
Maintenance Department.
5. The maintenance supervisor sorts the PM actions received and assigns
them to the responsible division (mechanical, electrical, instrumen-
tation).
6. The division head schedules the daily PM activities and assigns the
staff.
7. PM completed.
8. When the PM tasks are completed the maintenance personnel complete
the information on "PM Work Orders" and Maintenance Procedure Sheets.
9. The two documents completed in step 8 are returned to the Depart-
ment/Division.
10. The PM files are returned to the PMMS Technician.
11. The PMMS Technician returns the "PM Work Orders" to the Computing
Center.
12. The PMMS Technician summarizes the actual daily and weekly PM per-
formed and forwards to the Computing Center on a weekly basis.
19
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CORRECTIVE MAINTENANCE
Three types of CM actions are recognized at the Lower Potomac Wastewater
Treatment Plant - malfunction, incipient and elective. A malfunction is an
actual breakdown or problem; an incipient problem, which is usually reported
as part of PM work, is one that if not corrected will lead to breakdown; and
elective is maintenance or construction that is nonfunctional in nature,
e.g., painting, new safety features, change in location of meters or controls,
etc.
A CM is classified as minor, major or emergency. A minor CM is one which
can be corrected in less than one and one-half (1%) hours with parts costing
less than fifteen dollars ($15). An emergency CM is one required to keep the
plant, a major subsystem (e.g., aeration system), or a major piece of equip-
ment (e.g., compressor) in operation. All other CMs, including elective, are
considered major.
Corrective Maintenance Implementation
The. Equipment Malfunction Report Documents are available in all loca-
tions of the plant where equipment is located and are readily accessible to
all operations, maintenance and plant personnel. When a malfunction is dis-
covered, that document (which consists of two copies) is filled out; one copy
is posted on a notice board in the immediate vicinity of the equipment being
reported on, and the original is delivered to the Shift Foreman. If the Shift
Foreman determines that the malfunction is an "emergency," the Maintenance
Department is notified immediately. The Maintenance Department may proceed
to correct the malfunction without receiving a Corrective Maintenance Work
Order. The PMMS Technician working with the Supervisor of the appropriate
Maintenance Division has the responsibility of submitting the Equipment Mal-
function Report and the CM Initiation Request to the Computer Center. The
Computer Center generates the CM Work Order. When the malfunction has been
corrected, the completed CM Work Order is returned to the Center. At the
completion of the repair, the Equipment Malfunction Report Form that was
posted on the notice board is removed and destroyed.
All other Equipment Malfunction Report Documents that are not determined
to be an "emergency" are sent to the PMMS Technician who will refer them to
the appropriate Maintenance Department Supervisor (electrical, mechanical, or
instrumentation). If the CM action is a minor one, the CM action is completed
by the Maintenance Department and no written record is kept. The labor time
is billed to a standard work order, which is recorded at the Center. Upon
completion of the CM, the copy of the Equipment Malfunction Report Document
posted on the notice board is removed and destroyed.
If the CM action is determined to be major, the PMMS Technician sends the
Equipment Malfunction Report Document, to the Maintenance Department Super-
visor. The Maintenance Department indicates on the Malfunction Report Docu-
ment that a CM Work Order is needed and provides some information as to the
nature of the repairs required. That document is sent to the PMMS Technician
who prepares a CM Initiation Request, which is sent to the Computer Center. A
CM Work Order is generated by the Center and returned to the Maintenance
20
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Department via the PMMS Technician. At the completion of the CM action, the
bottom half of the CM Work Order Document is completed by the Maintenance
Department. The CM Work Order Document is then sent to the stockroom for cost
data on the parts used before being returned to the Computer Center via the
PMMS Technician. The copy of the Equipment Malfunction Report Document posted
on the notice board is removed and destroyed.
If the CM action is elective, a Corrective Maintenance Initiation Re-
quest is prepared by the PMMS Technician upon authorization from the Main-
tenance Department. This request document is then sent to the Computer
Center. A CM Work Order is prepared by the Center and returned to the
Maintenance Department via the PMMS Technician. Upon completion of the CM
action, the bottom half of the CM Work Order form is completed by the Main-
tenance Department and returned to the Computer Center via the PMMS Tech-
nician. Exhibit 4 is a flowchart for the PMMS implementation of corrective
maintenance actions as described above.
DOCUMENTS USED FOR IMPLEMENTATION OF THE PMMS FOR CM ACTIONS
The plant maintenance-staff routinely use-only three documents for CM
actions. These are the Equipment Malfunction Report, the Corrective Main-
tenance Initiation Request and the CM Work Order.
However, the following documents have to be utilized (prepared by senior
maintenance, operations and PMMS personnel) in order to provide for file up-
dating, maintenance scheduling and management reporting.
1. Equipment File Maintenance
2. Maintenance Procedure File
3. Parts File Maintenance
4. Standing Work Order File Maintenance
5. Personnel File Maintenance File
6. Action Codes File Maintenance
7. Description Code File Maintenance
8. Item Code File Maintenance
The scheduling of CM actions other than emergency repairs is done by the
senior maintenance personnel and is determined on the basis of PM actions
required, PM backlog, CM actions, CM backlog, personnel available, overtime
to be utilized, contractor services that can be utilized and emergency repairs
underway. Elective maintenance is also scheduled taking into account the
above factors. A list of uncompleted (backlog) CMs can be printed out by the
computer upon request.
DATA GENERATED BY THE EXISTING PMMS
The actual data on maintenance performed is provided by the maintenance
staff and the Maintenance Technician, who fill in parts of the following five
documents as shown in Table 1, that have been described and are shown in
Appendix B:
-------
FLOW CHART
EQUIPMENT
MALFUNCTION
REPORT
[
FILLED OUT BY OPERATIONS,
MAINTENANCE, PLANT
PERSONNEL
EQUIPMENJJWLFUNCTION • ' • EQUIPMENT HALF
4 i1 * » t
POSTED ON NOTICE BOARD (EMERGENCY |
i
'JI?C^LW?ENn "^ TO SHIFT FORMAN
^
TO MAINTENANCE
TO PMMS
TECH.
1
SORTED AND SENT TO
RESPONSIBLE DEPT./
ELECT. /MECH./INST.
c 1 1 WORK AUTHORIZED MINOR " MINOR/MAJOR
|rO PMMS TECH. ' ^ ' ' 1 '
WORK COMPLETED , — ,,.L .
UNCTION
tl
-{MAJOR
i .
K LM WORK UKUtK
HI ZED REQUESTED
STAFF . WOR
CM WORK ORDER
COMPLETED
(BOTTOM HALF)
TO PMMS
TECHNICIAN
.
TO COMPUTER
CENTER TO
UPDATE PMMS FILES
TO STOCK
COST OF
PARTS USED
K TO PMMS
ETED TECHNICIAN
CM INITIATION RE-
QUEST PREPARED BY
PMMS TECHNICIAN
CM INITIATION RE-
QUEST TO COMPUTER
CENTER FOR PREPARA-
OF CM WORK ORDER
1
CM WORK ORDER
1
TO PMMS TECHNICIAN
I
TO MAINTENANCE
STAFF
t
WORK AUTHORIZED
V
WORK coMPLETEu |
BOTTOM HALF OF CM
WORK ORDER COMPLETE
BY MAI NT. STAFF
'
TO PMMS TECHNICIAN
1
CM WORK ORDER TO
COMPUTER CENTER
I
PMMS PROGRAM
UPDATED
Exhibit 4. Corrective maintenance flowchart.
22
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TABLE 1. INPUT DATA DOCUMENTS FOR EXISTING PMMS
Maintenance
action
Document
Responsibility of
maintenance staff
Preventive Maintenance
Preventive Maintenance
Corrective Maintenance
Corrective Maintenance
Corrective Maintenance
Maintenance Procedure
Sheets
Preventive Maintenance
Work Order
Equipment Malfunction
Report
Corrective Maintenance
Initiation Request
Corrective Maintenance
Work Order
Sign and date after action
completed
Sign and date after action
completed
Indicate on document
problem observed
Filled out by PMMS
Technician
Sign and date after
work completed
The data generated through the actual PMMS in use at the Lower Potomac
Plant is itemized below.
Preventive Maintenance Data Generated
I. A. For every individual equipment item
(a) When maintenance took place (date)
(b) Who performed maintenance
(c) Parts and supplies utilized
(d) Cost of parts and supplies utilized
(e) Time required to perform maintenance
(i) Regular hours
(ii) Overtime hours
(f) Labor costs to perform maintenance
(g) Labor skills utilized for maintenance
(h) Outside contractor costs
(i) Total costs
B. For the plant as a whole
(a) Number of actions regularly scheduled during current week and
estimated man-hours by skill
(b) Number of actions backlog from previous week and estimated
man hours by skill
(c) Total number of outstanding actions for current week and esti-
mated man-hours by skill
23
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(d) Number of actions accomplished during current week and esti-
mated man-hours by skill
(e) Number of actions backlog for next week and estimated man-
hours by skill
(f) Labor costs for the week - regular time, overtime and total
(g) Outside contractor costs for the week
(h) Costs of parts and materials used during week
(i) Total costs for the week
(j) Number of actions completed during the month
(k) Number of hours utilized during month - regular time, overtime
and total
(1) Labor costs for the month
(m) Parts and material costs for the month
(n) Outside contractor costs for the month
(o) Total costs for the month
Corrective Maintenance Data Generated
II. B. For every malfunction
(a) Malfunction report - who prepared
(b) Work order request - who prepared and who authorized, when re-
quested
(c) Work order - who prepared and who authorized, when issued
(d) Time malfunction or trouble reported
(e) Nature of malfunction or trouble (description of symptoms)
(f) Identification of equipment (name and number)
(g) Job number
(h) Items needing repair
(i) Priority for repair
(j) Estimate of labor time and parts to repair
(k) Hours of running time for equipment (if applicable)
(1) Item repaired
(m) Labor time by skill - regular time, overtime, and total
(n) Labor costs by skill - regular time, overtime, and total
(o) Parts and materials used
(p) Costs of parts of materials
(q) Contractor costs
(r) Total costs to repair
(s) When job was complete
C. For the plant as a whole
(a) Number of actions regularly scheduled during current week and
estimated man-hours by skill
(b) Number of actions backlog from previous week and estimated
man hours by skill
(c) Total number of outstanding actions for current week and esti-
mated man-hours by skill
(d) Number of actions accomplished during current week and man-
hours by skill
24
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(e) Number of actions backlog for next week and estimated man-
hours by skill
(f) Labor costs for the week - regular time, overtime and total
(g) Outside contractor costs for the week
(h) Costs of parts and materials used during week
(i) Total costs for the week
(j) Number of actions completed during the month
(k) Number of hours utilized during month - regular time, overtime
and total
(1) Labor costs for the month
(m) Parts and material costs for the month
(n) Outside contractor costs for the month-
Co) Total costs for the month
The above list represents the actual data generated and does not repre-
sent the data that could be supplied by the PMMS. The recordkeeping and
feedback capabilities of the PMMS represent a powerful management tool, which
is underutilized at the present time. A complete accounting of maintenance
labor, material and contractor costs for management use in cost control and
budget preparation is available. Costs can be reported by plant area, func-
tional subsystem, types of equipment and individual items of equipment. Life
cycle costs can be determined. Actual performance of equipment can be com-
pared to manufacturer or design specifications. The cause and responsibility
for equipment failure can be assessed. Reliability of equipment, subsystems,
and systems can be determined. Historical data as well as current data on PM
and CM for each item of equipment are readily available.
MANAGEMENT REPORTS GENERATED
The only management reports that are now generated on a regular basis are
the Monthly CM Summary and the Work Accomplished Summary. The Monthly CM
Summary contains the following information:
o Date
o Plant
o Job Number
o Equipment Number
o Equipment Name
o Location
o Apparent Cause of Malfunction
o Completion Date
o Regular Hours
o Overtime Hours
o Labor Cost
o Parts Cost
o Contract Cost
o Grand Total Cost
The Work Accomplished Summary gives in tabular format the number of
Preventive Maintenance actions completed and the number of Corrective Main-
tenance actions completed during that reporting period.
25
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OPERATION OF THE EXISTING PMMS
The qualifications of the personnel required to operate the PMMS have
been documented earlier. Exhibit 5 is a current table of organization for the
operation and maintenance staff at the Fairfax Lower Potomac Wastewater
Treatment Plant. The efficient utilization of the PMMS is dependant upon the
availability of the following personnel categories:
1. Maintenance Technician (Engineering Technician on Table of Organi-
zation)
2. Senior staff who are responsible for the scheduling of the main-
tenance actions
3. Management personnel who utilize the generated data for planning
evaluation and budgeting purposes
4. Maintenance personnel who must be cooperative and participate if
the system is to work.
The training of the maintenance personnel is done on an ad hoc, informal
basis, which appears to be adequate since the actual plant maintenance is
being performed in a satisfactory manner.
There have been two major deficiencies in the operation and utilization
of the system. One relates to the interface between the maintenance personnel
and the Computer Center including the absence of a computer terminal at the
plant. The other relates to the limited use that is being made of the data
that are being collected and are available as data feedback.
26
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LOWER POTOMAC POLLUTION CONTROL PLANT
1 Engineer IV (1)
ro
WAREHOUSE
Warehouse Supv (1)
Supply Clerks (2)
OPERATIONS
Pit. Opns Supt. (1)
Pit. Opns. Supr. (5)
Pit. Opr. Ill (10)
Pit. Opr. II (15)
Utility Workers (4)
SECONDARY PLANT
1 Asst. PI. Manager (Eng
MAINTENANCE
1 Pit. Maint. Supt. (1)
0 Pit. Maint. Supr. (1)
1 Pit. Mech. Ill (1)
3 Pit. Mech II (3)
4 Pit. Mech I (4)
1 Welder II (1)
1 MTH II (1)
ELECTRICAL DEPARTMENT
1 Eng. Tech III (1)
2 Ind. Elect II (2)
1 Ind. Elect. I (2)
1 MTH II (4)
Clerk Typist II
HI) (1)
PLANT SUPPORT
1 Eng. II (1)
0 Eng. Tech III (1)
1 Eng. Tech II (1)
1 Clerical Spec (1)
0 Draftsman (1)
INSTRUMENTATIONS
1 Inst. Supr (1)
1 Inst. Tech. Ill (2)
2 Inst. Tech. II (4)
2 Inst. Tech. I (2)
(1)
PHOSPHORUS PLANT
1 Asst. PI. Manager (Eng III) (1)
1
OPERATIONS MAINTENANCE
1 Pit. Opns. Supt. (1) 0 Pit. Maint. Supt.
5 Pit. Opns. Supr. (5) 1 Pit. Maint. Supr.
10 Pit. Opr. Ill (10) 2 Pit. Mech III (2)
15 Pit. Opr. II (15) 3 Pit. Mech II (3)
3 Pit. Mech. I (5)
0 Welder II (1)
0 MTH II (1)
BLDG & GROUNDS
1 Bldg. Sup II (1)
1 Custodian (1)
0 Sr. U.W. (2)
2 Utility Worker (2)
1 MTH II (1)
0 Painter (1)
2 Laborers (2)
(1)
(1)
Exhibit 5. Organization of operation and maintenance staff.
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SECTION 6
METHODOLOGY FOR ASSESSING BENEFITS OF A MAINTENANCE SYSTEM
The primary methodology for assessing the benefits of a maintenance system
in general, and the PMMS in particular, is to (1) identify the benefits; (2)
quantify all actual or potential benefits; (3) consider alternative means for
achieving those benefits; and (4) determine the costs and values (in monetary
and nonmonetary terms) in achieving benefits.
The following are considered benefits for a maintenance system:
1. Improved plant performance.
2. Reduced number of plant, system, subsystem, equipment failures.
3. Improved reliability of system - reduce equipment downtime.
4. Reduced number of higher skilled staff.
5. Reduced overtime requirements for maintenance.
6. Number of maintenance backlog items at a level that does not increase
malfunction potential.
7. Improved personnel morale.
8. Provision for cost control and budget preparation.
9. Provision of information for better design, construction and equip-
ment evaluation for purchasing agents.
10. Reduced operational costs when compared to historical trends or
comparable alternative systems.
Cost comparison among maintenance systems is extremely difficult because
of the following considerations:
1. Costs must be normalized for different locations and time periods.
2. Institutional constraints can affect the numbers of personnel and
skills required to be employed.
28
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3. Total costs for a maintenance system should include startup costs,
administrative costs and management costs.
4. Systems when installed have more capacity than can be utilized.
5. Maintenance costs affect life cycle costs that are not readily a-
vailable.
6. Maintenance costs affect operating costs and these benefits are
difficult to assess.
7. The need for outside contractors to assure a backup capability may
require their use to assure their availability.
8. The method used for the allocation and accounting of the time of
personnel - maintenance, operation, administrative, supervisory,
management - varies from plant to plant.
There are two other approaches of assessing benefits other than the cost-
effective- approach described above.. These are:
1. A statement of criteria for a system that, if met would provide
positive benefits. These criteria are usually established by know-
ledgeable experienced experts in the field.
2. Direct comparison of systems -
a. Systems that have been or will be in use at a particular plant
(within plant comparison)
b. Systems that have been used at comparable plants (between
plant comparison)
29
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CRITERIA AND GUIDELINES FOR MEASURING BENEFITS OF MAINTENANCE MANAGEMENT SYS-
TEM
Criteria for measuring the benefits of an effective maintenance management
system were presented by Enviro Plan Incorporated (2). These included:
1. Reducing the maintenance of complex equipment to simple procedures
that are easily identified and managed;
2. Defining the minimum requirements of preventive maintenance;
3. Scheduling and controlling the performance of work tasks, inspec-
tions and tests;
4. Describing the methods, materials, tools and personnel required;
5. Providing for the prevention or detection of impending mal-
functions;
6. Providing a permanent record of equipment characteristics and a
maintenance history;
7. Providing periodic maintenance summary reports to plant management;
8. Providing a means for knowledgeable management of maintenance;
9. Ensuring the systematic, timely, safe, standardized and complete
accomplishment of equipment care and inspection;
10. Increasing plant reliability by preventing equipment breakdown and
by prolonging equipment life;
11. Minimizing maintenance manpower requirements;
12. Providing a complete record system and a system for feedback to man-
agement;
13., Providing management with the information required for cost con-
trol, work load assessment and work assignment according to priori-
ty and urgency.
30
-------
MAINTENANCE MANAGEMENT SYSTEM EVALUATION GUIDELINES
A report (3) on maintenance management systems prepared by an EPA contrac-
tor provided guidelines for evaluating a maintenance management system. Table 2
presents those evaluation guidelines and a rating system.
Those systems, which achieve a high rating would be expected to produce the most
benefits. Each guideline may be assigned a numerical value up to the maximum as
indicated in the "Maximum Rating" column. The columns "PMMS Potential" and
"PMMS In Use" are numerical values assigned by PEER Consultants to the current
PMMS at the Lower Potomac Wastewater Treatment Plant. It should be noted that
the PMMS has the potential of receiving the maximum rating based on these
guidelines.
SYSTEMS COMPARISON
A direct way of comparing systems would be to compare a new system such as
the PMMS with a system or procedure in use prior to the introduction of the new
system. The difficulty in obtaining quantitative data as to cost and to ef-
fectiveness of maintenance programs, particularly those which are not "planned
maintenance management systems," negates or limits the use of the approach.
However, a qualitative assessment based on comments of personnel and semi-
quantitative assessments can be of use. Qualitative assessments could include
appearance of plant, morale of personnel, number of emergencies or crises,
backlogs, etc. Semi-quantitative data could include the size of the maintenance
staff, number of breakdowns, number of hours of bypassing, etc.
Comparisons of systems, at different plants on the basis of costs to
accomplish results, would be extremely difficult because of the problem of nor-
malizing costs and differences in cost accounting. However, using the evalua-
tion guidelines presented earlier in this section, interplant systems can be
compared. Other comparisons that can be made include the following:
1. Cost of installing system (for an operating plant this could be dif-
ficult).
2. Problems in using system.
3. The extent to which the system is being used as contrasted to the
systems potential.
31
-------
TABLE 2. GUIDELINES FOR EVALUATING A MAINTENANCE MANAGEMENT SYSTEM
EVALUATION GUIDELINES Maximum PMMS PMMS
rating potential in use
Equipment Record System
1. Equipment numbering or 20 20 20
other identification
system
2. System for maintaining 50 50 50
nameplate data and other
essential information
3.
4.
5.
6.
7.
Planning
1.
2.
3.
4.
5.
Preventive maintenance
record system
Recording preventive
maintenance work
Recording manpower, spare
parts used
Recording cost data
Availability of
maintenance related
documents
and Scheduling
Schedule chart or list
Plan and schedule
a) PM frequency based
on manufacturers and
others
b) Integration of PM
and CM organization
CM considered in planning
Work order system
Manpower management
techniques
30
20
30
30
20
20
30
10
10
20
30
30
30
20
30
30
20
20
30
10
10
20
30
30
30
20
30
30
20
20
30
10
10
20
30
15
(continued)
32
-------
TABLE 2. (continued)
EVALUATION GUIDELINES Maximum
rating
6.
7.
Storeroom
1.
2.
-•
3.
4.
5.
Labor standards
Contract maintenance
and Inventory System
Storeroom
Analysis of maintenance
items needed
a) Monitor items in
stock
b) Min. and max.
requirements
c) Purchase order system
System for locating items
Index system
Withdrawal slip
30
20
40
40
— " -
20
20
20
20
20
20
PMMS "
potential
30
20
40
40
—
20
20
20
20
20
20
PMMS
in use
30
20
40
40
20
10
10
20
20
20
Maintenance Organization and Personnel
1.
2.
3.
4.
5.
6.
Organization chart
Update of chart
Job descriptions
Descriptions up to date
Analysis of job
requirements
Training program
30
20
30
20
50
50
30
20
30
20
50
50
30
20
30
20
30
30
(continued)
33
-------
TABLE 2. (continued)
EVALUATION GUIDELINES . Maximum PMMS PMMS
rating potential in use
Cost and Budgets for Maintenance Operations
1. Breakdown of costs
2. Labor and materials by
jobs
3. Maintenance cost history
4. Compilation of cost
50
40
30
50
50
40
30
- 50
50
40
30
20
information
5. Contract maintenance costs 30 30 30
34
-------
SECTION 7
DATA ANALYSIS
This section presents a number of examples of how the data being col-
lected by the PMMS can be analyzed.
The validity of data analyses would, of course, depend on the accuracy of
the data used for the analyses. The data collected by the maintenance staff
and entered on the forms for input to the computer appear to be reliable and
of sufficient accuracy. However, the interface activities between the main-
tenance staff and the computer has had problems that put in question some of
the data coming out of the computer. Data from the forms have not been
transcribed correctly, multiple entries of the same forms have been made, and
not all the data have been entered into the computer. It should be pointed
out that these deficiencies are not due to the PMMS but rather to an organiza-
tional problem and possibly because a computer terminal is not available at
the treatment plant. Many of the deficiencies have now been corrected by the
addition of a PMMS technician.
It should be further noted that in spite of what appears to be major
deficiencies, the preventive and corrective maintenance activities are being
carried out in a satisfactory manner due in a large measure to the PMMS. The
system is considerably underused in that it does not have a complete and ac=
curate record system that could be used by management for cost control and
budget preparation and such optional features as quantitatively assessing the
benefits of the system by analyzing such factors as life cycle costs, and
providing information for better design, construction, and equipment evalua-
tion and for purchasing agents.
Another major barrier to data analysis is that the records for the PMMS
prior to its computerization have not been stored in a manner whereby they can
be readily retrieved.
In spite of the data deficiencies enumerated above, an analysis of the
data generated through the actual PMMS in use at the Lower Potomac Wastewater
Treatment Plant is presented and some assessment of how benefits can be
measured.
PLANT CAPACITY
The average flow at the plant has increased from 5 million gallons per
day (MGD) in 1970 to 18 MGD in 1980 (over 19 MGD in 1979) - Figure 2; There has
also been a corresponding increase in the influent BOD and suspended solids
35
-------
22.0
20.0-
o
CD 18.0-j
16.0
14.01
O
i 12
u_
QJ 10.0-
8.0
DC
> 6°
<4.
0H
2.0 •
AVERAGE FLOW IN MGD VS TIME
1970-1980
1970 71
i
72
73 74 75 76 77 78 79 80
YEARS
LEGEND
O BOO - INFLUENT
X BOO - EFFLUENT
A SS - INFLUENT
Q S3 - EFFLUENT
Figure 2. Average flow in MGD vs. time 1970-1980.
36
-------
loading as shown in Figure 3. However, there has been a continuing improve-
ment in plant performance, again illustrated by an actual reduction in ef-
fluent BOD and suspended solids quantities from 1972 through 1980 as also
shown in Figure 3. In addition, phosphorus removal facilities were placed in
operation in 1977, which increased the number of items requiring maintenance
and added to the amount of solids handled at the plant.
DATA AVAILABLE FOR ANALYSIS
In the section entitled "Data Generated Through The Actual PMMS in Use,"
we have presented a summary of actual data generated. The only data generated
regularly for data analysis are the "Monthly Corrective Maintenance Sum-
maries" and the "Monthly Work Accomplished Summary." (See Section 5.)
These reports include the maintenance activities that are carried out at
facilities other than the Lower Potomac Plant and any data analysis should
take this into account.
However, in addition to the above two monthly reports, management can
request a report of any or all data inputed in a wide variety of formats. To
obtain this type of report may require the writing of a simple computer
program.
MAINTENANCE ACTIONS AND COSTS
The number of maintenance actions taken or required and the costs as-
sociated with those actions should present a method for assessing the benefits
or value of the- PMMS.
The number of maintenance actions would be related to the size and age of
plant, the amount of standby facilities, and the actual use of equipment.
Maintenance actions should be classified as preventive, corrective,
elective (which does not necessarily relate to a malfunction or preventive
maintenance), and general housekeeping. In the PMMS as now in use, elective
maintenance and general housekeeping are included in corrective maintenance.
Labor costs depend on hourly rates, whether regular or overtime is used,
overhead factors, and which functions, e.g., administrative, supervision,
management, are charged to maintenance. Since labor rates change, the use of
hours as the parameter would be a way of normalizing labor costs.
Maintenance Costs
The monthly preventive maintenance hours, standing work order hours, and
corrective maintenance hours and parts costs (adjusted for noncorrective
maintenance actions) are presented in Table 3.
The standing work orders include the following activities:
1. Custodial duties
37
-------
INFLUENT AND EFFLUENT OF BOD AND SS
VS TIME (1970-1980)
38OOO
3OOOO
250QD
200001
DC
LU
a.
1&OOO
10000
5000
1970 71 72 73 74 75 76 77 78 79 80
YEARS
LEGEND
O BOO .- MPLUENT
X BOD - EFFLUENT
A 8« - INFLUENT
Q 38 - EFFLUENT
Figure. 3.
influent and. effluent "of BODland SS- vs.- time (1970-1980)
38
-------
2. Supervision
3. Preparation of malfunction reports
4. Miscellaneous, buildings and grounds
5. Preventive maintenance management personnel and costs
6. Stock clerk
7. Training
8. Assist in start-up of new equipment
9. Minor maintenance
10. Clean up
11. Parts pick up
Management should be aware of the changes made against the standing work
orders and should consider these categories in budgetary analysis of what is
being included under maintenance costs and time.
The corrective maintenance hours and costs, which are developed for the
"Monthly Corrective Maintenance Summary" and "Work Accomplished Summary," in-
clude all reported maintenance costs for a number of facilities other than the
LPWTP. Before preparing Table 3, data were adjusted to include only LPWTP
costs. - - - --
The reported corrective maintenance costs included certain repair and
construction items that do not usually represent either preventive or cor-
rective maintenance activities. These include such items as:
1. Moving up equipment that was installed in the wrong location.
2. Installation of new equipment.
3. Installation of safety devices and equipment not originally
in stalled.
4. Modification necessary as a result of improper installations.
The reported corrective maintenance costs were adjusted by eliminating
the above items from monthly totals. It is these adjusted corrective main-
tenance labor hours and parts costs that are presented in Table 3.
Table 4 contains monthly average maintenance data derived from Table 3
and uncorrected data from the plant records for the period of 1973 to 1975
inclusive. The following observations may be made:
1. There has been little change in preventive maintenance effort.
2. There- has been a continuing increase in corrective maintenance ef-
fort. The increase generally follows the increase in plant flow.
Most of the increase has taken place among the standing work orders.
3. For the period of 1976 to 1979 inclusive, overtime hours have con-
tinued to increase. However, the total overtime hours per month are
approximately equivalent to one person.
39
-------
TABLE 3. PM AND CM HOURS AT LPWTP 1976
preventive
maintenance
corrective
standing work
orders
Jan.
Feb.
March
April
May
June
July
Aug.
Sept.
Oct.
Nov.
Dec.
1976
Monthly
Average
reg.
hrs.
358
244
414
432
367
375
386
493
548
294
597
346
o.t.
hrs.
11
43
0
9
8
0
16
1
16
16
56
40
18
total
hrs.
369
287
414
441
375
375
402
494
564
310
653
386
423
reg.
hrs.
2015
1277
2254
1611
1704
2109
1653
1347
2596
1264
2466
1633
o.t.
hrs.
16
7
17
21
25
79
59
42
77
45
138
33
47
tot.
hrs.
2031
1284
2271
1632
1729
2188
1712
1389
2673
1309
2604
1666
1874
reg.
hrs.
840
744
1193
1504
1248
1526
817
1530
1487
925
1521
1212
LPWTP
o.t.
hrs.
30
38
23
15
15
18
40
12
24
16
58
49
28
maintenance
swo plus LPWTP
total
hrs.
870
782
1216
1519
1263
1544
857
1542
1511
941
1579
1261
1240
reg.
hrs.
2855
2021
3447
3115
2952
3635
2470
2877
4083
2189
3987
2845
o.t.
hrs.
46
45
40
36
40
97
99
54
101
61
196
82
75
total
hrs.
2901
2066
3487
3151
2992
3732
2569
2931
4184
2250
4183
2927
3114
parts
in $
$2015
1033
1800
2196
2574
3308
2279
1799
9920
5697
3585
2515
(continued)
-------
TABLE 3. (continued)
preventive
maintenance
corrective
standing work
orders
Jan.
Feb.
March
April
May
June
July
Aug.
Sept.
Oct.
Nov.
Dec.
1977
Monthly
Average
reg.
hrs.
372
350
650
608
570
438
433
400
538
574
437
522
o.t.
hrs.
0
25
13
31
16
26
22
0
40
34
42
32
~2"3
total
hrs.
372
375
663
639
586
464
455
400
578
608
479
554
~5T4
reg.
hrs.
1879
1814
1905
2553
2484
2095
2201
2147
2374
1931
1776
2488
o.t.
hrs.
60
81
112
71
19
56
57
28
109
76
113
16
tot.
hrs.
1939
1895
2017
2624
2503
2151
2258
2175
2483
2007
1889
2504
2204
reg.
hrs.
1305
986
1113
857
819
1244
724
1021
932
982
1178
1018
LPWTP
O.t.
hrs.
33
5
42
18
10
5
13
2
4
38
14
28
maintenance
swo plus LPWTP
total
hrs.
1338
991
1155
875
829
1249
737
1023
936
1020
1192
1046
1032
reg.
hrs.
3184
2800
3018
3410
3303
3339
2925
3168
3306
2913
2954
3506
o.t.
hrs.
93
86
154
89
29
61
70
30
113
114
127
44
85
total
hrs.
3277
2886
3172
3499
3333
3400
2995
3198
3419
3027
3081
3550
3236
parts
in $
$2924
3031
4978
987
1562
3959
3167
2383
3471
5288
4930
4738
(continued)
-------
TABLE 3. (continued)
ro
preventive
maintenance
corrective
standing work
orders
Jan.
Feb.
March
April
May
June
July
Aug.
Sept.
Oct.
Nov.
Dec.
1978
Monthly
Average
reg.
hrs.
619
581
730
683
889
420
736
826
593
878
765
630
o.t.
hrs.
15
30
4
32
55
0
26
17
36
13
61
60
~29
total
hrs.
634
611
734
715
944
420
762
843
629
891
826
690
725-
reg.
hrs.
2270
2244
2919
3103
2931
1723
2442
3258
2487
3337
2455
2317
o.t.
hrs.
14
161
128
72
105
88
43
81
101
135
50
64
~87
tot.
hrs.
2284
2405
3047
3175
3036
1811
2485
3339
2588
3472
2505
2381
27TO
reg.
hrs.
1669
895
1042
1524
1578
1505
1162
1283
2155
1239
940
561
LPWTP
o.t.
hrs.
165
45
63
103
34
37
81
119
55
41
10
2
"61
maintenance
swo plus LPWTP
total
hrs.
1834
940
1105
1627
1612
1542
1243
1402
2210
1280
950
563
T3"59~
reg.
hrs.
3939
3139
3961
4627
4509
3228
3604
4541
4642
3576
3395
2878
o.t.
hrs.
179
206
191
175
139
125
124
200
156
176
60
66
T50
total
hrs.
4118
3345
4152
4802
4648
3353
3728
4741
4798
3752
3455
2944
3059
parts
in $
$7962
2293
11813
7066
3637
13081
2957
8730
3080
3553
1843
1299
(continued)
-------
TABLE 3. (continued)
co
preventive
maintenance
corrective
standing work
orders
reg.
hrs.
Jan. 1351
Feb. 399
March 694
April 713
May 160
June
1979
Monthly
Average
o.t. total
hrs. hrs.
76 1426
18 417
52 746
94 807
8 168
—
50 679
reg.
hrs.
4871
1445
2603
2440
592
4778
o.t.
hrs.
171
55
86
69
8
190
~97
tot.
hrs.
5042
1500
2689
2509
600
4968
2885
reg.
hrs.
1861
325
1708
2811
619
342
LPWTP
o.t.
hrs.
85
26
50
474
74
30
T23
maintenance
swo plus LPWTP
total
hrs.
1946
351
1758
3285
693
372
1400
reg.
hrs.
6732
1770
4311
5251
1211
5120
o.t.
hrs.
256
81
136
543
82
220
220
total
hrs.
6988
1851
4447
5794
1293
5340
4285
parts
in $
$9090
2137
9890
4166
2252
3555
-------
TABLE 4. MONTHLY AVERAGE MAINTENANCE MANPOWER (MAN HOURS)
year
1973*
1974*
1975*
1976
1977
1978
1979
preventive maintenance
total
hours
440
695
438
423
514
725
679
o.t.
hours
-
-
18
23
29
50
standing
work orders
total
hours
-
-
1874
2204
2710
2885
o.t.
hours
-
-
47
67
87
97
corrective maintenance
LPWTP
total
hours
-
-
1240
1032
1359
1400
o.t.
hours
-
-
28
18
63
123
swo plus
LPWTP
total
hours
1706
2691
3178
3114
3236
4069
4285
o.t.
hours
-
-
75
85
150
220
* UNCORRECTED DATA - MANUAL SYSTEM
-------
4. The data available for analysis must be carefully screened. As an
example in March 1978, CM was charged with 342 hours of overtime for
a single item. That item is for a new installation (elective
maintenance) and could readily result in data misinterpretation.
Note: The data that we have presented in Tables 3 and 4 have been
adjusted for new installations.
Analysis of Corrective Maintenance Histories
As described previously, data from the corrective maintenance actions
are entered into the computer. These data can then be retrieved in a number
of formats to facilitate analysis and evaluation.
A history of corrective maintenance actions can be assembled by (1) major
system, e.g., secondary treatment, (2) subsystem, e.g., air delivery, (3)
functional unit, e.g., blowers, (4) type of equipment, e.g. air blower motor
or (5) specific piece of equipment, e.g. air blower motor unit No. 3.
Each of the corrective maintenance histories could include any or all of
the following information: -
1. Equipment identification number
2. Equipment name
3. Job number
4. Labor hours - regular, overtime and total
5. Labor costs
6. Parts and material costs
7. Contractor costs
8. Total job costs
9. Date equipment taken out of service
10. Date corrective action completed
11. Total hours equipment has run since it was installed
12. What was wrong
13. What caused the malfunction
14. What was done to correct malfunction
15. What specific item was repaired or replaced.
Thus an analysis of a corrective maintenance history could yield the fol-
lowing types of beneficial information:
1. Cause of malfunction
2. Repeated malfunction of same item
3. Cost of corrective maintenance for each piece of equipment or for
the cost for a major system
4. A quantitative record of where most corrective maintenance takes
place
5. Cost of corrective maintenance related to age of equipment, cyclic
operation, equipment loading, general operating environment, pre-
ventive maintenance, manufacturer
45
-------
6. Life cycle costs
7. Frequency of corrective maintenance actions
8. Downtime of equipment for corrective maintenance
9. Optimizing parts inventory
10. Able to anticipate failure due to normal use or wear
11. Reliability of systems, equipment, etc.
Figures 4 and 5 are examples of corrective maintenance histories that can
be obtained from the computer.
In utilizing the corrective maintenance data for analysis, there are a
number of major factors that must be taken in account. Maintenance required
by breakdown or incipient failure must be distinguished from elective or
nonbreakdown maintenance. Records must be complete and accurate. There must
be sufficient data (or corrective maintenance actions) for the analyses to be
statistically sound.
To illustrate how data from corrective maintenance histories can be a-
nalyzed to assist maintenance and management personnel in improving plant
per formance, CM histories for a number of equipment items were analyzed. The
equipment items are:
1. Incinerators - ID No. 6111 .
2. Sludge Plunger Pumps - ID No. 5221 .
3. Air Blowers - ID No. 3221 .
4. Vacuum Pump Motors - ID No. 5912 .
5. Chlorinators
6. Low Lift Pumps - ID No. 4341 .
7. Sludge Conveyors - ID No. 534l__.
8. Secondary Clarifiers - ID No.
For each equipment item, CM histories were analyzed and corrected for
non-CM actions. The data and computed values for the following factors were
tabulated:
1. Hours of equipment run
2. Period of equipment use
3. CM labor hours for hours run
4. Number of CM during hours run
5. Parts cost during hours run
6. CM labor hours during period of equipment use
7. Number of CM actions during period of equipment use
8. Parts cost during period of equipment use
9. Run hours per hour of CM
10. Run hours between CM actions
11. Run hours per $ of CM part
12. Number of hours of CM per CM action
13. $ of CM parts per CM action
14. Time interval between CM actions in months
15. CM hours per month.
46
-------
CORRECTIVE MAINTENANCE HISTORY FUNCTNO 141 1576 TO DATE
PAGE
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CUPLX
DUPLX
OUPLX
DUPLX
OUPLX
OUPLX
OUPLX
DUPLX
OUPLX
OUPLX
DUPLX
OUPLX
CUPL'X
OUPLX
CUPLX
OUPLX
DUPLX
CUPLX
CUPLX
CLPLX
CUPLX
OUPLX
OUPLX
DUPLX
OUPLX
DUPLX
DUPLX
-. SLUOfie ELUNfiER
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
_SLUO£E
SLtDGE
SLUCGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDCE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUQGE
SLUDGE
SLUOCE
SLUDGE
SLUDGE
SLUCGE
SLUDGE
SLUDGE
SLUQ£E
SLUDGE
SLUDGE
SLUDGE
SLUD6E
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUCGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLCCCE
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
J?LJ1NGEB_
PLUNGER
PLUNGER
PLUNGER
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
NO
NO
NO
NO
6
5
4
6
MC-S..
NO 4
NO
NO
-Nfl.
NC
NO
NO
-PLUNSEB PUMP_-N.O
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
. ei.llNG.ER.
PLUNGER
PLUNGER
PLUNGER
PLUNGES.
PLUNGER
PLUNGER
PLUNGER
.PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNG.EH
PLUNGER
PLUNGER
PLUNGER
.PLUNGEB
PLUNGER
PLUNGER
PLUNGER
PLUNGES
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PUMP
PUMP
PUMP
PUMP"
PUMP
PUMP
.P.U.HP.
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
P.UMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
PUMP
NO
NO
NC
_MC
NO
NO
NO
NO
NC
NO
NO
NO
NO
NO
NO
NO
NO
NO
NC
NO
NC
NO
NO
NO
NC
NO
NO
NC
NO
NO
NC
NO
NC
NO
NO
NO
NC
NO
NO
1
1
3.
3
I
Z
3
5
4
6
5
4
4
1
2
1
2
1
3
3
3
3
4
3
1
3
z
z
1
3
z
6
3
3
Z .
\
6
5
4
3
Z
\
3
4
Z
\
.020.
020
020
020
_02Q._
020
020
020
020
020
020
020
020 .
020
020
020
020
020
020
020
020
020
020
020
020
020
020
CI20
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
020
JOBNO
. 002214
002213
002212
003194
003193
003192
002635
002615
002306
002455
002412
004928
. 004800
004645
004644
004539
004538
004537
OO4297
004180
004178
003786
003672
003671
003670
003431
003274
007659
007349
006693
005889
005788
005671
OOSS7S
005421
005113
011947
011945
011404
010626
010625
010624
010507
010415
009350
009131
008851
008S9A
008402
008380
013525
013468
ITEM ITEM
WRONG •RONG
2046
.2I8T._.23.03
2068
2046
2046
2144
2046
2046
2046
2046
2069 2197
2267
2191
1001
2069 2046
2199
2069 2046
2046 2068
1068
2069 2002
2053
2046
2046 2260
2046
2046
2046
2046
2046
2046
DESCP
•HONG
070
093
112
018
070
049
070
070
060
060
060
070
070
070
093
070
064
070
038
057
070
070
070
078
112
070
070
070
070
070
036
119
070
070
OESCP ACTN
WRONG DONE
2066
2066
2066
1022
1022
1022
2025
204S
2012
2014
2045
2025
2019
202S
2025
1024
102ft.
1024
2015
2025
2025
2003
2015
2014
2066
2015
2025
2066
2053
2027
2025
070 2025
2012
2012
2025
093 2025
20IS
1037
201S
2019
2027
043 2025
2025
201S
2019
2025
2025
2025
119 2066
2066
202S
2025
ACTN
DONE
ITEM
DONE
2040
ITEM
DONE
4071
2040 4071
2040 4071
1024
10.24 _ _
"2045"
2053
2066
2003'
202S
2040
201S
2015
20L2.
2049
2019
2012
1024
2053
2046
-.2303 . __ .
2241 2068
2046
2144
1074
1074
1074
2112
2053
.2053
2187
2267
2241
2191
1001
2053
2069
2199
2046
.2069
2053
2053
2068
2179
1068
2069
2046
2053
2112
2211
2053
2053
2298
2197
.. 22J I.
2069
2002
2002
2049
~ 2260"
2295
RUN ;
JOBVRCNP HOURS •
76
76
76
76
76
76
76 4.309
76 4.701
76 4.1 17
76 4.117
76 4.186
76 9.054
76 4.971
76 7
76 682
76 749
76 T
76 682
76 322
76 5. 100
76 8.544
76 <
76
76
76
76
76
76
76
76
76
76
76
76
76
77 1
77
77
77
77 11
>.779
3.294
.701
.664
.654
.654
.223
.109 .
.694 ,
.937
.023
.744
.744
.953
.382
.IO4
.916
.823.
.042
I. 019
77 9.948
77 1.328
77 896
77 l'T945
77 7.986
77 11.019
77 8.120
77 7*708
77 1.572
77 11.104
77 13.053 •
Figure 4. Corrective maintenance history no. 141 - 1976.
-------
1/22/81
CORRECTIVE MAINTENANCE HISTORY COST FOR SELECTED FUNCTION NO. 1976 TO DATE
PAGE
ID NO
522103 DUPLX
JOBNO TOTAL
522101 DUPLX
JOBNO TOTAL
522102 DUPLX
JOBNQ TOTAL
S22IOI DUPLX
JOBNO TOTAL
522104 DUPLX
JOBNO TOTAL
522101 DUPLX
JOBNO TOTAL
522104 DUPLX
JOBNO TOTAL
522104 DUPLX
JOBNO TOTAL
522104 DUPLX
JOBNO TOTAL
522103 DUPLX
JOBNO TOTAL
5221 01 DUPLX
JOBNO TOTAL
522103 DUPLX
JOBNO TOTAL
5221 03 DUPLX
JOBNO TOTAL
522103 DUPLX
JOBNO TOTAL
522104 DUPLX
JOBNO TOTAL
522102 DUPLX
JOBNO TOTAL
522102 DUPLX
JOBNO TOTAL
522101 DUPLX
JOBNO TOTAL .
SLUDGE
SLUDGE
SL UDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUDGE
SLUPGE
SLUDGE
SLUDGE
SLUDGE
SLUQCE.
SLUDGE
EQUIP NAM
.PLUNfiER_EUMP_
PLUNGER PUMP
PLUNGER PUMP
PLUNGER PUMP
RLUNSEH.EUHB.
PLUNGER PUMP
PLUNGER PUMP
PLUNGER PUMP
PLUNGES PUMP
PLUNGER PUMP
PLUNGER PUMP
PLU"NGER~PUMP
PLUNGEH .PUMP
PLUNGER PUMP
PLUNGER PUMP
PLUNGER PUMP"
.PLJNQE8_EU.MP
PLUNGER PUMP
E
Mil 3_-._
NO 1
NO 2
NO 1
NO 4
NO 1
NO 4
NO 4
-MO 4
NO 3
NO 1
Tib 3
MO 3
NO 3
NO 4
NO 2
NO. .2. ._
NO 1
020.
02O
020
020
020
020
020
020
020
O20
020
020
020
O2O
020
020
020
020
JOBNO
007874...
01 3000
010651
010650
010648
010647
010130
01S903
015468
014267
01372S
010070
018968
• 018039
023172
024350 "
024179 .
023471
REG HR
. . 80.0
80.0
8.O
8.0
8.0
8.0
12.0
12.0
3.0
3.0
2.O
2.0
16.0
16.0
31 .0
31 .0
25.0
25.0
H.O
8.0
12.0
12.0
16.0
16.0
20.0
20.0
2.O
2.0
16. O
16.0
2.0
2.0
. . .1.0
1.0
2.0
.2.0
DT HR
.0
.0
.0
.0
.0
.0
.0
.O
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
LABOR
COST
41*72
41.72
44.40
44.40
38.98
38.98
57.36
57.36
18.78
18.78
12.52
12.52
83.30
83.30
174.58
174.58
151.60 .
151.60
44.40
44.40...
57.40
57.40
103.44 ~
103.44
129.80 .
129.80
13.64
13.64
109.36
109.36
11.40
11.40
5.7.0
5.70
11.40
11. 40 .
PART
COST
.00
.00
.00
. . _. .00
.00
.00
.00
.00
. .jOO .
.00
.00
. . ,.0-Q...
.00
.00
Too
.00
... 36.0 .SO..
360.00
.00
.00
81 .20
81.20
9.46
9.46
948.46 .
948.46
.00
.00 .
21.31
21.31
.00
.00
.. . . .00.
.00
.00
.tOO_
TOTAL*JOB
COST
41 .7?
41 .72
44. 4O
44.40
38.98
38.98
57.36
57.36
18.78
18.78
12.52
-.12.52
83.30
83.30
174.58
174.58
511.60
511.60
44.40
44. 4O
138.60
138.60
1 12.90
112.90
1 .078.26
1 .076.26
13.64
13.64
130.67
130.67
11.40
II .40
5.7O
5.70
11.40
11.40
[
MNTH VR
Ol 77 1
1 1 77
O6 77
07 77
07 77
07 77
07 77
OS 78
O4 78
02 78
01 78 •
09 78
09 78
08 78 >
03 79
05 79
04 79
03 79
Figure 5. Corrective maintenance history cost 1976.
-------
The results of the analyses are presented in Tables 5 through 20 in-
clusive. A comparison among the various units within each equipment category
can be readily made.
A summary of analyses of corrective maintenance histories is presented
in Tables 21 and 22. A comparison among various equipment categories can be
readily made.
Use of Data Analyses
The purpose of analyzing maintenance data is to obtain the benefits that
were discussed in Section 6. These benefits could include the following:
1. Decreased downtime of equipment
2. Decreased costs of maintenance
3. More effective use of PM
4. Manufacturing, installation, or design defect identification
5. Improved plant performance
6. Determination of life-cycle costs
7. Reduction in spare parts inventory
8. Equipment evaluation
9. Effective use of maintenance personnel
The analyzed data should be of considerable value to management and main-
tenance personnel. However, JJ IS_ ESSENTIAL THAT SOMEONE BE ASSIGNED THE
RESPONSIBILITY OF ANALYZING THE DATA THAT ARE BEIFR? COLLECTED. Furthermore,
the results of the analysis should be implemented by modifying any necessary
maintenance procedures.
49
-------
TABLE 5. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
INCINERATORS ID NO. 6111
•Unit no. Hrs. run
Labor hrs.
for hrs. run
No. of CM
during hrs.
run
Parts
cost
during
hrs. run
Labor hrs.
during
time int.
No. of CM
during
time int.
Parts
cost
during
time int.
No. 1
1273
279
$ 1117
317
10
$ 1117
No. 2
4556
296
1703
376
10
1703
No. 3
34847
1679
54
21860
1691
57
21860
No. 4
32577
965
33
13342
973
33
13346
TOTAL
73253
3219
104
$ 38022 3357
110
$ 38026
-------
TABLE 6. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
INCINERATORS ID NO. 6111
Unit no.
Run
hrs. per
hr. of
CM
Hrs. of
run
between
CM actions
Hrs. of
run per
$ of
CM part
No. of hrs.
of CM
per
CM action
$ of CM
parts
per
CM action
Time
internal
between
CM actions
months
CM hrs.
per month
Incinerator
No. 1
No. 2
4.6
15
141
570
1.1
2.7
3.2
38
$ 110
170
4.8
4.8
6.6
7.8
No. 3
21
645
1.6
30
384
1.0
28
No. 4
34
990
2.4
29
404
1.6
16
All equip*
in category
23
700
1.9
31
$ 345
0.5
56
* Based on 60 months.
-------
TABLE 7. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
ro
SLUDGE PLUNGER PUMPS ID NO. 5221
Unit no.
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
TOTAL
Labor hrs.
Hrs. run for hrs. run
10085 288
2810 116
14133 233
14743 222
11680 30
3380 37
56831 ' 926
No. of CM
during hrs.
run
23
12
20
22
7
9
113
Parts
cost
during
hrs. run
$ 789
738
1022
863
t
83
208
$ 3703
Labor hrs.
during
time int.
288
127
241
242
40
49
987
No. of CM
during
time int.
24
13
21
23
8
10
99
Parts
cost
during
time int.
$ 789
745
1022
877
97
231
$ 3761
-------
TABLE 8. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
SLUDGE PLUNGER PUMPS ID NO. 5221
, Unit no.
Run
hrs. per
hr. of
CM
Hrs. of
run
between
CM actions
Hrs. of
run per
$ of
CM part
No. of hrs.
of CM
per
CM action
$ of CM
parts
per
CM action
Time
internal
between
CM actions
months
CM hrs.
per month
' Plunger Pump
No. 1
35
438
13
12
$ 33
2.5
4.8
co
No. 2
24
122
3.6
9.8
57
4.6
2.1
No. 3
61
710
13.8
11
49
2.9
4.0
No. 4
65
660
17
11
38
2.6
4.0
No. 5
390
1670
141
12
7.5
0.7
No. 6
91
375
16
23
0.8
All Equip.
in category
61
500
15
10
$ 38
0.6
16.5
-------
TABLE 9. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
en
AIR BLOWERS ID NO. 3221
Parts
No. of CM cost
Labor hrs. during hrs. during
Unit No. Hrs. run for hrs. run run hrs. run
1
2 7902 18 2 $ 0
3 14100 67 5 410
4 9941 384 7 73
5 15029 154 11 521
TOTAL 46972 623 25 $1004
Labor hrs.
during
time int.
26
65
392
168
625
Parts
No. of CM cost
during during
time int. time int.
3 $ 0
6 423
8 78
12 521
26 $1022
-------
TABLE 10. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
01
en
AIR BLOWERS
i
, Run Hrs. of Hrs. of
| hrs. per run run per
! hr. of between $ of
'Unit no. CM CM actions CM part
Blower No. 3 21 2820 35
; No. 4 26 26 136
No. 5 98 98 29
ID NO. 3221
No. of hrs.
of CM
per
CM action
13
55
14
$ of CM
parts
per
CM action
$ 11
49
14
Time
internal
between
CM actions
months
10
7.5
5
(60 Months)
CM hrs.
per month
1.1
6.5
2.8
No. 2 439
3950
All Equip.
in category
75
1880
47
24
$ 39
2.3
10.4
-------
TABLE 11. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
en
; VACUUM PUMP MOTORS ID NO. 5912_
' Parts
j No. of CM cost !
; Labor hrs. during hrs. during
, Unit no. Hrs. run for hrs. run run hrs. run
i
3 15438 141 5 $ 230
4 13264 40 6 0
( i
.'TOTAL 28702 181 11 $ 230
Labor hrs.
during
time int.
93
165
55
313
Parts
No. of CM cost
during during
time int. time int.
2 $ 760
6 505
7 130
15 $ 760
-------
TABLE 12. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
VACUUM PUMP MOTORS ID NO. 5912
Unit no.
Run
hrs. per
hr. of
CM
Hrs. of
run
between
CM actions
Hrs. of
run per
$ of
CM part
No. of hrs.
of CM
per
CM action
$ of CM
parts
per
CM action
Time
internal
between
CM actions
months
CM hrs.
per month
All equip.
in category
109
332
159
3090
2210
2610
67
47
28
125
21
$ 63
64
19
$ 51
-------
TABLE 13. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
en
00
: CHLORINATORS
5
Parts
No. of CM cost Labor hrs.
Labor hrs. during hrs. during during
, Unit no. Hrs. run for hrs. run run hrs. run time int.
1 Prechlor. ] 54
2 East 114
3 Standby 106
: 4 West 85
5 Gravity 15
TOTAL • 374
6 7
Parts
No. of CM cost
during during
time int. time int. .
2 $ 746
10 234
6 182
7 145
3 15
28 $1322
-------
TABLE 14. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
tn
<4D
! Pre.
East
Standby
West
Gravity
All equip.
in category
CHLORINATORS
Time
Run Hrs. of Hrs. of No. of hrs. $ of CM internal
hrs. per run run per of CM parts between
hr. of between $ of per per CM actions CM hrs.
CM CM actions CM part CM action CM action months per month
27 $ 370 30 0.9
11 23 6 1.9
18 30 10 1.8
14 21 9 1.4
5 5 20 0.4
13 $ 47 2.1 6.2
Assume 60 months
-------
TABLE 15. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
en
o
i
1
i Run
hrs. per
hr. of
Unit no. CM
' Low Lift Pump
: No. 1 250
'Low Lift Pump
No. 2 78
Low Lift Pump
No. 3 184
Low Lift Pump
No. 4 18
All equip.
in category 116
LOW LIFT PUMPS ID NO. 4341_
'
Hrs. of Hrs. of No. of hrs. , $ of CM
run run per of CM parts
between $ of per per
CM actions CM part CM action CM action
3590 230 13 $ 14
860 89 10 9
900 127 6 6
260 5 14 48
1320 56 11 $ 21
Time
internal
between
CM actions CM hrs.
months per month
4.8 2.8
5.3 1.9
4.4 1.4
3.7 3.8
1.1 9.8
-------
TABLE 16. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
LOW LIFT PUMPS
No. of CM
Labor hrs. during hrs.
Unit no. Hrs. run for hrs. run run
1 32325 130 9
2 6887 88 8
3 8998 49 10
; 4 3137 177 12
TOTAL 51347 444 39
ID NO. 4341
Parts
cost
during
hrs. run
$ 138
77
71
626
$ 912
Labor hrs.
during
time int.
134
90
67
181
472
Parts
No. of CM cost
during during
time int. time int.
10 $ 138
9 77
11 71
13 629
43 $ 915
-------
TABLE 17. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
CT>
PO
; SLUDGE CONVEYORS ID NO. 5341_
Parts
No. of CM cost Labor hrs.
Labor hrs. during hrs. during during
Unit no. Hrs. run for hrs. run run hrs. run • time int.
1
2 6199 313 21 $ 4198 313
3
4 5694 6514 22 4191 654
; 5 41047 159 12 . 1103 : 300
6 24346 115 15 1991 115
7 12097 613 27 4598 613
8 6883 272 10 354 272
TOTAL 96266 1986 107 $ 16435 2539
Parts
No. of CM cost
during during
time int. time int.
22 $ 4198
23 $ 5124
13 1103
16 1991
28 4598
11 354
113 $ 17368
-------
co
TABLE 18. ANLAYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
SLUDGE CONVEYORS ID NO. 5341
Unit. no.
Run
hrs per
hrs. of
CM
Hrs, of
run
between
CM actions
Hrs. of
run per
$ of
CM part
No. of hrs.
of CM
per
CM action
$ of CM
parts
per
CM action
Time
internal
between
CM actions
months
CM hrs.
per month
20
295
1.5
$ 191
11
260
1.4
2.8
222
258
3420
37
23
85
212
1620
12
124
20
450
2.6
22
164
25
688
19
25
32
All equip.
in category
48
900
5.9
22
$ 154
-------
TABLE 19. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
SECONDARY CLARIFIERS
No. of CM
Labor hrs. during hrs.
Unit no. Hrs. run for hrs. run run
1 22591 139 15
2 25492 38 5
3 5659 147 15
4 16694 254 16
TOTAL ALL 70436 578 51
Parts
cost
during
hrs . run
$ 268
47
165 |
388
$ 868
Labor hrs.
during
time int.
139
40
157
264
600
,r . -. .,
No. of CM
during
time int.
15
6
16
17
54
Parts
cost
during
time int.
$ 268
60
165
388
$ 881
UNITS
-------
TABLE 20. ANALYSIS OF CORRECTIVE MAINTENANCE HISTORY 1976-1980
1
• No. of unit
' Clarif ier
No. 1
en Clarifier
No. 2
.Clarifier
No. 3
Clarifier
No. 4
All equip.
in category
SECONDARY CLARIFIERS
Time
Run Hrs. of Hrs. of No. of hrs. , $ of CM internal
hrs. per run run per of CM parts between
hr. of between $ of per per CM actions CM hrs.
CM CM actions CM part CM action CM action months per month
163 1510 84 9.2 $ 18 3.2 2.9
670 5100 670 6.7 10 8.0 0.8
38 377 34 10 6 3.0 1.2
66 1040 43 16 23 2.8 5.5
122 • 1380 81 11 $ 16 0.9 12.5
-------
TABLE 21. SUMMARY OF ANALYSES OF CORRECTIVE MAINTENANCE HISTORIES
cr>
(
1
Equipment
category
Clarifiers
Low Lift Pumps
Incinerator
Chlorinators
Plunger Pumps
Sludge Conveyors
Vacuum Pump Motors
Air Blowers
No.
of
units
4
4
4
5
6
6
3
4
Run Hrs. of
hrs. per run
hr. of between
CM CM actions
122 1380
116 1320
23 700
61 500
48 900
159 2610
75 1880
Hrs. of No. of hrs.
run per of CM .
$ of per
CM part CM action
81 11
56 11
2 31
13
15 10
6 22
125 21
47 24
$ of CM
parts
per
CM action
16
21
345
47
38
154
51
39
Time
internal
between
CM actions CM hrs.
months per month
0.9 12.5
1.1 9.8
0.5 56
2.1 6.2
0.6 16.5
2.3 10.4
-------
TABLE 22. SUMMARY OF ANALYSES OF CORRECTIVE MAINTENANCE HISTORIES .
en
Total
CM
Equipment Labor hrs. Part costs labor
category per CM $ per CM hours
A VT AM
Clarifiers 11 71 $ 16 $ 278 600
Low Lift Pump 11 50 21 285 : 472
Incinerator 31 597 345 9454 3357
Chlorinator 13 35 47 684 374
Plunger pump 10 67 38 400 987
Air Blowers 24 340 39 436 625
Sludge Conveyors 22 148 154 3511 2539
Vacuum Pump Motors ' 21 80 51 275 313
Total
CM
Total parts
no. of CM $
54 $ 981
43 915
110 38026
28 1322
99 3761
26 1022
113 17368
15 760
-------
Data Analysis
The performance of the treatment plant since the introduction of the PMMS
in 1972 has yielded a satisfactory effluent (Figure 3) while the flow has
nearly doubled (Figure 2).
The increase in overtime hours has been minimal. The maintenance staff
reports that the frequency of emergency corrective maintenance actions has
decreased, impending failures have been identified and prevented, additional
elective maintenance can be performed with available staff and the general
appearance of the plant continues to improve.
Much of the above benefits can be attributed to the PMMS. However,
considerably more benefits could be obtained by the analysis and use of data
that are currently being stored in the computer. The following are examples
of how these data may be used.
Manpower and Costs—
Table 4 - Monthly Average Maintenance Manpower - summarizes the actual
reported manpower utilized for preventive and corrective maintenance. PM has
been 425 to 725 man-hours per month, which is approximately 15 to 25 percent
of CM. Over the years, CM has increased but the major position of that
increase has been in the Standing Work Orders (from 1870 to 2885 man-hours per
month from 1976 to 1979). The hours devoted to PM has not changed signi-
ficantly over the year. Overtime hours, although increasing from 93 to 270
man-hours per month from 1976 to 1979, have remained relatively low. These
data, particularly the time reported as Standing Work Orders, should be ana-
lyzed by management in detail to determine if data are being correctly record-
ed, personnel are correctly assigned, personnel can be more effectively uti-
lized, etc.
Corrective Maintenance Histories--
Tables 5 through 22 provide examples of how data can be analyzed to bring
about a reduction in downtime of equipment and costs (man-hours and parts).
Tables 5 and 6 present an analysis of data related to the four incinerators
for the period of 1976-80 and is used to illustrate how data may be analyzed.
Each of the following points should be reviewed by maintenance and management
personnel to determine the reasons for the variability of the data and whether
any changes in maintenance procedures or frequencies are in order.
1. Hours run per incinerator ranged from 1273 to 34,847, with two of
the incinerators in use most of the time.
2. The CM labor hours ranged from 279 to 1679 per incinerator. Al-
though the higher CM labor hours were associated with the incinera-
tors that were operated for longer periods, incinerator no. 3 re-
quired 1679 CM hours while incinerator no. 4 required only 965
hours. Parts costs were $21,860 and $13,346, and the number of CM
actions were 57 and 33, respectively for no. 3 and no. 4.
68
-------
3. The average number of hours run per hour of CM was 23 but the range
was 5 to 34.
4. The average number of hours run between CM actions was 700 but the
range was 141 to 990.
5. The hours of run per dollar of CM part averaged 1.9 with a range of
1.1 to 2.4.
6. The average number of hours of CM per CM action was 31 with a range
of averages of 3.2 to 38. Note: The maximum for a single CM was 597
(Table 22).
7. The average cost of parts per CM action was $345 with a range of
averages $110 to $404. Note: The maximum for a single CM was $9454
(Table 22).
8. The average time interval between CM actions ranged from 1.0 to 4.8
months.
9. The average CM hours ranged from 6.6 to 28 hours per month.
In addition to the analysis of specific pieces of equipment, e.g., in-
cinerators, a comparison among groups of equipment within the plant can also
be made. Table 22 presents a summary of CM data for that comparison.
An analysis of Table 22 indicates that the incinerators and sludge con-
veyors had extremely high CM labor and parts, 3357 and 2539 man-hours and
$38,026 and $17,368, respectively, during 1976 to 1980. Plunger pumps also
require frequent CM and costly parts.
The experience of other plants with the same equipment would make a
valuable comparison but those data are not as yet readily available.
It is important to note that there was no change in PM procedures or
frequencies during the period for which data are presented.
An even more detailed analysis, which should be carried out on a regular
basis, should attempt to determine why some units need more frequent and more
costly CM. Are there particular parts that are failing? Could additional PM
reduce CM? Would additional PM be cost-effectiveness? Is excessive CM due to
poor installation? Is proper equipment being used? Are there sufficient data
to determine expected life of part and provide for replacement before actual
failure? Etc.
Based on the data presented in Table 22, is the distribution of PM effort
among the various equipment appropriate?
Thus, by an analysis of data and, if necessary, a review of each CM
action as reported in the CM Work Order Request, steps can be taken to (1)
revise PM procedures, (2) assure proper installation of equipment, and/or (3)
69
-------
have properly sized and specified equipment. These steps would then provide
for obtaining the full benefits of the PMMS that have been previously dis-
cussed.
70
-------
APPENDIX A
FORMS FOR PMMS AS ORIGINALLY INSTALLED
Forms
Ml - Equipment Reference Data - Figure Al
Reverse side - Parts List - Figure A2
M2 - Equipment Maintenance Record - Figure A3
M3 - Preventive Maintenance Work Record - Figure A4
Reverse side - Report of Trouble - Figure A5
M3x - Preventive Maintenance Work Record (ALT) - Figure A6
M4 - Equipment Malfunction Report - Figure A7
M5 - Corrective Maintenance Work Order - Figure A8
M6 - Corrective Maintenance Work Order and Work Record -
Figure A9
M7 - Weekly Maintenance Summary Report - Figure 10
Reverse side - Corrective Maintenance Summary -
Figure All
M8 - Maintenance Procedure Sheet - Figure A12
Reverse side - Figure A13
In addition to the above forms, the system requires a functional
numbering and an equipment type number.
71
-------
EQUIPMENT REFERENCE DATA
Equipment Name and Number
Type No.
ID No.
Plant Area
Level
Location in Area
Rel. Location
Manufacturer
Local Representative
Part or Model Number
Serial Number
Reference Drawing
Reference Catalog
Instruction Book
Date Put in Service
Electric Motor
Pump
Drive or Reducer
in
c
-j
n>
o
HP
Frame
RPM
Capacity
TDH
RPM
HP
RPM In
RPM Out
Volts
Amps
Impeller
Packing
"a i
3 i
CO
-S i
n> i
r? '
n>
3 I
O
CO
c-t-
O>
Type
Q Series
O Shunt
D Synchronous
Q Induction
a
Specification
OOpen
O Exp. proof
O Drip proof
Q Totally enclosed
D
Type
Q Centrifugal
D Plunger
O Diaphragm
QGear
Q Screw
D
Installation
D Horiaontal
O Vertical
D Submerged
Lubrication
n Water
D Oil
O Crease
Type
QGear
D V-Belt
0 Chain
QVaridrive
Bearings
D Sleeve
DBall
D Roller
Bearings
D Sleeve
DBall
D Roller
Bearings
O Sleeve
DBall
D Roller
Lubricant
Lubricant
Lubricant
Other Equipment
Type, Speed, Size, Capacity, Range
Bearings, Lubricant
Other Features
Form M1-5/7Z
-------
PARTS LIST
Name of Part
Manufacturer
Cat. No.
Local Supplier
Cost
Form Ml Reverae)-5/72
Figure A2. Form Ml (reverse) parts list.
73
-------
rENANCE RECOAD
U4.utpm«nl N«m» «nd Hunttor
DA to
MVC No.
or
Job No.
L«bo>
Skill
biitialt
lloori
Ubf«r«atlon»
I~J.
Mod.
Voll>
L.« 1
U| 2
L.f 1
I.O. No.
I
Ampi
!-•• 1
l-« «
L.| J
5«i ill No.
U>| Ohmi
Lot 1
U|2
LOCMIM »«C«t
-------
PREVENTIVE MAINTENANCE W
INCINERATOR NO.
urt «. »•— •• '—• «
&IH1|1|-|D|1 FEEDER
MMfcMl.'. Hww*
W»» th«r* any indicuii
Any change in op
Any di((«r«nce (
Any broken or w
Any «xcei» leak
Any exceii dirt
Any fouling by fc
Wat Iniulation r
Any improvemtnti to pi
Any improvement! to u
K
•* CHECK blL LEVEL - bit/Hi
- TOP-BOTT. CENTER SHAFT
K.|. H*.
>n of troufe
• ration of
rom (imila
orn parti ?
i, heat, no
or corroii
reign obje
ocedure, 1
kfety preca
lb
or H>< '••• \
I"
^ 1
MMiM i iCM
»le?
r unit* ? »
it*, vibration? . . ,
eta9 .
ORK IECORO
LO. W. „_
1 1 1 1
>• 1 1*1 1 U« 1
•• 1 W«> Uf 1
. M n*a
Trouble OK
o Q
o a
O D
a a
.... o a
.... a °
o . a
IF ANY TROUBLE. FILL OUT REVERSE SIDE
Figure A4. Form M3, preventive maintenance work record.
REPORT OF TROUBLE
I«*«I«N ** f r
Q •»•*•« M"
O «...».»
QM*M
DM....
Q L«Mi»|
D,,...
LJO«»«T. '
Ov.ii...
Qc»»r«M
QR....IM
Dri» ,m
O Pf****
Q !«•*«
Oi.....-,
a ».•*••
Ooo.t -..•
Qo«*t«« FM
ODW.O cu
QD.....I.OO
QDi*fi*« OH
Figure A5. Form M3 (reverse) report of trouble.
/b
-------
Dace
Mechanic's Name
Reg. Hrs
INDICATION OF TROUBLE
_8roken part _Dlrty, fouled
_Worn pare _Volcage
~Heat _Current
"Noise 3Reslstance
"Smell _Flow rate
_Vlbratlon _Pressure
"Leaking _Speed
"other ~
Remarks and Recomnen
OT Hrs
Date
Mechanic's Name
Reg.Hrs
!
OT Hrs
REPORT OF TROUBLE
WHEN DISCOVERED CAUSE OF TROUBLE
Starting _HeaC/Cold/weather
"Stopping "Humidity/moisture
"During operation Foreign object
"During PM 3shoclt''vlbratlon
"During CM . 3Wear
During MOD 2E1ulPment defect
"During OH "improper installation
"Other "improper lubrication
~ "improper operation
"Other
rfarlnn.fi Check If
tagged o
equipment was
Jt of service
Figure A6. Form M3X, preventive maintenance record (ALT)
76
-------
EQUIPMENT MALFUNCTION REPORT
Equipment Name and Number
1 D No Serial No. Location
1 1 1
Date of Trouble Time Reported by Foreman
Indication of Trouble
Q Broken part Q Dirty, fouled
D Worn part D Voltage
Q Heat Q Current
fj Noiie Q Remittance
Q Smell Q Flow rate
Q Vibration Q Prenure
Q Leaking Q Speed
(I Other
When Die covered
Q Starling
LJ Stopping
O During operation
Q During PM
Q During CM
Q During MOD
Q During OH
(Bother
Remarke and Recommendation*
Check if
out of ee
Cauie of Trouble
D Heat/cold/weather
rj Humidity/moieture
Q Foreign object
Q Shock/vibration
D Wear
Q Equipment defect
O Improper initallalion
Q Improper lubrication
[3 Improper operation
C3 Other
equipment wa« tagged n
rvice
Form M4-5/72
Figure A7. Form M4, equipment malfunction report.
-------
CORRECTIVE MAINTENANCE WORK ORDER
Requeued by
Required
Completion Date
Equipment Name and Number
Serial No.
00
Indication of Trouble
Q Broken part
Q Worn part
O Heat
Q None
Q Smell
Q Vibration
Q Leaking
Q Other
Q Dirty, fouled
Q Voltage
Q Current
Q Remittance
Q Flo* rate
Q Pretsure
Q Speed
When Discovered
Q Starling
£j Stopping
Ij During operation
QDurtag PM
Q During CM
Q During MOD
Q During OH
Q Other
Cause of Trouble
Q Heat/cold/weather
Q Humidity/moisture
^J Foreign object
Q Shock/vibration
Q Wear
Q Equipment defect
Q Improper installation
Q Improper lubrication
Q Improper operation
n Other .
Estimated Costs
Labor
Pant
Contractors
Tot at
Estimated Down-Time
Approved by
Form MS-S/72
Figure A8. Form M5, corrective maintenance work order.
-------
CORRECTIVE MAINTENANCE WORK ORDER
O •»•••• »••«
Q MM*
QMM.
Q »
O »
Q Oi
QdHM|»M
a*
Qb
o*
a»
CORRECTIVE MAINTENANCE WORK RECORD
Figure A9. Form M6, corrective maintenance work order and work record,
79
-------
Fairfax County Lower Potomac Pollution Control Plant
MAINTENANCE SUMMARY REPORT FOR WEEK ENDING
WORK LOAD SUMMARY
Line
A
B
C
D
E
F
G
H
I
J
K
Item
Preventive Maintenance
Backloc I'rom previous week
Regularly scheduled ror this week
Total outstanding work (A&B)
Accomplished this Meek
Backlog for next week (C-D)
Backloc from previous week
Number
of
Action*
Estimated Manhours
Skill 1
I
j
New work orders, this week I
Total outstanding work (FiG)
Accomplished this week
Backlog for next week (H-I)
Total backlog for next week (E&J)
Skill 2
Skill 3
Total
WORK ACCOMPLISHED SUMMARY
Item
Preventive
Maintenance
o ,
Number of Actions Completed ;
Actual manhours expended <
Skill 1 (
Skill Z !
Skill 3 !
Total
Labor costs
Regular
O. T.
Total
Outside contractor costs j
Cost of parts and materials
Total costs
Corrective
Maintenance
Total
Maintenance
Form M7-5/72
Figure A10. Form M7, weekly maintenance summary report.
80
-------
CORRECTIVE MAINTENANCE SUMMARY
00
Job No.
Equipment Name
Equip.
1.0.
Statu*
Code*
Description of Work
To Be Done
k
Priority
Code**
Work Order
Date
Completion
Date
Remark!
• Equipment Statui Code ••Priority Code
0 - Operational U - Urgent repairt to correct conditions which prevent the plant
N - Nonoperational
R - Reduced capability
from operating or which involve the health and safety
of personnel
N - Needed repair! to correct conditions which seriously impair
plant efficiency or plant reliability
R - Routine repairs, tests and inspections
C • Convenience items
Figure All. Form M7 (reverse), corrective maintenance summary.
-------
MAINTENANCE PROCEDURE SHEET
Page 1 of 1
EQUIPMENT NAME
Plant Area
Level
Locacion
MPS No.
Aver ate
S-l
S-2
S-3
Time
min
min
min
MAINTENANCE DESCRIPTION
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
PROCEDURE
Figure A12. Form M8, maintenance procedure sheet.
82
-------
Date
Mechanic
Rag Hrs
OT Hrs
Date
Mechanic
*
Reg Hrs
OT Hrs
REPORT OF TROUBLE
INDICATION OF TROUBLE
Broken part Dirty, foule
__Worn part Voltage
Heat Current
Noise Resistance
Smell Flow rate
Vibration Pressure
Leaking Speed
__0ther
WHEN DISCOVERED CAUSE OF TROUBLE
c. Starting Heat/Coldkeather
Stopping Humidity /moisture
"During operation Foreign object
During PM Shock/vibration
During CM Wear
During MOD Equipment defect
During OH Improper installation
Other Improper lubrication
Improper operation
Other
Remarks and Recommendations Check if equipment was
tageed out ot service
-
Figure A13. Form M8 (reverse), maintenance procedure sheet.
83
-------
APPENDIX B
INPUT DOCUMENTS FOR PMMS NOW IN USE
The Users Manual prepared by the Community Development Branch,
Office of Research and Statistics, County of Fairfax for The Lower
Potomac Planned Maintenance Management System consists of detailed
instructions for every input document in the system. All file updating,
maintenance scheduling and management reporting can be accomplished by
utilizing these document:
1. Equipment File Maintenance (M-l Form)(includes Maintenance
Procedure Scheduling Criteria) - Figure Bl
2. Maintenance Procedure File Maintenance - Figure B2
3. Parts File Maintenance - Figure B3
4. Job File Maintenance Change Transactions - Figure B4
5. Standing Work Order File Maintenance - Figure B5
6. Personnel File Maintenance - Figure B6
7. Action Codes File Maintenance - Figure 87
8. Description Code File Maintenance - Figure B8
9. Item Code File Maintenance - Figure B9
10. Equipment Malfunction Report - Figure BIO
11. Malfunction Delete - Figure Bll
12. Corrective Maintenance Work Order - Figure B12
13. Corrective Maintenance Initiation Request - Figure B13
84
-------
14. Manpower Available Parameter (currently not used) - Figure B14
15. Meter Reading Card - Figure B15
16. Preventive Maintenance Work Order - Figure B16
17. Initiate a PM Action Out of Scheduling Cycle - Figure B17
18. PM and CM Request to Reprint a Work Order - Figure 818
19. PM Delete, CM Delete, and CM or PM Priority or Work Order
Status Change - Figure B19
In addition to the above documents, Maintenance Procedure Sheets
(Figure 20) for each piece of equipment requiring weekly and less-
than-weekly preventive maintenance are kept on file at the plant.
Each piece of equipment is given (1) a unique six (6) digit
identification number based on a functional numbering system; and (2) a two
(2) digit number which indicates the type of equipment. This has been
described in the original installed system.
EQUIPMENT FILE MAINTENANCE (81)
The Equipment File Maintenance Form or M-l Form is completed for each
item in the plant identifying the item with its equipment identification
number from the functional numbering system and the equipment type number.
The Equipment File Maintenance (M-l Form) contains the following
information:
Equipment I.D.
Equipment Name
Equipment Type
85
-------
Building Number
Building Level
Location in Area
Relative Location (optional)
Manufacturer/Local Representative
Part or Model Number
Serial Number
Instruction Book File Number
Date Put in Service
Electric Motor Data (if applicable)
Pump Data (if applicable)
Drive or Reducer Data (if applicable)
Daily Preventive Maintenance Time
Weekly Preventive Maintenance Time
Equipment Status
Meter Code
Maintenance Procedure Scheduling Criteria
Run Time and Downtime of Equipment
Number of PMs Missed
Total PM Actions
Lifetime CM Actions
Total CM Actions
86
-------
Card Tran
Code Code
EQUIPMENT ID.
0.1
eta—nuiiMw
1I ~ ..
13
EQUIPMENT NAME
Page 1 of 4
I II
14
Brtxr,r BN£ BW*- Ll
u n _
54 55 56 57 58 59
ReL Manufacturer/Local
Location Rep.
63
67
53
Card Tran
Code
1 2
EQUPMENTD.
Ban.
a 1
5
Serial No.
34
Instruction Book
51
Part or Model No.
13 14
50
33
Re No. Date Put in i
74
79
Card
1 2
Tran
Code
EQUIPMENT ID.
34
Pfert
0 1
tOUO. NO.
lilt
1
ELECTRIC MOTOR DATA
Horse Power Frame No.
i
i i i i i i i i i
13 14 19 20
ELECTRIC MOTOR DATA CONTINUED
Volts Amps Hase Ty
30 33 34
Pump Capacity
PSI/TDH
lidicdtor
54
D
41 42
PUMP DATA
PSI or TDH
49
Impeller
61 62 63
68 69
ELECTRIC MOTOR TYPE ELECTRIC MOTOR SPECFCATON PSI/TDH N3CATOR
1-Series 1 - Open 1 - PSI
2 - Shunt 2 - EYP. Proof 2 - TDH
3 - Synchronous 3 - Drip Proof
4 - Induction 4 - Totally Enclosed
5-Other 5-Other
Date Prepared
By
hsUation
29
Specify
53
78
Figure Bl. Equipment file maintenance (M-l Form) (includes maintenance
procedure scheduling criteria).
87
-------
Page 3 of 4
Card Trap
Code Co
Rs] [E
EG
Hart
0 1
UIPMENT ID.
AR
1
EqucxNa.
I 1 1 i 1
13
Schedule Maintenance Meter/Bapse LastCocuance
ProcedreCode Time factor Code CU. Date or Mr. Rda)
14 15
i . . . . . i i~7j D
15 S) 21 24 25
5 2B
i i i i
u
31 32
Card Tran
Code
EQUIPMENT ID.
Plant
01
Equip. No.
13
P.M.
Martenance
Procedure Code. Tune Factor
15
20
(Jut Date or Mir.
PM
Adjust
w B t—a
Card Tran
Code Code
EQUIPMENT ID.
0.8
1 2
Plant
0,1
AR
1
EquixNa
i i_ i. i •_
13
15
20
PM
I7771 D FT. . 77]
21 24 25 - 26 31
Date Prepared
By
Figure Bl. (continued)
-------
Page 2 of 4
Card Tran
Code
EQUIPMENT P.
Plant
,
AH
EqfeNO.
i I i . i
12 3 A 5
RPM. Packing
13
rrrj rn
1417 TB
PUMP DATA CONTINUED
Horse Power RPM ki RPM Out
Type hstal
_ D D
Daiy 43 Weekly
. pjm. Tine om Time
Ratio Type (min) (min)
"I I • I M " ''
d y '; 'sJ I
7l' '73
45 50 PUMPTYPE ^ ^ ^ ^ ^ 6970
EquiP Meter i - RentMuoal Pt^P NSTAILATPN TYPE DRTVE^EDUCER TYPE METER CODE
Status Code 2 - ptrSif1981 1 - Horizontal 1 ^Gear 1 - Metered Tme
3-Diaphragm 2 - Vertical 2 - V-Belt
4 - Gear 3 - Submerged
TTT
2 - Elapsed Tine
Card Tran EQUIPMENT D.
Ptet |AR|
1 2
General Information Continued
_
General Infotmation
(continued on next fine)
13 14
39
iiii iii i i i
40
80
Card Tran EQUIPMENT D.
Code Code
12345
Geral Information Continued
Plat
nn
— gq^^ 1 General Information
,,,,, || ,,,,,,,, ,
(continued on next line
,iii iii,
13 14
39
i
40
80
Card Tran
Code code
EQUIPMENT D.
Plant
AR
EqufxNo.
General Information (continued on next ine;
-
12345
General Information Continued
13
39
I I 1
40
80
Date Prepared
By
Figure Bl.. (continued)
89
-------
Page 4 of 4
Card
Code
EQUFMENTD.
Plant
0,1
AR
1
EqjjxNo. I
i i , i . 1
Presort Qrt tstPrev.C*.
Life ftn Tne (hre) ftnTme
-------
THE MAINTENANCE PROCEDURE FILE FORM (82)
The Maintenance Procedure File form is used for the additions,
corrections, and deletions to the Planned Maintenance Management System
Maintenance Procedure File.
The Maintenance Procedure File form contains the following
information:
Maintenance Procedure Code
Description
Instruction Book
File Number
Primary Skill Code
Estimated Time (Min.)
Fairfax County Inventory Number (FCIN)
Quantity
Unit of Measure
PARTS FILE MAINTENANCE FORM (B3)
The Parts File Maintenance form is used for additions, changes, or
deletions to the Parts Master File when Preventive and Corrective
Maintenance jobs are competed.
The Parts File Maintenance form contains the following information:
Job number
Fairfax County Inventory Number (FCIN)
Parts Status
91
-------
MAINTENANCE PROCEDURE FILE
card tran maintenance
coda coda procedure code
n n i.....I
12 34 5 10
Dlacrlptlon
11
Instruction book
51
flla no. coda
orimary aatbnated
time
D
Cmln)
73 74 75 77
SO
PARTS NEEDED (OCCURS 5 TIMES )
card trap maintenance
code code procedure code
FCIN
unit of
quantity measure
1
1 J 1 1 1 1 1 1 1 1 1 1 1 1 1 . 1 1
12345 10 11 23 24 26 26 27
unit of
FCIN quantity measure
2
i I i I i ' i 1 I I 1_ 1 -I _
1
28 40 41 42 43 44
unit Of
FCIN quantity measure
3
1
46 57 58 59 60 61
unit of
FCIN quantity measure
i i i i i i i i i i i i
62 74 75 76 77 78
card tran maintenance
code coda procedure code
12 34
FCIN
11
unit of
quantity measure
23 24 26 26 27
DATE PREPARED
.BY_
Figure 82. Maintenance procedure file.
92
-------
PARTS FILE MAINTENANCE CARD
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CARD
CODE
TRAM
cooe
JOS RUBBER
1 1 1 1 1
5 10
1 1 1 1 1 1 1 1 1 1 1 1
11 23
PART CONTR.
STATUS RBQ'D? ESTIMATED COST
ACTUAL COST
ESTIMATED ACTUAL
NO. NEEDED NO. NEEDED
III , , !
24 25 26
SOUIPMEN
MEASURE TYPE PLANT ..
I 1 ^l1
44 45 46 47 48
1
1 1 1 1 ! 1 II II
31 32 37 38 40 41 43
PART STATUS CONTR. REO'D.
1 - COMPLETED Y = YES
T JD 2- ON ORDER N = NO
I. EQUIP. NO. JOB TYPE
1 1 1 1 1 1 «««
»4 a CM-NO EQUIP. ID.
Date Prepared.
-By.
Figure 83. Parts file maintenance.
93
-------
Contractor Requested
Actual Costs
Actual Number Needed
Unit of Measure
Job Type
Equipment Identification
JOB FILE MAINTENANCE CHANGE TRANSACTIONS FORM (B4)
The Job File Maintenance Change Transactions form is used to change
data on the Job Master File.
The Job File Maintenance Change Transactions form contains the
following information:
Job Number
Date Requested
Out-of-Service
Work Completed Date
Requested By
Indication of Trouble
When Discovered
Cause of Problem
Effect of Problem
Corrective Work Requested
What Was Found Wrong
Work Done
94
-------
JOB FILE MAINTENANCE
CHANGE TRANSACTIONS
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CARD
CODE
TRAN
CODE
JOB NUMBER
DATE REQUESTED
OUT-Or-SERVlCE DATE >0»K COMPLETED DATE
INDICATION >HeN CAUSE OP PROBLEM
OP TROUBLE DISCOVERED I ITEM | DESCRIP
32 33 34 35
EFFECT OF PROBLEM
ITEM
1 1 1
OESCRIP
1 1
CORRECTIVE VORK REQUESTED
ACTION
1 1 1
ACTION
1 1 1
DE SCRIP
1 1
ITEM
1 1 1
ITEM
1 1 1
DESCRIP
1 1
CARD
CODE
TRAN
CODE
JOS NUMBER
• HAT WAS FOUND VROKIG
ITEM
1 1 1
ITEM
1 1 1
OESCRIP
1 1
DESCRIP
1 1
ACTION
III
ACTION
1 1 1
ITEM
1 1 1
ITEM
1 1 1
CONTRACTOR
REQ* D? LIFE RUN H88.
D
40 41
ACTUAL PARTS COST
I I I I I I
ACTUAL TIME
REGULAR MRS.
ACTUAL TIME
OVERTIME HRS.
ACTUAL
MAN HOURS COST
CONTRACTOR
COST
ii r
i i i i
58 39
12 63
ii i i
EMPLOYEE ID.
Date Prepared.
By.
Figure B4. Job file maintenance change transactions.
95
-------
Contractor Requested
Life Run Hours
Actual Parts Cost
Actual Time Regular Hours
Actual Time Overtime Hours
Actual Man-Hours Cost
Contractor Cost
Employee Indentification
STANDING WORK ORDER FILE MAINTENANCE (B5)
The Standing Work Order File Maintenance form is used to provide for
the addition or change of a Standing Order.
The Standing Work Order File Maintenance form contains the following
information:
Standing Work Order Number
Description
PERSONNEL FILE MAINTENANCE CARD (B6)
The Personnel File Maintenance Card is used to provide for the
additions, changes, and deletions to the Planned Maintenance System
Personnel File.
The Personal File Maintenance Card contains the following
information:
Social Security Number
Employee Identification
Employee Status Code
96
-------
STANDING WORK ORDER FILE MAINTENANCE
PIAKKID HAINTENAHCI MANAGEMENT ST3TSK
CAtO
COOI
TIM
C00»
12 1 «
' STAJIOIRO
TOKK QgQgK MO.
0 a 9
OESCtlPTION
• NOTtl THf STAND I NO IOBC OlOEt NUHBM BUST U LIM THAI) 1000.
Date Prepared
Figure B5. Standing work order file maintenance.
97
-------
PERSONNEL FILE MAINTENANCE CARD
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CAP" TBM SIIPLOYM ID._ «T'T"1 "ILL
CODE CODE SOCIAL SBCUBITT NO. PLANT ID. NO. CODS CODE HOURLY BATE
v T MM,!,
12345 13 14 16 19 20 - 21 24
gMPLOYEE STATUS .-SKILL CODE
MONTHLY HB8. 1 » ACTIVE 1 ELECTRICIAN
OVERTIME BURDEN RATE 2 • RETIRED 2 MECHANIC
. Jw QUIT 3 UTILITY MAN
1 4 • TEMPORARY 4 INSTRUMENTATION
» " " " I OPERATOR
Date Prepared BY
MONTH!. T HBS.
KEGULAR TIME
1
1
1 | |
35 2>
Figure 86. Personnel file maintenance.
98
-------
ACTION CODES FILE MAINTENANCE
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CARD
CODE
TRAN
CODE
ACTION CODE DESCRIPTION
1 2 34
CARD
CODE
TRAN
CDDE
ACTION CODE DESCRIPTION
12 34 5
CARD TRAN
CODE CODE ACTION CODE DESCRIPTION
12 34
CARD TRAN
CODE CODE
ACTION CODE DESCRIPTION
Date Prepared.
By
Figure B7. Action codes file maintenance.
100
-------
Skill Code
Hourly Rate
Monthly Hours Regular Time
Monthly Hours Overtime
Burden Rate
ACTION CODES FILE MAINTENANCE (B7)
The Action Codes File Maintenance form provides for the additions or
changes of records on the Action Code Master File.
The Action Codes File Maintenance form contains the following
information:
Action Code
Description
DESCRIPTION CODE FILE MAINTENANCE (B8)
The Description Code File Maintenance form provides for additions and
changes to the Description Code Master File.
The Description Code File Maintenance form contains the following
information:
Description Code
Description
ITEM CODE FILE MAINTENANCE (B9)
The Item Code File Maintenance form provides for additions and
changes to the Item Code Master File.
99
-------
DESCRIPTION CODES FILE MAINTENANCE
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CODE
'l1
CODE
D
CODE
1 1
12 3 4 5 7
DESCRIPTION
I I I I I I I I I I I I I I I I I I I I I I I I
CARD TRAN DESCRIPTION
CODE CODE CODE DESCRIPTION
'l1
1 2
°.
1 1
34 5 7
1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 1 1 1 1 1 1 1 1 1
I 32
CARD
COPE
TRAD
CODE
12 34 5 7
DESCRIPTION
CARD
CODE
TRAH
CODE
DESCRIPTION
CODE
12 34 5 7
DESCRIPTION
Date Prepared .
Figure B8. Description code file maintenance.
101
-------
ITEM CODES FILE MAINTENANCE
PLANNED MAINTENANCE MANAGEMENT SY8TSM
CARD
COD»
•nut
CODS
13 34
DESCRIPTION
I I I I
CARD
CODE
TBAH
CODB
DESCRIPTION
I I I I
CABO THAN
CODE CODE
DESCBIPTION
CARD
CODE
TEAR
CODE I TEH CODS
12 14
DESCRIPTION
I I I I I I I I I I I I I I I I I I I I I
Date Prepared.
Figure B9. Item code file maintenance.
102
-------
The Item Code File Maintenance form contains the following
information:
Item Code
Description
EQUIPMENT MALFUNCTION REPORT (BIO)
The Equipment Malfunction Report form is used to initiate a
malfunction report by providing a malfunction number for the Malfunction
Register until it is deleted as a Corrective Maintenance Initiation
Request is processed against it.
The Equipment Maif unction Report form contai ns the f ol 1 owing inf ormation:
Equipment Name and Number
Identification Number
Building Number
Date of Trouble
Time
Reported By
Foreman
MALFUNCTION DELETE (Bll)
The Malfunction Delete form is used to provide for the deletion of a
malfunction record off the Malfunction Master File.
The Malfunction Delete form contains the following information:
Equipment Identification Number
Malfunction Number
103
-------
01MF d-4)
EQUIPMENT MALFUNCTION REPORT
EQUIPMENT NAME AND NUMBER
DATE OF TROUBLE (20-25
MONTH 1 DAY YEA
1 1 | 1
.INDICATION OF TROUBLE
«i Q BROKEN PART
02 Q WORN PART
'a D HEAT
•I'D NOISE
«s Q SMELL
**Q VIBRATION
?'Q LEAKING
is Q OTHER ..
) TIME REPORTED BY
R
(J6-27)
"D DIRTY, IFOULED
"9 D VOLTAGE
>o D CURRENT
»D RESISTANCE'
12 D FLOW RATE
"Q PRESSURE
"Q SPEED
I.D. NUMBER (5-13) BUIL
• N'llll 1
DING NO.
027762 (— J
FOREMAN •»
WHEN DISCOVERED (28-29)
to D STARTING
** Q STOPPING
»3O DURING OPERATION
04 D DURING PM
*sQ DURING CM
«6 D DURING MOD
?7Q DURING OH
08 D ftTHITR
CAUSE OP TROUBLE (30-31)
m Q HEAT/COLD/WEATHER
02 Q HUMIDITY/MOISTURE
03 D FOREIGN OBJECT
*« D SHOCK/VIBRATION
Is D WEAR
06 Q EQUIPMENT DEFECT
*?Q IMPROPER INSTALLATION
08 Q IMPROPER LUBRICATION
«>Q IMPROPER OPERATION
in n ATIH7R
REMARKS AND RECOMMENDATIONS CHECK IP EQUIPMENT *AS TAGGED
OUT OF SERVICE Q
FORM M4-1-2/75
Figure BIO. Equipment malfunction report.
-------
MALFUNCTION DELETE
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CARD ™** EQUIPMENT ID
CODE
M F
PLANT
V
k*f ft
1
EQUIP. NO.
1 1 1 1 1
MALFUNCTION NO.
I I I I
Date Prepared.
By.
Figure Bll. Malfunction delete.
105
-------
CORRECTIVE MAINTENANCE WORK ORDER (B12)
The Corrective Maintenance Work Order form is used to capture data
while completing a corrective maintenance action for the updating of the
Job Master, Equipment Master, and Parts Master files. This form also
serves as an indicator to the automated system that a corrective action has
been completed.
The Corrective Maintenance Work Order form contains the following
information:
Date Printed
Date Requested
Requested By
Equipment Name and Number
Part or Model Number
Serial Number
Instruction Book/File Number
Skill Code
Job Number
Unit of Measure
How Was It Fixed
Outside Contractor Required
Date Out of Service
Date Job Completed
Contractor Cost (if applicable)
106
-------
CORRECTIVE MAINTENANCE WORK ORDER
Date printed
Date requested
Requested by
EQUIP. NAME & NO.
Part or model no.
Serial No.
INSTRUCTION BOOK/FILE NO.
SKILL CODE
Electric motor data:
HP
Frame no.
Pump packing:
GENERAL INFO:"
Volts
Amps
JOB NUMBER
Priority
Malfunc. no.
Plant area
Bldg. no.
Level
Loc. in area
Rel. location
Indication of trouble
Apparent cause
Effect
When discovered
CORRECTIVE WORK REQUIRED:
Sketch required? Estimated cost
REMARKS
Card code 01
(1-2)
Parts used:
Tran. code RA
(3-4)
Of fee use only:
FCIN
(11-23)
Job no.
(5-10)
Contr. Estimated
Reqd.? Cost
(25) (26-31) OR
Estimated time
Type job Equip.
(46-47)
Actual Estimated Actual
Cost ^Needed INeeded
(32-37) (38-40) OR (41-43)
ID
(48-56)
Unit of
Measure
(44-45)
Card code 01 Tran. code CC Job no.
(1-2) (3-4) (5-10)
What was found wrong?
Equip. ID
(11-19)
How was it fixed?
Office use only:
Item code
Descr. code^ Action code Ttem code
(2U-23)(24-27) (28-30)(31-33) (34-37)(38-41) <42-45)(46-49)
Outside contractor re.quired?_Yes_No Date cut of service
(50) NO- uay ir.
Contractor cost (51-56)
Date job completed
(63-69)
Requestor
ID no.
Mechanic
(70-74)
Maint. Foreman
no. Day Yr.
(57-62")
Figure B12. Corrective maintenance work order.
107
-------
Mechanic
Identification Number (from employee file)
Requestor
Maintenance Foreman
CORRECTIVE MAINTENANCE INITIATION REQUEST (B13)
The Corrective Maintenance Initiation Request form is used to
initiate a Corrective Maintenance Action.
The Corrective Maintenance Initiation Request form contains the
following information:
Equipment Identification
Building Number
Date Requested
Out-of-Service Date
Requested By
Priority
Job Type
Cause of Problem
Effect of Problem
Corrective Work Requested
Estimated Time (Hours)
Estimated Cost
Malfunction Number
Remarks
108
-------
CORRECTIVE MAINTENANCE INITIATION REQUEST
PLANNED HAINTBKANCE MANAGEMENT SYSTEM
CARD
CODE
TRAM
CODE
EQUIPHEHT IP.
PLANT
8 \
tMLJ
1
BQUIP. NO.
1 I 1
I
MO. DATE REQUESTED
OUT-OP-EIRVICR
DATE
IT • It It 10
REQUESTED JOB CAUSE OT PROBLEM
PRIORITY TYPE
32 34 35 37 31 39 4O
COBRRCTIVB WORK RBQUBSTKD
I TEH
1 1 1
DSSOIP.
, ,
EPPECT OP PROBLEM
«6 47
I TK
1 1 1
DESCEIP.
1 1
ACTION
1 | 1
ACTION
1 1 I
DISCRIP.
1 1
ITBH
i I i
ITKH
.III
DBSCRIP.
1 |
SSSTCH
rr
VlrnPH
nm at
'* fim Cll-110 RALrUKCTIOli
•4» en-no Equip. ID.
gETCH REO-D.
T»I«S
nmn
CARD
CODE
TRAN
CODE CI BUIIBER
C 1
12 34
ESTIHATBD
TIKE (HRS.) EgTI«ATBD COST
9 11 13
MLruncrion no.
(ceirt. on »EIT tiro)
I I t 1 I i i i i I I i i i t I I I I I I i I I 1 I I i i i t i t
24 IT
»E»A«E8 COOT.
I i i i i i ! i ! j ! ! I I I I I I I I I I 1
9< «0
Date Prepared.
By-
Figure B13. Corrective maintenance initiation request.
109
-------
MANPOWER AVAILABLE PARAMETER (B14)
The Manpower Available Parameter form provides for the entering of
available manpower into the weekly Preventive Maintenance Scheduling Cycle
thereby determining which preventive maintenance action will be released
to the schedule for the upcoming week.
The Manpower Available Parameter form contains the following
information:
Available Man-Hours (pm skill)
METER READING CARD (815)
The Meter Reading Card is used for placing a meter into service for a
piece of equipment, which has never been metered; for recording the first
reading when replacing a meter; for placing a repaired meter back into
service and for reporting the current meter reading on an existing meter.
The Meter Reading Card contains the following information:
Equipment Identification
Current Meter Reading
New Meter Reading (in case or repair)
Accept Code
PREVENTIVE MAINTENANCE WORK ORDER (816)
The Preventive Maintenance Work Order form is used to capture data
while completing a preventive maintenance action for the updating of the
Job Master, Equipment Master, and Parts Master file.
110
-------
MANPOWER AVAILABLE PARAMETER
M.AHHCB HAIXTINAKCt HiHAGMSBT STSTtM
AVAILABLE
Ull HOURS
MPI
11 1 «
AVAILAHI
KAJI HOUlg
ATAtLAILI
»A» HOUta
ATAILAIL*
mn HOUM
AVtIUB.1
•*» MOUIS
THI ftixan SKTU. coot
Data Prepared.
By.
Figure B14. Manpower available parameter (currently not used),
111
-------
METER READ I KG CARD
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CARD TRAN
CODE COPE
EQUIPMENT ID.
12 34 5
PLANT
V
>M.
EQUIP.
1 1
NO.
1 1
1
CURRENT
METER READING
ACCEPT
CODE*
D
A-l" SHOULD BE FILLED IN HERE IP THE CURRENT METER READING IS TO BE ACCEPTED AS IB. NO CHECK (ILL BE MADE ON
THE NUMBER OP ELAPSED HOURS.
Date Prepared.
By
Figure 815. Meter reading card.
112
-------
PREVENTIVE MAINTENANCE WORK ORDER JOB NQ
Date printed
EQUIPMENT ID ' Building no..
Equipment name ' Building level
Part or model no. Location in area
Serial no. Rel. location
ELECTRIC MOTOR DATA:
HP Amps Volts Frame no. RPM
PUMP DATA:
Type Installation
DRIVER OR REDUCER DATA:
Type
MAINTENANCE PROCEDURE CODE
DESCRIPTION
Instruction book/file no.
PRIMARY SKILL CODE
Estimated time
Card code 01 Tran. code RC Job no. .
d-2) (3-4) Terror
Parts requtred/used: Estimated Quantity Unit of
FCIN Quantity Used Measure
(11-23) Description (38-40) 41-43 (44-45)
Card Code 01 Tran. Code PC Job no. Equip. ID Maint. Proc. code
(1-2) (3-4) (5-10)(11-19)(203257
Leg 1: Volts Amps Leg 2: Volts Amps Leg 3: Volts Amps
(2F^9~) (3IP33T (3^37) (38^47) (42^457 {46^49}
Megohms Time, in minutes, to complete job
(50-52) (Only if different than est time (53-55)
Job completed by:
Employee ID no:
(.56-60) Signature Maint. Foreman
Figure B16. Preventive maintenance work order.
113
-------
The Preventive Maintenance Work Order form contains the following
information:
Job Number
Date Printed
Building Number
Building Level
Location in Area
Relocation
Equipment Identification
Equipment Name
Part or Model Number
Serial Number
Electric Motor Data (if applicable)
Pump Data (if applicable)
Drive or Reducer Data (if applicable)
Maintenance Procedure Code
Description
Instruction Book/File Number
Primary Skill Code
Estimated Time
Parts Required/Used
Time in minutes to complete the job (Only if different than estimated time)
Employee Identification Number
114
-------
Signature
Maintenance Foreman
INITIATE A PM ACTION OUT OF SCHEDULING CYCLE (B17)
The Initiate a P.M. Action Out of Scheduling Cycle form is used to
provide for the initiation of preventive maintenance actions out of the
normal scheduling cylce.
The Intiate a P.M. Action Out of Scheduling Cycle form contains the
following information:
Equipment Identification
Maintenance Procedure Code
PM AND CM REQUEST A WORK ORDER (818)
The PM and CM Request a Work Order form is used to provide for the
reprinting of a Corrective or Preventive Maintenance Work Order.
The PM and CM Request to Reprint a Work Order form contains the
following information:
Job Number
Equipment Identification
Job Type Code
PM DELETE, CM .DELETE, AND CM OR PM PRIORITY OR WORK ORDER STATUS CHANGE
(B19)
The PM Delete, CM Delete, and CM or PR Priority or Work Order Status
Change form is used to provide for the deletion of a Preventive Maintenance
Work Order or a Corrective Maintenance Work Order and to change the Work
115
-------
Order status or priority of a Corrective of Preventive Maintenance Work
Order.
The PM Delete, CM Delete, and CM or PM Priority or Work Order Status
Change form contains the following information:
Job Number
Equipment Identification
Maintenance Procedure Code
Priority
Work Order Status
116
-------
INITIATE A PH ACTION OUT OF THE SCHEDULING CYCLE
PLANNED MAINTENANCE MANAGEMENT SYSTEM
THAN
CODE
P.S
12 J «
EQUIPMENT ID.
PLANT
-V
•MA
EQUIP.
t I
NO.
t 1 1
MAINTENANCE
P»OCEDU«E CODE
I I 1 I
13 M
QattLPrepared.
By-
Figure B17. Initiate a. PM action out of scheduling cycle,
117
-------
PREVENTIVE MO CORRECTIVE MAINTENANCE
REQUEST TO REPRINT A WORK ORDER
PLANNED *AINTENANCE UANACENENT SYSTEM
CAtD
CODE
JOS NUMBER
EQUIPMENT ID.
PLANT
V
UU
EQUIP.
1 1 1
m.
1 I
JOB
TYPE CODE
20 11
01—P«
03mC»
03aCH*NO MALFUNCTION
04«CH>NO EQUIP. ID.
Date Prepared.
By.
Figure B18. PM and CM request to reprint a work order,
118
-------
PREVENTIVE MAINTENANCE DELETE
PLANNED MAINTENANCE MANAGEMENT SYSTEM
CARD
CODE
*1
TRAN
COOS
JOB NUMBER
EQUIPMENT ID.
PLANT
V
*•(*
EQUIP.
1 1 1
NO.
1 1
•AINTENANCB
PROCEDURE COOS
CORRECTIVE MAINTENANCE DELETE
CARD
CODS
ii
TSAH
CODE JOB NUMBER
CD
1 i i i i i
11 14 i 10
CA80
CODE
CM OR PM PRIORITY OR WORK ORDER STATUS CHANGE
•QBE ORDER STATUS
TRAD
CODE
JOB NUMBER
IORK
ORDER STATUS
D
• NOT WRITTEN
• TO BE WRITTEN/NOT SCHBD.
• TO BE VRITTBN/SCHBD.
nWRITTEN/BUT NOT SCHED.
• WRITTEN/SCHEDULED
• HOLD
• NEVER COMPLETED
• COMPLETED/NOT REPORTED
ON WEEKLY
9 • COMPLETED/NOT REPORTED
ON MONTHLY
tm COMPLETED
Date Prepared.
By-
Figure B19. PM delete, CM delete, and CM and PM priority or work order
status change.
119
-------
MAINTENANCE PROCEDURE SHEET
EQUIPMENT
Page 1 of 1
NAME
Plane Area
Level
Location
MPS No.
Average
S-l
S-2
S-3
Time
mln
mln
mln
MAINTENANCE DESCRIPTION
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service"
TOOLS, PARTS, MATERIALS, TEST EOJUIPMENT
PROCEDURE
Figure B20. Maintenance procedure sheet.
120
-------
Bate
Mechanic
Rag Hrs
OT Hrs
Date
Mechanic
Reg Hrs
OT Hrs
REPORT OF TROUBLE
INDICATION
_Broken part
Worn part
"Heat
"Noise
"Smell
"Vibration
"Leaking
"Other
OF TROUBLE
Dirty,foulec
Voltage
Current
Resistance
Flow rate
Pressure
Speed
WHEN DISCOVERED
Starting
Stopping
__During operation
__During PM
___During CM
__During MOD
__During OH
Other
CAUSE OF TROUBLE
Heat/Coldweather
Humidity/moisture
Foreign object
Shock/vibration
Wear
Equipment defect
Improper installation
Improper lubrication
Improper operation
Other
Remarks and Recommendations
Check if equipment was
tagged out ot service
Figure B21. _Marntenance procedure sheet (reverse).
121
-------
REFERENCES
1. Federal Guidelines, Design, Operation and Maintenance of Wastewater
Treatment Facilities. U.S. Department of Interior, Federal Water
Pollution Control Administration. U.S. Government Printing Office.
Washington, D.C. Report No. 0-406-409. September 1970.
2. Environmental Protection Agency. A Planned Maintenance Mangement
System for Municipal Wastewater Treatment Plants. U.S. Government
Printing Office, Washington, D.C. Report No. EPA-600/2-73-004.
3. Tuxbury D.C. and B.E. Srite. Laboratory Services Series a Programmed
Maintenance System.
122
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing) '-.
1. REPORT NO.
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
EVALUATION OF MAINTENANCE MANAGEMENT SYSTEM AT LOWER
POTOMAC WASTEWATER TREATMENT PLANT
FAIRFAX COUNTY VIRGINIA
5. REPORT DATE
May,1981 (issuing date)
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S) .
Lilia A. Abron-Robinson, Ph.D.
Leon W. Weinberger, Sc.D., P.E.
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEER Consultants, Inc.
1160 Rockville Pike, Suite 202
Rockville, Maryland 20852
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-01-6222
12. SPONSORING AGENCY NAME AND ADDRESS
Office of Water and Waste Management
Office of Research and Development
U.S. Environmental Protection Agency
Washington. D.C. 20460
13. TYPE OF REPORT AND PERIOD COVERED
Research & Development
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The Planned Maintenance Management System (PMMS) installed at Lower Potomac Wastewater
Treatment Plant of Fairfax County, Virginia was evaluated.
Descriptions are presented of the original manual system and the current computerized
version. Although the current system is computerized, senior personnel are still
required to make key decisions if the system is to work. The system, to work effective-
ly, requires the cooperation and participation of all plant personnel.
The system is easy to use and only one person is required to code data for computer
interface. The system can be enlarged to accommodate plant expansion, other plants
within the County's jurisdiction, other utilities and other facilities.
The data collected are enumerated and the benefits of the PMMS are described. Data are
analyzed to demonstrate some of the benefits of the system. Valuable data could be
supplied to designers, equipment manufacturers, and purchasing agents.
This report was submitted in fulfillment of Contract No. 68-01-6222 by PEER Con-
sultants, Inc. under the sponsorship of the U.S. Environmental Protection Agency.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COS AT I Field/Group
Maintenance systems, preventive main-
tenenace, corrective maintenance, planned
maintenance, evaluation, effectiveness
Wastewater treatment,
sewage treatment, main-
tenance, operations,
treatment costs, treat-
ment effectiveness,
management
18. DISTRIBUTION STATEMENT
RELEASE TO PUBLIC
19. SECURITY CLASS (ThisReport)'
UNCLASSIFIED
21. NO. OF PAGES
122
20. SECURITY CLASS (Thispage)
UNCLASSIFIED
22. PRICE
EPA Form 2220-1 (9-73)
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14. SPONSORING AGENCY CODE
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EPA Form 2220-1 (9-73) (Reverse)
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