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:

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                  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

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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

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     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

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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

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                            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

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                                 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

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   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

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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

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  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

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           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

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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)

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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
10 NO
                   EQUIP NAME
£.22106 .
£33105
£22104
£3210C
£3210!
£22104
£33101
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£22102
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522102
£32105
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I3210S
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S221C2
£3210*
£23103
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E22ICC
£33IC£
£22104
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£33ICi
£22101
£22103
£32104
£23102
£32101
. DUPLX
OUPLX
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SLUDGE
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SLUDGE
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SLCCCE
PLUNGER
PLUNGER
PLUNGER
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J?LJ1NGEB_
PLUNGER
PLUNGER
PLUNGER
PUMP
PUMP
PUMP
PUMP
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PUMP
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PUMP
PUMP
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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
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PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNGER
PLUNG.EH
PLUNGER
PLUNGER
PLUNGER
.PLUNGEB
PLUNGER
PLUNGER
PLUNGER
PLUNGES
PLUNGER
PLUNGER
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PLUNGER
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PUMP"
PUMP
PUMP
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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
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PLUNGER PUMP
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.PLJNQE8_EU.MP
PLUNGER PUMP

E
Mil 3_-._
NO 1
NO 2
NO 1
NO 4
NO 1
NO 4
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-MO 4
NO 3
NO 1
Tib 3
MO 3
NO 3
NO 4
NO 2
NO. .2. ._
NO 1

020.
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020
020
020
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020
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020
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JOBNO
007874...
01 3000
010651
010650
010648
010647
010130
01S903
015468
014267
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018968
• 018039
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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
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.0
.0
.0
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.0
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.0
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.0
.0
.0
.0
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.0
.0
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.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
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.00
.00
. .jOO .
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. . ,.0-Q...
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.00
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360.00
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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

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                                  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

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     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

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                              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

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                                    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

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     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

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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.

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                                     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

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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

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                             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

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     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

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                              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

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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

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                               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

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                                         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

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                            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

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     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

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     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

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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

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                     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

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                     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

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                                 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

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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

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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

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                                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

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                                   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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                                                     INSTRUCTIONS

1.  REPORT NUMBER
    Insert the EPA report number as it appears on the cover of the publication.

2.  LEAVE BLANK

3.  RECIPIENTS ACCESSION NUMBER                                        ;   . _ .   .'     f   .  I      ."
    Reserved for use by each report recipient.

4.  TITLE AND SUBTITLE
    Title should indicate  clearly and briefly the subject coverage of the report, and be displayed prominently. Set subtitle, if used, in smaller
    type or otherwise subordinate it to main title. When a report is prepared in more than one volume, repeat the primary title, add volume
    number and include subtitle for the specific title.

5.  REPORT DATE
    Each report shall carry a date indicating at least month and year.  Indicate the basis on which it was selected (e.g., date of issue,  date of
    approval, date of preparation,  etc.).

6.  PERFORMING  ORGANIZATION CODE
    Leave blank.

7.  AUTHOR(S)
    Give name(s) in  conventional order (Johri.R. Doe, J. Robert Doe, etc.).  List author's affiliation if it differs from the performing organi-
    zation.                         -.'-••

8.  PERFORMING  ORGANIZATION REPORT  NUMBER .
    Insert if performing organization wishes to assign this number.

9.  PERFORMING  ORGANIZATION NAME AND ADDRESS
    Give name, street, city, state, and ZIP code. List no more than two levels of an organizational hirearchy.

10. PROGRAM ELEMENT NUMBER
    Use the program element number under which the report was prepared. Subordinate numbers may be included in parentheses.

11. CONTRACT/GRANT NUMBER
    Insert contract or grant number under which  report was prepared.

12. SPONSORING AGENCY NAME AND ADDRESS
    Include ZIP code.

13. TYPE OF REPORT AND PERIOD COVERED
    Indicate interim final, etc., and if applicable, dates covered.

14. SPONSORING AGENCY CODE
    Leave blank.

15. SUPPLEMENTARY  NOTES
    Enter information not included elsewhere but useful, such as: Prepared in cooperation with, Translation of, Presented at conference of,
    To be published in, Supersedes, Supplements, etc.

16. ABSTRACT
    Include a brief (200 words or less) factual summary of the most significant information contained in the report. If the report contains a
    significant bibliography or literature survey, mention it here.

17. KEY WORDS AND DOCUMENT ANALYSIS
    (a) DESCRIPTORS - Select from the Thesaurus of Engineering and Scientific Terms the proper authorized terms that identify the major
    concept of the research and are sufficiently specific and precise to be used as index entries for cataloging.

    (b) IDENTIFIERS AND OPEN-ENDED TERMS - Use identifiers  for project names, code names, equipment designators, etc. Use open-
    ended terms written in descriptor form for those subjects for which no descriptor exists.

    (c) COSATI FIELD GROUP - Field and group assignments are to be taken from the 1965 COSATI Subject Category List. Since the ma-
    jority of documents are multidisciplinary in nature, the Primary Field/Group assignment(s) will be specific discipline, area of human
    endeavor, or type of  physical object.  The application(s) will be cross-referenced with secondary Field/Group assignments that will follow
    the primary posting(s).

18. DISTRIBUTION STATEMENT
    Denote releasability to the public or limitation for reasons other-than security for example "Release Unlimited." Cite any availability to
    the public, with address and price, r

19. & 20. SECURITY CLASSIFICATION
    DO NOT submit classified reports to the National Technical Information service.

21. NUMBER OF PAGES              •. ,  .       -
    Insert the total number of pages, including this one and'unnumbered pages, but exclude distribution list, if any.

22. PRICE
    Insert the price set by the National Technical Information Service or the Government Printing Office, if known.
    EPA Form 2220-1 (9-73) (Reverse)

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