EPA-600/2-73-004
NOVEMBER 1973
Environmental Protection Technology Series
A Planned Maintenance
Management System for Municipal
Wastewater Treatment Plants
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Office of Research and Development
U.S. Environmental Protection Agency
Washington, D.C. 20460
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Monitoring, Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and appli-
cation of environmental technology. Elimination of traditional grouping
was consciously planned to foster technology transfer and a maximum
interface in related fields. The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to
develop and demonstrate instrumentation, equipment and methodology
to repair or prevent environmental degradation from point and non-point
sources of pollution. This work provides the new or improved technology
required for the control and treatment of pollution sources to meet
environmental quality standards.
The U. S. Environmental Protection Agency, as a subsequent action to
the publishing of this report, may publish as a separate document, the
entire group of Maintenance Procedure Sheets developed by this program
for the Lower Potomac Wastewater Treatment Plant. If published, this
supplemental publication will constitute a valuable source document for
the adaptation of the Planned Maintenance Management System to other
plants throughout the nation.
EPA REVIEW NOTICE
This report has been reviewed by the Office of Research and Monitoring,
EPA, and approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the Environmental
Protection Agency, nor does mention of trade names or commercial
products constitute endorsement or recommendation for use.
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EPA-600/2-73-004
November 1973
A PLANNED MAINTENANCE MANAGEMENT SYSTEM
FOR MUNICIPAL WASTEWATER
TREATMENT PLANTS
By
Donald H. Sargent, P. E.
David A. Rudich
Project No. 11010 GWI
Program Element 1B2033
Project Officer
Royal C. Thayer
Construction Projects Branch
U. S. Environmental Protection Agency
Washington, D. C. 20460
Prepared for
OFFICE OF RESEARCH AND DEVELOPMENT
U. S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D. C. 20460
For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20102
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ABSTRACT
A Planned Maintenance Management System (PMMS) has been developed
and successfully demonstrated at the 18-mgd Lower Potomac Wastewater
Treatment Plant of Fairfax County, Virginia, establishing a model
maintenance management program for waste water treatment plants
throughout the United States.
This PMMS provides for the specific-maintenance needs of each item of
plant equipment and reduces the maintenance of complex equipment to
simple procedures. For each procedure, the PMMS details the methods,
materials, tools and personnel required; schedules the task; and provides
for data recording and feedback.
The success of this PMMS was measured during the 12-month demon-
stration phase by a steady downward trend in the malfunction of
mechanical equipment. Incipient failures were detected in many cases
and corrective action was taken to avoid breakdowns.
This report describes the PMMS in technical detail; discusses the instal-
lation of the PMMS, including acceptance by the mechanics and coordination
with plant operations; and outlines the application of the PMMS to other
wastewater systems.
This report was submitted in fulfillment of Project Number 11010 GWI by
EnviroPlan, Incorporated, College Park, Maryland, under contract to
the County of Fairfax, Virginia, and under the sponsorship of the United
States Environmental Protection Agency. Work was completed as of
July 1973.
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CONTENTS
Page
Abstract ii
List of Figures iv
List of Tables v
Acknowledgements vi
Sections
I
II
III
IV
V
VI
vn
VIII
IX
X
Conclusions
Recommendations
Introduction
Background of Maintenance Management
Description of the Planned Maintenance
Management System
Program Installation and Demonstration
Application To Other "Waste-water Treatment Plants
References
Glossary
Appendices
1
3
5
9
14
46
55
60
62
63
111
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FIGURES
No. Pa§e
1 Form Ml, Equipment Reference Data 22
2 Form Ml (Reverse), Parts List 23
3 Form M2, Equipment Maintenance Record 30
4 Form M3, Preventive Maintenance Work Record 31
5 Form M3 (Reverse), Report of Trouble 31
6 Form M3X, Variation of Form M3 32
7 Form M4, Equipment Malfunction Report 33
8 Form M5, Corrective Maintenance Work Order 35
9 Form M6, Corrective Maintenance Work Order and
Work Record 36
10 Form M7, Weekly Maintenance Summary Report 37
11 Form M7 (Reverse), Corrective Maintenance Summary 38
12 Corrections to Measured Insulation Resistance 44
Appendix II
A-l through A-18 Examples of Maintenance Procedure
Sheets (MPSs) 67
IV
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TABLES
No.
Page
1 Functional Number System 16
2 Samples From Equipment Configuration List 18
3 Samples From Equipment Data List 20
4 Samples From List of Additional Equipment Data 21
5 Sample From List of Maintenance Procedures 26
6 Example of "Weekly PM Schedule 28
Appendix HI
A-l Equipment Type Classification 96
A-2 Indicators and Modifiers 97
A-3 Annual PM Manpower Requirement 98
A-4 Cross Reference To Equipment Configuration List 99
A-5 List of Maintenance Procedures For Remote
Electrical Controls 103
A-6 Cross Reference, Alarm Sensors to Alarm Indicators 105
A-7 Incineration Equipment Which May Not Be Shut
Down Arbitrarily 107
A-8 Maintenance Procedures in Category A 108
A-9 Maintenance Procedures in Category B 109
A-10 Estimated and Actual Time (Minutes) For PM Actions 111
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ACKNOWLEDGEMENTS
The support of Dr. George J. Kelley, Jr. , former County Executive of the
County of Fairfax, is acknowledged with sincere thanks.
Much valuable guidance from the County of Fairfax was provided by
Mr. Harry L. Hale, Special Assistant to the County Executive, Mr. J. H.
Liedl, Acting Director, Department of Public "Works, Mr. Robert B. Atkins,
Director, Office of Waste Management, Mr. Richard Gozikowski, Director,
Wastewater Treatment Division, and Mr. J. Kelly Paull, Manager, Lower
Potomac Wastewater Treatment Plant. Mr. Charles A. Tedesco, Assistant
County Purchasing Agent, was responsible for contractural arrangements.
Mr. Royal C. Thayer, the Project Officer for the Operations and Main-
tenance Branch of the U. S. Environmental Protection Agency, provided
close administrative support, and most gratefully, continual technical
contributions through this effort. Mr. Sidney Beeman represented the
EPA Office of Research and Monitoring in this program.
Early in the program, Mr. Frank H. Mclvor and the late Mr. Lavern A.
Hoercherl of Computer Sciences Corporation contributed under a subcon-
tract to EnviroPlan, Incorporated.
The success of the 12-month demonstration phase of this program at the
Lower Potomac "Wastewater Treatment Plant was largely the result of
the day-to-day efforts of Mr. Ralph Schlesinger, the Plant Maintenance
Engineer, Mr. Donald Stone, the Senior Maintenance Foreman, and most
important, the maintenance personnel who actually performed the "hands-
on" work. Their continual enthusiasm for this program and their tangible
contributions towards the improvement of this program are appreciated.
A major contributor to the success of this program is Mr. Stanley Miller,
the County's Maintenance Technician for the program at the Lower Potomac
Plant. The recordkeeping and schedule coordination by the Maintenance
Technician are critical to the success of this Planned Maintenance Manage-
ment System, and Mr. Miller discharged his duties with dedication,
timeliness and accuracy. Moreover, Mr. Miller was the source of many
of the innovations and improvements to the System for this pilot program.
Credit for form layout and report editing is given to Ms. Marcia Kasow.
VI
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SECTION I
CONCLUSIONS
Since this Planned Maintenance Management System (PMMS) was initiated
at Fairfax County's Lower Potomac Wastewater Treatment Plant, there
has been a steady trend towards reduction of mechanical equipment
malfunctions, bringing mechanical trouble to the lowest point since the
start up of the plant.
The key to this PMMS is its extensive detail. The one-time effort of
creating the basic equipment and maintenance data base, which provides
for every maintenance need of every individual item of equipment in the
plant, is a substantial task. Once in operation, however, the PMMS is
a working, straightforward guide to the systematic, timely, safe and
complete accomplishment of equipment care and inspection. The main-
tenance of numerous and complex installations is reduced to simple,
specific procedures which are easily identified, followed and managed.
The PMMS, once installed, is easily operated and updated by plant
personnel. In addition to the major mechanical and hydraulic equipment,
the PMMS pays equal attention to the electrical equipment and controls,
to the process measuring and read-out devices and to the alarm systems
in the plant; in short, to every item in the plant necessary for continuous
and optimum wastewater treatment.
Instead of complete reliance upon blanket recommendations of equipment
manufacturers, the PMMS incorporates the environment and service duty
of the equipment, the operational constraints upon equipment maintenance,
and the skill levels and availability of personnel in defining the main-
tenance program.
The PMMS minimizes the paperwork burden for both the mechanics and
the plant management. The paperwork is isolated so that it is performed
by a clerk with or without the aid of data processing machinery. The
mechanics are not required to understand or to use the internal numbering
systems of the PMMS; all that is required is that they have the technical
skills to perform the tasks with the aid of the step-by-step procedures
furnished by the PMMS.
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The PMMS has been developed as a,model for nationwide application.
It has been intentionally kept straightforward for use by small plants,
and it is intentionally expandable to accommodate larger and/or more
complex plants. The PMMS is also applicable to wastewater collection
and pumping systems, fresh water treatment and pumping systems and
storm water systems.
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SECTION II
RECOMMENDATIONS
A significant recommendation is the effective introduction of the Planned
Maintenance Management System (PMMS) to plant mechanics to enlist their
cooperation and acceptance of the rather formal system. The PMMS must
be presented as a vehicle for the mechanics to more effectively perform
their jobs without undue paperwork, and to ensure that their observations
and recommendations are recognized and followed.
The PMMS must be set up and conducted at a particular plant with full
cooperation between the Maintenance and Operations Departments. Some
unit operations cannot or should not be interrupted arbitrarily for servicing;
conversely, operating schedules for parallel units should accommodate the
maintenance requirements.
Well over half of the required preventive maintenance manpower require-
ment is in conducting routine and frequent tasks which might possibly be
performed by regular operators rather than by assigned maintenance
personnel. However, it is extremely desirable that the Maintenance
Department perform these tasks since, in reality, they constitute a
regular and frequent inspection of all of the plant's equipment by
knowledgeable and observant mechanics. At the Lower Potomac Plant, many
incipient malfunctions were detected before breakdowns occurred simply
because assigned maintenance personnel made a thorough systematic
inspection on a daily basis.
The monitoring task of scheduling, or recording, and of reporting is a
continuing job which the PMMS isolates from both the mechanics and the
plant management. For the 18-mgd Lower Potomac Plant, this task was
performed manually by one Maintenance Technician, but only with some
difficulty due to the large number of maintenance actions and the corres-
ponding large volume of data. For smaller plants, a manual system may
be installed; but for plants as large or larger than the Lower Potomac
Plant, it is strongly recommended that some form of data processing
system be utilized. The system may include, depending upon plant size,
mechanical filing equipment, retrieval equipment or electronic data
processing equipment.
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The one-time task of tailoring the PMMS and creating a basic data base
for the PMMS for a particular plant is substantial, simply because great
detail is required to include each and every item of equipment into the
PMMS. This one-time task should not be attempted by regular staff
members on a part-time basis; it should have the full attention of an
experienced staff maintenance engineer, or of a contractor experienced
in wastewater systems maintenance management. Once installed, the
PMMS can be operated and readily updated by regular plant personnel.
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SECTION III
INTRODUCTION
PRIMARY OBJECTIVE
The primary objective of this program was to develop and demonstrate
a Planned Maintenance Management System (PMMS) at the Lower Potomac
Wastewater Treatment Plant of Fairfax County, Virginia, to establish a
model maintenance management program for wastewater treatment plants
throughout the United States, and to demonstrate increased plant relia-
bility for the continuous protection of the quality and uses of the receiving
waters.
DESCRIPTION OF THE LOWER POTOMAC PLANT
As a point of reference for those who may adapt this PMMS to other
wastewater treatment plants, the Lower Potomac Plant is an 18-mgd
secondary treatment plant which has been in service for approximately
three years. It basically consist of:
1. An administration building (Area A).
2. A raw wastewater pumping station (Area B), with two parallel,
mechanically cleaned bar screens upstream of three raw waste-
water pumps (two-speed, constant-speed and variable-speed).
Belt conveyors are used for the screenings.
3. Primary Treatment (Area C), with two parallel, three-bay
rectangular settling tanks. There are three parallel primary
sludge pumps and two parallel scum pumps in Area C.
4. Primary Sludge Degritting (Area H) with two cyclone-type units.
5. Secondary Treatment (Area D), consisting of two parallel three-
pass aeration tanks for the step-aeration activated sludge process.
The three air blowers are in Area E, along with three return
sludge pumps, two excess (waste) sludge pumps and other major
equipment items.
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6. Secondary Clarification (Area F), with two circular clarifiers.
7. Chlorination (Area G).
8. Return Process Water Pumping Station (Area G), with two high-
lift and four low-lift pumps.
9. Sludge Thickening (Area J), with two circular gravity thickeners,
and four plunger pumps.
10. Sludge Processing (Area K), with a thickened sludge storage tank,
three sludge plunger pumps, two sludge conditioning tanks with
associated lime and ferric chloride feeding capability, and two
vacuum filters. Dewatered sludge from other County plants is occas-
sionally brought to Lower Potomac, and all dewatered sludge is
conveyed to either of two multiple-hearth incinerators equipped with
exhaust gas scrubbers and ash conveying and conditioning capability.
11. Plant shop and service building (Area L).
GOALS OF THE PLANNED MAINTENANCE
MANAGEMENT SYSTEM (PMMS)
The PMMS was targeted towards achieving the highest level of plant
performance by:
1. Providing a means for knowledgeable management of maintenance.
2. Ensuring the systematic, timely, safe, standardized and complete
accomplishment of equipment care and inspection.
3. Increasing plant reliability by preventing equipment breakdown
and by prolonging equipment life.
4. Minimizing maintenance manpower requirements.
5. Providing a complete record system and a system for feedback
to management.
6. Providing management with the information required for cost
control, work load assessment and work assignment according
to priority and urgency.
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Prior to the development and demonstration of this PMMS, the state-of-
the-art of maintenance management at wastewater treatment plants
generally consisted of, in many cases, a set of guidelines for generic
classes of. equipment, such as "change the oil in all mechanical drives
and reducers every six months or sooner. " The application of such
general guidelines to the actual effort of servicing each of the hundreds
or thousands of individual items of equipment in the plant has been a
restrictive condition for the following reasons:
1. Lack of a concise list, for example, of all the mechanical drives
in the plant.
2. Lack of a precise time called out for servicing any specific item
of equipment.
3. Lack of a document which was easily accessible to the mechanic
that specified which type of oil to use, what special procedure
was required, what special tools were required, what special
safety precautions were to be taken, or what operational con-
straints existed.
4. Lack of coordination in combined servicing of a pump, motor,
drive, controller, etc. , which operate as a unit.
5. Lack of a prior estimate of what manpower was required, both
in terms of time and type.
6. Lack of an easy way for anyone to analyze or summarize the
maintenance records, assuming that maintenance records were
kept. If adequate maintenance records were kept, the mechanics
might have been spending too much time in paperwork.
The PMMS developed and demonstrated in this program bridges the gap
between general guidelines and the actual item-by-item maintenance of
plant equipment. It reduces the maintenance of complex and/or numerous
and widely scattered equipment into simple procedures, specific for each
equipment item and each task. These specific, simple procedures are
directly useful to the mechanic on the job; they are also easily identified
and managed. For each preventive maintenance work task, the PMMS
identifies each task; describes the methods, materials, tools and per-
sonnel required; schedules the tasks; and provides for data recording
and feedback.
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Nationwide Applicability
The PMMS developed in this program has a dual purpose: to provide a
maintenance management program specific to the Lower Potomac Waste -
water Treatment Plant, and to provide a model program for other plants
across the nation. This latter purpose required that, from the very start
of the PMMS development, it be adaptable and flexible to make its useful-
ness as broad as possible. However, under no circumstances was the
PMMS for the County of Fairfax to be degraded by a lack of specificity.
Manual- and Computer-Adaptable Systems
The PMMS developed and demonstrated by this program is a manual
system, with all data handling, recordkeeping and reporting accomplished
within the existing capabilities of the plant, i. e. , without mechanical or
electronic data processing equipment.
However, it was recognized from the start that data processing aids
would eventually be utilized in conducting the PMMS either at the Lower
Potomac Plant or in its application to other wastewater systems.
Consequently, the PMMS was developed from the start so that com-
puterization would be a straightforward task.
SYSTEM DEVELOPMENT AND DEMONSTRATION
PHASES OF THE PROGRAM
The actual program was conducted in 16 months, concluding on April 6,
1973. The development of the PMMS was Phase I of the program, and
was completed in the first four months. Phase II was a 12-month effort
to monitor, evaluate, update and modify the PMMS during its actual use
and demonstration at Fairfax County's Lower Potomac Wastewater
Treatment Plant.
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SECTION IV
BACKGROUND OF MAINTENANCE MANAGEMENT
GENERAL DISCUSSION OF MAINTENANCE
Maintenance is the function of sustaining or restoring equipment so that
the equipment performs its intended job safely, effectively and economically.
The three basic types of maintenance are:
1. Preventive—periodic tasks of care and inspection scheduled to
prevent a breakdown or prolong the life of equipment.
2. Corrective—unscheduled tasks required to restore equipment to
operational status after a breakdown or impending failure is
discovered.
3. Overhaul —complete disassembly and reconditioning to like-new
status.
The tasks of maintenance are combinations of inspection and care.
Examples of inspection tasks are:
1. Looking or listening for wear or malfunction
2. Checking out electric circuits
3. Looking for cracks and tightness
4. Measuring clearance
5. Looking at corrosion protection.
Examples of equipment care tasks are:
1. Lubricating
2. Renewing seals and packings
3. Adjusting equipment
4. Sharpening cutting edges
5. Replacing worn parts; e. g. , drive belts, safety pins, wear plates
6. Renewing corrosion protection
7. Restoring worn areas to an acceptable tolerance
8. Exercising seldomly used units.
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The kinds and amounts of both inspection and care tasks are usually based
upon extreme conditions. Review of these tasks should be made periodi-
cally to relate them to the actual service conditions, but this step is
difficult because feedback from the operator and the maintainer are not
easily coordinated.
PREVENTIVE AND CORRECTIVE MAINTENANCE
Preventive Maintenance (PM) is scheduled and regulated care intended to
prevent a breakdown or to prolong the life of the equipment, coupled with
intervals of recorded inspections can portray a trend or a.deviation from
operating standards. Any deviation must be presented to the controller
in sufficient time to allow the care to be altered, thus eliminating the
breakdown and a later need for Corrective Maintenance. The amount of
care and inspection must be carefully considered so that time, effort or
material is not wasted on over care.
The decision affecting quantity and quality of PM also should be governed
by need. To satisfy the above conditions, it is necessary to have a realistic
set of PM requirements, defined in a language all concerned can under-
stand and published in a form useful to the person doing the work. Each
work task must be assigned to a specific person, in writing and relative
to when it was last accomplished and when it again falls due, to maintain
the cycle.
A usable record of accomplished PM and Corrective Maintenance not
covered by PM is necessary so that a history may be accumulated to
justify relaxing some requirements or establishing new ones. This history
must be relayed to a central point so that all similar activities can benefit
through method improvements generated as a result of the feedback, and
decisions can be made more rapidly.
Generally, PM requirements should not remove the equipment from an
operationally ready status. This does not preclude the scheduled removal
of components to accomplish the prescribed care during an idle period of
the equipment. It is not always possible to configure equipment so that
removal of parts for care will not interfere with the equipment's readi-
ness to perform. Also, few pieces of equipment are required for continuous
operation without a back-up. The back-up will require some operation to
ensure reliability, therefore providing a relief for main equipment, at
which time the maintenance can be performed. Any needed maintenance
that can be scheduled for timely occurrence will then be classified as PM.
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Corrective Maintenance (CM) is work that is required to restore a piece
of equipment to an operational status after a breakdown or when the
inspection cycle indicates a corrective task must be performed before
further reliable use can be assured. The latter is similar'to the PM
requirement in that the prescribed inspection would monitor the ques-
tioned tolerance of an item until it nears out-of-limits. The task of
correction is required when the equipment is found to be unsatisfactory
to operate through another inspection cycle.
Overhaul means a complete disassembly of an item of equipment;
removing it from an operationally ready status. Each piece is carefully
inspected, restored to original operating characteristics and reassembled
to start an operating cycle similar to a new piece of equipment.
MAINTENANCE MANAGEMENT SYSTEMS
The Federal Guidelines for the Design, Operation and Maintenance of
Waste "Water Treatment Facilities'•"•) specify that wastewater treatment
plant designs must make equipment accessible for maintenance, that an
effective equipment maintenance program is necessary and that sufficient
funds must be provided for maintenance. The U. S. Environmental
Protection Agency construction grant program requires that the grantee
provide, for each grant-assisted plant, provisions for adequate main-
tenance in accordance with Section 35. 935-12 of 40 CFR Part 35.
There are several comprehensive maintenance management systems
which have been developed to satisfy the particular requirements of the
armed services and of the aircraft industry. The Standard Navy Main-
tenance and Materiel Management System,' ) commonly referred to as
the "3M System", takes cognizance of and offers remedial solutions to
the increasing complexity of equipment being introduced into the U. S.
Navy Fleet and the decreasing availability of skilled personnel to main-
tain them.
The Air Force Maintenance Management System,(3) commonly referred
to as the 66-1 System, is applicable to all Air Force activities engaged
in the maintenance of aircraft, missiles, munitions, aerospace ground
equipment, training equipment, airborne communications-armament-
electronics equipment and ground communications -electronics-
meteorological equipment.
The general literature reveals the recognition of maintenance manage-
ment as a key element of plant engineering. Vida*4) recommends
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employing an outside consulting firm to gain management control of
maintenance, with the installation of a PM system, a work order system,
an inventory control system and personnel training. Kittnerv-*) is in favor
of a formal PM system even for small plants, including such elements as
work requests, schedules for PM and manpower requirements analyses.
The advantages he gives include more effective scheduling of personnel,
reduction of delays from lack of materials, reduction of travel time,
better use of employee skills and better relationships with supervisors.
Baronet'")also is strongly in favor of formal scheduling, but feels that
smaller plants are less in need of formality.
Carson and Mailhos^ ' give a method for compiling a maintenance budget
which involves breaking the services down into preventive maintenance,
routine repairs and major repairs or alterations. Careful recording of
costs leads to realistic budgets. Fuchs(^) outlines a work order system
for a small plant, and argues that since maintenance problems are universal,
small plants are not immune to such problems, and therefore need a sys-
tem just as do large plants.
The idea of contract maintenance, or maintenance work performed by
other than in-plant forces, was .explained by Sullivan''' and by Sarappo. '*™
This system is geared for maintenance managers concerned with having
an adequate quantity of skilled personnel available at the proper time.
Sarappo's article contains a questionnaire aimed at evaluating whether
or not a plant could effectively use contract maintenance.
A computerized maintenance management program in the Russian chemical
industry was described by Antropov and Zuev,' ^> with a mathematical
treatment of optimum scheduling. Buttery^ ' also described a computer-
based system for maintenance recordkeeping of manpower, materials and
equipment.
The organization of a maintenance department to clearly define responsi-
bilities was the subject of James'(^) article and Hooper's(^) paper.
Edmonson, et al. , '*->) explained how management usually does not know
the true cost of maintenance, since much of these costs are hidden in
general plant overhead and in other items. Dodds(l") listed the features
of a system to minimize the paperwork in a maintenance system by setting
up job control centers throughout the plant.
Two studies by Michel, et al. ,' ' ' classified municipal waste water
treatment plants according to region, population served and type of
equipment. Plant size is probably the most important single factor
influencing the type of maintenance management system. Smaller plants,
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of 10 mgd capacity or less, usually have very limited resources for main-
tenance in terms of number of employees, their special skills and the
repair facilities available. They are generally unable to do any complex
maintenance tasks and must look to outside help. Very large wastewater
plants like the Hyperion Plant in Los Angeles, described by Garber, V^°)
have elaborate staffs and facilities and can be virtually self-sufficient.
Garber also gave examples of the Hyperion work order and recordkeeping
system.
tabulated in detail O&M cost data which can serve as starting
points in constructing a guideline for a wastewater treatment plant budget.
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SECTION V
DESCRIPTION OF THE PLANNED MAINTENANCE
MANAGEMENT SYSTEM
The objective of the Planned Maintenance Management System (PMMS) is
to reduce the preventive maintenance of a large number of equipment items,
many of which are complex, to a set of explicit, simple tasks which can be
easily scheduled, managed, performed and recorded. The system:
1. Reduces the maintenance of complex equipment to simple procedures
which are easily identified and managed.
2. Defines the minimum requirements of planned maintenance.
3. Schedules and controls the performance/of work tasks, inspections
and tests.
4. Describes the methods, materials, tools and personnel required.
5. Provides for the prevention or detection of impending malfunctions.
6. Provides a permanent record of equipment characteristics and a
maintenance history.
7. Provides periodic maintenance summary reports to plant management.
Although the PMMS is aimed at ensuring the systematic, timely, safe and
complete accomplishment of equipment care and inspection, two factors
must be emphasized.
1. PMMS is a tool of management rather than a substitute for a manager.
2. No system can substitute for the actual technical ability required of
personnel who direct and perform the upkeep of equipment.
It is important to appreciate the scope of the PMMS. For it to be effective
in achieving the highest continuous level of plant performance, all of the
plant equipment must be included in the PMMS. It is not sufficient to
merely attend to the mechanical and hydraulic equipment; the PMMS must
pay "equal attention to electrical equipment, electrical controls, electrical
supply smbstations, measuring devices, meters and recorders, alarm
sensors and alarm indicators.
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The detailed description of the PMMS is contained in the remainder of
this Section. First, the five basic parts of the PMMS are described,
and then a number of special considerations (for municipal waste water
treatment plants) are discussed.
BASIC PARTS OF THE PMMS
The five basic parts of the PMMS are:
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
The initial step in the development of the PMMS is the one-time accomplish-
ment of a complete inventory of plant mechanical and electrical equipment,
including a take-off of nameplate data utilizing Form Ml, shown in Figures 1
and 2 on pages 22 and 23. The resultant inventory list is then restructured
into the Equipment Configuration List by sorting into appropriate groupings,
equipment related to each of the various plant unit process functions. Within
each grouping, equipment is oriented by a numbering system described below.
Table 2 is a sample page from the Equipment Configuration List of the Lower
Potomac Plant.
Each item of equipment in the plant is assigned a unique five-digit identifica-
tion (ID) number. The first three digits identify the function of the equipment.
Table 1 is the functional numbering system for the 18-mgd Lower Potomac
Wastewater Treatment Plant of Fairfax County, Virginia. The first digit
identifies one of the major systems in the plant, the second identifies the
subsystem and the third identifies the particular function. For example,
referring to Table 1, 522 refers to all sludge pumping equipment in the sludge
thickening area. The digit 5 refers to Sludge and Scum Processing; the
second digit, 2, refers to Sludge Thickening; and the third digit, 2, refers
to Pumping. This functional numbering system was designed to be expandable
both vertically, for more complex plants with more systems, subsystems
and functions, such as AWT; and horizontally, for larger plants with more
parallel items of equipment, or for plant expansion.
The fourth and fifth digits of the ID number specify exactly and uniquely
each item of equipment, as illustrated in Table 2. The fourth digit identifies
the piece of equipment within the functional unit—the drive, for example,
in a pump-motor-drive-controller unit; and the fifth digit identifies which
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Table 1. FUNCTIONAL NUMBER SYSTEM
100 Raw Wastewater Station
110 Screening
111 Bar Screens
112 Conveyors
120 Grinding
121 Grinders
130 Wastewater Flow
131 Pumping
132 Valves and Gates
133 Wet Well Level Control
134 Flow Measurement
135 Pump Seal Water
136 Compressed Air
140 Auxiliary Services
141 Sump Pumping
142 Ventilation
143 Hoists
144 Electrical Supply
200 Primary Treatment
210 Primary Settling
211 Tanks and Gates
212 Sludge Collectors
213 Scum Launders
220 Sludge Handling
221 Pumping
222 Pump Seal Water
223 Flow Measurement
224 Sludge Degritting
230 Scum Handling
231 Pumping
232 Pump Seal Water
233 Scum Well Level Control
240 Auxiliary Services
241 Sump Pumping
242 Ventilation
243 Hoists
244 Electrical Supply
300 Secondary Treatment
310 Aeration
311 Tanks and Gates
312 Adjustable Weirs
313 Tank Air Diffusers
314 Incremental Feed Channel Air Diffusers
316 Tank and Feed Channel Water Sprays
316 Mixed Liquor Flow Measurement
317 Diffuser Sock Washing
320 Air Delivery
321 Filters
322 Blowers
323 Flow Measurement
324 Pressure Relief
325 Channel Sparger Air Delivery
326 Compressed Air
330 Secondary Clarifiers
331 Mixed Liquor Channel Air Spargers
332 Mixed Liquor Channel Water Sprays
333 Clarifier Mechanism and Gates
340 Chemical Treatment
341 Flocculant Mixing
342 Flocculant Pumping
350 Return Sludge
351 Pumping
352 Pump Seal Water
353 Return Sludge Wet Well Level
354 Dewatering
355 Flow Measurement
360 Excess Sludge
361 Pumping
362 Pump Seal Water
363 Flow Measurement
364 Dilution
370 Scum
371 Scum Well Level Control
372 Scum Pumping
380 Auxiliary Services
381 Sump Pumping
382 Ventilation
383 Hoists
384 Electrical Supply
400 Chlorination and Effluent Flow
410 Chlorination
411 Chlorine Handling and Weighing
412 Evaporation
413 Chlorinators
414 Chlorine Detection and Venting
415 Injectors and Diffusers
416 Contact Chambers
420 Residual Chlorine Analysis
421 Analyzers
422 Influent Sampling
423 Effluent Sampling
430 Effluent Water
431 Weirs and Gates
432 Level Measurement
433 Return Water Pumping, High Lift
434 Return Water Pumping, Low Lift
435 Pump Seal Water
440 Auxiliary Services
441 Sump Pumping
442 Ventilation
443 Hoists
444 Electrical Supply
16
-------
Table 1 (continued). FUNCTIONAL NUMBER SYSTEM
500 Sludge and Scum Processing
510 Auxiliary Services
511 Sump Pumping
512 Ventilation
513 Hoists
514 Electrical Supply
520 Sludge Thickening
521 Thickeners
522 Pumping
523 Flow Measurement
524 Chlorination
525 Compressed Air
530 Sludge Storage and Handling
531 Sludge Storage Tank
532 Screw Feeders
533 Pumps
534 Conveyors
535 Flow Measurement
536 Flushing Water
537 Hydraulic Power
538 Sump Pumping
540 Scum Handling
541 Weir Control
542 Pumping
550 Lime Treatment
551 Dry Lime Storage Tank
552 Level Indication
553 Vibration
554 Dust Collection
555 Dry Lime Feeding
556 Lime Mixing
557 Lime Slurry Pumping
560 Ferric Chloride Treatment
561 Storage Tanks
562 Compressed Air Supply
563 Day Tanks
564 Pumping
570 Polymer Treatment
571 Mixing
572 Pumping
580 Sludge Conditioning
581 Conditioning Tanks
590 Vacuum Filtration
591 Vacuum Pumping
592 Filtering
593 Filter Agitation
594 Filtrate Pumping
600 Incineration
610 Incinerators
611 Mechanisms
620 Gas Supply
621 Oil Supply
631 Shutoff
632 Filtration
633 Pumping
634 Flow Rate
640 Air Supply and Foul Gases
641 Cooling Air
642 Combustion Air
643 Four Gas Delivery
650 Scrubbing
651 Scrubbers
652 Flush Water
653 Exhaust Fans
660 Ash Handling
661 Elevators
662 Conveyors
663 Storage
664 Conditioning
665 Feeding
670 Auxiliary Services
671 Sump Pumping
672 Ventilation
673 Hoists
674 Electrical Supply
700 Utilities and Services
710 Recorders and Meters
711 Flow
712 Pressure
713 Level
714 Concentration
715 Electrical and Position
720 Laboratory Facilities
721 Lab Equipment
730 Plant Service Equipment
731 Plant Water
732 Heating
733 Hot Water
734 Lighting
740 Outside Utility Supply
741 Electricity
742 Gas
743 County Water
750 Maintenance 8c Repair Facilities
751 Machine Shop
752 Mechanical Shop
753 Electrical Shop
760 Buildings and Grounds
770 Safety Equipment
771 Fire Extinguishers
772 Hydrants
773 Emergency Lighting
774 First Aid Equipment
17
-------
Table 2. SAMPLES FROM EQUIPMENT CONFIGURATION LIST
ID
Equipment Name
Type
Location
520 SLUDGE THICKENING
521 Thickeners
52111
52112
52121
52122
52131
52132
52141
52142
52151
52152
52161
52162
Sludge Thickener No. 1
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
522H
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. 1
Motor, Pump No. 2
Motor, Pump No. 3
Motor, Pump No. 4
Variable Speed Reducer, No. 1
Variable Speed Reducer, No. 2
Variable Speed Reducer, No. 3
Variable Speed Reducer, No. 4
Gear Drive, 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 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
J L NW
J L NE
J L SW
J L SE
523 Flow Measurement
52311
52321
52331
Thickened Sludge Magnetic F'lowmeter
Flow Transmitter
Influent Sludge Channel Level Recorder
61
61
63
J L
J L
JO W
Location areas (refer to pages 5 and 6):
sludge thickening
plant shop and service building
outside
J
L
O
18
-------
of the parallel units is being specified. The numbering system permits
all similar parallel units to be grouped by the first four digits, and it
permits all equipment which operates together as a unit to be grouped by
the first, second, third and fifth digits.
The Equipment Configuration List, based upon this numbering system,
identifies all of the equipment in the plant. In addition to the identification
number and the common name, other information is provided. An equip-
ment type number tells what the equipment item is; for example, 33 means
electric controls, regardless of the function of the item in the plant (Table A-1
of Appendix III is the list of equipment type numbers for the Lower Potomac
Plant). The location tells the area in the plant, the level within the area
(upper, middle, lower), the location within the area (N."W., S.E., etc.) and
the relative location with respect to similar or parallel items.
The Equipment Data List (illustrated by Table '3) augments the main Equip-
ment Configuration List and is grouped by equipment type. For each item
of equipment, identified by its five-digit ID number; the Equipment Data List
contains the manufacturer's name, the part or model number and the serial
number.
The Equipment Data List, with the equipment type number, is useful for
grouping equipment with similar maintenance requirements and with similar
spare parts requirements. This list is extremely useful in searching for
replacement units or parts in the event of a breakdown leading to an emer-
gency situation.
Even more detailed data are tabulated in a similar fashion to augment the
Equipment Configuration List. Table 4, a sample list from the Lower
Potomac Plant, shows how pumps are separately listed with their head,
capacity, size, impeller and RPM; and how electric motors are separately
listed with their horesepower, frame, RPM, voltage, amperage and number
of phases.
In addition to these tabular equipment inventory lists, which should be kept
at a central location, the pertinent data for each item of equipment is also
recorded on a single sheet of paper, Form Ml, for easy reference (close
to the equipment).
Form Ml, "Equipment Reference Data, " is an 8-1/2 x 11-inch permanent
record for each item of equipment. Figures 1 and 2 show both sides of
Form Ml. All descriptive data from manufacturer's catalogs, drawings,
bulletins and reference documents are transcribed onto Form Ml. This
form has three special blocks for data should the item of equipment be an
electric motor, a pump or a drive or reducer. For items of equipment
19
-------
Table 3. SAMPLES FROM EQUIPMENT DATA LIST
ID
Manufacturer
Part Number
Serial Number
21 Centrifugal Pumps
1311Z
13113
13114
23113
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 Morse
Fairbanks Morse
Fairbanks Morse
Fairbanks Morse
Fairbanks Morse
Fairbanks Morse
Eastern
Eastern
Eastern
Eastern
Eastern
Eastern
Fairbanks Morse
5710
5710
5710
Model G
Model G
Model G
Model E
Model E
Model 5720
Model 5720
Model 5720
5423B-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
K2NI 044068
K2N1 044069
K2N1 044070
6895610-3
6895610-2
6895610-1
6895610-4
6895610-5
K2N1 044071
K2N1044071-1
K2N1044071-2
K2N1 044073
K2N1044072
K2N1044072-1
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
35121
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
F BNF - 1
F BNF - 1
KZK, T1004-2
M
VEU
VEU
VEU
ERHB
ERHB
ERHB
KZK, T1007-2
VLUHVGS
VLUHVGS
ERHP
ERHP
680B101G27-6807
680B101G27-6807
8A2528-2
8A2528-1
F291080
311P178-A
J1421251
J1421249
J1421250
B121781
B121781
B121781
F-457875
P4177843
P4177842
121781
121781
20
-------
Table 4. SAMPLES FROM LIST OF ADDITIONAL
EQUIPMENT DATA
ADDITIONAL DATA FOR PUMPS
13112
13113
13114
22113
22114
22115
23111
23112
35111
35112
35113
35411
36113
36114
43311
43312
43411
43412
43413
43414
TDH
27.5
25.5
27
35
35
35
8
8
29
29
29
25
16.5
16.5
160
160
60
60
60
60
GPM
19200
14000
• 100
100
100
100
100
4200
4200
4200
1000
1250
1250
1500
1500
1200
1200
1200
1200
SIZE
24
24
20
4X4
4X4
4X4
4X9
4X9
12
12
12
6
8
8
5X8
5X8
5
5
5
5
IMP
24 3/8
22 1/4
20 5/8
9
9
12 3/8
12 3/8
12 3/8
12
14
14
13 7/8
13 7/8
9 7/8
9 7/8
9 7/8
9 7/8
RPM
585
585
665
800
800
800
600
600
1170
1170
1170
875
640
640
1750
1750
1750
1750
1750
1750
ADDITIONAL DATA FOR ELECTRIC MOTORS
42221
42222
42223
42321
42322
42323
43321
43322
43421
43422
43423
43424
43521
43522
44121
44221
44222
HP
0.5
0.5
0.5
0.5
0.5
0.5
100
100
30
30
30
30
5
5
0.75
0.5
0.17
FRAME
H48
M48
M48
M48
M48
M48
445UP
445UP
A326UPY
A326UPY
A326UPY
A326UPY
213
213
56C
J56
F48
RPM
3450
3450
3450
3450
3450
3450
1770
1780
ieoo
1800
1800
1800
3180
3180
1725
1140
1725
VOLTS
115/230
115/230
115/230
115/230
115/230
115/230
230/460
230/460
230/460
230/460
230/460
230/460
230/460
230/460'
230/460
220/440
115
AMPS
6.8/3.4
6.8/3.4
6.8/3.4
6.8/3.4
6.8/3.4
6.8/3.4
228/114
228/114
72.7/36.4
72.7/36,4
72.7/36.4
72.7/36.4
13.8/6.8
13.8/6.8
3.1/1.55
1.9/0.95
3.4
PH
1
1
1
1
1
1
3
3
3
3
3
3
3
3
3
3
1
21
-------
EQUIPMENT REFERENCE DATA
Equipment Name and Number
Type 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 ID Service
Electric Motor
Pump
Drive or Reducer
Capacity
Volt!
Amp*
Impeller
Packing
Type
QSeriea
D Shunt
Q Synchronous
Q Induction
D
Specification
QOpen
QCxp. proof
Q Drip proof
Q Totally enclosed
D
Type
Q Centrifugal
D Plunger
Q Diapbragm
O Gear
Q Screw
a
In* tali at ion
Q Horisontal
D Vertical
Q Submerged
Lubrication
D Waur
DOil
O Create
Type
QGear
QV-Bell
D Chain
QV arid rive
Bearing*
Q Sleeve
DBall D Roller
Bearing!
DSleeve
DBall
D Roller
Bearing!
D Sleeve
DBall
DRolle
Other Equipment
Type, Speed, Size, Capacity, Range
Bearing*, Lubricant
form W1-W72
Figure 1. Form Ml, Equipment Reference Data
22
-------
PARTS LIST
Name of Part
Manufacturer
Cat. No.
Local Supplier
Cost
Form Ml Reverse)-5/7Z
Figure 2. Form Ml (Reverse), Parts List
23
-------
not falling into one of these common categories, the data is entered in
the block at the bottom of the form. The reverse side of Form Ml is for
listing parts which are likely to be replaced. The basic purpose of
Form Ml is to provide an accessible file of manufacturer's data for use
in the event of a breakdown, or a proposed modification or replacement.
The data on the form is also useful for generating an equipment inven-
tory list and for planning a spare parts inventory.
The Maintenance Procedures
Each individual Maintenance Procedure (MP) is detailed on a numbered
Maintenance Procedure Sheet (MPS), and:
1. Defines the maintenance task in terms that allow all concerned
to know what is required, who must perform, estimate of time
required and how often.
2. Standardizes the procedure and sequence for doing a job in the
best known wary.
3. Expedites the accomplishment of the task by stating the tools and
materials needed and the safety precautions to be observed.
4. Provides a concise and complete work instruction to the main-
tenance personnel in the work space. The basic objective of the
MPS is to be all inclusive. References to other publications are
not required since availability of outside references other than
instructions posted on or near the equipment cannot be assured.
For each equipment item in the plant, an MPS is included for each PM
action. Since the maintenance requirements for parallel units are
identical, the MPS is identified by the first four digits only and is appli-
cable to all equipment items with those first four digits.
Each MPS has an additional two-character code. The first character
specifies the required frequency for the particular maintenance according
to the following list:
D - Daily Q - Quarterly
W - Weekly S - Semiannually
M <- Monthly A - Annually
• R - As required
The second character is the designated number of MPs to be performed
at the specified frequency.
24
-------
Examples of some MPSs are included in Appendix IE as Figures A-l through
A-18. A variety of MPSs are included to show the type and extent of the
information included for different classes of equipment and maintenance
actions. Each MPS contains:
1. The number, the descriptive title and the frequency of the main-
tenance action to be performed.
2. The skill level required to perform the maintenance.
3. An average time required to perform the maintenance, not including
""make ready" and "put away'r time.
4. The' complete title, identification number, nameplate data and
location of the equipment to avoid any ambiguity over which item ^
of equipment is to be serviced.
5. The specific safety precautions to be observed when performing
the maintenance action(s).
6. A list of tools, parts, materials and test equipment required.
7. The individual step-by-step instructions for the maintenance
action. The instructions are specific, stating which type of
lubricant to use, or what torque to use for tightening bolts, etc.
The first instruction is always a repetition of the safety precautions.
A concise summary list of Maintenance Procedures (MPs) was generated
to enable the Maintenance Engineer to rapidly identify the PM actions for
each unit in the plant. Table 5 is a sample page of the summary list of
Maintenance Procedures for the Lower Potomac Plant. This summary
lists the operating unit, the description of the work to be performed for
each Maintenance Procedure, the frequency of each PM task, the man-
power requirement by skill and time _in minutes for each PM task, and
a key which initiates the schedule for performing each PM task. This
key is simply the first scheduled week number, not necessarily January 1,
but the .week selected for PMMS start up, from which all other scheduled
week numbers automatically follow.
1. Daily and weekly MPs are, of course, scheduled for every week
from one to fifty-two.
2. For monthly MPs, add to the key number: 0, 4, 8, 13, 17, 21,
26, 30, 34, 39, 43, 47.
25
-------
.Table 5. SAMPLE FROM LIST OF
MAINTENANCE PROCEDURES
(keyed to Maintenance Procedure Sheets [MPSsl)
MP No.
*1111
1111 Dl
1111 D2
1111 Ml
*1112
1112 Ql
1112 Al
*1113
1113 Wl
1113 Ql
*1114
1114 Al
1114 A2
*1121
1121 Wl
*1122
1122 Ml
1122 Ql
1122 Al
*1123
1123 Wl
1123 SI
*1124
1124 Al
1124 A2
*1211
1211 Wl
1211 Ml
1211 M2
*1212
1212 Ql
1212 Al
*1213
1213 Al
1213 A2
*1311
1311 Wl
1311 HI
1311 SI
1311 S2
Task Description
2 Bar Screen Mechanical Cleaner
Lubricate bar screen
Inspect rake assembly and chain
Inspect counterweight shock absorbers
2 Motor, Bar Screen Cleaner
Clean motor and perform elec. inspection
Lubricate motor
2 Drive, Bar Screen Cleaner
Check oil level
Change oil
2 Control, Bar Screen Cleaner
Clean and inspect controller
Clean ajid inspect remote control switch
3 Conveyor, Bar Screen Cleanings
Inspect and lubricate conveyor
3 Motor, Conveyor, Bar Screen Cleanings
Inspect drive belt(s) tension
Clean motor and perform elec. inspection
Lubricate motor
3 Drive, Conveyor, Bar Screen Cleanings
Check oil level
Change oil
3 Control, Conveyor, Bar Screen Cleanings
Clean and inspect controller
Clean and inspect remote control switch
2 Grinder, Bar Screen Cleanings
Lubricate grinder
Inspect drive belt(s) tension
Inspect grinder
2 Motor and Drive, Grinder, Bar Screen Cleanings
Clean motor and perform elec. inspection
Lubricate motor
2 Control, Grinder, Bar Screen Cleanings
Clean and inspect controller
Clean and inspect remote control switch
3 Raw Wastewater Pump A
Inspect packing gland adjustment
Renew packing
Lubricate pump bearings
Lubricate coupling
Skill /Minute 3
1
18
48
30
18
48
30
18
48
30
*Equipment name
2
20
15
30
24
12
30
18
90
12
180
3
20
15
18
18
30
12
48
18
24
12
48
18
180
18
30
48
12
6
Week
No.
1
1
1
1
1
1
1
1
1
1
3
3
3
1
3
3
3
1
2
2
b
6
6
6
I
9
9
26
-------
3. For quarterly MPs, add to the key number: 0, 13, 26, 39.
4. For semiannual MPs, add to the key number:. 0, 26.
5. For annual MPs, the key number is the scheduled week number.
The Preventive Maintenance (PM) Cycle Schedule
The PM actions are scheduled for each of the 52 weeks of the year.
Table 6 is a sample listing of the Maintenance Procedures (MPs) scheduled
for a particular week at the Lower Potomac Plant. The list is generally
organized so that all MPs for a single unit in the plant are listed together
for the purpose of assigning them to a single team at a time. Hence, the
unit need be removed from service only once. Furthermore, the schedule
was generated to group MPSs on the same unit, although of differing
frequencies, during the same weeks.
The actual work assignment on a daily basis is left to the discretion of
the foreman and plant management, since operational constraints,
corrective maintenance work loads and employee absenteeism cannot be
fully anticipated.
During one week in each quarter of the year, only daily and weekly PM
is scheduled. The remaining time may be used by the plant to catch up
on delayed preventive and corrective maintenance, and may also be used
to allow for periods of high absenteeism (vacations, Easter week,
Christmas week, etc.).
In addition to a list of MPs for each week of the year, the schedule lists
the daily and weekly tasks separately. To augment the lists for each of
the weeks, a master schedule displays the individual PM tasks for each
operating unit in the plant for the entire year. This master schedule is
part of the summary of Maintenance Procedures described previously
(Table 5). An optional display in the form of a wall chart would enable
the Maintenance Engineer to see at a glance what the PM work load will
be, or alternately, to see when PM is to be performed on any particular
unit.
The Recordkeeping System
The recordkeeping system of the PMMS consists of six forms. Forms
Ml and M2 are permanent records for each item of equipment, containing
reference data and cumulative maintenance data. Form M3 is a temporary
record of preventive maintenance actions, and Forms M4, M5 and M6
are temporary records of corrective maintenance actions.
27
-------
Table 6. EXAMPLE OF WEEKLY PM SCHEDULE
Week 1
1111 Ml
1112 Ql
1112 Al
1113 Ql
1114 Al
1114 A2
1334 Ml
2112 Ml
2131 Ml
2132 Ql
2132 Q2
2133 Ml
2133 Ql
2242 Ml
2332 Ml
2332 M2
2332 M3
2332 Ql
2332 SI
2332 S2
5221 Ml
5221 M2
5222 Ql
5224 Ql
5225 Ql
5312 Ml
5564 Ml
5571 Ml
5573 Ml
5581 Ml
5583 Ml
> 5711 Ql
5712 Ql
Perform these plus all Daily and Weekly
Maintenance Procedures (MPs), keyed to
Maintenance Procedure Sheets (MPSs).
28
-------
Form Ml, "Equipment Reference Data," was described previously and
is shown in Figures 1 and 2.
Form M2, the "Equipment Maintenance Record, " provides an historical
file of all PM and CM performed on a particular item of equipment. This
8-1/2 x 11-inch permanent record, shown in Figure 3, will be useful in
the event of a breakdown or an impending breakdown, and for an examina-
tion of trends and of any indications of equipment deterioration with time.
Each time a maintenance action is performed an entry is made on Form M2.
The MPS number or the job number specifies, respectively, whether the
action is PM or CM. The "Labor" entry is for recording the skill level,
the initials of the mechanic and the actual manhours expended. The
"Observations" entry is coded according to the list of Indicators and
Modifiers, which is included as Table A-2. In addition to this coded
entry, a descriptive statement can be made, when necessary, in the
"Remarks and Data" column. The "Volts," "Amps" and "Megohms"
entries are reserved for maintenance on electric motors.
Forms M3, M4 and M5 are temporary 5 x 8-inch records. Form M3,
Figures 4 and 5, is a "Preventive Maintenance Work Record, " which
the mechanic uses while on the job to document that the PM work has
been done and to record the labor expended and the measurements made.
The checklist on Form M3 is used by the mechanic to indicate whether
there was any indication of trouble during the routine PM and inspection.
If any of the "Trouble" boxes are checked, the reverse side of Form M3,
"Report of Trouble, " is used by the mechanic to provide a detailed
explanation.
Form M3X, a variation of Form M3, is shown in Figure 6. This format
is used for daily and weekly actions, and conserves the amount of paper
handled by having multiple entries on one form. In practice, this form
is printed on the back of the 8-1/2 x 11-inch Maintenance Procedure
Sheet, on heavy card stock, which is used repetitively until the available
spaces are filled or until the card is mutilated. At that point, a replace-
ment is made.
Whichever of the two Form M3 formats is used, and whether or not any
of the "Trouble" boxes are checked, the data from Form M3 is transcribed
onto the permanent Form M2. If there is no "Trouble, " Form M3 can be
discarded once the PM data have been recorded. If trouble has been
spotted, Form M5 must be filled out to initiate CM action.
Form M4, the "Equipment Malfunction Report, " shown in Figure 7, serves
a similar purpose as the "Report of Trouble" side of M3, except that M4
29
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EQUIPMENT MAINTENANCE RECO.1D
Equipment Name and Number
Date
MPC No
or
Job No.
Labor
Skill
Initials
Hours
Obaorvationa
Ind.
Mod.
Volla
Leg 1
L=B2
LeR 3
1. D. No.
Amps
Leg 1
Leg 2
Leg 3
Senal No.
Location Record Sheet No.
Meg Ohm's
Leg 1
Leg 2
Leg 3
Form U2 -5m
Figure 3. Form M2, Equipment Maintenance Record
30
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PREVENTIVE MAINTENANCE WORK RECORD
Equipment N*me and Number
INCINERATOR NO.
MP5 No. "•">• «' Proc.d
6|1|1|1|_ D 1 FEEDER
Meclwik'i N*rne
K
r. CHECK OIL LEVEL - SIGHT
- TOP-BOTT. CENTER SHAFT
Reg. Hn
Wai there any indication of troul
Any change in operation of
Any difference front simila
Any broken or worn parts?
Any excess leaks, heat, nc
Any fouling by foreign obje
Was insulation resistance
Any improvements to safety preca
OT Mr* Volti
Mefobmi (Co
>le?
appearance? ....
eta?
oo low? ......
I.D. Ho. Dalt
1 1 1 1
Work Computed {Sl|nMnr«>
•*"
-«! 1 L«| 2 U| 1
r. l» TS* C>
Trouble OK
a D
O D
a D
D a
... a a
a o
D D
a a
o a
IF ANY TROUBLE, FILL OUT REVERSE SIDE
ft..*. U 1-4/11 1
Figure 4. Form M3, Preventive Maintenance Work Record
Indlc.ooii ot Trouble
Q Broken p.rt D Dirty, louled
Qwoinpin Dvoll.K"
DH..I D €„,.„,
DNO... DR,.,.,,«,
Dsm.ll nFlo.ru<
Dv,br..,o- Dpre.lur.
QL.«klng Dsp«ed
Do,k.r
R*m>rk> uu) Rflcomm«nd»tiOn«
REPORT OF TROUBLE
Dsi.rnng
Dstcpp.na
QDurini operation
QOurlntt PM
D During CM
Qdurinit MOD
D During OH
D Other
C*ui« of TroubU
O He«t/ cold /OT*ttur
DHumid.iy/moifUM
Dror*lBnotij«cl
Dsh«k/Tlbr«tio«
Dw,»
D Equipment d«(*Cl
Q Improper IniUlluiM
Q Improper op* ration
D Other
Chech If equipment *»• i«(g.xi out o( ivrvicc Q
Form Ml(revar*.t.t/TZ
Figure 5. Form M3 (Reverse), Report of Trouble
31
-------
Date
Mechanic's Name
Reg.Hrs
OT Mrs
Date
Mechanic's Name
Reg.Hrs
OT Hrs
REPORT OF TROUBLE
INDICATION OF TROUBLE WHEN DISCOVERED CAUSE OF TROUBLE
_Broken part _Dirty, fouled _Starting _Heat/Cold/weather
Worn part "Voltage _Stopping _Humidity/moisture
Heat "Current _During operation _Foreign object
_Notse ~Resistance "During PM 3shock/vlbration
"Smell "Flow rate _During CM _Wear
"Vibration "Pressure During MOD _Equipment defect
_Leaking "Speed _During OH "^Improper installation
"other ~ Other "improper lubrication
~" "improper operation
"Other
Remarks and Recommendations Check if
tagged o
equipment was
ut of service
Figure 6. Form.M3X, Variation of Form M3*
*Summary of listing on reverse side of various maintenance procedure sheets.
32
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EQUIPMENT MALFUNCTION REPORT
Equipment Name and Number
, n _, Serial No. Location
Date of Trouble Time Reported by Foreman
Indication of Trouble
D Broken part Q DirtY. fouled
D Worn part O Voltage
n Heat D Current
Q Noise Q Resistance
D Smell Q Flow rate
Q Leaking Q Speed
d Other
When Discovered
C3 Starting
Q Stopping
Q During operation
C3 During PM
C] During CM
P During MOD
C] During OH
ti Other
Remarks and Recommendations
Check if
out of se
Cause of Trouble
Q He at /cold /weather
Q Humidity/moisture
d*"°r«ign object
n Shock/ vibration
D Wear
Q Equipment defect
Q Improper installation
Q Improper lubrication
QJ Improper operation
C3 Other
equipment was tagged r-j
rvice
Form M4-5/7Z
Figure 7. Form M4, Equipment Malfunction Report
33
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is intended for use by plant operators or anyone else noticing a malfunc-
tion (M3 is intended for use by maintenance mechanics while performing
PM). Completed Forms M4 should, of course, be promptly delivered to
the Maintenance Department. Pads of blank M4 Forms should be in con-
venient locations throughout the plant.
Forms M5 and M6, shown in Figures 8 and 9, are for initiating CM
whenever the "Trouble" side of Form M3 or Form M4 has been received
by the Maintenance Department. Form M5, a 5 x 8-inch "Corrective
Maintenance Work Order," is prepared with cost and downtime estimates
when analysis indicates that corrective action is required. This infor-
mation is automatically reproduced, by the use of carbon or NCR-type
paper, onto the top of Form M6. The combined forms then are signed,
and a job number is issued, allowing the CM work to be initiated. At this
point, the forms are separated; Form M5 is retained as an open work
order, while Form M6 is used by the field maintenance personnel.
The lower half of M6, which is an 8-1/2 x 11-inch form, is used to record
the labor, parts arid materials used, descriptions and recommendations,
equipment status and spare parts availability, and actual corrective
maintenance costs and downtime. The maintenance foreman and the
requestor sign off on the completed work. At this time, Form M5 may
be discarded. An appropriate entry is made on'Form M2, and Form M6
is kept in the permanent equipment file with the Ml and M2 forms.
The Recordkeeping System has been constructed to segregate the coding
and the paperwork from the mechanics. The mechanics are given appro-
priate MPSs which explicitly identify both the equipment and procedure
in common language. The mechanics fill out Forms M3 (or M4) and M6,
which are designed as simple checklists. No other paperwork burden
is placed upon the mechanics.
The Maintenance Data Feedback System
Form M7, shown as Figures 10 and 11, is a weekly maintenance summary
report which is prepared by the Maintenance Technician for plant
management. There are three parts to Form M7: a Work Load Summary
and a Work Accomplished Summary on the front of the form, and a Correc-
tive Maintenance Summary on the back.
The Work Load Summary corresponds to the balance sheet in a financial
report. The new work load for the week is added to the old backlog for
the total outstanding work; from this total is subtracted the work accomp-
lished during the week to establish the new backlog for the following week.
34
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CORRECTIVE MAINTENANCE WORK ORDER
OO
U1
Requested by
Equipment Name and Number
Indication of Trouble
LJ Broken part
LJ Worn part
O Heat
LJ Noise
Q Smell
Q Vibration
Q Leaking
C3 Other __
Corrective Work Requested
Approved by
Dirty, fouled
Q Voltage
n Current
Q Resistance
Q Flow rate
Q Pressure
Q Speed
Required
Completion Date
When Discovered'
Q Starting
n Stopping
^J During operatio
CDDurhig PM
C] During CM
Q During MOD
n During OH
n Other
Cause of Trouble
[] Heat/cold/weather
lj Humidity/moifiture
U Foreign object
^] Shock/vibration
[] Wear
^J Equipment defect
n] Improper installation
^J Improper lubrication
Qj Improper operation
n Othe r
Estimated Costs
Labor
Parts
Contractors
Total
Estimated Down-Time
Form M5-5/72
Figure 8. Form M5, Corrective Maintenance Work Order
-------
CORRECTIVE MAINTENANCE WORK ORDER
CumpUlion O*M
I I I
D D.,,,. r.i.d
O v.,,...
When Di.
Q SurH
QDur-ngO
CM» ol Treubl
D Tor-tg- MJ.CI
Q SJwch/olbruLan
O Improper
Q Improper
O Other
Carnetlv* Work R*qu**t
CORRECTIVE MAINTENANCE WORK RECORD
d hew il .*• [IKCI]
Fill IT op*r*tion*l
NtHi-lioa>l
Figure 9. Form M6, Corrective Maintenance
Work Order and Work Record
36
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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 1'rom previous week
Regularly scheduled lor this week
Total outstandme work (A&B)
Accomplished this ueek
Backlog for next week (C-D)
Corrective Maintenance
Backlog from previous week
New work orders, this week
Total outstanding work (F&G)
Accomplished this week
Backlog for next week (H-I)
Total backlog for next week (E&J)
Number
of
Actions
Estimated Manhours
Skill 1
Skill Z
Skill 3
Total
WORK ACCOMPLISHED SUMMARY
Item
Number of Actions Completed
Actual manhours expended
Skill 1
Skill Z
Skill 3
Total
Labor costs
_ Regular
0. T.
Total
Outside contractor costs
Cost of parts and materials
Total coats
Preventive
Maintenance
Corrective
Maintenance
Total
Maintenance
Form M7-5/72
Figure 10. Form MY, "Weekly Maintenance Summary Report
37
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CORRECTIVE MAINTENANCE SUMMARY
Job No.
1
Equipment Name
Equip.
I.D.
Status
Code*
Description of Work
To Be Done
Priority
Code**
Work Order
Date
Completion
Date
Remarks
*Equipment Status Code **Priority Code
O - Operational U - Urgent repairs to correct conditions which prevent the plant
N - Nonope rational from operating or which involve the health and safety
R - Reduced capability of personnel
N - Needed repairs to correct conditions which seriously impair
plant efficiency or plant reliability
R - Routine repairs, tests and inspections
C - Convenience items
Figure 11. Form M7 (Reverse), Corrective Maintenance Summary
38
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A separate balance sheet is included for PM and for CM, and the new total
backlog is shown. For the Work Load Summary, all manhours are expressed
as "estimated" manhours.
The Work Accomplished Summary corresponds to the income statement
in a financial report. The objective is to show the actual labor and the
actual costs incurred during the week.
The Corrective Maintenance Summary lists all CM work orders (Form M5)
that were outstanding at the beginning of the week and those that were
initiated during the week. Those items that were completed during the
week are noted by an entry in the "Completion Date" column. For plant
management to decide which jobs to attack first, this Summary lists an
Equipment Status Code and a Priority Code for each job. The "Remarks"
column should be used for comments such as "awaiting spare parts. "
The weekly maintenance summary report is prepared for plant management
by the Maintenance Technician. The report is generated directly from the
data in the Recordkeeping System. Aside from providing management with
timely important data, the Feedback System is designed to relieve manage-
ment of any paperwork burden.
SPECIAL CONSIDERATIONS IN THE PMMS
The Maintenance Technician
The permanent records, the Indicators and Modifiers Code, the PM Cycle
Schedule, and the Equipment Configuration numbering system do not con-
cern the mechanics in the performance of their work. All of the scheduling
and monitoring for the PMMS is performed by a Maintenance Technician.
His efforts may be strictly manual in smaller plants, or he may use
computers or other data processing devices in medium-to-large plants.
The Technician position is essential to the successful implementation of
the PMMS. It is the intention of the PMMS to remove the paperwork burden
from the mechanics and from plant management, and to concentrate the
paperwork and coordination of details upon the Technician.
The duties of the Maintenance Technician are:
1. To maintain and update a file for each item of equipment in the
plant. The Technician records, on a continual basis, each pre-
ventive maintenance action taken. The data recorded includes
the date, a code describing what was done, the initials and labor
39
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category of the mechanic(s), the labor hours consumed, readings
or measurements taken, and a coded entry of observations the
mechanic will make regarding equipment condition. The Technician
relieves the mechanics of any formal record-taking by transcribing
his freestyle comments onto a permanent record. The Technician
should therefore be familiar with equipment and with maintenance
procedures to effectively communicate with the mechanics, and
should be capable of using codes for recording and retrieval
purposes.
2. To record corrective maintenance actions and equipment modifi-
cations in the equipment file. For corrective maintenance actions,
the record will include labor hours, spare parts and purchased
services, a cost for each item and for the total, the reasons for
the breakdown, and suggestions for preventing similar breakdowns.
The Technician is expected to understand and summarize the inputs
from engineers and mechanics.
3. To maintain and update a file on equipment data, which will include
type, model number, serial number, size, capacity, spare parts
numbers, etc.
4. To prepare, on a weekly basis, the working copies of the MPSs
(for planned PM actions) from a schedule and from a master file
of sheets.
5. To retrieve and summarize data on equipment history, equipment
condition, maintenance history, maintenance costs, and manpower
requirements for the use of plant management. The Technician
should be capable of providing meaningful summaries to relieve
management of the burden of examining large quantities of data
items.
6. To identify and implement improvements to the maintenance system.
Skills of Field Personnel
Three categories of labor are involved under the PMMS:
Skill 1—Electrician
Skill 2 —Mechanic
Skill 3-Utility Man
Appendix I contains detailed job descriptions -for these three labor categories.
40
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In very small plants, a single individual generally performs all main-
tenance (possibly in addition to plant operations), so that this individual
should have overall capability. Conversely, there is some trend today
even in large plants to train maintenance personnel to perform both elec-
trical and mechanical tasks, so that when a unit is taken out of service
it may be completely attended to by a single man. This philosophy also
aids in diagnosing malfunctions, where the precise cause of trouble is
not readily apparent. This PMMS was developed to differentiate between
skills; however, it is useful whether or not a wastewater treatment
plant differentiates between skills.
For some plants, a separate instrumentation mechanic may be on the staff.
To be most widely useful, this model PMMS did not assume that a separate
skill existed for maintaining measurement devices and meters and recorders,
but assigned these tasks as appropriate to either Skill 1 or Skill 2. In actual
practice at the Lower Potomac Plant of Fairfax County, an Instrumentation
Technician was added to the staff midway through the demonstration phase
of the program. The PMMS was readily adaptable to this change without
formally changing the PMMS paperwork. When the week's PM tasks were
given to the maintenance foreman, he easily identified those appropriate
to the Instrumentation Technician.
The Skill 3 category is labeled "Utility Man, " and it indicates a lower
level of experience than either Skill 1 or Skill 2. This distinction is
extremely important in conserving the skilled manpower available for
those tasks requiring the higher experience. Table A-3, the PM man-
power requirement for the Lower Potomac Plant, shows that well over
50 percent of the total PM manhours is in the Skill 3 category, the cate-
gory where personnel should be more available and of lower cost.
Consistent with the philosophy of this program to make the model PMMS
most useful on a nationwide basis, no attempt was made to further break
down Skill 3 into sub-skills perculiar to any plant or organization.
In actual practice at the Lower Potomac Plant, the bulk of the Skill 3
work has been accomplished by mechanics' helpers within the Maintenance
Department. Several exceptions were made, with Operations personnel
performing time-consuming tasks such as cleaning the sludge belt con-
veyors (prior to Skill 2 inspection and lubrication) and draining and cleaning
primary settling tanks, secondary aeration tanks and chlorination contact
chambers (prior to Skill 2 inspection).
Many of the Skill 3 tasks consist of routine repetitive PM actions requiring
a minimum of judgement or special skills. At the option of the plant
utilizing the PMMS, much of the Skill 3 workload may be accomplished
41
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by plant operators, rather than by assigned personnel from the Maintenance
Department. There are two sides to this question. In favor of such a
division is the potentially significant cost and manpower savings, since
Skill 3 tasks comprise well over 50 percent of the overall work load.
Against such a division are:
1. A division is made in pride and responsibility; i. e. , in the sense
of "ownership" of equipment by regular maintenance mechanics
which was evident at Lower Potomac.
2. An important feature of the routine repetitive PM actions is that
maintenance personnel get around the plant on a regular daily basis
and are therefore quick to spot any signs of impending trouble.
Conversely, a shift operator may not be trained well enough to
either notice the abnormality or to assign proper significance
to it.
Judging by the tangible positive results at the Lower Potomac Plant, it is
recommended that the Maintenance Department perform as much of the
PMMS as is feasible within the very real constraints of the personnel
available and the budget.
Cross Reference With Design Engineer's Code
When an existing, operating plant such as the Lower Potomac Plant installs
a PMMS, the PMMS must take into account that the design engineer's
equipment names and codes have become commonly used means for iden-
tifying equipment. The introduction of a new nomenclature via the PMMS
does not change the commonly used nomenclature overnight. Hence, the
PMMS must be structured so that the common names of equipment are
retained in the lists, procedures, schedules, etc.
To correlate this dual nomenclature, a concise cross-reference list was
prepared. Table A-4, for the Lower Potomac Plant, includes the design
engineer's code for pumps, measurement transmitters and measurement
receivers. Additional pumps in Area K are also included in Table A-4
for completeness.
Cross References for Remote Electrical Controls and
Remote Alarm Indicators
In addition to measurement receivers (meters and recorders), which
were covered in the previous section, there are two other instances where
an equipment item may be quite remote from its functionally operating
unit. One instance is the remote electrical controls. Table A-5 lists
42
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the MPS numbers corresponding to the operating functional unit IP number,
cross referenced to one or more remote controllers. Table A-6 cross
references alarm operating functional numbers to one or more remote
alarm indicators.
These cross-reference lists are to be used, of course, with the basic
Equipment Configuration List, which provides data and location for each
equipment item.
These cross references have been incorporated into the appropriate
Maintenance Procedure Sheets. The remote electrical controllers are
scheduled to be serviced at the same time as the PM on the process unit,
while it is out of service. Observers are stationed at alarm indicators
while malfunctions or abnormal conditions are simulated at the operating
locations.
Insulation Resistance of Electric Motors
Since the insulation resistance of electric motors is very highly tempera-
ture dependent, a means for standardizing measured values is needed.
There are two reasons why these insulation resistance measurements
must be made when the motor is at ambient temperature: first, to avoid
any appreciable temperature gradients, either spatial or temporal; and
second, there is generally only the capability of measuring a constant
ambient temperature. Once the insulation resistance at a measured
ambient temperature is known, Figure 12 may be used to correct this
value to a standard 70 deg F value.
Repainting of Plant Equipment
The PMMS includes a detailed MPS for repainting plant equipment and
piping. No formal schedule or manhour estimate is associated with this
MPS since requirements depend largely upon location, service, climate,
etc. ; and since the need for repainting is readily apparent.
Preventive Maintenance for Incineration
The sludge incineration and auxiliary process equipment require special
attention in scheduling and performing preventive and corrective
maintenance. The plant design provided redundant incinerator systems.
Each incinerator system and its related equipment must be operated as
a unit except for the induced draft fans which can be temporarily bypassed.
Table A-7 is a list of the sensitive equipment requiring special attention
in the maintenance management system. Two categories of special pre-
ventive" maintenance have been identified:
43
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o
o
r-
O
n)
a
o
o
u
0)
V
Pf{
INSULATION RESISTANCE CORRECTION-multiply measured
resistance correction factor
Minimum corrected resistance:
Class A insulation, 40 megohms
Class B insulation, 6 megohms
8
6
4
3
2
1
0.8
0.6
0.4
0.3
0.2
0. 1
0. 08
0.06
0.04
0.03
0.02
0.02
0 10 20 30 40 50 60 70 80 90 100 110 120
Ambient Temperature, °F-
Figure 12. Corrections to Measured Insulation Resistance
44
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1. Category A—The MP is to be performed without shutting down
the equipment.
2. Category B—The MP is to be performed with the equipment taken
out of service, but it must be scheduled to coincide with a shut-
down of the entire incinerator by coordination between Maintenance
and Operations.
Corrective maintenance may or may not require complete shut down of
the affected incinerator and the auxiliary equipment. A judgement must
be made by the Maintenance Department and coordinated with Operations.
In addition, should one unit not be in service for an extended period, the
unit and its auxiliary equipment should be exercised under full Maintenance/
Operations coordination.
Table A-8 is a list of the MPSs in Category A, and Table A-9 is a list of
the MPSs in Category B. Table A-9 should be used as a checklist to ensure
that all scheduled MPSs are accomplished when the incinerator is shut
down.
On each of the MPSs corresponding to Table A-8, there is a notation that,
"This procedure is to be performed without shutting down the equipment. "
On the MPSs corresponding to Table A-9, the notation reads, "This
procedure is to be performed only when the entire incinerator has been
shut down. "
45
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SECTION VI
PROGRAM INSTALLATION AND DEMONSTRATION
INITIATION OF CYCLE SCHEDULING
The Planned Maintenance Management System (PMMS) has been in effect
at Fairfax County's Lower Potomac Plant since May 25, 1972. The system
was installed gradually to enable the maintenance personnel to become
familiar with the work requirements and with the format of the main-
tenance procedures, work orders and other forms without the full burden
of the work load of the entire system.
There are two options for gradually installing the system. At the Lower
Potomac Plant, the daily procedures and the weekly procedures were
started first. These maintenance actions are an effective vehicle for
familiarizing the personnel with the system simply because they are
frequently repeated. The other option is to start the full system in only
one area or building of the plant, adding additional areas later on. This
second option may be appropriate for a very large wastewater system.
ACCEPTANCE BY THE MECHANICS
Great care was taken at Lower Potomac to effectively introduce the waste-
water treatment plant mechanics to a formal PMMS. The success of a
PMMS depends primarily upon the cooperation and acceptance by the
personnel. The PMMS was presented as a vehicle for the mechanics to
more effectively perform their jobs and to have their observations and
recommendations recognized and followed. If the PMMS is viewed by the
mechanics with hostility as another time-motion study or as a paper-
work burden, then the PMMS will be doomed.
The Plant's Maintenance Engineer and Maintenance Foreman conducted
an initial introductory meeting with the mechanics to explain the program's
purpose and how it works. During the initial effort, the mechanics were
frequently interviewed while on the job to ask their opinions and recom-
mendations for improving the PMMS. This yielded valuable comments
which were incorporated into the system, and it helped convince the
mechanics that the PMMS was their program.
46
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The initial acceptance and workability of the PMMS was so complete that
the full preventive maintenance cycle schedule, including monthly, quarterly,
semiannual and annual actions, in addition to the initial daily and weekly
actions, was adopted by the maintenance personnel at Lower Potomac on
June 5, 1972, only seven full working days after the original inception of
the partial PMMS.
During the first four weeks of operation of the system, the following obser-
vations were made:
1. The system was enthusiastically accepted by the mechanics right
from the start.
2. The personnel needed little convincing that preventive maintenance
was a worthwhile endeavor. Since a prime objective of the system
is to make preventive maintenance possible, feasible and effective;
the system was by definition a worthwhile endeavor.
3. The Lower Potomac mechanics did indeed use the system as a
vehicle for passing on their observations and recommendations.
4. The mechanics found little difficulty is using and following the
Maintenance Procedure Sheets (MPSs). These step-by-step
procedures appeared to be near the optimum level of detail—they
were written so that the tasks could be effectively and properly
performed, yet did not burden or insult the mechanics by including
too much instruction.
COORDINATION OF PREVENTIVE MAINTENANCE
WITH OPERATIONS
The PM Program at Lower Potomac was conducted entirely by the Main-
tenance Department. There was an early coordination problem which
eventually was ironed out —some scheduled PM could not be accomplished
because the units could not be removed from service by Operations, and
some PM procedures had to be modified so that a limited amount of main-
tenance could be accomplished while a unit was running. A particular
case concerned the vacuum filters. Once a good cake has been built up,
the filters should not be shut down arbitrarily for PM. Since only one
of the two filters is normally in operation, the solution was for Operations
to alternate units in cooperation with the Maintenance Department.
Some procedures were divided so that Operations and Maintenance can
each have separately defined tasks. An example is the maintenance on
conveyors in K Building. Operations was made responsible for cleaning,
and Maintenance for the inspection and lubrication.
47
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It was possible in some cases for units to be taken out of service for PM
with the cooperation of Operations. In other cases, Operations was unable
to comply. An example of the latter is the incinerators in K Building,
where daily PM must be performed without shutting down the rotating
mechanism.
Another problem area identified was that, although the formal PM Program
was being conducted entirely by the Maintenance Department, Operations
had been performing informal PM on the same equipment. Operators
had been lubricating machinery and adding oil without the benefit of a
planned schedule and without the benefit of the detailed procedures (which
specify the recommended lubricant). Instances of gross over-greasing
and of using the wrong grade of oil were confirmed by the Maintenance
personnel. Just as Maintenance must consult with Operations before
removing a unit from service for PM, Operations must consult with
Maintenance before servicing equipment.
EARLY RESULTS
Observations that were made on the workability and the effectiveness of
the program during the first four weeks are presented in the following
paragraphs.
The first few weeks of the program demonstration uncovered a problem
in work assignments, due to a misunderstanding. The weekly PM schedule
was intentionally constructed so that as many tasks as possible on the
same unit are accomplished in the same week to minimize the number of
times a unit must be removed from service. However, the individual
PM tasks on the same unit were not grouped for assignment. The result
was that different mechanics were working on the same piece of equipment
at different times during the week. This was not only a waste of time,
resulting in the mechanics getting in each other's way, but was directly
contrary to the intent of the schedule. To resolve this problem, the PM
actions for each week were grouped by unit (easily accomplished with the
equipment numbering system, as described on Page 15), and assigned as
a package to a single mechanic.
Several of the original labor estimates were quickly reduced. For example,
the weekly tasks on the sludge plunger pumps in J and K Buildings originally
called for 36 minutes per pump, which included running the pump for a
while to inspect for packing leaks and to adjust the sight feed oiler. Since
there are four pumps in J Building and three in K Building, significant
time is saved by letting one pump run for observation while accomplishing
work on the adjacent unit.
48
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Similarly, needed revisions to the original PM schedule were quickly
implemented. An example is the weekly tasks on the bar screens, calling
for lubrication and inspection of the rake assembly and chain. Since
Operations only uses one of the two bar screens at a time and rotates
between the two on a weekly basis, there was obviously no need to per-
form weekly PM on both bar screens. Another suggestion on the bar
screens was that lubrication should be daily instead of weekly, based
on experience and also that bearing designs are such that overlubrication
cannot be harmful.
The value of the Planned Maintenance Management System to the Lower
Potomac Plant was quickly proven within less than four weeks of
demonstration; numerous potential trouble spots were uncovered and
corrected, thus preventing equipment breakdowns and the resulting "fire
drills" in the future. The following list is a sampling of mechanics'
comments:
1. Incinerators, K Building. Buckets on chain drive in poor condition,
two new shear pins added. No. 2 shear pin had no snap ring.
2. Sludge pumps, J Building. Found wrong oil in oil cups. No. 4
needs new belt. Order balls and seats. No. 3 needs repacking.
3. Air filter, E Building. Filter status indicator has reversed and
erratic readings—request manufacturer repair man to correct.
4. Vacuum filters, K Building. The varidrives for No. 1 drum and
for the No. 1 agitator are noisy at high speeds. Repair kits are
needed. No. 2 filter needs a drum seal. Both filters had too much
oil and grease. Both vacuum lines to filters are out of alignment.
No. 2 vacuum gauge line was plugged with dirt.
5. Hydraulic power unit, K Building. A 2, 000 psi gauge is needed.
6. Ferric pumps, K Building. No. 1 needs new link pins; No. 3 has
a broken rod and needs two new link pins. Need new studs on all
three pumps.
7. Raw wastewater pump controllers, B Building. Changed contacts,
A-4, and tightened a loose ground connection.
8. Sludge screw feeders, K Building. Both drives were empty, had
to fill with oil.
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The value of the system is aptly demonstrated by this list of early field
results. The skill and motivation of the mechanics at Lower Potomac
were basically responsible for discovering and correcting potentially
disastrous equipment deterioration. The formal program of PM is the
vehicle by which the mechanics can find the trouble spots, can express
and record their observations and recommendations, and can undertake
corrective maintenance where needed. With the formal program, all
equipment needs are attended to on a timely basis.
LONG-TERM EXPERIENCE
During June 1972, the flooding caused by Hurricane Agnes demanded a
great deal of corrective maintenance at the Lower Potomac Plant. Because
of the extraordinary CM workload, the scheduled PM program was sus-
pended for approximately two weeks. As soon as the critical repairs were
accomplished, however, the PM program was back in full operation.
During the entire year of operation, the preventive maintenance program
for the entire plant proceeded smoothly. The enthusiasm of the mechanics
for the program was consistent, and did not wane appreciably after the
initial installation of the program. Conversely, the mechanics became
fully familiar with their duties, the cycle schedule, procedures and
recording system, so that the PM program was conducted with increasingly
higher efficiency.
A pickup truck was designated for the plant's preventive maintenance,
with all of the tools and lubricants readily available. This action signi-
ficantly reduced the dead time between PM actions.
Each equipment unit was prominently labeled with large reflective red
stick-on numerals on a painted black background, easily seen even at
night. This action eliminated any chance of ambiguity over which of the
parallel units was to be serviced.
Attention was brought to the necessity for alternate cycling of parallel
units when all units are not required to run continuously. A schedule
was set up by Operations to ensure that no unit remains idle for great
lengths of time while other units run extensively. Running-time meters
were installed to aid in this objective.
After the system had been in operation for about six months, a lengthy
walking inspection of the plant revealed many significant accomplishments.
Some improvements were very readily apparent, such as the appearance
of the ash conditioner and the sludge conveyors in K Building, the running-
time meters to promote equal use of parallel equipment, and the general
50
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cleanliness of the plant. The visible effects were, however, just the tip
of the iceberg; the improved mechanical condition of the equipment is the
major goal of this program. Six months previously, there was an almost
continuous occurrence of equipment breakdowns which completely occupied
the time and attention of the mechanics in a series of "fire drills" to avoid
disaster. Now, the mechanics have the additional time to systematically
improve the plant through modifications and additions to the original
equipment.
Since this program was initiated, there has been a steady trend towards
reduction of the malfunction reports on mechanical equipment because of
the systematic action of the preventive maintenance program. Incipient
failures are being detected in many cases and prompt corrective action
is accomplished. This has brought mechanical troubles caused by the
lack of preventive maintenance to its lowest point since the start up of
the plant.
Several recommendations were made to the County to maintain the effec-
tiveness of the system over the long haul. The importance of keeping
preventive maintenance actions going continuously should be emphasized
even when the plant is in apparently good mechanical condition. Of special
importance are the daily procedures, which have the beneficial effect of
a daily inspection of virtually the entire plant by mechanics trained to
spot any impending problems. Non-urgent CM and less frequent PM tasks
may be delayed if necessary; daily PM tasks cannot be delayed and should
not be bypassed. Periodic meetings should be held with the mechanics to
reinforce morale for the PM system which may suffer from the repetitive
nature of the work. Management should ensure that the mechanics'
suggestions are being considered and incorporated into the system.
The mechanics should feel that the system is flexible enough to be
improved and that it is their vehicle for instituting needed changes.
MAINTENANCE MANPOWER REQUIREMENTS
Each preventive maintenance task is accompanied by a nominal manpower
requirement of a certain skill. These skill and manhour requirements
for the individual MPs are used to generate the total annual manpower
requirements for the plant by skill level. Table A-3 is a list of manpower
required for PM at the Lower Potomac Plant, organized by major systems
in the plant.
Early experience has indicated that a man-day is limited to approximately
6. 5 manhours of "hands-on" time, not counting the time required to gather
tools and materials or get to and from the equipment. Hence, a man-year
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contains approximately 1,625 manhours. The total annual PM require-
ment at the Lower Potomac Plant of 7, 934 manhours is therefore equivalent
to 4. 9 full-time maintenance personnel.
An analysis was made of the preventive maintenance data gathered during
the year-long demonstration phase of the Lower Potomac Program. Each
PM action has been recorded, with an entry of the time consumed. Table A-10
lists some representative PM actions, with a comparison between the
originally estimated time and the range of actual times.
Both types of times shown in Table A-10 are "hands-on" times for actual
maintenance work. On the average for the Lower Potomac Plant, a man-
day consists of approximately six to six and a half hours of hands-on time.
However, this Plant is relatively compact, and the time consumed in getting
to and from the operating units is small.
The first observation made from the actual times in Table A-10 is that
there is a great variability for any PM action. A statistical analysis has
shown that the span of times containing 90 percent of the entries for a
given PM action is approximately twice the value of the mean time—in
other words, any entry can reasonably be plus or minus 100 percent of
an "average" time (the distribution is obviously skewed since no entry
can be less than zero).
From a practical standpoint, it is well understood in the maintenance field
that a great variation in performance time is to be expected. The job is
always a little different, depending upon in what condition the mechanic
finds the equipment. Maintenance is not a production line, where each
task is well defined and may be quantified more easily. Many other factors
enter into the recorded time for a particular maintenance action that add
to the variability. More or less experienced personnel will consume dif-
ferent amounts of time. The recorded time is only an estimate of the actual
time, since no effort was made to require the mechanic to precisely measure
elapsed time. The times are usually documented in even increments, i. e. ,
20 or 30 minutes rather than 23 or 27 minutes. No attempt has been made,
nor is any suggested, to ask the mechanics to account for all of the eight
hours in a shift; this alone introduces a level of expected inconsistency in
the data records.
The comparison in Table A-10 shows that for the most part, the original
estimates are as valid as any other estimate in light of the great variability
of the actual data. If anything, the original estimates were somewhat more
conservative (higher) than some actual "averages." No justification was
seen, therefore, to revise the original estimates of nominal time. The
strong recommendation is made, however, to treat these times and all
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manpower requirement conclusions derived from these times, with
temperance commensurate with the observed variability in the actual
data.
The preventive maintenance manpower requirement must, of course,
be augmented by the manpower requirements for corrective maintenance
and for equipment modifications or additions. The PMMS provides the
necessary methods and records for documenting and analyzing the man-
power and cost data for corrective maintenance and equipment modifications.
However, any prediction of these requirements was beyond the scope of
this program. The manpower requirements for corrective maintenance
and equipment modifications depend to a great extent upon the age and
condition of the equipment, the type of processes and equipment employed,
and the adequacy of the plant's hydraulic capacity and treatment efficiency.
It is, of course, the objective of the PMMS to significantly increase the
plants reliability by reducing the requirements for corrective maintenance,
and this has been demonstrated at the Lower Potomac Plant.
The actual manhours expended by skill level for both PM and CM are
summarized by the PMMS and can be compared to the original estimates.
The estimates can be modified to become more realistic so that the
schedule can be revised. Conversely, the maintenance tasks that con-
sume large amounts of labor can be examined to see if improvements in
the procedure can safely conserve labor. These data are directly useful
to plant management in planning and justifying the size of the labor force.
MAINTENANCE COSTS, SPARE PARTS INVENTORY
AND EQUIPMENT CONDITION
The recordkeeping and feedback features of the PMMS provide for the
complete accounting of maintenance labor, material and contractor costs,
for management's use in cost control and budget preparation. The costs
can be reported by plant area, functional subsystem, types of equipment
and individual equipment items, so that cost control measures can be
directed in a rational manner. In addition to current costs, management
can retrieve historical data for any desired period of time.
The PMMS provides the basis for a spare parts inventory control system
in three ways:
1. An integral part of the Equipment Configuration List is a listing
of spare parts for each item of equipment, with the emphasis on
parts likely to be replaced, such as bearings, drive belts, filter
elements, etc.
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2. The Equipment Configuration List may be organized according to
the equipment type code, which immediately offers data on com-
monality of parts, regardless of the function or the location of the
operating unit within the plant.
3. The corrective maintenance work record, an integral part of the
recording system, provides a current tally on parts usage.
The recordkeeping and data feedback features of the PMS are also useful
in evaluating equipment condition. The complete maintenance history of
each item of equipment is in a single place in the file, readily accessible
for analysis in the event of a breakdown or preferably before a breakdown
occurs. This historical data record will prove invaluable in analyzing
how well the equipment is performing its function and when a major over-
haul or replacement, if indicated, should be made. Conversely, the
historical record may indicate that the mode of operation needs to be
changed. In addition, an analysis of the historical data record will permit
the preventive maintenance frequency to be adjusted, making more frequent
PM actions for equipment which deteriorates or goes out of adjustment
rapidly, thus preventing breakdowns; and making less frequent PM actions
for equipment which shows little deterioration, saving PM costs.
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SECTION VII
APPLICATION TO OTHER WASTEWATER
TREATMENT PLANTS
FLEXIBILITY AND EXPANDABILITY OF THE PMMS
One of the primary objectives of the effort described in this report was
that the PMMS be directly applicable on a nationwide basis to all types
of wastewater systems, including both treatment plants and collection
systems.
The equipment ID numbering system is designed to be expandable both
vertically, for more complex plants with more systems, subsystems
and functions, such as AWT; and horizontally, for larger plants with
more parallel items of equipment, or for plant expansion. Additional
digits can'be added preceding the first five digits to specify to which of
several locations or plants the equipment belongs. The other elements
of the system, such as the Equipment Configuration List, the Maintenance
Procedures, the PM Cycle Schedule, the Recordkeeping System, and the
Data Feedback System, are general and are not constrained by either
the size of the plant or the type of treatment.
The key to the flexibility and adaptability of the Planned Maintenance
Management System is that it is at a level of detail to accomplish one
task at a time on a particular item of equipment by a single maintenance
crew. Any wastewater operation is made up of such individual main-
tenance tasks; hence, any wastewater operation may utilize the PMMS.
TAILORING TO PLANT REQUIREMENTS
The geographical distribution of facilities and personnel is an important
consideration for each application of the PMMS. The Fairfax County
Lower Potomac Plant is a rather compact operation, with all of the
maintenance personnel and shops based at the plant. One centralized
recordkeeping center at the plant serves both purposes: to have the
necessary information readily accessible to the mechanics on the job;
and to enable centralized overview, control, reporting and analysis.
55
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More widespread systems may require a different approach. Examples
of other systems are:
1. More than one treatment plant in the same municipal organization,
with maintenance personnel based at one or several locations.
2, A widespread sewage collection system, including pumping stations,
in which travel time of maintenance personnel is an appreciable
factor.
3. A very large treatment plant with separate maintenance groups
for various parts of the plant.
For these situations, a dual recordkeeping system would likely be called
for to accomplish both local accessibility to the mechanics and centralized
control, analysis and reporting. This dual system could be implemented
with the use of copying machines and simple filing aids.
TAILORING TO EXISTING METHODS AND PERSONNEL
The PMMS should take every advantage of the existing knowledge,
.experience and modes of operation. Instead of arbitrarily creating a
PMMS in a vacuum, the program should incorporate all of the valuable
background that the personnel have to offer. It is recognized that sys-
tems with varying degrees of formality may have been built up over the
years, and the PMMS should take full advantage of these systems. This
approach includes, of course, the existing forms, filing methods, scheduling
methods and recordkeeping methods of management; but it emphasizes
the practical know-how of maintenance mechanics and foremen. For long-
existing operations, equipment maintenance characteristics may have
been documented, including subtle differences between nominally identical
units. This type of data is 'priceless, and must certainly become an
important part of the PMMS.
Large wastewater operations which may have been built up piecemeal
over the years may show a diversity of maintenance organizations and
systems. Some portions of the organization may have been run over
the years by maintenance teams which have independently developed
procedures, schedules, filing systems and records for their areas of
responsibility. The system used by one team may be significantly dif-
ferent from the systems of other teams. Some systems may be more
formal and detailed than others. Some may be so unique that they are
almost totally dependent upon the individual who originated them.
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In creating a PMMS for such a system, the largest challenge will be to
balance the desire for a unified system covering all aspects of the opera-
tion with the alternate desire of preserving and strengthening those
effective maintenance systems which have evolved over the years. The
former desire is based upon the advantages of commonality of parts,
procedures, forms and personnel; with the overriding advantage that
good maintenance techniques are used by all of the personnel on all of
the equipment. The latter desire may be based upon the pride and effec-
tiveness in portions of the operation.
The intention should be to satisfy both desires whenever feasible, instead
of making changes just for the sake of change. Something very simple
like a numbering order for parallel units should be retained'rather than
revised (unless there is a fundamental ambiguity or error). In every
way possible, any transition that people will have to make to a unified
PMMS should be eased.
From a technical viewpoint, the maintenance engineering staff will form
the backbone of the maintenance requirements and procedures in the
PMMS. Technical judgements should be made objectively, with the full
benefit of all available knowledge, and should not presume to eliminate
or supercede arbitrarily the contributions of the personnel already
within the system.
In essence, then, the approach toward creating a PMMS should be to
delicately preserve the best of what exists, and incorporate these best
parts into the entire PMMS, utilizing the technical capabilities and the
experience of the plant's personnel, and adding or innovating where
required.
AUTOMATION OF DATA HANDLING
The PMMS in operation at Fairfax County's Lower Potomac Plant is a
manual system. A full-time Maintenance Technician is employed at this
18-mgd plant for the express purpose of relieving all of the paperwork
burden from both the mechanics and the plant management.
For a much larger plant, some level of automation of the data handling
task would be anticipated. From the very start, the manual system was
developed with the requirement that it be directly amenable to compu-
terization. The following items of a manual system are directly useful,
without change, to an automated system.
1. Equipment Configuration List. All items of equipment have a five-
digit identification number which permits all similar parallel units
of equipment to be grouped by the first four digits; and permits all
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equipment items which operate together as a unit to be grouped
by the first, second, third and fifth digits.
Z. Equipment Data List. The two-digit numbering system specifying
types of equipment, regardless of function. This is useful for
grouping equipment with similar maintenance requirements and
with similar spare parts requirements.
3. Preventive Maintenance Cycle Schedule. The Maintenance Pro-
cedure numbering system includes a specification of frequency
and the scheduled week numbers, which is directly useful for
computerization.
4. Maintenance Personnel. The numbered Skill Code, with job
descriptions for each skill level, is directly useful in a compu-
terized system. A manual system can identify each mechanic
by his initials, but a computerized system would simply use an
employee number instead.
5. Indication of Trouble. The numbered coding system, which
describes observations by mechanics or operators, is directly
useful in a computerized system.
6. Reasons for Breakdowns. The numbered coding system is directly
useful in a computerized system.
7. Work Order, PM Work Records, CM Work Records, Reports of
Trouble, and Equipment Malfunction Reports. All forms used by
plant personnel should utilize checklists wherever possible. These
forms can be used for machine coding.
The computerized system should be identical to the manual system from
the viewpoint of the mechanics. They would use the same maintenance
procedures, perform work under the same preventive maintenance
schedules, use the same forms for recording their observations and PM
actions and for initiating corrective maintenance, and use the same forms
for recording corrective maintenance actions. The computerized system
should be designed so that the maintenance mechanics would not be at all
affected by any computer-related requirements.
In addition to full computerization using electronic data processing
equipment, the Planned Maintenance Management System -could also
utilize less sophisticated (and less expensive) machines for portions of
the system, or for auxiliary use in remote locations in the event that dual
records must be maintained.
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CREATION OF A BASIC DATA BASE
As is readily apparent from the description of the PMMS, the day-to-day
operation of the PMMS is dependent upon a detailed Equipment Configura-
tion List, a set of Maintenance Procedures and a Preventive Maintenance
Cycle Schedule. These items may be called the basic data base for the
PMMS.
A wastewater treatment plant, system or organization wishing to apply
this PMMS must create, on a one-time basis, this basic data base.
There is no substitute for the detail, since the success of the PMMS
operation is due to the specific maintenance attention given each and
every item of equipment in the plant.
The creation of this data base may be relatively straightforward, as in
the case of a plant under construction where every item of equipment
will have designer's specifications and the actual purchase orders
available, and where the equipment manufacturer's drawings and instruc-
tion bulletins are available immediately upon receipt of the equipment.
In the case of an older, operating plant, the creation of a data base is
also relatively straightforward if a good filing system of equipment
drawings and bulletins has been conscientiously maintained and if later
equipment replacements or changes have been documented. Moreover;
an older plant may have accumulated actual equipment maintenance data
and specific observations and comments; both of which are extremely
valuable.
In every case, regardless of the condition of the equipment paperwork,
an actual item-by-item check against the equipment nameplates must be
performed. In older plants, this may require removing layers of paint
from nameplates. The equipment that is actually installed in the plant
and as modified must be known and verified.
This one-time effort of creating the basic data base for the PMMS must
be the primary assignment of either a staff maintenance engineer, or
an outside maintenance management firm experienced in wastewater
systems. It is very strongly recommended that this effort not be attempted
by regular staff members who have continuing day-to-day responsibilities;
the creation of a basic data base is a full-time effort. Once this is
accomplished, the system is easily updated and operated by plant personnel.
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SECTION vm
REFERENCES
1. Federal Guidelines, Design, Operation and Maintenance of Waste Water
Treatment Facilities. U. S. Department of the Interior, Federal Water
Pollution Control Administration. U. S. Government Printing Office,
Washington, D. C. Report No. O-406-409. Sept. 1970. 44 p.
2. Maintenance and Material Management (3-M) Manual, OPNAV 43P2.
Department of the Navy. U. S. Government Printing Office, Washington,
D. C. Report No. O-402-770. 1970.
3. PACAF Supplement 1, Maintenance Management Manual. U.S. Air
Force. U. S. Government Printing Office, Washington, D. C. Report
No. AFM 66-1.
4. Vida, R. S. Modernizing Maintenance Techniques. Plant Engineering.
September 17, 1970.
5. Kittner, E. H. Planning and Scheduling of Maintenance in a Small
Plant. Plant Engineering. March 5, 1970.
6. Baronet, R. P. To Meet Today's Maintenance Needs—Formal Scheduling
a Must. Plant Engineering. January 21, 1971.
7. Carson, B., and J. E. Mailhos. Plan Carefully for a Sound Maintenance
Budget. Plant Engineering. March 7, 1968.
8. Fuchs, S. J. Planning Guidelines for a Small Plant Work Order System.
Plant Engineering. December 24, 1970.
9. Sullivan, J. A. Contractor's View of Contract Maintenance. (Presented
at AICHE 63rd Annual Meeting. Chicago. November 29-December 3,
1970. Paper No. 96.)
10. Sarappo, J. W. Contract Maintenance: It's Place in Chemical Plants.
Chem Eng. 7i6(25;264), November 17, 1969.
11. Antropov, M. V., and A. A. Zuev. System of Optimum Scheduling of
Repairs for Basic Equipment of Chemical Factories. Chem & Pet
Eng N. 11-12:928-31, November-December 1968.
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12. Buttery, L. M. Maintenance Planning System Designed for Process
Plants. Oil fc Gas J. Ł6(17): 190-3, April 22, 1968.
13. James, E. Successful Maintenance Reorganization. Hydrocarbon
Processing. 46(3): 191-4, March 1967.
14. Hooper, C. F. Maintenance of Chemical Plants. Chem & Process
Eng. _46(2):6l-8, February 1965.
15. Edmonson, C.H., F.P. Flesca, and J. A. Sullivan. Cost and Control
of Maintenance. Chem Eng Progress. 62(5):33-8, May 1966.
16. Dodds, R. L. Streamlining Maintenance Paperwork. Chem Eng.
70J19):200, September 16, 1963.
17. Michel, R. L., A. L. Pelmoter, and R. C. Palange. Operation and
Maintenance of Municipal Waste Water Treatment Facilities. JWPCF.
4l(3)Pa.xt 1:335-354, March 1969.
18. Michel, R. L. Costs and Manpower for Municipal Wastewater Treat-
ment Plant Operation and Maintenance, 1965-1968. JWPCF.
42(11):1883-1910, November 1970.
19. Garber, W. F. Treatment Plant Equipment and Facilities Maintenance.
JWPCF. 42(10): 1740-1770, October 1970.
20. Smith, R. Cost of Conventional and Advanced Treatment of Wastewater.
JWPCF. 40:1546, 1968.
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SECTION IX
GLOSSARY
CM Corrective Maintenance
MP Maintenance Procedure
MPS Maintenance Procedure Sheet
PM Preventative Maintenance
PMMS Planned Maintenance Management System
62
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SECTION X
APPENDICES
Table of Contents
Appendix Page
I Job Descriptions for Maintenance Personnel .... 64
II Figures A-l through A-18, Examples of
Maintenance Procedure Sheets 67
III Table A-l through A-10 95
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APPENDIX I
JOB DESCRIPTIONS FOR MAINTENANCE PERSONNEL
SKILL I. ELECTRICIAN
Inspects, repairs and maintains electrical and/or electronic operating
and control systems, equipment, fixtures and instruments; including
wiring and lighting systems, electrical control equipment, meters,
outlets and panels. Uses standard and special electrical tools and equip-
ment, such as voltmeters, ammeters, ohmmeters, meggers and synch-
roscopes. Interprets oral and written instruction, specifications, pro-
cedures, wiring diagrams, schedules and codes. Exercises independent
judgement in solving normal work problems under general supervision;
and is able to recognize abnormally functioning electrical equipment and
to describe, both orally and in written form, the indications of trouble
to his supervisor.
Performs ordinary arithmetical procedures involving fractions, decimals
and percentages. Has thorough knowledge of electrical systems, equip-
ment and fixtures; and of approved methods, practices, code requirements
and safety standards.
A list of maintenance procedures assigned to Skill 1 is:
Test insulation resistance-of motor
Clean motor
Clean and inspect controller
Clean and inspect remote control switch
Clean ionizer and inspect ionizer wires.
SKILL 2. MECHANIC
Performs preventive maintenance, inspections and repairs on mechanical
and electromechanical machinery and equipment. Lubricates equipment
and checks for malfunctions. Replaces packing in pumps or valves.
Replaces bearings in motors, pumps and other equipment. Adjusts and
cleans equipment, cleans out pipes and performs other plumbing and
pipefitting tasks as required. Uses standard and special mechanical
tools. Interprets oral and written instructions, technical manuals,
drawings, specifications, layouts, blueprints and schematics. - Exercises
64
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independent judgement in solving normal work problems under general
supervision; and is able to recognize abnormally functioning mechanical
equipment and to describe, both orally and in written form, the indica-
tions of trouble to his superior. Is capable of independently disassembling
and reassembling mechanical equipment and of replacing defective parts.
Performs ordinary arithmetical procedures involving fractions, decimals
and percentages. Has thorough knowledge of wastewater treatment
machinery and equipment.
A representative list of maintenance procedures assigned to Skill Z are:
• Inspect rake assembly and chain on bar screen
• Inspect counterweight shock absorbers on bar screen
• Clean, inspect and lubricate flexible coupling
• Change oil
• Inspect and lubricate conveyor
• Inspect drive belt tension
• Inspect packing gland adjustment
• .Renew packing
• Inspect oil level, check automatic start and stop, blow down
receivers on air compressor
• Clean and inspect pump
• Inspect aeration tank, clean and inspect swing diffusers
• Check oil condition and oil level
• Check oil and grease pinion bearing; clean and repack pinion
bearing
• Clean and inspect chlorinators
• Clean and inspect fan
• Inspect packing, adjust sight feed oiler, lubricate plunger packing
and crosshead on sludge plunger pump
• Clean vacuum filter subsystem, check tine bar and spring alignment,
inspect spray nozzles on vacuum filter
• Lubricate disk assembly, lubricate ball oiler, lubricate slide
shifting screw, adjust high and low speed stops on incinerator.
SKILL 3. UTILITY MAN
Assists maintenance mechanics and electricians in maintaining and re-
pairing equipment, under direct supervision of Skill 1 or Skill Z personnel.
Assists in removing, repairing and replacing equipment as directed.
Carries or holds materials, supplies or tools to assist mechanics or
electricians. Is familiar with standard safety procedures and precautions.
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Also, independently and without direct supervision performs routine
cleaning and lubrication, and checks oil levels where no equipment
disassembly, adjustment or significant element of judgement is involved.
Is able to understand and follow oral and written instructions. Is familiar
enough with plant equipment to locate grease fittings or oil fill and drain
ports, or to locate and read sight gauges. Is able to use a variety of
hand and power tools and equipment. Is capable of recognizing abnormal-
ly operating equipment and or making verbal and written notification
of abnormalities and indications of trouble to his supervisors.
Assists mechanics or electricians in performing some of the maintenance
procedures listed for Skill 1 and Skill 2. Skill 3 also performs the following
maintenance procedures by himself from written instructions.
• Lubricate motor
9 Check oil level
• Lubricate pump bearings
• Lubricate and exercise sluice and slide gates
• Inspect foundation bolt tightness
• Clean and inspect strainer
• Lubricate sludge collector
• Inspect oil for water
• Lubricate roller chain on sludge thickener
• Check sight feed oiler, lubricate pillow block bearings on
sludge plunger pump
• Lubricate conveyor and check chain oil level
• Lubricate trunion bearings, aligning roll and discharge roll
bearings, and chain on vacuum filter
• Lubricate master gear and pinion on incinerator
• Lubricate conveyor
• Clean and lubricate ash conditioner.
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APPENDIX II
FIGURES A-l THROUGH A-18,
Examples of Maintenance Procedure Sheets (MPSs)
67
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MAINTENANCE PROCEDURE SHEET
EQUIPMENT NAME
Chlorinator
Plant Area ,_
Level TJ
Page 1 of 3
Location
MPS No. 4131 Al
Average Time
S_l min.
S-2 480 min.
S-3 min.
MAINTENANCE DESCRIPTION
Clean and inspect chlorinator.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service*
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Safety tag
Soft rags
Adjustable wrench
Set of gaskets
Wood alcohol
Muriatic acid (dilute hydrochloric acid)
PROCEDURE ~~ '
Preliminary—1. Close the gas supply valve.
2. Continue to operate dispenser until the gas pressure gauge and
flow meter readings drop to zero, indicating that gas supply line
has been evacuated.
3. Close gas supply shut-off valve at dispenser.
4. Remove test plug from vacuum regulator stack, allowing air to be
pulled in. Operate the dispenser on air for a few minutes to purge
j^as from dispenser components.
5. Stop booster pump (is used) and close ejector water supply valve.
'6. Close valves in chemical solution line.
7. If dispenser uses automatic control(s), deactivate the control system(s^
8. Connect the test plug back on vacuum regulator.
9. Turn off power to electrical heater. De-energize circuit and tag
"out of service. "
NOTE 1: Use wood alcohol to remove any accumulated organic residues
from gas dispenser parts. The parts being cleaned may be
dipped in the wood alcohol or wiped with a cloth wetted with
the solvent, whichever is more convenient. Muriatic acid
(dilute hydrochloric acid) can be used to remove accumulated
mineral deposits from parts. Dip the part into the muriatic
acid, being careful that the acid does not come into contact
with the skin or clothing.
To clean vacuum regulating valve and gas filter:
1. Remove the gas filter block by disconnecting the gas line and the coupling
nut at bottom of vacuum regulator. Be careful to catch the spring, spring
retainer and valve plug at the regulator.
(Continued)
Figure A- 1
68
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MAINTENANCE PROCEDURE SHEET
Page 2 of 3 MPS No. 4131 Al
PROCEDURE (continued)
2. Clean the valve plug. Use a soft cloth and reach into the inlet fitting to
clean the seat. Inspect seat surfaces thoroughly for any scratches or
roughness. Replace if defective.
3. Unscrew the bottom nut, then remove the end plug.
NOTE 2: When removing or tightening the end nut, be sure to hold the gas filter
block steady with a wrench.
4. Clean gas filter.
5. Inspect "O" rings and replace if required.
6. On reassembly, be sure to replace all gaskets at gas filter block and gas
line connections. Tighten these connections with a wrench.
To clean and inspect flowmeter:
1. Remove metering tube assembly by grasping tube with both hands, the heel
of one hand pressing down on the lower adaptor while bringing the upper
adaptor forward with the other hand.
NOTE 3: Do not use excessive force on the tube itself.
2. Disassemble and clean all parts. Inspect all parts for wear or damage and
replace if necessary. Replace any "O" rings showing signs of brittleness,
cuts or abrasion.
3« Reassemble. Lubricate "O" rings sparingly.
4. Insert metering tube assembly into dispenser, holding the tube the same as
in the first step. Makr sure adaptor "O" rings are properly seated.
To clean and inspect flowrater valve:
1. Disconnect and remove piping from top of flowrater valve.
2. Remove orifice tube by pulling it straight up while holding adaptor place.
3, Remove orifice plug by pulling it straight up, being careful not to drop plug
or it may be damaged.
4. Pull out tube adaptor (if used) and remove "O" rings.
5. Clean orifice plug and adaptor. Inspect plug for roughness or damage.
Replace if necessary. Inspect "O" rings and replace if necessary.
6. On reassembly, lubricate "O" rings sparingly. Make sure "O" rings are
properly seated and orifice plug, tube and adaptor are "bottomed".
To clean vacuum stabilizing valve:
1. Disconnect vacuum line from upper valve body. Disconnect piping from
lower valve body.
2. Remove bolts and separate valve body halves, prying loose if necessary.
(Continued)
Figure A-l (Cont)
69
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MAINTENANCE PROCEDURE SHEET
Page 3 of 3 MPS No. 4131 Al
PROCEDURE (continued)
3. Remove diaphragm, spring, sleeve and valve plug from the body as one
assembly. Inspect diaphragm for cracks or weakness. Replace if
necessary.
4. Mark position of valve seat assembly in body. Unscrew valve seat
assembly by using a steel or plastic strip to fit the 3/16-inch slots.
5. Clean valve seat and plug. Inspect for roughness or damage. Replace
if necessary. Renew "O" rings if necessary.
6. On reassembly, screw the valve seat assembly to original position marked.
NOTE 4: Clearance between plug and seat must be 1/4-inch. A 1/4-inch drill should
just fit between plug and seat.
To clean vacuum relief valve:
1. Disconnect the tubing from vacuum relief valve.
2. Unscrew nuts at mounting bracket and remove valve from dispenser.
3. Unscrew coupling nut and separate the valve body halves. Pry loose, if
necessary, and remove spring.
4. Clean valve seat and plug. Inspect contacting surfaces for scratches, nicks
or roughness. Inspect diaphragm for cracks or weakness. Replace parts
if necessary.
5. Unscrew plug on upper valve body and remove dampening ball. Clean the
ball and inspect it for chips or cracks. Replace if necessary.
6. Reassemble vacuum relief valve.
To clean drain relief valve:
1. Remove piping from bottom of drain relief valve. Unscrew coupling nut at
the tee and remove valve.
2. Remove bolts from valve body. Separate the body halves, prying loose, if
necessary.
3. Clean valve seat and plug. Inspect contacting surfaces for scratches,
nicks or roughness. Inspect diaphragm for cracks or weakness. Replace
any defective parts.
4. Reassemble drain relief valve.
To inspect all hose lines:
1. Inspect all hose lines for cracks or weak spots that may develop with aging.
Faulty lines should be replaced. Hose should be protected from strain,
freezing or any mechanical damage.
2. Restart chlorifiator in accordance with current instructions. Remove safety
tag.
NOTE 5: Calibrate flowrater valve (zero adjustment) before resuming normal
operation.
Figure A-l (Cont)
70
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MAINTENANCE PROCEDURE SHEET
Page 1 of 1
EQUIPMENT NAME
Sampling Pump M, Chlorination Influent
Plant Area
Level
Location
MPS No. 4221 Ml
Average Time
<: - ] m i n
S-Z 12 min.
S - 3 min.
MAINTENANCE DESCRIPTION
Inspect packing gland adjustment.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize circuit and tag "out of service"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Rags
Flashlight
Safety tag
7/8-inch combination wrench
Flexible rule or steel rule w'ith holder
PROCEDURE
Preliminary— De-energize circuit and tag "out of service. "
To inspect packing gland adjustment:
NOTE 1: Damage to shaft sleeve or shaft occurs when:
(1) Rings are added to stop leakage rather than repacking.
(2) Gland nuts are not adjusted evenly.
(3) Gland is improperly adjusted for lubrication.
(4) Packing becomes hard and gland is overtightened to stop leakage.
1. Ensure gland nuts have been adjusted evenly and properly.
2. Measure distance packing gland can be moved before contact is made with
housing. Distance should be greater than 1/4-inch; if not, renew'stuffing
box packing as described on MPC R-l.
3. Remove safety tag and energize circuit.
Figure A-2
71
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MAINTENANCE PROCEDURE SHEET
Page 1 of 1
MPS No. 42Z1 Rl
EQUIPMENT NAME
Influent Sampling Pump M
Plant Area
Level
Location
MAINTENANCE DESCRIPTION
Renew packing.
Average Time
S-l min.
S-Z 180 min.
S-3 min.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize circuit and tag "out of service"
Wire suction and discharge valves shut and tag "do not open"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Rags
Knife
Wire brush
Safety Tags
Packing
6-inch Slip Joint Pliers
PROCEDURE
24 Gauge Wire
Packing Puller
Combination Wrench
NOTE 1: Accomplish when packing gland has been tightened to within 1/4-inch
of pump housing.
Preliminary—De-energize circuit and tag "out of service".
Wire suction and discharge valves shut and tag "do not open".
To renew packing:
1. Remove packing gland.
2. Remove old packing.
3. Remove lantern ring.
4. Remove remaining packing.
5. Clean stuffing box and sleeves; inspect for wear.
6. Clean packing gland and bolts with wire brush.
NOTE 2: Angle cut packing ends and stagger'joints around shaft while installing.
7. Install rings of packing (2 rings required).
8. Reinstall lantern ring.
9. Install rings of packing (2 rings required).
10. Reinstall packing gland and tighten packing gland nuts handtight.
11. Remove wire and safety tags; open suction and discharge valves.
12. Remove safety tag and energize circuit.
13. Operate pump for two hours to "run-in" the packing; adjust packing gland
nuts for greater than normal leakage during this "run-in1!
14. Readjust packing until there is a slight leakage.
15. Stop pump if not needed for service.
Figure A-3
72
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MAINTENANCE PROCEDURE SHEET
Page 1 of 1
EQUIPMENT NAME
Gear Reducer, Sludge Thickener
Plant Area
Level
Location
MPS No. 5214 Wl
Average Time
fi.l min-
S-2 42 min.
S-3 ._ min.
MAINTENANCE DESCRIPTION
Check oil condition and oil level.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service1
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Rags Allen wrench
Safety tag
Container
Lock jaw pliers or pipe wrench
Lubricant—AGMA No. 8 EP or AGMA No. 5 EP
Flashlight
PROCEDURE —' •
Preliminary— De-energize unit and tag "out of service".
To check oil condition and oil level:
1. Remove cover.
2. Loosen drain plugs on lower reservoir and drain off any accumulated
water and foreign matter. Draw off a small amount of additional oil
In a clean container and check its condition; tighten drain plug.
3. Loosen drain plug on drive head and drain off any accumulated water and
foreign matter. Draw off a small amount of additional oil in a clean
container and check its condition; tighten drain plug.
4. Check oil level (sight glass) of the drive head and the lower reservoir
NOTE 1: The oil level marks are located as follows:
(A) Drive head —1 -inch above the centerline of the connection nipple.
(B) Lower reservoir—3 7/16-inch above the centerline of the connection
pipe.
5. Refill to level marks if necessary.
NOTE 2: Reservoir is filled from the top of the drive head.
NOTE 3: The following lubricant should be used:
(A) Ambient temperature 0-125 deg. F. , use AGMA No. 8 EP.
(B) Ambient temperature 0-40 deg. F. , use AGMA No. 5 EP.
6. Replace cover.
7. Remove safety tag and energize unit.
Figure A-4
73
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MAINTENANCE PROCEDURE SHEET
Page 1 of 1
MPS No. 5214 Ql
EQUIPMENT NAME
Gear Reducer, Sludge Thickener
Plant Area
Level
Location
MAINTENANCE DESCRIPTION
Change oil and grease pinion bearing.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Rags
Safety tags
Container
Pipe wrench
Combination wrench
Flashlight
PROCEDURE
Allen wrench
Lubricant
Grease gun filled with Lubriplate No. 630AA or
equivalent
Preliminary— De-energize unit and tag "out of service."
To change oil and grease pinion bearing:
1. Remove split cover.
2. Remove fill plugs on drive head cover (2 heads).
3. Remove pipe cap on drive head and drain out oil.
4. Remove 1/2-inch drain plug on drive head and drain out oil.
5. Remove drain plug and drain lower reservoir (located at end of sight glass
piping).
6. Replace drain plug on lower reservoir.
7. Replace drain plug on drive head.
8. Replace pipe cap on drive head.
9. Fill with lubricant.
NOTE 1: Both reservoirs are filled from the top of the drive head.
NOTE 2: The following lubricant should be used:
(a) Ambient temperature 30-125 degrees F, use AGMA No. 8 EP.
(b) Ambient temperature 0-40 degrees F, use AGMA No. 5 EP.
NOTE 3: Turntable base oil capacity including drive head is 8 gallons.
10. Lubricate pinion bearings using the grease gun.
11. Check oil levels.
12. Replace split cover.
13. Remove safety tag and energize unit.
*•
D
Figure A-5
74
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MAINTENANCE PROCEDURE SHEET
EQUIPMENT NAME
Motor, Sludge Belt Conveyor
Plant Area „
K
Level
Page 1 of 2
Location
MPS No. 5342 Ql
Average Time
S-l . 18 rr,in.
55-2 . mm.
S-3 18 min.
MAINTENANCE DESCRIPTION
Clean motor and perform electrical inspection.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service1
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Safety tags
500 volt megger
Voltmeter
Ammeter
Ohmmeter
Screv/driver
Thermometer
Rags
Non-flammable solvent (LIX Cleaning Solvent or equivalent)
Preliminary—De-energise unit and tag "out of service. "
Allow motor to cool to ambient temperature
To clean motor:
1. Clean exterioB of motor of all foreign matter. For open or drip-proof
motors, make note of extreme dirty condition and take corrective action
if necessary.
To test insulation resistance:
1. Turn circuit breaker at Motor Control Console to "off."
2. Turn local electrical control (at motor) to "on". Measure the ambient
temperature at the motor in degrees Fahrenheit.
3. Remove access panel at the very bottom of the Motor Control Console,
exposing terminals.
4. Meg the motor circuits at these terminals, after application of a 500-volt
direct current for one minute.
NOTE 1: Use an ohmmeter on those circuits which would be damaged by a. 500-volt
megger.
5. Correct the insulation resistance measurement to a standard 75 F. and
record the corrected reading on the PM Work Record.
NOTE 2: If the corrected reading shows a significant drop from previous readings,
or if the corrected reading is less than 40 megohms (Class A ) or 8
megohms (Class B), corrective action should be taken.
(Continued)
Figure A-6
75
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MAINTENANCE PROCEDURE SHEET
Page 2 of 2 MPS No. 5342 Ql
PROCEDURE (continued), "Clean motor and perform electrical inspection."
To measure voltage and current:
1. After ensuring the unit may be operated, energize the unit by turning
breaker at Motor Control Console to "on. "
2. At the terminals at the very bottom of the Motor Control Console,
measure the voltage and current for each of the three legs (for 3-phase
motors). Record these readings on the PM Work Record.
NOTE 3: Take corrective action should any discrepancies be observed.
3. De-energize unit at the local electrical controller.
4. Replace access panel on the Motor Control Console.
Remove safety tag and return unit to service.
D
Figure A-6 (Cont)
76
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MAINTENANCE PROCEDURE SHEET '
Page 1 of 1
EQUIPMENT NAME
Control, Sludge Belt Conveyor
Plant Area
fv
Level
Location
MPS No. 5344 Al
Average Time
S.I 48 „,;„
S-2 . , min
S-3 48 min
MAINTENANCE DESCRIPTION
Clean and inspect controller.
SAFETY PRECAUTIONS
Observe standard safety precautions
Tag "out of service".
TOOLS, PARTS. MATERIALS, TEST EQUIPMENT
Rags
Flashlight
Safety tag
Dusting brush
Voltage tester
Screwdriver
Vacuum cleaner-.non-metallic nozzle
1/4 inch drive socket set
500 volt megger
Contact dressing file
Ohmmeter
PROCEDURE ~ —
Preliminary— Tag "out of service".
To clean and inspect controller:
1. Open access to controller.
Z. Remove controller assembly.
NOTE 1: Caution. Avoid the energized lead.
3. Remove arc chutes where applicable. Inspect for carbonizing. Scrape
clean or renew as necessary.
4. Inspect all contacts. If main line contacts are rough, burned or pitted,
dress with contact dressing file.
NOTE 2: The brown discoloration found on silver and silver-plated auxiliary or
relay contacts is harmless and need not be removed.
5. Inspect components and wiring for evidence of overheating,
6. Inspect and tighten all connections as necessary.
7. Clean controller assembly.
8. Vacuum and clean inside of panel; avoid the energized leads.
9. Manually check for binding in moving parts.
10, Meg circuits to ensure insulation resistance is satisfactory.
NOT-E 3: Use an ohmmeter on those circuits which could be damaged by a 500 volt
megger.
11. Replace controller assembly.
1Z. Close controller and remove safety tags.
13. Observe for proper operation.
Figure A-7
77
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MAINTENANCE PROCEDURE SHEET
Page 1 of 1
EQUIPMENT NAME
Control, Sludge Belt Conveyor
Plant Area
1\
Level
Location
MPS No. 5344 A2
.Average Time
S-2 min-
S.3 min
MAINTENANCE DESCRIPTION
Clean and inspect remote control switch.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service"
TOOLS. PARTS, MATERIALS, TEST EQUIPMENT
Screwdriver Rags
Flashlight
Safety tags
Voltage tester
500 volt megger
Ohmmeter
Dusting brush
Vacuum cleaner (non-mettalic nozzle)
Contact dressing file
1/4-inch drive socket set
Spare indicator lights
Spare fuses
Spare overload heaters
Spare contacts
PROCEDURE ~ •
Preliminary— De-energize unit and tag "out of service".
Tag any alternate switches in other locations.
To clean and inspect remote control switch:
1. Open door or remove cover.
2. Test with voltage tester to ensure circuit is de-energized.
3. Remove accumulated dust and dirt with brush, soft cloth or vacuum cleaner.
4. Wipe all bus insulators and bus barriers.
5. -Inspect bus joints and bus supports and tighten if necessary.
6. Check all wiring for deterioration of insulation and tighten all connections.
7. Inspect components and wiring for evidence of overheating.
8. Inspect overload heater for distortion; replace as required.
9. Inspect contacts. If beads have formed due to arcing, or where rough, burned
or pitted, replace contacts or dress with contact dressing file.
10. Remove draw-out units and check stabs and wiring. Remove accumulated
dust from barriers and in area of stabs.
11. Manually check I'or binding in all moving parts.
•12. Megger all terminals and circuits to ensure insulation resistance is adequate.
NOTE: Instruments or control devices sensitive to megger voltage should be isolated
from circuit, or an ohmmeter should be used.
13. Check all indicating lights and replace as required.
14. Check unit door .interlock for proper operation.
15. Check door or cover gasket and replace as required.
16. Close door or replace cover.
Perform this procedure on any alternate switches in other locations.
Remove safety tags and energize unit.
Figure A-8
78
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MAINTENANCE PROCEDURE SHEET
Page 1 of 1
EQUIPMENT NAME
Flowrate, Flushing Water (Nl)
Plant Area
K
Level L
Location
MPS No. 5364 Wl
Average Time
S_l mio
S-2 12 min.
S.3 min_
MAINTENANCE DESCRIPTION
Clean flow tube, adjust purge rates, bleed air.
SAFETY PRECAUTIONS
Observe standard safety precautions
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
PROCEDURE
1. Clean flow tube orifices using manual vent cleaners on both high and low
pressure sides.
2. Check purge water flow rates on both high and low sides using sight flow
indicators. Adjust flow if indicators are off the red reference marks.
3. Slowly open air vent valve on high pressure side. Rap mercury well and
test pipe to dislodge air bubbles. Close air vent valve.
4. Repeat for air vent valve on low pressure side.
Figure A-9
79
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MAINTENANCE PROCEDURE SHEET
Page 1 of 2
EQUIPMENT NAME
Flowrate, Flushing Water (Nl)
Plant Area
K
Level
I_i
Location
MPS No. 5364 SI
Average Time
C-l 4R min_
S-3 min.
MAINTENANCE DESCRIPTION
Inspect, lubricate, and index flow transmitter.
SAFETY PRECAUTIONS
Observe standard safety precautions
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Marking crayon or pen
Rags
Lithium-base grease type lubricant, Molykote G or equal
Adjustable wrench
Pipe wrench
Screwdriver
Automatic precision electrical interval timer, accurate to 0.01 seconds
PROCEDURE
To inspect transmitter:
1. Check for excessive accumulation of water or flooding in area.
2. Check for leaks in piping and fittings both outside and inside the transmitter.
Eliminate any leaks.
3. Check for loosened mounting, cracked or broken cover, damaged mechanism,
loosened electrical connections, or other damage.
To lubricate cam:
1. Clean and re-lubricate the face of the cam and the cam gear stud bearing
with a grease type lubricant (Molykote G or equal).
NOTE—Do not lubricate any other points in the mechanism.
To index transmitter:
1. Close high and low pressure needle valves at the transmitter.
2. Ensure bypass valve is shut between high and low pressure lines.
3. Remove both air vent valves from top of test pipe and from low pressure pipe.
4. Slowly fill test pipe and low pressure pipe with additional water if necessary.
Rap mercury wells and test pipes with fist to remove air bubbles. Level
off water at top of pipes.
5. Attach the electrical interval timer to terminals 10 and 11 of the terminal
strip.
(Continued)
Figure A-10
80
-------
MAINTENANCE PROCEDURE SHEET
Page 2 of 2 MPS No. 5364 SI
PROCEDURE (continued)
6. Wait four revolutions of the cam and then measure the time with the interval
timer for the trip arm to ride on the cam face (which moves the magnet on
the trip lever away from the mercury switch).
7. Compare this time with the standard time taken from the data plate on the
transmitter under test head-signal seconds. If they do not agree to within
0.02 seconds, adjustment should be made as follows to the trip arm position:
Caution—do not change the adjustment of the link lever slide. Red paint
was put on at the factory to seal its position.
Mark the knurled head of the trip arm micrometer screw to enable
approximation of amount of turning.
Carefully back off clamping screw.
Reposition the micrometer screw a small amount — to increase time
reading, turn screw so trip arm moves towards center of cam.
Wait four revolutions of cam and take time interval reading.
Repeat adjustment if necessary to make time agree with standard.
Tighten clamping screw, wait four revolutions, and take final time
interval reading,- which should agree with standard to within 0. 02
seconds,
8* Remove interval timer from terminal strip.
9. Replace both air vent valves.
10. Open high and low pressure needle valves at the transmitter.
Figure A-10 (Cont)
81
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MAINTENANCE PROCEDURE SHEET
Page 1 of 1
MPS No. 5621 Al
EQUIPMENT NAME
Air Compressor, Area K
Average Time
Plant Area
K
Level
Location
S-2
S-3
mm.
min.
30 min.
MAINTENANCE DESCRIPTION
Inspect foundation bolt tightness.
SAFETY PRECAUTIONS
Observe standard safety precautions
Deactivate unit and tag "out of service"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Torque wrench
Safety tags
PROCEDURE
Preliminary— Deactivate unit and tag "out of service. "
To test foundation bolt tightness on wetwell blower:
1. Test tightness of foundation bolts with torque wrench.
CAUTION: Improper torqueing of foundation bolts may cause misalignment
of internal parts.
2. Tighten loose bolts (see standard steel bolt and nut specifications below)
3. Remove safety tag and activate unit.
NOTE: Observe torque value for applicable bolts from following list.
Standard steel bolt and nut torque specifications
Size nut or bolt/
No. threads per inch
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
Torque Size nut or bolt/
(ft-lbs) No. threads per inch
7-9 1/2-20
8-10 9/16-12
13-17 9/16-18
15-19 5/8-11
30-35 5/8-18
35-39 3/4-10
46-50 3/4-16
57-61 7/8-9
71-75 7/8-14
Torque
(ft-lbs)
83-93
90-100
107-117
137-147
168-178
240-250
290-300
410-420
475-485
Figure A- 11
82
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MAINTENANCE PROCEDURE SHEET
Page 1 of 2
MPS No. 5921 Wl
EQUIPMENT NAME
Sludge Vacuum Filter
Plant Area
K
Level
Location
Average Time
S-l __ min.
S-2 150 min.
S-3 150 min.
MAINTENANCE DESCRIPTION
Clean vacuum filter subsystem, check tine bar and spring alignment, inspect
spray nozzles. __
SAFETY PRECAUTIONS
Observe standard safety precautions
Tag unit "out of service"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Rags
Safety tag
Water hose
Pipe wrench
PROCEDURE ~~ ~~~
Preliminary— Tag unit "out of service. "
To clean vacuum filter subsystem:
1. Put unit into operation.
2. Stop sludge feed to the filter.
3. Stop the sludge conditioning feeder.
4. Stop the conditioning tank.
5. Open the conditioning tank drain valve.
6. Stop the filter agitator when the sludge level is way down.
7. Operate the filter until the filter vat sludge level is too low for filtering.
8. Stop vacuum pump and filtrate pump.
9. Open the filter vat drain valve.
10. Stop the belt conveyor.
11.- Turn on valve to top wash water spray pipe for cleaning springs.
V2. Hose down filter, conditioning tank and vat.
13. Replace conditioning tank drain cap; fill conditioning tank with water
and allow it to rotate while hosing down the rest of the equipment.
14. Stop filter drum and shut valves to wash water sprays.
1 15, Remove conditioning tank drain cap and drain tank.
16. Replace conditioning tank drain cap.
17. Drain vat; hose down as required to clean vat.
To Check Tine Bar Alignment:
1. Check Tine bar alignment; adjust as necessary to center tines between
the coil springs.
(Continued)
Figure A- 12
83
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MAINTENANCE PROCEDURE SHEET
P age 2 of 2 MPS No. 5921 Wl
PROCEDURE (continued) Clean vacuum filter subsystem, check tine bar and spring
alignment, inspect spray nozzles.
To Check Spring Alignment:
1. Check spring alignment; adjust as necessary.
NOTE 1: Proper alignment means that the centers of the end grooves on the
upper aligning roll (small upper roll nearest drum) are equidistant
from the outer surface of the drum head (a straight-edge on this
cleaned surface is the best point to measure from).
CAUTION: Do not shorten springs to remove sag. Dp not overstretch springs.
To Inspect Spray Nozzles:
1. Inspect spray nozzles for clogging; clean as required.
2. Remove safety tag and return unit to service.
•0
v
OQ
(I
tJ
O
O
Figure A-12 (Cont)
84
-------
MAINTENANCE PROCEDURE SHEET
EQUIPMENT NAME
Sludge Vacuum Filter
Plant Area
K
Level y
Page 1 of Z
Location
MPS No. 59Z1 Rl
Average Time
S-2 120 min.
S-3 _ 120 min.
Acid wash springs and drum.
SAFETY PRECAUTIONS
Observe standard safety precautions
Tag unit "out of service"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Rags
Safety tags
Scraper
Drums of Oakite CPD No. 32.
Rubber protective clothing and eye goggles
Brush
NOTE 1: To be performed when scale deposits become excessive. A positive
indication is spring sag between the take-off point on the drum and the
discharge roll.
Preliminary—Tag unit '^out of service. "
Clean drum, springs and vat. See MPC W-l procedure 1 for proper
cleaning procedure.
To acid wash springs and drum:
1. Clean vat; if heavy deposits exist on the vat agitator, raise agitator out of vat
and scrape off deposits. Return agitator to normal position and use to mix
the acid and the water.
2. Wet the springs and the drum sruface thoroughly with water.
3. Run 300 gallons of water and 100 gallons (5 drums) of acid—CA 36% HCL
(Oakite CPD No. 32) —into vat.
4. CAUTION: Always add acid to water. Do not add water to the acid.
NOTE 2: An additional drum of acid will be required for makeup.
5. Start all wash water sprays.
6. Rotate drum intermittently so that each section remains immersed about
5 minutes.
NOTE 3: As the alkaline carbonate scale is being removed, the acid will be
neutralized and will slow down the scale removal. Check acid strength
with a Titraion Kit. Acid should not be allowed to, go below 9% of
Oakite No. 32 or 3% HCL. Add more acid to vat as required.
(Continued)
Figure A-13
85
-------
MAINTENANCE PROCEDURE SHEET
Page 2 of 2 MPS No. 5921 Rl
PROCEDURE' (continued)
NOTE 4:. Scale removal can be hastened by brushing the springs and scraping the
drum.
CAUTION: Care should be taken to hose off discharge rolls and galvanized piping
to prevent acid damage.
7. When scale has been removed, drain vat and thoroughly wash down all
equipment exposed to the acid with water.
8. Immediately resume sludge dewatering so that any residual acid will be
neutralized.
9. Remove safety tag.
Figure A-13 (Cont)
86
-------
MAINTENANCE PROCEDURE SHEET
Page 1 of 1
EQUIPMENT NAME
Exhaust ID Fan, Incinerator
Plant Area
A
Level y
Location
MPS No. 6531 Q2
Average Time
S-l . .. min.
S-2 _ 24 min_
S-3 ,, min ,
MAINTENANCE DESCRIPTION
Inspect drive belt(s) tension.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag "out of service"
NOTE: This procedure is to be performed only when the entire incinerator
has been shut down.
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Combination Wrench
Screwdriver
Safety Tags
PROCEDURE ' ~
Preliminary— De-energize circuit and tag "out of service".
To inspect drive belt(s) tension:
1. Remove drive belt guard, if installed.
2. Inspect drive belt for cracks, fraying or evidence of unusual wear,
3. Depress drive belt by hand in a central location between pulleys. Belt
should depress from 1/2 to 3/4 of an inch.
4. Caution: Do not tighten drive belt to have less than 1/2-inch depression.
NOTE 1: When renewal of one belt of a multiple V-belt drive is necessary, a
complete new set of matched belts should be installed.
5. Reinstall belt guard, if installed.
6. Remove safety tag; energize circuit.
Figure A-14
87
-------
MAINTENANCE PROCEDURE SHEET
Page 1 of 1
EQUIPMENT NAME
9 Recorders, Blower Building Console
Plant Area
E
Level v
Location ~w
MPS No. 7151 Al
Average Time
s_) 270 Tnin.
S-2 min.
S-3 min.
MAINTENANCE DESCRIPTION
Clean and calibrate recorder.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit
TOOLS, PARTS. MATERIALS, TEST EQUIPMENT
Mild Non-abrasive Soap Strand of 6 mil Wire
Warm Water
Alcohol
Clean Cloth or Tissue
Soft Brush
Small Screwdriver
PROCEDURE ' '
Preliminary—De-energize unit.
NOTE 1: Under no circumstances should internal mechanism be lubricated.
Do not tamper unnecessarily with internal mechanism.
To clean recorder:
1. Clean dials and chart plate with a mild non-abrasive soap and warm water.
2. Remove dust from gears with a soft brush.
3. Clean pen point with strand of 6 mil wire, and flush with water or alcohol.
Clean outside of pen by wiping the pen from the body toward and beyond the
point.
To calibrate recorder:
1. Re-energize the unit.
2. Check pen carriage alignment so that the pen will track a chart time line.
Adjust if necessary.
3. Check indicator and pen zero position. Adjust if necessary.
Return unit to service.
Figure A-15
88
-------
MAINTENANCE PROCEDURE SHEET
Page 1 of 1
MPS No. 7700 Ql
EQUIPMENT NAME
Alarm Annunciators
Plant Area B E G J K Level
Location
Average Time
S-l 60 min.
S-2 min.
S-3 min.
MAINTENANCE DESCRIPTION
Test Annunciator Operation.
SAFETY PRECAUTIONS
Observe standard safety precautions
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
PROCEDURE —'
To test annunciator operation:
1. Push Annunciator Test Buttons and check for proper operation of both horn
and light. The following annunciators are to be checked:
I. D.
77200
77300
77400
77500
77600
77700
Area
B
E
G
J
K
K
Level
U
U
U
U
U
M
Location
SW
S
S
S
No. of
Annunciators
11
30
4
2
8
10
D
Figure A-16
89
-------
MAINTENANCE PROCEDURE SHEET
Page 1 of 3
MPS No. 7700 S6
EQUIPMENT NAME
Alarm Systems — Area K (Incineration Operations)
Plant Area
Level
Location
S-2
S-3
Average Time
1 Afl mi n
60 min.
60 min.
MAINTENANCE DESCRIPTION
Test alarm systems by simulating alarm conditions
SAFETY PRECAUTIONS
Observe standard safety precautions
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
3 copies of this MPS
PROCEDURE — —
Preliminary—Station observers at these alarm indicator (annunciator) locations:
77300 (Area E) and 77700 (Area K, Incinerator Room). Each observer
should check off proper operation of the alarm indicators at his location.
To test alarm systems:
NOTE: The following steps are temporary tests. Normal operation should be
resumed promptly.
1. To simulate a stopped shaft for each of the incinerators, turn off the incinerator
mechanism for approximately 60 seconds (to exceed the normal time delay of
55 seconds for one revolution). Do not allow shaft to be stopped for any longer
period of time.
2. To simulate a clogged condition for each of the flushing water strainers,
hand-trip the appropriate mercury switch.
3. Simulate a high-level alarm for the ash bin by removing the sensor assembly
from the bin and holding the propeller by hand, preventing it from turning.
4. Simulate a high temperature for each of the incinerators by lifting the
contact bar on the appropriate strip chart recorder.
5. Simulate a high temperature for each of the ID fans by lifting the contact bar
on the appropriate strip chart recorder.
Figure A-17
90
-------
MAINTENANCE PROCEDURE SHEET
Page 2 of 3
MPS No. 7700 S6
PROCEDURE (continued)
6. Simulate a flame failure in the sludge building boiler by (hutting off the
pilot light.
7. Simulate an electrical failure in the incinerator area by pulling the main
breaker in the motor control console.
Figure A-17 (Cont)
91
-------
MAINTENANCE PROCEDURE SHEET P age 3 of 3 MPS No. 7700 S6
PROCEDURE (continued)
Alarm Indicator
a
9
rt
h
a
Alarm Condition
Operating Unit and Seasor
3
j
rt
E
a
MPS Step |
Number ["
u
O
r-
t-
**********'.
ooooooooo _, —
i a
E E
H a. H a. u
.•8 3 S 8 i! 5
(JJyJ«w.ŁcQcQ .-
*'i:drtx'j::'c~'? ^ °
2M2w »„»« „
JJ33 SS2S 2
MKMMKMMMMKie
» « rj is)
22 S g S S
tJ v rt rt fl rt
11 IIIIM
_ M 0 0 _. _. _. . » g
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p
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o
Figure A-17 (Cont)
92
-------
MAINTENANCE PROCEDURE SHEET
Page 1 of 2
EQUIPMENT NAME
Alarm Systems — Electrical Substations
Plant Area
B. E. K
Level
Location
MPS No. 7700 Al
Average Time
fi.i 1(1 m!n.
S-2 min.
S-3 120 min.
MAINTENANCE DESCRIPTION
Test alarm systems by simulating alarm conditions
SAFETY PRECAUTIONS
Observe standard safety precautions
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
5 copies of this MPS
PROCEDURE ~*~ —
Preliminary—Station observers at these alarm indicator (annunciator) locations:
77100 (Area L, 77200 (Area B), 77300 (Area E) and 77600 (Area K,
Filter Room). A VEPCO service man is required to perform Step 2
of this MPS.
To test alarm systems
NOTE: The following steps are temporary tests. Normal operation should be
resumed promptly.
1. For each of the four electrical substations, simulate an emergency power
failure by transferring from normal to emergency power, and simulate a
ground fault by transferring power.
2. Simulate a failure of emergency power at Electrical Substation No. 1 by having
the VEPCO service man de-energize the emergency power.
Figure A-18
93
-------
MAINTENANCE PROCEDUR
E S
O
2
F
*
.
•<
i
i
•
', and S«n*or
a
O
I
1
MPS Step
HE I
:
a
s
9
4
h
a
(
'
:
3
V
i?
F
1
fl
i
:T i
M K
rt o
r- r-
a u u x a u
23 S S S 5
r- t- r^ i1* r- r*
r- r- i- P. r- r»
JB«JUJMJU
2=S°sisis
w
I* »4 h h fc.
t * i s a
CU*jD-0,*.;(l,— Q.*.*
IJl^MM
E S i E Ł I Ł E Ł
uouuououo
oo o
«««XKMUMW
oodoodooo
»3S3»*S3»
J?*«^-*
uiSscijanHs
==r2~==z:
=>ageZ of 2 MPS No. 7700 A 1
V
OQ
A
0
Nl
O
-J
0
o
Figure A-18 (Cont)
94
-------
.APPENDIX III
TABLE A-l THROUGH A-10
95
-------
Table A-l.' EQUIPMENT TYPE CLASSIFICATION
10
11
12
13
14
20
21
22
23
24
25
26
27
28
30
31
32
33
34
35
40
41
42
43
44
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
70
71
72
73
Tanks and Tank Equipment
Tanks, Channels, Bins
Slide Gates, Sluice Gates
Sludge and Scum Collectors
Weirs
Pumps, Compressors, Blowers
Centrifugal Pumps
Piston Pumps
Gear, Vane, Screw, Diaphragm Pumps
Air Compressors
Air Blowers
Sump Pumps
Submersible Pump/Drive Assemblies
Vacuum Pumps
Electrical Equipment
Motors, Motor and Drive Assemblies
Supply Panels and Boxes
Controls
Transformers, HV Power Supplies
Delays, Relays, Timers
Mechanical Equipment
Drives and Bearings
Hoists and Cranes
Conveyors
Special Equipment
Hydraulic and Pneumatic Components
Strainers, Filters, Screens
Heat Exchangers, Evaporators
Diffusers, Injectors, Nozzles
Valves, Dampers
Pressure Reducers, Relief Devices
Silencers, Scrubbers
Mixers, Agitators, Vibrators
Chlorinators, Feeders
Hydraulic Power Components
Measurement and Control
Flowrate Transducers
Pressure Transducers
Level Transducers and Controls
Analyzers
Scales
Meters, Alarms, Recorders
Float, Pressure, and Limit Switches
Plant Service Equipment
Fire Extinguishers
Heaters, Ventilators
Laboratory Equipment
96
-------
Table .A-2. INDICATORS AND MODIFIERS
Indicators
11
12
13
14
15
16
17
18
22
zi
24
25
26
31
32
33
34
41
42
43
44
45
51
52
53
54
Start/Turn on
Stop/Turn off
Open
Shut/ Close
Tune, adjust, align, calibrate
Safety hazard
Defective material
Broken, cracked, bent
Corroded /Rusted
Dirty/Fouled
Leaking
Vibration
Alignment /Fit
Smell
Heat /Temperature
Noise
Smoking /Arc ing
Flow rate
Speed/Rotation
Frequency
Pressure
Suction/ Vacuum
Current
Voltage
Resistance
Power
Modifiers
i
2
3
4
5
6
• 7
8
9
0
No, none, fails to
Poor, improper
Unstable, unbalanced
Difficult to
High, fast, excessive
Low, slow, too little
Intermittent, erratic,
uncontrollable
Drifting, shifting, fluctuating
Steady
No modifier required
97
-------
Table A-3. ANNUAL PM MANPOWER REQUIREMENT
System
ID
110
120
130
210
220
230
240
310
320
330
340
350
360
370
380
410
420
430
440
510
520
530
540
550
560
570
580
590
610
620
630
640
650
660
100
200
300
400
500
600
Name
Screening
Grinding
Wastewater flow
Primary settling
Sludge handling
Scum handling
Auxiliary services
Aeration
Air delivery
Secondary clarifiers
Chemical treatment
Return sludge
Excess sludge
Scum
Auxiliary services
Chlorination
Residual chlorine analysis
Effluent water
Auxiliary services
Auxiliary services
Sludge thickening
Sludge storage and handling
Scum handling
Lime treatment
Ferric chloride treatment
Polymer treatment
Sludge conditioning
Vacuum filtration
Incinerators
Gas supply
Oil supply
Air supply and foul gases
Scrubbing
Ash handling
Raw wastewater station
Primary treatment
Secondary treatment
Chlorination &t effluent flow
Sludge &t scum processing
Incineration
Total for plant
Annual Manhours Required
Skill 1
15
6
12
12
13
5
6
2
21
6
3'
12
6
6
12
0
18
24
3
15
18
32
3
--
9
4
6
24
6
0
9
15
6
18
33
36
68
45
111
54
347
Skill 2
211
43
124
27
11
33
14
6
99
90
4
74
25
2
28
56
14
62
7
18
272
224
2,
_.
84
3
1
378
540
12
0
37
26
128
378
85
328
1,39
982
743
2,655
Skill 3
189
108
65
121
94
12
5
111
260
70
6
75
6
5
10
6
24
60
2
13
617
954
3
..
282
4
99
984
490
0
6
56
28
167
362
232
543
92
2,956
747
4, 932
Total
415
157
201
160
118
50
25
119
380
166
13
161
37
13
50
62
56
146
12
46
907
1,210
8
..
375
11
106
1, 386
1, 036
12
15
108
60
313
773
353
939
276
4, 049
1, 544
7,934
98
-------
Table A-4. CROSS REFERENCE TO EQUIPMENT
CONFIGURATION LIST
Design
Engineering Code
A2
A3
A4
Bl
B2
B3
C3
C4
Dl
El
E2
E3
E4
Fl
F2
G3
G4
G5
HI
H2
Jl
J2
Kl
K2
K3
K4
LI
Ml
M2
M3
Nl
N2
N3
Ol
02
PI
P2
Ql
Q2
Q3
Q4
Pump
Raw Wastewater
Raw Wastewater
Raw Wastewater
Return Sludge (RA-1)
Return Sludge (RA-2)
Return Sludge (RA-3)
Excess Sludge
Excess Sludge
Dewatering
Low Lift
Low Lift
Low Lift
Low Lift
High Lift
High Lift
Primary Sludge
Primary Sludge
Primary Sludge
Primary Scum
Primary Scum
Secondary Scum Well
Secondary Scum Well
Sludge Plunger
Sludge Plunger
Sludge Plunger
Sludge Plunger
Scum Pit
Influent Sampling
Influent Sampling
Influent Sampling
Effluent Sampling
Effluent Sampling
Effluent Sampling
Sump
Sump
Sump
Sump
Sump
Sump
Sump
Sump
Area
B
B
B
E
E
E
E
E
E
G
G
G
G
G
G
C
C
C
C
C
F
F
J
J
J
J
K
G
G
G
G
G
G
B
B
C
C
E
E
E
E
ID Number
13112
13113
13114
35111
35112
35113
36113
36114
35411
43411
43412
43413
43414
43311
43312
22113
22114
22115
23111
23112
37121
37122
52211
52212
52213
52214
54211
42211
42212
42213
42311
42312
42313
14111
14112
24111
24112
38111
38112
38113
38114
99
-------
Table A-4 (Continued)
Design
Engineering Code
Rl
SI
Tl
T2
Ul
VI
V2
Wl
W2
XI
X2
--
__
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Pump
Sump
Sump
Sump
Sump
Sump
Seal Water
Seal Water
Meter Purge Water
Meter Purge Water
Sump
Sump
Sludge Plunger
Sludge Plunger
Sludge Plunger
Ferric Chloride
Ferric Chloride
Ferric Chloride
Lime (Screw)
Lime (Plunger)
Vacuum
Vacuum
Filtrate
Filtrate
Oil
Oil
Oil
Hydraulic Fluid
Area
G
J
K
K
H
G
G
K
K
D
D
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
ID Number
44111
51111
53811
53812
24113
43511
43512
53611
53612
38115
38116
53311
53312
53313
56411
56412
56413
55711
55811
59111
59112
59411
59412
63311
63312
63313
53741
100
-------
Table A-4 (Continued)
Design
Engineering Code
A3
A4
B3
B4
D
E
Fl
F2
G2
G3
G4
H4
H5
H6
K
L
Nl
Transmitter
Mixed Liquor From No. 3
Mixed Liquor From No. 4
Return Sludge to No. 3
Return Sludge to No. 4
Excess Sludge to Thickeners
Total Flow to Thickeners
Primary Sludge to No. 1 Degrit
Primary Sludge to No. 2 Degrit
Blower No. 2 Output
Blower No. 3 Output
Blower No. 4 Output
Air to 3A and 3B
Air to 3C and 4C
Air to 4A and 4B
Chlorine Residual in Effluent
Return Sludge Well Level
Flushing Water
Area
E
E
D
D
E
E
H
H
E
E
E
E
E
E
G
E
K
ID Number
31613
31614
35513
35514
36311
36321
22311
22312
32312
32313
32314
31343
31340
31344
42123
35321
53640
101
-------
Table A-4 (Continued)
Design
Engineering Code
A3
A4
A7
A7
B3
B4
B7
B7
C3
C4
C7
D
D
E
Fl
F2
F4
F4
G2
G3
G4
G6
H4
H5
H6
H10
H10
K
K
K
L
Nl
01
Ol
Ol
Ol
Ol
Receiver
Mixed Liquor Flow From No. 3
Mixed Liquor Flow From No. 4
Total ML Flow (A3 and A4)
Total ML Flow (A3 and A4)
Return Sludge to No. 3
Return Sludge to No. 4
Total Return Sludge (B3& B4)
Total Return Sludge (B3 & B4)
Wastewater to No. 3 (A3 - B3)
Wastewater to No. 4 (A4 - B4)
Total Wastewater (C3 and C4)
XS Sludge to Thickeners
XS Sludge to Thickeners
Total Flow to^Thickeners
Primary Sludge to No. 1 Degrit
Primary Sludge to No. 2 Degrit
Total Primary Sludge (Fl & F2)
Total Primary Sludge (Fl & F2)
Blower No. 2 Output
Blower No. 3 Output
Blower No. 4 Output
Total Blower O'put (G2&G3&G4)
Air to 3A and 3B
Air to 3C and 4C
Air to 4A and 4B
Total Air to Aerators (H4, 58t6)
Total Air to Aerators (H4, 5&6)
Chlorine Residual
Chlorine Residual
Chlorine Residual
Return Sludge Well Level
Flushing Water Flow
Raw W'water Flow (C7-E-N1)
Raw W'water Flow (C7-E-N1)
Raw W'water Flow (C7-E-N1)
Raw W'water Flow (C7-E-N1)
Raw W'water Flow (C7-E-N1)
Area
E
E
E
L
E
E
E
L
E
E
E
E
L
E
H
H
E
C
E
E
E
E
E
E
E
E
L
E
L
G
E
K
E
L
A
B
G
ID Numb e it
71525
71526
71511
71111
71523
71524
71512
71112
71521
71522
71513
71514
71113
71515
71411
71412
71516
71311
71534
71535
71536
71518
71531
71532
71533
71519
71115
71581
71116
71613
71527
71811
71517
71114
71121
71211
71612
102
-------
Table A-5. LIST OF MAINTENANCE PROCEDURES
FOR REMOTE ELECTRICAL CONTROLS
MPS No.
1114 A2
1124 A2
1213 A2
1316 A2
1364 Al
1411 Al
2124 A2
2 1 34 A2
2213 A2
•2245 A2
2313 A2
2333 Al
2414 A2
3214 Al
3228 A2
3264 Al
3337 A2
3514 A2
3543 A2
3614 A2
3641 Al
3814 A2
4121 A2
4123 Al
4131 A2
4141 Al
4211 Al
4224 A2
4234 A2
'4333 A2
4343 A2
4353 A2
4414 A2
5114 A2
5123 A2
5216 A2
5226 A2
5253 Al
5314 A2,
5336 A2
5344 A2
Equipment Controlled
Bar Screens
Bar Screen Conveyors
Grinders
Raw Wastewater Pumps A
Control, Air Compressor
Sump Pump O
Sludge Collectors, A&B
Sludge Collectors, C & Cross
Primary Sludge Pumps G
Grit Classifiers
Primary Scum Pumps H
Motor, Air Compressor
Sump Pumps P, U
Air Damper Motor DM-FAI
Blowers
Pressure Switch, Air Compressor
Secondary Classifiers
Return Sludge Pumps B
Dewatering Pump D
Excess Sludge Pumps C
Motor Valve, XS Sludge Dilution
Sump Pumps Q, X
Chlorine Evaporator
Chlorine Pre s sure Reducing Valve
Chlorinator
Chlorine Gas Detector
Chlorine Analyzer
Influent Sampling Pumps M
Effluent Sampling Pumps N
High Lift Pumps F
Low Lift Pumps E
Seal Water Pumps V
Sump Pumps R
Sump Pump S
Dome Fan, Thickeners
Sludge Thickeners
Sludge Plunger Pumps K
Pressure Switch, Air Compressor
Compressor, Sludge Storage Tank
Sludge Plunger Pumps
Sludge Belt Conveyors
Remote
Control ID
7811
7812
7813
7816
7814
7815
7821
7822
7824
7831
7823
7826
7825
7849
7854
7847
7841
7842
7844
7843
7846
7848
7876
7881
7885
7886
7884
7875
7882
7871
7872
7873
7874
7894
7895
7892
7891
7893
7922
7911
7961
Remote
Control ID
7833
7832
7853
7861
7851
7852
7883
7942
7931
103
-------
Table A-5 (Continued)
MPS No.
5363 A2
5423 A2
5544 A2
5547 A2
5551 Al
5563 A2
5574 A2
5584 A2
5624 Al
5633 Al
5644 A2
5814 A2
5913 A2
5925 A2
5934 A2
5943 A2
6117 A2
6413 A2
6423 A2
6433 A2
6533 A2
6614 A2
6624 A2
6644 A2
6654 A2
6711 Al
Equipment Controlled
Meter Purge Water Pumps W
Scum Pump L
Lime Dust Collector Fan
Lime Dust Collector Vibrator
Lime Gravimetric Feeder
Lime Slurry Tank Mixer
Lime Slurry Pump No. 1 (Screw)
Lime Slurry Pump No. 2 (Plunger)
Control, Air Compressor
Motor, Ferric Chloride Tank Mixer
Ferric Chloride Feed Pumps
Sludge Conditioning Tanks
Vacuum Pumps
Vacuum Filter Drums
Filter Agitators
Filtrate Pumps
Incinerator Mechanisms
Cooling Air Fans
Turbo Blowers
Foul Air Fan
Exhaust ID Fans
Ash Bucket Elevators
Ash Screw Conveyors
Rotary Ash Conditioner
Ash Vane Feeder
Sump Pump T
Remote
Control ID
7921
7923
7928
7929
7940
7927
7925
7926
7914
7919
7918
7912
7915
7913
7.914
7916
7951
7952
7953
7954
7955
7956
7957
7958
7959
7924
Remote
Control ID
7941
7943
7948
7949
7947
7945
7946
7937
7939
7938
7932
7935
7933
- 7934
7936
7944
104
-------
Table A-6. CROSS REFERENCE, ALARM SENSORS TO ALARM INDICATORS
Operating Unit and Sensor
ID
11111
11112
13122
13123
13124
13311
13311
13511
32212
32213
32214
32640
33311
33312
35221
35321
35321
38115
38116
• 41221
41222
41230
52111
52112
53121
55211
55212
Name
Bar Screen No. 1
Bar Screen No. 2
Motor, Raw Wastewater Pump A2
Motor, Raw Wastewater Pump A3
Motor, Raw Wastewater Pump A4
Raw Wastewater Wet Well Control
Raw Wastewater Wet Well Control
Strainer, Pump Seal Water
Blower No. 2
Blower No. 3
Blower No. 4
Blower Building Compressors
Secondary Clarifier No. 1
Secondary Clarifier No. 2
Strainer, Pump Seal Water
Return Sludge Wet Well
Return Sludge Wet Well
Cross-Tunnel Sump Pump X-l
Cross-Tunnel Sump Pump X-2
West Evaporator
East Evaporator
Chlorine Pressure Reducing Valves
Scraper Drive, Thickener No. 1
Scraper Drive, Thickener No. 2
Sludge Storage Tank Air Compressor
Lime Storage Bin
Lime Storage Bin
Area
B
B
B
B
B
B
B
B
E
E
E
E
F
F
E
E
E
D
D
G
G
G
J
J
K
K
K
Level
U
U
U
U
U
U
U
L
U
U
U
L
L
U
U
L
L
U
U
U
o
U
L
Loc
N
S
N
M
S
w
M
E
S
NW
NE
W
S
S
W
E
W
E
N
S
N
Alarm Condition
.High Differential
High Differential
Power Failure
Power Failure
Power Failure
Low Level
High Level
Strainer Clogged
Low Oil Pressure
Low Oil Pressure
Low Oil Pressure
Instrument Air Failure
Overload
Overload
Strainer Clogged
Low Level
High Level
Sump Pump Failure
Sump Pump Failure
High Water Temperature
High Water Temperature
Motor Valve Failure
Overload
Overload
Electrical Failure
High Level
Low Level
Alarm Indicators
. ID
77202
77203
77206
77207
77208
77204
77205
77201
77320
77321
77322
77314
77312
77313
77319
77303
77304
77317
77318
77401
77402
77403
77501
77502
77605
77602
77603
Area
B
B
B
B
B
B
B
B
E
E
E
E
E
E
E
E
E
E
E '
G
G
G
J
J
K
K
K
ID
77301
77302
77601
77601
Area
E
E
K
K
ID
Area
-------
Table A-6 (Continued)
Operating Unit and Sensor
ID
55641
61161
6116Z
65211
65212
66331
71851
71851
71852
71852
73211
73212
73213
74111
74111
74111
74112
741 12
74113
74113
74114
74114
77400
77600
78100
78200
78500
78700
78900
79100
79500
Name
Lime Slurry Tank
Incinerator No. 1
Incinerator No. 2
Flushing Water to Scrubber No. 1 -
Flushing Water to Scrubber No. 2
Ash Bin
Temp. Recorder, Incinerator No. 1
Temp. Recorder, Incinerator No. 1
Temp. Recorder, Incinerator No. 2
Temp. Recorder, Incinerator No. 2
Blower Building Boiler
Sludge Building Boiler
Raw Wastewater Station Boiler
Electrical Substation No. 1
Electrical Substation No. 1
Electrical Substation No. 1
Electrical Substation No. 2
Electrical Substation No. 2
Electrical Substation No. 3
Electrical Substation No. 3
Electrical Substation No. 4
Electrical Substation No. 4
Alarm Systems
Alarm Systems
Raw Wastewater Pumping Station
Primary Sludge Pumping Station
Blower Air Intake Filter
Chlorine Building
Thickener Building
Sludge Filtration
Sludge Incineration
Area
K
K
K
K
K
K
K
K
K
K
E
K
B
B
B
B
K
K
E
E
E
E
G
K
B
C
E
G
J
K
K
Level
L
L
L
U
U
M
M
M
M
M
U
M
Loc
N
S
N
S
S
S
S
S
o
0
0
S
S
Alarm Condition
Low Level
Shaft Stopped
Shaft Stopped
Strainer Clogged
Strainer Clogged
Ash Bin Full
Hiyh Incinerator Temp.
High ID Fan Temp.
High Incinerator Temp.
High ID Fan Temp.
Flame Failure
Flame Failure
Flame Failure
Emergency Power On
Ground Fault
Emergency Power Failure
Emergency Power On
Ground Fault
Emergency Power On
Ground Fault
Emergency Power On
Ground Fault
Power On
Power On
Electrical Failure
Electrical Failure
Electrical Failure
Electrical Failure
Electrical Failure
Electrical Failure
Electrical Failure
Alarm Indicators
ID
77604
77702
77706
77704
77708
77709
77701
77703
77705
77707
77316
77710
77209
77101
77211
77212
77102
77326
77103
77328
77104
77330
77404
77608
77305
77306
77307
77308
77309
77310
77311
Area
K
K
K
K
K
K
K
K
K
K
E
K
B
L
B
B
L
E
L
E
L
E
G
K
E
E
E
E
E
E
E
ID
77315
77315
77210
77324
77325
77607
77327
77329
Area
E
E
B
E
E
K
E
E
ID
77323
77606
Area
E
K
-------
Table A-7. INCINERATION EQUIPMENT WHICH MAY NOT
BE SHUT DOWN ARBITRARILY
ID Number
Equipment
6111
6112
6113
6115
6116
6117
6411
6412
6413
6421
6422
6423
6511
6531
6532
6533
6611
6612
6613
6614
6621
6622
6623
6624
Incinerator mechanism
Motor
Drive
Gear reducer
Limit switch
Control
Cooling air fan
Motor
Control
Turbo blower
Motor
Control
Scrubber
Exhaust ID fan
Motor
Control
Ash bucket elevator
Motor
Drive
Control
Ash screw conveyor
Motor
Drive
Control
107
-------
Table A-8. MAINTENANCE PROCEDURES
IN CATEGORY A*
MPS No.
Equipment
Maintenance
6111 Dl
6111 Ml
6113 Ml
6115 Dl
6116 Ml
6411 Wl
6611 Wl
6613 Wl
6621 Wl
6623 Wl
Incinerator mechanism
Incinerator mechanism
Drive, incinerator mechanism
Gear reducer, incinerator
mechanism
Limit switch, incinerator
mechanism
Cooling air fan
Ash bucket elevator
Drive, ash bucket elevator
Ash screw conveyor
Drive, ash screw conveyor
Check oil level
Lubricate master gear & pinion
Lubricate disk, oiler, screw
Check oil level
Check switch operation
Lubricate fan
Lubricate elevator
Check oil level
Lubricate conveyor
Check oil level
*These procedures are to be performed without shutting down the equipment.
108
-------
Table A-9. MAINTENANCE PROCEDURES
IN CATEGORY B*
MPS No.
Equipment
Maintenance
6111 Ql
6111 Q2
6111 Q3
6112 Ql
6112 SI
6113 SI
6115 SI
6117 Al
6117 A2
6411 Ql
6411 Q2
6412 Ql
6412 Q2
6413 Al
6413 A2
6421 SI
6422 Ql
6422 SI
6423 Ql
6423 Al
6423 A2
6511 Ql
6531 Ql
6531 Q2
6531 SI
6531 S2
6532 Ql
6532 SI
Incinerator mechanism
Incinerator mechanism
Incinerator mechanism
Motor, incinerator mechanism
Motor, incinerator mechanism
Drive, incinerator mechanism
Gear reducer, incinerator
mechanism
Control, incinerator mechanism
Control, incinerator mechanism
Cooling air fan
Cooling air fan
Motor, cooling air fan
Motor, cooling air fan
Control, cooling air fan
Control, cooling air fan
Turbo blower
Motor, turbo blower
Motor, turbo blower
Control, turbo blower
Control, turbo blower
Control, turbo blower
Scrubber
Exhaust ID fan
Exhaust ID fan
Exhaust ID fan
Exhaust ID fan
Motor, exhaust ID fan
Motor, exhaust ID fan
Change oil, inspect & lubricate
Inspect incinerator
Inspect shear pin
Clean and perform electrical
inspection
Lubricate motor
Adjust Hi &t Lo speed stops
Change oil
Clean and inspect controller
Clean and inspect remote control
switch
Clean and inspect fan
Inspect drive belt tension
Clean & perform electrical
inspection
Lubricate motor
Clean and inspect controller
Clean & inspect remote control
switch
Clean and inspect blower
Clean and perform electrical
inspection
Lubricate motor
Check oil and gas interlocks
Clean and inspect controller
Clean and inspect remote control
switch
Clean and inspect scrubber
Lubricate fan bearings
Inspect drive belt tension
Clean and inspect fan
Inspect foundation bolt tightness
Clean and perform electrical
inspection
Lubricate motor
109
-------
Table A-9 (Continued)
MPS No.
Equipment
Maintenance
6533 Al
6533 A2
6611 Al
6612 Ql
6612 Q2
6612 SI
6613 SI
6614 Al
6614 A2
6622 Ql
6622 Q2
6622 Q3
6623 SI
6624 Al
6624 A2
Control, exhaust ID fan
Control, exhaust ID fan
Ash bucket elevator
Motor, ash bucket elevator
Motor, ash bucket elevator
Motor, ash bucket elevator
Dirve, ash bucket elevator
Control, ash bucket elevator
Control, ash bucket elevator
Motor, ash screw conveyor
Motor, ash screw conveyor
Motor, ash screw conveyor
Drive, ash screw conveyor
Control, ash screw conveyor
Control, ash screw conveyor
Clean and inspect controller
Clean and inspect remote control
switch
Clean and inspect elevator
Clean and perform electrical
inspection
Lubricate motor
Clean and inspect coupling
Change oil
Clean and inspect controller
Clean and inspect remote control
switch
Clean and perform electrical
inspection
Lubricate motor
Inspect drive belt tension
Change oil
Clean and inspect controller
Clean and inspect remote control
switch
*These procedures require the equipment to be taken out of service—they must
be performed when the entire incinerator is shut down.
110
-------
Table A-10. ESTIMATED AND ACTUAL TIME (Minutes) FOR PM ACTIONS
MP No.
Equipment
PM Action
Estimated
Time
Range of
Actual Time
1111 Dl
1111 D2
1311 Wl
1312 Wl
2123 Wl
2211 Wl
2211 W2
2311 Ml
2312 Ml
2312 Ql
3511 Wl
3512 W2
3512 Al
3514 Al
351-4 A2
4342 Ql
5221 Dl
5221 Wl
5221 Rl
5221 Ml
5221 M2
5222 Ql
5222 SI
5223 Wl
5224 Wl
5224 Ql
5225 Wl
5225 Ql
5226 Al
5226 A2
5341 Wl
5341 W2
5341 Ml
5342 Ql
5343 Wl
Bar Screen
Bar Screen
Raw Wastewater Pump
Motor, Raw Wastewater Pump
Reduction Gear, Sludge Collector
Primary Sludge Pump
Primary Sludge Pump
Primary Scum Pump
Motor, Primary Scum Pump
Motor, Primary Scum Pump
Return Sludge Pump
Motor, Return Sludge Pump
Motor, Return Sludge Pump
Control, Return Sludge Pump
Control, Return Sludge Pump
Motor, Low Lift Pump
Sludge Plunger Pump
Sludge Plunger Pump
Sludge Plunger Pump
Sludge Plunger Pump
Sludge Plunger Pump
Motor, Sludge Plunger Pump
Motor, Sludge Plunger Pump
Variable Reducer, Sludge Plunger Pump
Gear Drive, Sludge Plunger Pump
Gear Drive, Sludge Plunger Pump
Reduction Gear, Sludge Plunger Pump
Reduction Gear, Sludge Plunger Pump
Control, Sludge Plunger Pump
Control, Sludge Plunger Pump
Sludge Belt Conveyor
Sludge Belt Conveyor
Sludge Belt Conveyor
Motor, Sludge Belt Conveyor
Drive, Sludge Belt Conveyor
Lubricate Bar Screen
Inspect Rake Assy. fa Chain
Inspect Packing Gland Adjustment
Check Oil Level
Check Oil Level
Inspect Packing Gland Adjustment
Check Bearing Oil Level
Inspect Packing Gland Adjustment
Lubricate Motor Base Adjusting Screw
Clean fa Perform Electrical Inspection
Inspect Packing Gland Adjustment
Lubricate Motor Bearings
Lubriflush Varidrive Motor
Clean fa Inspect Controller
Clean fa Inspect Remote Control Switch
Clean fa Perform Electrical Inspection
Check Sight Feed Oiler, Lube Pillow Block Bearings
Inspect Packing, Adjust Oiler, Lube Plunger Packing
Renew Packing
Inspect Valve Balls fa Seats, Check Conn. Rod
Inspect Drive Belt Tension
Clean fa Perform Electrical Inspection
Lubricate Motor
Lube VarLdrive Gear Motor, Cycle Handwheels
Check Oil Level
Change Oil
Check Oil Level
Change Oil
Clean fa Inspect Controller
Clean fa Inspect Remote Control Switch
Clean Conveyor
Lubricate Conveyor
Inspect Conveyor, Check Chain Oil Level
Clean fa Perform Electrical Inspection
Check Oil Level
24
48
12
6
12
12
12
12
6
18
12
24
30
48
30
36
12
36
120
36
18
36
18
54
12
30
12
30
48
30
60
42
36
36
12
10-36
5-20
4-10
4-10
10-20
4-20
4-10
5-20
5-30
20-36
4-20
7-20
20-36
30
24-30
36
3-10
5-30
120
5-30
5-40
48
5-15
5-40
5-20
15-60
5-20
15-60
30
24-30
40-540
10-40
10-30
36
5-10
-------
SELECTED WATER
RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
• 1. Rep •
3. Accession ffo.
w
4. Title A PLANNED MAINTENANCE MANAGEMENT
SYSTEM FOR MUNICIPAL WASTE WATER
TREATMENT PLANTS
5.
;; April 1973
7. Authorfs)
Sargent, Donald H., Rudich, David A;
3. Performing Orgsri' >a.tion
90060
W. Project No. •
11010 GWI
9. Organization . .
EnviroPlan, Incorporated, College Park, Maryland
and County of Fairfax, Fairfax, Virginia
•'13'. ' Tvne:>f Rerior'jind
re.poi
„ , „ .,,_-, ...-..- _-;..-..-,.,,..-.™.T..-,_, .,, ^ i; , . . -.,-:/•;_,. ..;..-,:.-..-. . ... fc
i; Sponwnzg Orgnnu<-i*'osa. U.S. Environmental Protectipn Agency Nov. 1971-April 1973
75. Supplementary Notes
11. Contract/Gram N'o.
Environmental Protection Agency report number,
EPA-600/2-73-004, November 1973.
.16. Abstract A Planned Maintenance Management System (PMMS) has been developed and
successfully demonstrated at the 18-MGD:. Lower Potomac Plant of Fairfax County, Va.,
establishing a model maintenance management program for wastewater treatment plants
throughout the United States. .
This PMMS provides for the specific maintenance needs of:each item of, plant equip-
ment and reduces the maintenance of complex equipment to simple procedures. For each
procedure the PMMS details the methods, materials, tools and personnel required;
schedules the task; and provides for data recording and feedback.
The success of this PMMS during the 12-month demonstration phase was measured by
a steady downward trend in the malfunction of mechanical equipment. Incipient failures
were detected in many cases and corrective action was taken to avoid breakdowns.
This report describes the PMMS in technical detail; discusses the installation of the
PMMS, including acceptance by the mechanics and coordination with plant operations;
and outlines the application of the PMMS to other wastewater systems.
This report was submitted-to fulfill Project Number 11010 GWI by EnviroPlan, Inc.,
College Park, Maryland, under contract to the County of Fairfax, Virginia, under the
sponsorship of the Environmental Protection Agency. Work was completed as of
July 1973.
17». Descriptors'*Waste Water Treatment, * Maintenance, *Management, *Scheduling,
*Manpower, Operation and Maintenance, Maintenance Costs, Equipment,
Mechanical Equipment, Hydraulic Equipment, Electrical Equipment, Instru-
mentation, Warning Systems, Control Systems
17b. Identifiers
*Planned Maintenance, *Maintenance Management, *Preventive Maintenance,
*Corrective Maintenance, ^Maintenance Procedures
17c. COWRR Field & Group
IS. .Availability
21. . .'.of
• 'Pases
Send To:
WATER RESOURCES SCIENTIFtC INFORMATION CENTER
U.S. DEPARTMENT OF THE INTERIOR
WASHINGTON. D. C. 2O24O
tractor Donald H. Sargent
:hn EnviroPlan, Inc.
WHS'.C 102 (REV. JUNE I 3'7 P
* U. S. GOVERNMENT PRINTING OFFICE : 1974 731-937/344
------- |