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 ona 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


Table 4, SAMPLES FROM LIST OF ADDITIONAL
EQUIPMENT DATA

ADDITIONAL DATA FOR PUMPS

TOH | GPM |sIze| IMP | RPM
13112 276S| 19200] 24] 24 378] Ses
13213 25.5] 14000] 24] 22 174] 585
13114 27 20] 20 57a] 665
22213 35 + 100} 4x4 800
22114 35 100} 4x4 800
221s 35 100} 4x4 800
23112 8 100} 4x9] 9 600
23112 8 100] 4x9] 9 600
35111 29 4200] 12] 12 378 | 1170
35112 29 4200] 12 {12 378 | 1170
35113 29 4200] 12] 12 378 | 1170
35411 25 1000] «6 | 12 875
36113 16.5] 1250 als 640
36114 16.5] 1250 car 640
43311 160 1s00] 5x8 | 23 778 | 1750
43312 160 1S00] 5x8] 13 7/8 | 1750
43411 60 1200] 5] 9 778] 1750
43412 60 1200] S| 9 778] 1750
43413 60 1200] 5 | 9 778 | 1750
43416 60 1200} 5 {| 9 778 | 1750

JAVOITIONAL DATA FOR ELECTRIC MOTORS
up | FRAME | RPM VOLTS AMPS PH

42221 065 | M48 3450] 115/230 | 648/364 | 1
42222 0.5 | M48 3450} 115/230] 6.8/3.6 | 1
42223 0.5 M48 3450 115/230 668/364 1
42321 0.5 | Maa 3450] 115/230} 668/3.4 | 1
42322 0.5 | M48 3450] 1157230] 6.8/3.4 | 1
42323 0.5 | Mae 3450] 115/230] 6.8/3.4 | 1
43321 100 ausup | 1770] 2307460] 2287114 | 3
43322 100 aasup | 1780] 2307460} 22871146 | 3
43421 30 a3zeuPy| 1800] 2307460 | 72.7/36.4| 3
43422 30 azzeurY| 1800] 230/460 | 72.7/36.4] 3
43423 30 azz26uPY| 1800] 2307460 | 72.7/36.4] 3
434246 30 A326UPY 1800 230/460 | 72+7/36.4 3
43521 Ss 213 3180 230/460 | 13+8/6.8 3
43522 5 213 3180] 2307460] 13.8/6.8 | 3
44121 0.75] sec 1725] 230/460] 3.171655] 3
44221 0.5 | 56 1140] 2207440] 1.970.95| 3
aazee O.17| F4a 1725 w5 34 [1

21


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:

Environmental Health Effects Research
Environmental Protection Technology
Ecological Research

Environmental Monitoring
Socioeconomic Environmental Studies

Rw

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.


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, suchas 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 invdlving 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.

eeeee

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


MAINTENANCE PROCEDURE SHEET Page 1 of 2 | MPS No, 5342 Q1)

EQUIPMENT NAME

Motor, Sludge Belt Conveyor

Average Time

S-1 18 min.
Plant Area Level Location S-2 min,
K 18
$23 min,
MAINTENANCE DESCRIPTION
Clean motor and perform electrical inspection.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag “out of service"
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
Safety tags Thermometer
500 volt megger Rags
Voltmeter Non-flammable solvent (LIX Cleaning Solvent or equivalent)
Ammeter
Obmmeter
Screv-driver
PROCEDURE
Preliminary—De-energize unit and tag “out of service."
Allow motor to cool to ambient temperature
To clean motor:
1, Clean exterioz 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 2
direct current for one minute. 3
NOTE 1: Use an ohmmeter on those circuits which would be damaged by a 500-volt "
megger. 5
5. Correct the insulation resistance measurement toa 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, g
or if the corrected reading is less than 40 megohms (Class A ) or 8 e
megohms (Class B), corrective action should be taken. z
(Continued) g
2

Figure A-6

75



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

11


MAINTENANCE PROCEDURE SHEET Page 30f 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 4
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 "0! 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, i
nicks or roughness. Inspect diaphragm for cracks or weakness. Replace "a
any defective parts, w

2

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, 3
freezing or any mechanical damage. 2

2, Restart chlorinator in accordance with current instructions, Remove safety | °
tag. =

NOTE 5: Calibrate flowrater valve (zero adjustment) before resuming normal =
operation. >

Figure A-1 (Cont)

70


Table 6. EXAMPLE OF WEEKLY PM SCHEDULE

Week 1
1111 M1 2133 Ml 5222 Q1
1112 Q1 2133 Q1 5224 Q1
1112 Al 2242 M1 5225 Ql
1113 Ql 2332 M1 5312 M1
1114 Al 2332 M2 5564 M1
1114 A2 2332 M3 5571 M1
1334 M1 2332 QL 5573 M1
2112 M1 2332 S1 5581 M1
2131 M1 2332 S2 5583 M1
2132 Ql 5221 M1 5711 Q1
2132 Q2 5221 M2 5712 Ql

Perform these plus all Daily and Weekly
Maintenance Procedures (MPs), keyed to
Maintenance Procedure Sheets (MPSs).

28


Table A-4. CROSS REFERENCE TO EQUIPMENT

CONFIGURATION LIST

Design
Engineering Code Pump Area |ID Number
A2 Raw Wastewater B 13112
A3 Raw Wastewater B 13113
A4S Raw Wastewater B 13114
Bl Return Sludge (RA-1) E 35111
B2 Return Sludge (RA-2) E 35112
B3 Return Sludge (RA-3) E 35113
C3 Excess Sludge E 36113
C4 Excess Sludge E 36114
D1 Dewatering E 35411
El Low Lift G 43411
E2 Low Lift G 43412
E3 Low Lift G 43413
E4 Low Lift G 43414
Fl High Lift G 43311
F2 High Lift G 43312
G3 Primary Sludge Cc 22113
G4 Primary Sludge Cc 22114
G5 Primary Sludge c 22115
Hl Primary Scum Cc 23111
H2 Primary Scum Cc 23112
Ji Secondary Scum Well F 37121
J2 Secondary Scum Well F 37122
Kl Sludge Plunger J 52211
K2 Sludge Plunger J 52212
K3 Sludge Plunger J 52213
K4 Sludge Plunger J 52214
Ll Scum Pit K 54211
Mil Influent Sampling G 42211
M2 Influent Sampling G 42212
M3 Influent Sampling G 42213
Nl Effluent Sampling G 42311
N2 Effluent Sampling G 42312
N3 Effluent Sampling G 42313
ol Sump B 14111
02 Sump B 14112
Pl Sump Cc 24111
P2 Sump Cc 24112
Ql Sump E 38111
Q2 Sump E 38112
Q3 Sump E 38113
Q4 Sump E 38114

99



SE

CORRECTIVE MAINTENANCE WORK ORDER

Date

Requested by

Required
Completion Date

Equipment Name and Number

1.D. No.

Ly TI

‘Serial No. Location

Indication of Trouble
1 broken part

D Worn part
Dea

Di noise

Oi smen
Dvitration

D eeaking

Dotter

Di diety, fovea
D vottaze

Di current

D Renetance
DD Fiow rate

O Pressure
Dspeea

When Discovered
Di starting

DD stopping

0 during operation
Didurme pm

Di buring cm
Oouring moo
During on

Dotter

Gause of Trouble
DD neat /cota/weather
DD Humidity moisture
D Foreign object

DD shock/vibeation

D wear

1 Equipment erect
improper installation

Di improper tubsication

Oi improper operation

Dloiner

Corrective Work Requested

Estimated Costs
Labor
Parts
Contractors

Totat

Estimated Down-Time

‘Approved by

Date

Job Ne.

Figure 8.

Form M5-$/72

Form M5, Corrective Maintenance Work Order



10,

ll.

SECTION VIII

REFERENCES

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.

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.

PACAF Supplement 1, Maintenance Management Manual. U.S. Air
Force. U.S, Government Printing Office, Washington, D.C. Report
No. AFM 66-1.

Vida, R.S. Modernizing Maintenance Techniques. Plant Engineering.
September 17, 1970,

Kittner, E,H. Planning and Scheduling of Maintenance in a Small
Plant. Plant Engineering. March 5, 1970.

Baronet, R.P. To Meet Today's Maintenance Needs—Formal Scheduling
a Must. Plant Engineering. January 21, 1971.

Carson, B., and J.E, Mailhos. Plan Carefully for a Sound Maintenance
Budget. Plant Engineering. March 7, 1968.

Fuchs, S.J, Planning Guidelines for a Small Plant Work Order System.
Plant Engineering. December 24, 1970.

Sullivan, J.A. Contractor's View of Contract Maintenance. (Presented
at AICHE 63rd Annual Meeting. Chicago. November 29-December 3,
1970. Paper No. 96.)

Sarappo, J.W. Contract Maintenance: It's Place in Chemical Plants.
Chem Eng, 76(25;264), November 17, 1969.

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.

60


on [lems or preceaure CHECK OYL LEVEL ~ SICHT [work Complvea (Signaveresh,
FEEDER - TOP=BOTT, CENTER SHAFT

jeer we pany
Mechanic's Name Reg. Hee oF ure vous

on at ner

Amps

Mepohme (care, 02 18° @)

Was there any indication of trouble? Trouble
Any change in operation of appearance?. . .
Any difference from similar unite? , .
Any broken or worn parts?. 6... ee
Any excess leaks, heat, noise, vibration? .

Any exceas dirt or corrosion?» ... 6.
Any fouling by foreign objecte?. . 2. .
Was insulation resistance too low? . . . «

Any improvements to procedure, tools or parte? . . .
Any improvements to safety precautions? .... . - .

oo ooD0000
2
oo ooonooog

IF ANY TROUBLE, FILL OUT REVERSE SIDE

Figure 4. Form M3, Preventive Maintenance Work Record

REPORT OF TROUBL

fatestion ot Trouwie ‘Covve of Trouble

Deaton pare earsco/woatner
Dstoporne Dtemisicy/messtare
Dowring operation
Qoovring PM
Doering coe
Deresvare ‘Dioueiny s100
Ospece Dhosring O11 Dlimproper insatation
Dower Cimproper tbricstion

‘Chack equipment wee tgged ot

sii

Figure 5. Form M3 (Reverse), Report of Trouble

31


SECTION X

APPENDICES

Table of Contents

Appendix
I Job Descriptions for Maintenance Personnel
af Figures A-1 through A-18, Examples of
Maintenance Procedure Sheets. see ee
il Table A-l through A-10. ......

63

Page

64

67

95


Table A-4 (Continued)

Design
Engineering Code Pump Area |ID Number
Rl Sump G 44111
Sl Sump J 51111
Tl Sump K 53811
T2 Sump K 53812
Ul Sump H 24113
vil Seal Water G 43511
v2 Seal Water G 43512
wl Meter Purge Water K 53611
w2 Meter Purge Water K 53612
x1 Sump D 38115
X2 Sump D 38116
-- Sludge Plunger K 53311
-- Sludge Plunger K 53312
-- Sludge Plunger K 53313
-- Ferric Chloride K 56411
-- Ferric Chloride K 56412
-- Ferric Chloride K 56413
-- Lime (Screw) K 55711
-- Lime (Plunger) K 558i1
-- Vacuum K 59111
-- Vacuum K 59112
-- Filtrate K 59411
-- Filtrate K 59412
-- Oil K 63311
-- Oil K 63312
-- Oil K 63313
-- Hydraulic Fluid K 53741

100


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

Al


MAINTENANCE PROCEDURE SHEET Page 1 of 2

MPS No. 5921 W1

EQUIPMENT NAME
Sludge Vacuum Filter

Average Time

S-1 min.
Plant Area [ee Location S-2 min,
K U S-3 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.
ll. Turn on valve to top wash water spray pipe for cleaning springs. Py
12. Hose down filter, conditioning tank and vat. a
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, m
. 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. z
5
To Check Tine Bar Alignment: °
1. Check Tine bar alignment; adjust as necessary to center tines between 3
the coil springs.
3
(Continued) =
3

Figure A-12

83



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.


CONTENTS

Page
Abstract ii
List of Figures iv
List of Tables v
Acknowledgements vi
Sections
I Conclusions 1
ane Recommendations 3
Ul Introduction 5
Iv Background of Maintenance Management 9
Vv Description of the Planned Maintenance
Management System 14
vI Program Installation and Demonstration 46
VIL Application To Other Wastewater Treatment Plants 55
vu References 60
IX Glossary 62

x Appendices 63

iii


CORRECTIVE MAINTENANCE SUMMARY

Job No. | Equipment Name

Equip.
LD.

Status
Codex

Description of Work | Priority
To Be Done Code**

Work Order
Date

‘Completion
Date

Remarke

ZL/S-(284900¥) LW UII0,

*Equipment Status Code

O = Operational

N = Nonoperational
R = Reduced capability

‘**Priority Code

U - Urgent repairs to correct conditions which prevent the plant
from operating or which involve the health and safety

of personnel

N - Needed repairs to correct conditions which seriously impair
plant efficiency or plant reliability

R - Routine repairs, tests and inspections

€ = Convenience items

Figure 11, Form M7 (Reverse), Corrective Maintenance Summary

38



MAINTENANCE PROCEDURE SHEET

Page 2 of 3 | ues No. 4131 Ab

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.

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

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 "0" rings sparingly.

4, Insert metering tube assembly into dispenser, holding the tube the same as
in the first step. Makr sure adaptor "0" 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.

*

. 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 "0" rings and replace if necessary.

o

. On reassembly, lubricate "0" 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)

€ jo Zafeg

TY TeIb “ON SAW

Figure A-1 (Cont)

69



MAINTENANCE PROCEDURE SHEET Page lof 1 |MPS No, 5344 A2

EQUIPMENT NAME
Control, Sludge Belt Conveyor

Plant Area

K

Level ‘Location 8-2
S-3

Average Time
S-1 a0 min.
min;
minJ

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 Spare indicator lights
Flashlight Dusting brush Spare fuses

Safety tage Vacuum cleaner (non-mettalic nozzle) Spare overload heaters
Voltage tester Contact dressing file Spare contacts

500 volt megger

Obmmeter 1/4-inch drive socket set

PROCEDURE

Preliminary— De-energize unit ond tag "out of service".

Tag any alternate switches in other locations.

To clean and inspect remote control switch:

1
2
3.
4
5.
6.
1.
8.
%

10,

AL
Bra

NOTE:

13,
14,
in
16,

Open door or remove cover,

Test with voltage tester to ensure circuit is de-energized,

Remove accumulated dust and dirt with brush, soft cloth or vacuurn cleaner.
Wipe all bus insulators and bus barriers.

Inspect bus joints and bus supports and tighten if necessary.

Check all wiring for deterioration of insulation and tighten all connections.
Inspect components and wiring for evidence of overheating.

Inspect overload heater for distortion; replace as required.

Inspect contacts, If beads have formed due to arcing, or where rough, burned
or pitted, replace contacts or dress with contact dressing file.

Remove draw-out units and check stabs and wiring. Remove accumulated
dust from barriers and in area of stabs.

Manually check for binding in all moving parts.

Megger all terminals and circuits to ensure insulation resistance is adequate,

Instruments or control devices sensitive to megger voltage should be isolated
from circuit, or an ohmmeter should be used.

Check all indicating lights and replace as required,
Check unit door interlock for proper operation,
Check door or cover gasket and replace as required,
Close door or replace cover,

Perform this procedure on any alternate switches in other locations.
Remove safety tage and energize unit,

T jot ofeg

2V FFES “ON SHIN

Figure A-8

78


EPA-600/2-73-004
NOVEMBER 1973

Environmental Protection Technology Series



Table A-5 (Continued)

Remote Remote

MPS No. Equipment Controlled Control ID | Control ID
5363 A2| Meter Purge Water Pumps W 7921 7941
5423 A2| Scum Pump L 7923 7943
5544 A2| Lime Dust Collector Fan 7928 7948
5547 A2| Lime Dust Collector Vibrator 7929 7949
5551 Al| Lime Gravimetric Feeder 7940

5563 A2| Lime Slurry Tank Mixer 7927 7947
5574 A2| Lime Slurry Pump No. 1 (Screw) 7925 7945
5584 A2} Lime Slurry Pump No, 2 (Plunger) 7926 7946
5624 Al] Control, Air Compressor 7914 7937
5633 Al | Motor, Ferric Chloride Tank Mixer 7919 7939
5644 A2| Ferric Chroride Feed Pumps 7918 7938
5814 A2| Sludge Conditioning Tanks 7912 7932
5913 A2| Vacuum Pumps 7915 7935
5925 AZ| Vacuum Filter Drums 7913 7933
5934 A2| Filter Agitators 7914 7934
5943 A2| Filtrate Pumps 7916 7936
6117 A2] Incinerator Mechanisms 7951

6413 A2| Cooling Air Fans 7952

6423 A2| Turbo Blowers 7953

6433 A2| Foul Air Fan 7954

6533 A2| Exhaust ID Fans 7955

6614 AZ| Ash Bucket Elevators 7956

6624 A2| Ash Screw Conveyors 7957

6644 A2| Rotary Ash Conditioner 71958

6654 A2| Ash Vane Feeder 7959

6711 Al | Sump Pump T 7924 7944

104



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 wastewater 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.

ii


sol

Table A-6.

CROSS REFERENCE, ALARM SENSORS TO

ALARM INDICATORS

Operating Unit and Sensor

Alarm Condition

Alarm Indicators

1D Name Area |Levei] Loc +I [Area] 1D [Area] WD | Area
11111 | Bar Screen No, 1 B u| N_ |.High Differential 77202] B
11112 | Bar Screen No, 2 B U Ss High Differential 77203 B
13122 | Motor, Raw Wastewater Pump A2 B u| N | Power Failure 77206] B
13123 | Motor, Raw Wastewater Pump A3 B u| M | Power Failure 77207] B
13124 | Motor, Raw Wastewater Pump A4 B U Ss Power Failure 77208 B
13311 |Raw Wastewater Wet Well Control B U Low Level 77204 B 77301 E
13311 |Raw Wastewater Wet Well Control B U High Level 77205 B 77302 E
13511 | Strainer, Pump Seal Water B L Strainer Clogged 77201] B
32212 | Blower No. 2 E u| w | Low Oil Pressure 77320|  E
32213 | Blower No. 3 E u| M | Low Oil Pressure 77321! E
32214 | Blower No. -4 E u]| E | Low Oil Pressure 77322) E
32640 | Blower Building Compressors E L| S | Instrument Air Failure | 77314] E
33311 | Secondary Clarifier No. 1 F Nw] Overload 77312) E
33312 | Secondary Clarifier No. 2 F NE| Overload 77313| E
35221 | Strainer, Pump Seal Water E L]| W | Strainer Clogged 77319|  E
35321 | Return Sludge Wet Well E u| s_ | Low Level 77303] E
35321 | Return Sludge Wet Well E u] Ss | High Level 77304 E
38115 |Cross-Tunnel Sump Pump X-1 D L | w | Sump Pump Failure 77317] E
38116 }Cross-Tunnel Sump Pump X-2 D u| E | Sump Pump Failure 77318] E*
- 41221 | West Evaporator G u| w | High Water Temperature | 77401{ G
41222 |East Evaporator G u| E | High Water Temperature | 77402| G
41230 |Chlorine Pressure Reducing Valves | G u Motor Valve Failure 77403] G
52111 | Scraper Drive, Thickener No. 1 J N | Overload 77501 J | 77601] K
52112 | Scraper Drive, Thickener No. 2 J S | Overload 77502| J | 77601] K
53121 | Sludge Storage Tank Air Compressor] K oO] N | Electrical Failure 77605] K
55211 | Lime Storage Bin K u High Level 77602] K
55212 |Lime Storage Bin K L Low Level 77603| K



Table 5. SAMPLE FROM LIST OF
MAINTENANCE PROCEDURES

(keyed to Maintenance Procedure Sheets [MPss])

‘Skill/ Minutes

ed, Week

MP No, Task Description 172/43 Ne
‘ll 2 Bar Screen Mechanical Cleaner

111 DI Lubricate bar screen 20 | 20 1

1111 D2 Inspect rake assembly and chain 15} 15 L

1111 ML Inspect counterweight shock absorbers 18 1
a1 2 Motor, Bar Screen Cleaner

1112 Q1 Clean motor and perform elec. inspection 18 18 1

M112 Al Lubricate motor 30 1
“13 2 Drive, Bar Screen Cleaner

1113 Wi Check oil level wz 1

1113 QL Change oil 30 1
#1114 2 Control, Bar Screen Cleaner

1114 Al Clean and inspect controller 48 48 r

1114 A2 Clean and inspect remote control switch 30 1
#1121 3 Conveyor, Bar Screen Cleanings

1121 Wi Inspect and lubricate conveyor 24 1
#1122 3 Motor, Conveyor, Bar Screen Cleanings

1122 ML Inspect drive belt(s) tension 12 3

1122 QI Clean motor and pérform elec. inspection 18 18 3

1122 Al Lubricate motor 24 3
#1123 3 Drive, Conveyor, Bar Screen Cleanings

1123 Wi Check oil level 12 1

1123 SI Change oil 30 3
1124 3 Control, Conveyor, Bar Screen Cleanings

1124 Al Clean and inspect controller 48 48 3

1124 Az Clean and inspect remote control switch 30 3
*1211 2 Grinder, Bar Screen Cleanings

1211 Wi Lubricate grinder 18 1

q211 M1 Inspect drive belt(s) tension 18 2

1211 M2 | Inspect grinder 90 | 180 2
#1212 2 Motor and Drive, Grinder, Bar Screen Cleanings

1212 Q1 Clean motor and perform elec. inspection 18 18 6

1212 Al Lubricate motor 30 6
#1213 2 Control, Grinder, Bar Screen Cleanings

1213 Al Clean and inspect controller 48 48 6

1213 AZ Clean and inspect remote control switch 30 6
#1311 3 Raw Wastewater Pump A

1311 Wi Inspect packing gland adjustment 12 1

1312 RL Renew packing 180

1311 SI Lubricate pump bearings 12 9

1311 s2 Lubricate coupling 9

*Equipment name

26



MAINTENANCE PROCEDURE SHEET Page | of 2. |MPS No.

5921 RI

EQUIPMENT NAME

Average Time

Sludge Vacuum Filter S-1 min,
Plant Area K [eet v Location, S-2 __120_ min,

$3 120_ min,
“MAINTENANCE DESCRIPTION

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

PROCEDURE

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 | 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

2 JOT Beg

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)

Te (265 "ON Sd,

Figure A-13

85



MAINTENANCE PROCEDURE SHEET Page lof 2. |MPS No. 5364 Sl

EQUIPMENT NAME Average Time
Flowrate, Flushing Water (NI) S-1 48 min
Plant Area Level ‘Location S-2 min,
kK L 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

Adjustable wrench Rags

Pipe wrench Lithium-base grease type lubricant, Molykote G or equal
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

7301 Beg

off water at top of pipes.
5, Attach the electrical interval timer to terminals 10 and 11 of the terminal
strip.

(Continued)

1S PIES “ON SAW

Figure A-10

80



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,


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


MPS No. 7700 S6

Page3 of3

Page 3 of 3 MPS No. 7700 $6

MAINTENANCE PROCEDURE SHEET

PROCEDURE (continued)

Ta ]am[ omer wana eT ep aT curou Sioa] women |e
a sreze{ 9 [ou] sanneg owes | | a | sayog Suipuing azpnig | z17¢2 5
Mf Loree ‘dwatuea ar win | os] Ww x” 2 (ON Zoqeseuyouy ‘zepsorzy “duiaL | 26810 s
x sous] dong soresoour tut |g | me | | fo Souessuot caspsoory dune fente |
x | éovee Tied ug Wey x ‘og aey| tee9 |e
w | poets pasdoqD s2uyeaig sia a TON FaqQnz2g OF TOIEMm SuyYENIT| 21259 z
ow | poLee pesdoqg saujers | N] a ‘| HW TON Zaqqnacg oF raxeMm BuryEMTS | T1259 z
a | gone peddoig yeus | s | 7 m 2 ‘ON roveraUsIuT | 29119 i
mM | zoeee peddors yeas | N | T mw (ON s0yesouroUT | 19TT9 t
ox) ales} a oa] eorew — a | maum
comnpuog ety é
sa0yeo]puy we aosneg pus yup Suyyesedg ns Sat

Figure A-17 (Cont)
92



MAINTENANCE PROCEDURE SHEET Page lof 1 |MPS No. 4221 M1

EQUIPMENT NAME Average Time
Sampling Pump M, Chlorination Influent S-1 min.
Plant Area Level Location $-2 __l2__ min,
8-3 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 with 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 3
box packing as described on MPC R-l. é

3

3. Remove safety tag and energize circuit. +
2

‘4

5

a

z

°

=

E

Figure A-2

71



Date [Mechanic's Name

Reg.Hrs

Mechanic's Name

Reg.Hrs | OT Hrs

OT Hrs fos

REPORT OF TROUBLE

Broken part
Worn part
at

Noise
‘Sme11
Vibration
‘Leaking
Other

Tol,

INDICATION OF TROUBLE’

Dirty, fouled
Voltage
Current
Resistance
Flow rate
Pressure
Tspeed

total

WHEN DISCOVERED
Starting
Tstopping
“During operation
TDuring PM
“During CM
“During MOD

CAUSE OF TROUBLE
|_Heat/Cold/weather
Humidity /moisture
TForeign object
|Shock/vibration
TWear
[Equipment defect
‘Timproper installation
Timproper lubrication
TImproper operation
Tother

Remarks and Recommendations.

Gheck if equipment was

tagged out of service

Figure 6, Form.M3X, Variation of Form M3*

*Summary of listing on reverse side of various maintenance procedure sheets.

32



Resistance Correction Factor to 70° F.

INSULATION RESISTANCE CORRECTION—multiply measured
resistance correction factor
Minimum corrected resistance:

Class A insulation, 40 megohms
Class B insulation, 6 megohms

nan wo

»

Nn Ww

one

\y

Cy
Wh

°

0.08
0. 06

0,04
0.03

0. 02 J

0 10 20 30 40 50 60 70 80 90 100 110 120

Ambient Temperature, °F.

Figure 12. Corrections to Measured Insulation Resistance

44


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.

49


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


MAINTENANCE PROCEDURE SHEET Page 1 of 1

MPS No, 5214 Q1

EQUIPMENT NAME
Gear Reducer, Sludge Thickener

Average Time

S-1 min.

Plant Area J | Level Location

S-2 ___20__ min,

$-3 min.

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 Allen wrench
Safety tags Lubricant

Container Grease gun filled with Lubriplate No, 630AA or

Pipe wrench equivalent
Combination wrench
Flashlight

PROCEDURE
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.
LL, Check oil levels.

12, Replace split cover.

13, Remove safety tag and energize unit.

T JOT Bea

TO F175 "ON SAN

Figure A-5

74



MAINTENANCE PROCEDURE SHEET Page2 of 2 | MPS No. 5921 WI

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 overatretch springs.
To Inspect Spray Nozzles:

1, Inspect spray nozzles for clogging; clean as required.
2. Remove safety tag and return unit to service.

2 jo? a8eq

*ON Saw

1M 126$

Figure A-12 (Cont)

84



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


MAINTENANCE PROCEDURES.

Table A-9.
IN CATEGORY B*

MPS No. Equipment Maintenance

6111 Q1 Incinerator mechanism Change oil, inspect & lubricate

6111 Q2 Incinerator mechanism Inspect incinerator

6111 Q3 Incinerator mechanism Inspect shear pin

6112 Ql Motor, incinerator mechanism Clean and perform electrical
inspection

6112 S1 Motor, incinerator mechanism Lubricate motor

6113 Sl Drive, incinerator mechanism Adjust Hi & Lo speed stops

6115 Sl Gear reducer, incinerator Change oil

mechanism

6117 Al Control, incinerator mechanism | Clean and inspect controller

6117 A2 Control. incinerator mechanism | Clean and inspect remote control
switch

6411 Ql Cooling air fan Clean and inspect fan

6411 Q2 Cooling air fan Inspect drive belt tension

6412 Ql Motor, cooling air fan Clean & perform electrical
inspection

6412 Q2 Motor, cooling air fan Lubricate motor

6413 Al Control, cooling air fan Clean and inspect controller

6413 A2 Control, cooling air fan Clean & inspect remote control
switch

6421 S1 Turbo blower Clean and inspect blower

6422 Ql Motor, turbo blower Clean and perform electrical
inspection

6422 S1 Motor, turbo blower Lubricate motor

6423 Ql Control, turbo blower Check oil and gas interlocks

6423 Al Control, turbo blower Clean and inspect controller

6423 A2 Control, turbo blower Clean and inspect remote control
switch

6511 Ql Scrubber Clean and inspect scrubber

6531 Ql Exhaust ID fan Lubricate fan bearings

6531 Q2 Exhaust ID fan Inspect drive belt tension

6531 Sl Exhaust ID fan Clean and inspect fan

6531 S2 Exhaust ID fan Inspect foundation bolt tightness

6532 Q1 Motor, exhaust ID fan Clean and perform electrical
inspection

6532 S1 Motor, exhaust ID fan Lubricate motor

109



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.8. Government Printing Office, Washington, D.C. 2002


Table A-4 (Continued)

Enginecrnn Code Receiver Area |ID Number
A3 Mixed Liquor Flow From No. 3} E 71525
A4 Mixed Liquor Flow From No. 4] E 71526
AZ Total ML Flow (A3 and A4) E 71511
AT Total ML Flow (A3 and A4) L 71111
B3 Return Sludge to No. 3 E 71523
B4 Return Sludge to No. 4 E 71524
B7 Total Return Sludge (B3& B4) E 71512
BT? Total Return Sludge (B3 & B4) L 71112
G3 Wastewater to No. 3 (A3 - B3) E 71521
C4 Wastewater to No. 4 (A4 = B4) E 71522
CT Total Wastewater (C3 and C4) E 71513
D XS Sludge to Thickeners E 71514
D XS Sludge to Thickeners L 71113
E Total Flow to Thickeners E 71515
Fl Primary Sludge to No.1 Degrit] H 71411
F2 Primary Sludge to No.2 Degrit| H 71412
F4 Total Primary Sludge (F1&F2)| E 71516
F4 Total Primary Sludge (F1&F2)| C 71311
G2 Blower No, 2 Output E 71534
G3 Blower No. 3 Output E 71535
G4 Blower No. 4 Output E 71536
G6 Total Blower O'put (G2&G3&G4)}_ E 71518
H4 Air to 3A and 3B E 71531
H5 Air to 3C and 4C E 71532
H6 Air to 4A and 4B E 71533
H10 Total Air to Aerators (H4, 5&6) E 71519
H10 Total Air to Aerators (H4, 5&6) L 71115
K Chlorine Residual E 71581
K Chlorine Residual L 71116
K Chlorine Residual G 71613
L Return Sludge Well Level E 71527
Nl Flushing Water Flow K 71811
ol Raw W'water Flow (C7-E-N1) E 71517
ol Raw W'water Flow (C7-E-N1) L 71114
Ol Raw W'water Flow (C7-E-N1) A 71121
ol Raw W'water Flow (C7-E-N1) B 71211
ol Raw W'water Flow (C7-E-N1) G

102

71612



CM

MP

MPS

PM

PMMS

SECTION IX

GLOSSARY

Corrective Maintenance
Maintenance Procedure
Maintenance Procedure Sheet
Preventative Maintenance

Planned Maintenance Management System

62


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


Table A-2, INDICATORS AND MODIFIERS

Indicators

Modifiers

a
12
13
14
15
16
17

18
22
23
24
25
26

31

33
34

41
42
43
44
45

51
52
53
54

Start/Turn on
Stop/Turn off

Open

Shut/Close

Tune, adjust, aliga, calibrate
Safety hazard

Defective material

Broken, cracked, bent
Corroded/Rusted
Dirty/Fouled

Leaking

Vibration
Alignment/Fit

Smell
Heat/Temperature
Noise
Smoking/Arcing

Flow rate
Speed/Rotation
Frequency
Pressure
Suction/Vacuum

Current
Voltage
Resistance
Power

97

Yourene

oe @

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



EQUIPMENT REFERENCE DATA

‘Equipment Name and Number Type No. ] IWNo. | Plant Area] Level [Location in Arew Ret. Location
Manufacturer [Decal Representative [Part or Model Number [Serial Number
Relevance Drawing [ReTarence Catalog finstruciTon Book [Date Pat to Service
Electric Motor Pump
co Tame TM [capacity ror a x
Varta ape ae impelier Teen tio
Type Specification Type Tantallation Type
Dseries Dopen centrifuged (CHorisontal Doear
shunt Deep. proot OPtunger D vertical Ov-pew
D syachronoue ODrip proof Odiapheagm [1 submerged Dctaia
Dinduction O Totally enclosed Ocear [Lubrication OVaridrive
o o. Oscrew O weer
o Dou
DGrease
Bearings tops
Disieeve Gen ____[)Rotter Disteeve Daan Drctier pau
Lubricant Labricant Lubricant
Other Equipment

Type, Speed, Size, Capacity, Range

Bearings, Lavricant

Form HI-STZ

Figure 1,

22

Form M1, Equipment Reference Data


Table 2. SAMPLES FROM EQUIPMENT CONFIGURATION LIST

ID Equipment Name Itypq Location
520 SLUDGE THICKENING
521 Thickeners
52111 | Sludge Thickener No. | nfs N
52112 | Sludge Thickener No. 2 iy s s
52121 | Gear Motor No. 1 ats N
52122] Gear Motor No. 2 aps s
52131 | Chain Drive No. 1 ai] 7 N
$2132 | Chain Drive No. 2 alts s
$2141] Gear Reducer, No. 1 al] N
52142 | Gear Reducer, No. 2 al| J s ‘
$2151 | Ventilator, No. 1 Thickener 72| 5 N
52152 | Ventilator, No. 2 Thickener ws s
52161 | Control, No. 1 33] 3 N
52162 | Control, No. 2 33] 5 s
522 Pumping
52211 | Duplex Plunger Pump No, 1 ays ob NW
52212 | Duplex Plunger Pump No. 2 2zjr ob NE
52213 | Duplex Plunger Pump No. 3 zz}iou sw
52214| Duplex Plunger Pump No. 4 2z}a ou SE
52221| Motor, Pump No. 1 aipgou Nw,
52222 | Motor, Pump No. 2 aif aoL NE
52223 | Motor, Pump No. 3 ai] ou sw
52224] Motor, Pump No. 4 ayo SE
52231 | Variable Speed Reducer, No. 1 afgoL NW
52232 | Variable Speed Reducer, No. 2 41] ou NE
52233 | Variable Speed Reducer, No. 3 au; oou sw
52234 | Variable Speed Reducer, No. 4 41) 3 L SE
52241 | Gear Drive, No. 1 a1]3 ou NW
52242 | Gear Drive, No. 2 41)s ou NE
52243 | Gear Drive, No. 3 ai} Jou sw
52244 | Gear Drive, No. 4 41,3 u SE
52251 | Reduction Gear No. 1 4p ou NW
52252 | Reduction Gear No. 2 al] Jou NE
52253 | Reduction Gear No. 3 41} ou sw
52254 | Reduction Gear No. 4 ai} r ou SE
52261 | Control, No. 1 a3} 3 L NW
52262 | Control, No. 2 a3) 3 u NE
52263 | Control, No. 3 33) 3 1 sw
52264| Control, No. 4 33) 3 4 SE
523 Flow Measurement
52311 [Thickened Sludge Magnetic Flowmeter | 61] JL
52321 | Flow Transmitter eifs ou
52331 | Influent Sludge Channel Level Recorder} 63} J O w

Location areas (refer to pages 5 and 6):

a
1

sludge thickening
plant shop and service building
O = outside

a

18


Table A-4 (Continued)

Design .

Engineering Code Transmitter Area |ID Number
A3 Mixed Liquor From No. 3 E 31613
A4 Mixed Liquor From No. 4 E 31614
B3 Return Sludge to No. 3 D 35513
B4 Return Sludge to No. 4 D 35514
D Excess Sludge to Thickeners E 36311
E Total Flow to Thickeners E 36321
Fl Primary Sludge to No, 1 Degrit| H 22311
F2 Primary Sludge to No, 2 Degrit] H 22312
G2 Blower No. 2 Output E 32312
G3 Blower No, 3 Output E 32313
G4 Blower No. 4 Output E 32314
H4 Air to 3A and 3B E 31343
H5 Air to 3C and 4C E 31340
H6 Air to 4A and 4B E 31344
K Chlorine Residual in Effluent G 42123
L Return Sludge Well Level E 35321
Nil Flushing Water K 53640

101



IPMENT INTENANCE_ RECORD

[Equipment Name and Number LD, Na, Pera Ne, [Location (ecord Sheet No.
Mpc No. Labor [observations Volts ‘Amps Meg Ohms

pate! or Remarks and Data
Job No. {sbitt|imtiate| Hours] ind. |Mod, [Leg 1|Leg 2{Leg 3|Leg 1] Leg 2|Leg 3] Leg 3] Leg 2 {Leg ?

Figure 3.

Fora ME-SITE

Form M2, Equipment Maintenance Record

30


It

Table A-10.

ESTIMATED AND ACTUAL TIME (Minutes) FOR PM ACTIONS

. . Estimated] Range of
MP No. Equipment PM Action Time | Actual Time
1111 D1 | Bar Screen Lubricate Bar Screen 24 10-36
1111 D2 | Bar Screen Inspect Rake Assy, & Chain 48 5-20
1311 Wl | Raw Wastewater Pump Inspect Packing Gland Adjustment 12 4-10
1312 Wl | Motor, Raw Wastewater Pump Check Oil Level 6 4-10
2123 W1 | Reduction Gear, Sludge Collector Check Oil Level 12 10-20
2211 W1 | Primary Sludge Pump Inspect Packing Gland Adjustment 12 4-20
2211 W2| Primary Sludge Pump Check Bearing Oil Level 12 4-10
2311 M1 | Primary Scum Pump Inspect Packing Gland Adjustment 12 5-20
2312 Ml | Motor, Primary Scum Pump Lubricate Motor Base Adjusting Screw 6 5-30
2312 Q1 | Motor, Primary Scum Pump Clean & Perform Electrical Inspection 18 20-36
3511 W1 | Return Sludge Pump Inspect Packing Gland Adjustment 12 4-20
3512 W2 | Motor, Return Sludge Pump Lubricate Motor Bearings 24 7-20
3512 Al | Motor, Return Sludge Pump Lubriflush Varidrive Motor 30 20-36
3514 Al | Control, Return Sludge Pump Clean & Inspect Controller 48 30
3514 A2 | Control, Return Sludge Pump Clean & Inspect Remote Control Switch 30 24-30
4342 Q1 | Motor, Low Lift Pump Clean & Perform Electrical Inspection 36 36
5221 D1 } Sludge Plunger Pump Check Sight Feed Oiler, Lube Pillow Block Bearings 12 3-10
5221 W1 | Sludge Plunger Pump Inspect Packing, Adjust Oiler, Lube Plunger Packing 36 5-30
5221 Rl | Sludge Plunger Pump Renew Packing 120 120
5221 M1 | Sludge Plunger Pump Inspect Valve Balls & Seats, Check Conn. Rod 36 5-30
5221 M2| Sludge Plunger Pump Inspect Drive Belt Tension 18 5-40
5222 Q1 | Motor, Sludge Plunger Pump Clean & Perform Electrical Inspection 36 48
5222 $1 | Motor, Sludge Plunger Pump Lubricate Motor 18 5-15
5223 W1]| Variable Reducer, Sludge Plunger Pump | Lube Varidrive Gear Motor, Cycle Handwheels 54 5-40
5224 W1| Gear Drive, Sludge Plunger Pump Check Oil Level 12 5-20
5224 Ql | Gear Drive, Sludge Plunger Pump Change Oil 30 15-60
5225 W1] Reduction Gear, Sludge Plunger Pump | Check Oil Level 12 5-20
5225 Q1 | Reduction Gear, Sludge Plunger Pump __| Change Oil 30 15-60
5226 Al | Control, Sludge Plunger Pump Clean & Inspect Controller 48 30
5226 A2 | Control, Sludge Plunger Pump Clean & Inspect Remote Control Switch 30 24-30
5341 W1]| Sludge Belt Conveyor Clean Conveyor 60 40-540
5341 W2]| Sludge Belt Conveyor Lubricate Conveyor 42 10-40
5341 M1| Sludge Belt Conveyor Inspect Conveyor, Check Chain Oil Level 36 10-30
5342 Ql | Motor, Sludge Belt Conveyor Clean & Perform Electrical Inspection 36 36
5343 W1| Drive, Sludge Belt Conveyor Check Oil Level 12 5-10



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.

54


Table A-8. MAINTENANCE PROCEDURES
IN CATEGORY A*

MPS No, Equipment Maintenance
6111 Dl Incinerator mechanism Check oil level
6111 M1 Incinerator mechanism Lubricate master gear & pinion
6113 M1 Drive, incinerator mechanism Lubricate disk, oiler, screw
6115 Dl Gear reducer, incinerator Check oil level

mechanism
6116 Mi Limit switch, incinerator Check switch operation

mechanism
6411 Wl Cooling air fan Lubricate fan
6611 WL Ash bucket elevator Lubricate elevator
6613 Wl Drive, ash bucket elevator Check oil level
6621 W1 Ash screw conveyor Lubricate conveyor
6623 Wl Drive, ash screw conveyor Check oil level

*These procedures are to be performed without shutting down the equipment.

108



MAINTENANCE PROCEDURE SHEET

Page lof 1 |MPS No. 4221 Rl

EQUIPMENT NAME
Influent Sampling Pump M

Plant Area

nan

1

; 2
Location

G Level L | 0c: 3

Average Time

min,

180 min.

min.

MAINTENANCE DESCRIPTION

Renew packing.

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

24 Gauge Wire
Packing Puller

Wire brush Combination Wrench

Safety

Tags

Packing
6-inch Slip Joint Pliers

PROCEDURE,

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.
4
5.
6.

Remove lantern ring.

Remove remaining packing.

Glean stuffing box and sleeves; inspect for wear.
Clean packing gland and bolts with wire brush,

NOTE 2: Angle cut packing ends and stagger’ joints around shaft while installing.

Install rings of packing (2 rings required).

Reinstall lantern ring.

Install rings of packing (2 rings required).

Reinstall packing gland and tighten packing gland nuts handtight,

Remove wire and safety tags; open suction and discharge valves.
Remove safety tag and energize circuit,

Operate pump for two hours to "run-in'' the packing; adjust packing gland
nuts for greater than normal leakage during this "run-in!

Readjust packing until there is a slight leakage.

Stop pump if not needed for service.

1 y0 1 obeg

‘ON Say!

Te zy

Figure A-3

72



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 M1 is for
listing parts which are likely to be replaced. The basic purpose of
Form M1 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 way.

/
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 allinclusive. 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


MAINTENANCE PROCEDURE SHEET Page | of 3

MPS No, 7700 S6

EQUIPMENT NAME
Alarm Systems— Area K (Incineration Operations)

Average Time
S-1 —A0__ min.

Plant Area K [ Level ‘Location

$-2 __60___ min,
S-3 60 i

MAINTENANCE DESCRIPTION

Test alarm systems by simulating alarm con

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.

€ joy Beg

9$ 0022 “ON SAW

Figure A-17

90



SECTION Lil

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) withtwo 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 purnps, two excess (waste) sludge pumps and other major
equipment items.


MAINTENANCE PROCEDURE SHEET Page l ofl |MPS No, 5214 W1

EQUIPMENT NAME
Gear Reducer, Sludge Thickener

Average Time

S-1 min,
Plant Area Level Location s-2 __#2 __ min.
8-3 min,
MAINTENANCE DESCRIPTION
Check oil condition and oil level.
SAFETY PRECAUTIONS
Observe standard safety precautions
De-energize unit and tag “out of service"
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 ina 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. S
5. Refill to level marks if necessary. 3
NOTE 2: Reservoir is filled from the top of the drive head. -
NOTE 3: The following lubricant should be used: a
(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. 5
a
Zz
°
g
8
=
z

Figure A-4

73



MAINTENANCE PROCEDURE SHEET Page lof 1 |MPS No. 5364 W1

EQUIPMENT NAME

Average Time
Flowrate, Flushing Water (NI)

S-1 min,
Plant Area Level Location s-2 __12__ min,
K L
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.
PT
S
a
°
2
&
3
a
Zz
2
g
z
=
2

Figure A-9

79



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.


Table A-7, INCINERATION EQUIPMENT WHICH MAY NOT
BE SHUT DOWN ARBITRARILY

ID Number Equipment
6111 Incinerator mechanism
6112 Motor
6113 Drive
6115 Gear reducer
6116 Limit switch
6117 Control
6411 Cooling air fan
6412 Motor
6413 Control
6421 Turbo blower
6422 Motor
6423 Control
6511 Scrubber
6531 Exhaust ID fan
6532 Motor
6533 Control
6611 Ash bucket elevator
6612 Motor .
6613 Drive
6614 Control
6621 Ash screw conveyor
6622 Motor
6623 Drive
6624 Control

107


MAINTENANCE PROCEDURE SHEET! Page lof1 |MPS No. 5344 Al

EQUIPMENT, NAME
Control, Sludge Belt Conveyor se

Plant Area Level Location S-2
K 8-3

Average Time

min,
min,
min.

MAINTENANCE DESCRIPTION

Clean and inspect controller.

SAFETY PRECAUTIONS

Observe standard safety precautions
Tag "out of service",

TOOLS, PARTS, MATERIALS, TEST EQUIPMENT

Rags Vacuum cleaner--non-metallic nozzle
Flashlight 1/4 inch drive socket set

Safety tag 500 volt megger

Dusting brush Contact dressing file

Voltage tester Onmmeter

Screwdriver

PROCEDURE

Preliminary— Tag "out of service".

To clean and inspect controller:
1, Open access to controller.
2, 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.

NOTE 3: Use an ohmmeter on those circuits which could be damaged by a 500 volt
megger.
11, Replace controller assembly.

12, Close controller and remove safety tags.
13, Observe for proper operation.

130 T Bed

‘ON Sd

IV FPES

Figure A-7

77



LIST OF MAINTENANCE PROCEDURES

Table A-5.
FOR REMOTE ELECTRICAL CONTROLS
Remote Remote

MPS No, Equipment Controlled Control ID| Control ID
1114 A2 | Bar Screens 7811

1124 A2 | Bar Screen Conveyors 7812

1213 A2 | Grinders 7813

1316 A2 | Raw Wastewater Pumps A 7816

1364 Al | Control, Air Compressor 7814

1411 Al | Sump Pump O 7815

2124 A2 | Sludge Collectors, A&B 7821

2134 A2 | Sludge Collectors, C & Cross 7822

2213 A2 | Primary Sludge Pumps G 7824 7833
2245 A2 | Grit Classifiers 7831

2313 A2 | Primary Scum Pumps H 7823

2333 Al | Motor, Air Compressor 7826

2414 A2 | Sump Pumps P, U 7825 7832
3214 Al | Air Damper Motor DM-FAI 7849 7853
3228 A2 | Blowers 7854 7861
3264 Al | Pressure Switch, Air Compressor 7847

3337 A2 | Secondary Classifiers 7841 7851
3514 A2 | Return Sludge Pumps B 7842

3543 A2 | Dewatering Pump D 7844 7852
3614 A2 | Excess Sludge Pumps C 7843

3641 Al | Motor Valve, XS Sludge Dilution 7846

3814 A2 | Sump Pumps Q, X 7848

4121 A2 | Chlorine Evaporator 7876 7883
4123 Al | Chlorine Pressure Reducing Valve 7881

4131 A2 | Chlorinator 7885

4141 Al | Chlorine Gas Detector 7886

4211 Al | Chlorine Analyzer 7884

4224 A2 | Influent Sampling Pumps M 7875

4234 A2 | Effluent Sampling Pumps N 7882

4333 A2 | High Lift Pumps F 7871

4343 AZ | Low Lift Pumps E 7872

4353 A2 | Seal Water Pumps V 7873

4414 A2 | Sump Pumps R 7874

5114 A2 | Sump Pump S 7894

5123 A2 | Dome Fan, Thickeners 7895

5216 A2 | Sludge Thickeners 7892

5226 A2 | Sludge Plunger Pumps K 7891

5253 Al | Pressure Switch, Air Compressor 7893

5314 A2 | Compressor, Sludge Storage Tank 7922 7942
5336 A2 | Sludge Plunger Pumps 7911 7931
5344 A2 | Sludge Belt Conveyors 7961

103


MAINTENANCE PROCEDURE, SHEET Page 1 of 1

MPS No. 7151 Al

EQUIPMENT NAME

Average Time

9 Recorders, Blower Building Console S-) 270 min.
Location S-2 min.
Plant Area E [bevet v ‘SW s3 mine

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

Do not tamper unnecessarily with internal mechanism.

To clean recorder:

2, Remove dust from gears with a soft brush.

point.

To calibrate recorder:
1, Re-energize the unit.

Adjust if necessary.
3. Check indicator and pen zero position, Adjust if necessary.

Return unit to service.

2, Check pen carriage alignment so that the pen will track a chart time line.

Under no circumstances should internal mechanism be lubricated.

2, Clean dials and chart plate with a mild non-abrasive soap and warm water.

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

TJOT a8eq

‘ON SAW.

Ty 1STL

Figure A-15

88



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. Avery 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.

56


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

52


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 aré 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 substations, measuring devices, meters and recorders, alarm
sensors and alarm indicators.

14


the MPS numbers corresponding to the operating functional unit ID 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 alist of the sensitive equipment requiring special attention

in the maintenance management system. Two categories of special pre-
ventive maintenance have been identified:

43


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.

AT


MAINTENANCE PROCEDURE SHEET Page2 of 2 | MPS No.

5342 QI

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.

Zjo 7 eBed

*ON Sa

1O 2s

Figure A-6 (Cont)

76



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
Checking out electric circuits

Looking for cracks and tightness

Measuring clearance

Looking at corrosion protection,

PWN

Examples of equipment care tasks are:

Lubricating

Renewing seals and packings

Adjusting equipment

Sharpening cutting edges

Replacing worn parts; e.g., drive belts, safety pins, wear plates
Renewing corrosion protection

Restoring worn areas to an acceptable tolerance

Exercising seldomly used units.

OANRaBWNHE


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

51


FIGURES

No. Page
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
il Form M7 (Reverse), Corrective Maintenance Summary 38
12 Corrections to Measured Insulation Resistance 44

Appendix II

A-1] through A-18 Examples of Maintenance Procedure
Sheets (MPSs) 67

iv


MAINTENANCE PROCEDURE SHEET Page lof 3 |MPS No. 4131 Al

EQUIPMENT NAME Average Time
Chlorinator s-1 vin.
Plant Area G Level u Location 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

as from dispenser components.

Stop booster pump (is used) and close ejector water supply valve.
Close valves in chemical solution line.

7. If dispenser uses automatic controi(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

Nout of service. 0
4
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 a
the solvent, whichever is more convenient. Muriatic acid e

(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 5
with the skin or clothing, a
Zz
To clean vacuum regulating valve and gas filter: 2
2
1, Remove the gas filter block by disconnecting the gas line and the coupling bd
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



PARTS LIST

Name of Part

Manufacturer

Cat. No.

Local Supplier Cost

Figure 2,

‘Form MI Reverse)-5/72

Form M1 (Reverse), Parts List

23


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

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

e Lubricate master gear and pinion on incinerator

Lubricate conveyor

e Clean and lubricate ash conditioner.

@eeeoeeoeeoeee ©

66


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, ona 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.

59


Table 1. FUNCTIONAL

NUMBER SYSTEM

100 Raw Wastewater Station

300

110

120

130

140

Screening
lil Bar Screens

112 Conveyors

Grinding

121 Grinders

Wastewater Flow

131 Pumping

132 Valves and Gates

133 Wet Well Level Control
134 Flow Measurement
135 Pump Seal Water

136 Compressed Air
Auxiliary Services

141 Sump Pumping

142 Ventilation

143. Hoists

144 Electrical Supply

Primary Treatment

210

220

230

240

Primary Settling
211 Tanks and Gates

212 Sludge Collectors

213 Scum Launders

Sludge Handling

221 Pumping

222 Pump Seal Water

223 Flow Measurement

224 Sludge Degritting

Scum Handling

231 Pumping

232 Pump Seal Water

233 Scum Well Level Control
Auxiliary Services

241 Sump Pumping

242 Ventilation

243 Hoists

244 Electrical Supply.

Secondary Treatment

310

320

330

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

Air Delivery

321 Filters

322 Blowers

323 Flow Measurement

324 Pressure Relief

325 Channel Sparger Air Delivery

326 Compreased Air

Secondary Clarifiers

331 Mixed Liquor Channel Air Spargers

332 Mixed Liquor Channel Water Sprays

333 Clarifier Mechanism and Gates

400

340 Chemical Treatment
341 Flocculant Mixing

342 Flocculant Pumping
Return Sludge

351 Pumping

352 Pump Seal Water

353 Return Sludge Wet Well Level
354 Dewatering

355 Flow Measurement
Excess Sludge

361 Pumping

362 Pump Seal Water

363 Flow Measurement

364 Dilution

Scum

371 Scum Well Level Control
372 Scum Pumping

Auxiliary Services

381 Sump Pumping

382 Ventilation

383 Hoists

384 Electrical Supply

350

360

370

380

Chlorination and Effluent Flow
410 Chlorination

411 Chlorine Handling and Weighing
412. Evaporation

413 Chiorinators

414 Chlorine Detection and Venting
415 Injectors and Diffusers

416 Contact Chambers

Residual Chlorine Analysis

421 Analyzers

422. Influent Sampling

423. Effluent Sampling

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

Auxiliary Services

441 Sump Pumping

442 Ventilation

443 Hoists

444 Electrical Supply

420

430

440

16



EQUIPMENT

MALFUNCTION REPORT

Equipment Name and Number

LD. No. [Serial No. [Location

Date of Trouble Time eported by 1 Ll

Indication of Trouble When Discovered Cause of Trouble
CO Broken part C1 Dirty, fouled Ci starting Cl Heat/cold/weather
Worn part Voltage Ci stopping Di Humidity/moisture
D Heat CO current During operation OiForeiga object
Noise (During PM OD Shock/vibration
Osmen CG Flow rate Ol During cM O Wear
Ovvivration O Pressure 1 During MoD CLEquipment defect
ClLeaking Cispeea Di During On improper installation
Dotter. Clother Cl improper lubrication

{improper operation

Dother

Remarke and Recommendations

Check if equipment was tagged Gy

lout of service

Form M4-5/72

Figure 7. Form M4, Equipment Malfunction Report

33



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.

53


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 M1, 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


MAINTENANCE PROCEDURE SHEET Page 2of2 |MPS No. 5921 RI

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.

230 208eq

1a 1265 "ON SAW

Figure A-13 (Cont)

86



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


MAINTENANCE PROCEDURE SHEET Page2 of2 {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
waa 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.

Ropeat 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.

2 30 2 eBea

1S $9€5 “on SaW

Figure A-10 (Cont)

81



equipment items which operate together as a unit to be grouped
by the first, second, third and fifth digits,

2. 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.

58


MAINTENANCE PROCEDURE SHEET Page lof 1 |MPS No. 5621 Al

EQUIPMENT NAME Average Time
Air Compressor, Area K S-1 min.
7 S-2 min.
Plant Area Level M [Eesation 8.3 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 "tout 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/ Torque Size nut or bolt/ Torque | §
No. threads per inch (ft-1bs) No, threads per inch (ft-1bs) | &
1/4-20 729 1/2-20 82-93 Qa
1/4-28 8-10 9/16-12 90-100 -
5/16-18 13-17 9/16-18 107-117
5/16-24 15-19 5/8-11 137-147
3/8-16 30-35 5/8-18 168-178] &
3/8-24 35-39 3/4-10 240-250!
T/16-14 46-50 3/4-16 290-300] z
7/16-20 57-61 7/8-9 410-420] °
1/2-13 71-75 1/B-14 475-485]
8
=

Figure A-11]

82



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) Cyde 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 atime. 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 sixforms. Forms

M1 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 Mé

are temporary records of corrective maintenance actions.

27


SECTION IL

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.



by plant operators, rather than by assigned personnel from the Maintenance
Department. There are two sides to this question. In favor of sucha
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


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,


CORRECTIVE MAINTENANCE WORK ORDER

Da pers

A re E
‘Qeonne Doin, nit Denne Thvenieouovoer
D vtorn pare Cl vetaee D seeping Dirtemiaiey/moiature
Dae Chose ero Drom snme
Drove Gowran Demarnvain
Oo Dower cu oe
Drvnse Clown woo Cecirent ne
Duane Dew on alec

jo dou mor
aor Dlimpropar aperation
Dow.

promerrs

CORRECTIVE MAINTENANCE WORK RECORD

‘eupnotBane wt Coreioven Seve pevehosssy er

Figure 9.

Form M6, Corrective Maintenance

Work Order and Work Record

36


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 wastewater
treatment plants) are discussed.

BASIC PARTS OF THE PMMS

The five basic parts of the PMMS are:

The Equipment Configuration List

The Maintenance Procedures

The Preventive Maintenance Cycle Schedule
The Recordkeeping System

The Maintenance Data Feedback System.

Ub wWONe

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 M1, 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

“15


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.

10


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 OI

A-1 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 lll


901

Table A-6 (Continued)

Operating Unit and Sensor Alarm Indicators
- Alarm Condition
iD Name Area| Level | Loc ID |Area| ID | Area | ID | Aréa

55641 | Lime Slurry Tank K L Low Level 77604] K

61161 | Incinerator No, 1 K L N Shaft Stopped 77702 K

61162 | Incinerator No. 2 K L s Shaft Stopped 77706 K

65211 | Flushing Water to Scrubber No. 1- K U | N | Strainer Clogged 77704 | K

65212 | Flushing Water to Scrubber No. 2 K U |S | Strainer Clogged 77708 | K

66331 | Ash Bin K Ash Bin Full 77709 K

71851 | Temp. Recorder, Incinerator No. 1 | K M |S | High Incinerator Temp. | 77701 | K

71851 | Temp. Recorder, Incinerator No. 1 | K M | S_ | High ID Fan Temp. 77703 | K

71852 | Temp. Recorder, Incinerator No. 2 | K M |S | High Incinerator Temp. |77705| K

71852 | Temp. Recorder, Incinerator No. 2 | K M |S | High ID Fan Temp. 77707 | K

73211 | Blower Building Boiler E Flame Failure 77316| E

73212 | Sludge Building Boiler K Flame Failure 777210 K 77315 E
73213| Raw Wastewater Station Boiler B M Flame Failure 77209 | -B |77315| E
74111 | Electrical Substation No. 1 B © | Emergency Power On 77101 | L |77210| B |77323 | E
74111 | Electrical Substation No, 1 B fe} Ground Fault 77211 B 17324 E
74111 | Electrical Substation No. 1 B © | Emergency Power Failure] 77212 | B

74112 | Electrical Substation No. 2 K Emergency Power On 77102 | L |77325| E |77606] K
74112 | Electrical Substation No, 2 K Ground Fault 77326 | E |77607| K
74113 | Electrical Substation No. 3 E Emergency Power On 77103 | L |77327| E
74113 | Electrical Substation No. 3 E Ground Fault 77328 | E

74114 | Electrical Substation No. 4 E Emergency Power On 77104] L |77329| E
74114 | Electrical Substation No. 4 E Ground Fault 77330 | E

77400 | Alarm Systems G Power On 774041 G

77600 | Alarm Systems K Power On 77608 | K

78100 | Raw Wastewater Pumping Station B Electrical Failure 77305 | E

78200 | Primary Sludge Pumping Station c Electrical Failure 77306 | E

78500 | Blower Air Intake Filter E Electrical Failure 77307 | E

78700 | Chlorine Building G Electrical Failure 77308 | E

78900 | Thickener Building J Electrical Failure 77309 | E

79100 | Sludge Filtration K u |S | Electrical Failure 77310 | E

79500 | Sludge Incineration K M |S | Electrical Failure 77311 | E



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 2 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

e Inspect packing, adjust sight feed oiler, lubricate plunger packing
and crosshead on sludge plunger pump

e Clean vacuum filter subsystem, check tine bar and spring alignment,
inspect spray nozzles on vacuum filter

e Lubricate disk assembly, lubricate ball oiler, lubricate slide

shifting screw, adjust high and low speed stops on incinerator.

@eeeeosveee?

SKILL 3. UTILITY MAN

Assists maintenance mechanics and electricians in maintaining and re-
pairing equipment, under direct supervision of Skill 1 or Skill 2 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.

65


Table 3.

SAMPLES FROM EQUIPMENT DATA

ID Manufacturer Part Number er ial Number
21 Centrifugal Pumps
13112 | Fairbanks Morse 5710 K2N1044068
13113 | Fairbanks Morse 5710 K2N1044069
13114 | Fairbanks Morse 5710 K2N1044070
22113 | Wemco Torque Flow | Model G 6895610-3
22114 | Wemco Torque Flow | Model G 6895610-2
22115 | Wemco Torque Flow | Model G 6895610-1
23111 | Wemco Torque Flow | Model E 6895610-4
23112 | Wemco Torque Flow | Model E 6895610-5
35111 | Fairbanks Morse Model 5720 K2N1044071
35112 | Fairbanks Morse Model 5720 K2N1044071-1
35113 | Fairbanks Morse Model 5720 K2N1044071-2
35411 | Fairbanks Morse 5423 B-28 K2N1044073
36113 | Fairbanks Morse 5424D K2N1044072
36114 | Fairbanks Morse 5424D K2N1044072-1
42211 | Eastern U-34-C, 107-3 | CJ8-0802
42212 | Eastern U-34-C, 107-3 | CJ8-0801
42213 | Eastern U-34-C, 107-3 | CJ9-1305
42311 | Eastern U-34-C, 107-3 | CJ8-0797
42312 | Eastern U-34-C, 107-3 | CJ8-0800
42313 | Eastern U-34-C, 107-3 | CJ8-0798
43311 | Fairbanks Morse 5414E 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
FBNF-1
FBNF-}

KZK, T1004-2
M

VEU

VEU

VEU

ERHB

ERHB

ERHB

KZK, T1007-2
VLUHVGS
VLUHVGS
ERHP

ERHP

680B101G27-6807
680B101G27 -6807
8A2528-2
@A2528-1
F291080

311 P178-A
31421251
31421249
31421250
B121781

B121781

B121781

F -457875
P4177843
4177842

121781

121781

20

LIST


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.


Examples of some MPSs are included in Appendix Il as Figures A-} 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" 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


MPS No. 7700 Al

Page2 of 2

MAINTENANCE PROCEDURE SHEET

Page2 of 2

MPS No, 7700 Al

exoyeorpoy wisely

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aT | ezeee anes punosg a T

a fezcee] 1 [come] 00 semog Aovadsomg a 1

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‘M [9o9ee] aS [szeee] TF | core Ug s9mog kou2Br0urg x q

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a |czcee| a forzce| 1 | tore] v0 smog Aoua8somg | 0 @ “on woqreangng 121212913 t

me] a Tew] alow @ So con an

‘ojpueg waety a5 sae

‘aoeug pew aun Suprezsdo

PROCEDURE (continued)

Figure A-18 (Cont)

94



MAINTENANCE PROCEDURE SHEET Page 1 of 1 |MPS No. 6531 Q2

EQUIPMENT NAME

Exhaust ID Fan, Incinerator

Average Time

S-1 min,
Plant Area Level y Location 8-2 min.
K S$-3 a
5 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 beit of a multiple V-belt drive is necessary, a .
complete new set of matched belts should be installed, 3
5, Reinstall belt guard, if installed. 2
6, Remove safety tag; energize circuit.
z=
”
a
Zz
e
o
g
=
fed
R

Figure A-14

87



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.

Lack of a precise time called out for servicing any specific item
of equipment.

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.

Lack of coordination in combined servicing of a pump, motor,
drive, controller, etc., which operate as a unit.

Lack of a prior estimate of what manpower was required, both
in terms of time and type.

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,


MAINTENANCE PROCEDURE SHEET Page 1 of 2. |MPS No. 7700 AL

EQUIPMENT NAME

Average Time

Alarm Syetems~Electrical Substations S-1 __30__ min.
Plant Area Level Location S-2 min,
BE. K $-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.

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.

Simulate a failure of emergency power at Electrical Substation No, 1 by having
the VEPCO service man de-energize the emergency power,

Z OT aBeg

‘ON SAW!

TV 0022

Figure A-18

93



Table A-3. ANNUAL PM MANPOWER REQUIREMENT

System ‘Annual Manhours Required
1D Name Skill 1 | Skill 2 | Skill 3 | Total
110 | Screening 15 au 189 A415
120 | Grinding 6 43 108 157
130 | Wastewater flow 12 124 65 201
210 | Primary settling Te 27 Tat 160
220 | Sludge handling 13 uM 94 118
230 | Scum handling 5 33 12 50
240 | Auxiliary services 6 14 5 25)
310 | Aeration 2 6 prey 119
320 | Air delivery 21 99 260 380
330 | Secondary clarifiers 6 90 70 166
340 | Chemical treatment ey 4 6 13)
350 | Return sludge 12 4 15 161
360 | Excess sludge 6 25 6 37
370 | Scum 6 2 5 13
380 | Auxiliary services i2 28 10 50
410 | Chlorination 0 56 6 62!
420 | Residual chlorine analysis 18 14 24 56)
430 | Effluent water 24 62 60 146
440 | Auxiliary services 3 7 2 12
510 | Auxiliary services 15 18 13 46)
520 | Sludge thickening 18 272 617 907
530 | Sludge storage and handling] 32 224 954 | 1,210)
540 | Scum handling 3 2 3 al

550 | Lime treatment -- -- -- --

560 | Ferric chloride treatment 9 84 282 375]
570 | Polymer treatment 4 3 4 n
580 | Sludge conditioning 6 1 99 106]
590 | Vacuum filtration 24 378 984 | 1,386]
610 | Incinerators 6 540 490 | 1,036
620 | Gas supply 0 12 0 12]
630 | Oil supply 9 0 6 15
640 | Air supply and foul gases 15 37 56 108]
650 | Scrubbing 6 26 28 60]
660 | Ash handling 18 128 167 31
100 | Raw wastewater station 33 378 362 773
200 | Primary treatment 36 85 232 353)
300 | Secondary treatment 68 328 543 93
400 ] Chlorination & effluent flow 45 139 92 276
500 | Sludge & scum processing a. 982 | 2,956 | 4,049
600 | Incineration 54 743 747 | 1,544
Total for plant 347 | 2,655 | 4,932 | 7,934

98


12.

13.

14,

15.

16.

17,

18.

19.

20.

Buttery, L,M. Maintenance Planning System Designed for Process
Plants. Oil & Gas J. 66(17):190-3, April 22, 1968.

James, E. Successful Maintenance Reorganization, Hydrocarbon
Processing. 46(3):191-4, March 1967.

Hooper, C.F. Maintenance of Chemical Plants. Chem & Process
Eng. 46(2):61-8, February 1965,

Edmonson, C.H., F.P. Flesca, and J. A. Sullivan. Cost and Control
of Maintenance. Chem Eng Progress, 62(5):33-8, May 1966.

Dodds, R.L. Streamlining Maintenance Paperwork. Chem Eng.
70(19):200, September 16, 1963.

Michel, R.L., A.L. Pelmoter, and R.C, Palange. Operation and
Maintenance of Municipal Waste Water Treatment Facilities. JWPCF.
41(3)Part 1:335-354, March 1969,

Michel, R.L. Costs and Manpower for Municipal Wastewater Treat-
ment Plant Operation and Maintenance, 1965-1968. JWPCF.
42(11):1883-1910, November 1970.

Garber, W.F. Treatment Plant Equipment and Facilities Maintenance.
JWPCF. 42(10):1740-1770, October 1970.

Smith, R. Cost of Conventional and Advanced Treatment of Wastewater.
JWPCF. 40:1546, 1968.

61


APPENDIX I
FIGURES A-1 THROUGH A-18,

Examples of Maintenance Procedure Sheets (MPSs)

67


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. Kittner(5) 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(8) 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. (10)
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 progam in the Russian chemical
industry was described by Antropov and Zuev, 11) with a mathematical
treatment of optimum scheduling. Buttery 12) 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'(13) article and Hooper's(14) paper.
Edmonson, et al., (15) 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(16) 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. 07, 18) classified municipal wastewater
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,

12


-APPENDIX II

TABLE A-1 THROUGH A-10

95


Table 1 (continued).

FUNCTIONAL NUMBER SYSTEM

500 Sludge and Scum Processing

600

510

52

$

530

540

550

560

570

580

590

Auxiliary Services

511 Sump Pumping

512 Ventilation

513 Hoists

514 Electrical Supply
Sludge Thickening

521 Thickeners

$22 Pumping

523 Flow Measurement
524 Chlorination

525 Compressed Air
Sludge Storage and Handling
531 Sludge Storage Tank
532 Screw Feeders

533 Pumps

534 Conveyors

535 Flow Measurement
536 Flushing Water

$37 Hydraulic Power

538 Sump Pumping

Scum Handling

541 Weir Control

542 Pumping

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
Ferric Chloride Treatment
561 Storage Tanks

562 Compressed Air Supply
563 Day Tanks

564 Pumping

Polymer Treatment

571 Mixing

572 Pumping

Sludge Conditioning

581 Conditioning Tanks
Vacuum Filtration

591 Vacuum Pumping
592 Filtering

593 Filter Agitation

594 Filtrate Pumping

Incineration

610

620

Incinerators
611 Mechanisms
Gas Supply

621 Oil Supply
631 Shutoéf

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
Auxiliary Service’
671 Sump Pumping
672 Ventilation
673 Hoists
674 Electrical Supply

671

3

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 & 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


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


MAINTENANCE PROCEDURE SHEET

Page 2 of 3

MPS No, 7700 S6

PROCEDURE (continued)

6, Simulate a flame failure in the sludge building boiler by shutting off the

pilot. light,

7, Simulate an electrical failure in the incinerator area by pulling the main

breaker in the motor control console.

€ 30 2e8er

‘ON Saw

98 OOLL

Figure A-17 (Cont)

91



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 ll-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


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 genérally 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, (19)
have elaborate staffs and facilities and can be virtually self-sufficient.
Garber also gave examples of the Hyperion work order and recordkeeping
system.

Smith(29) tabulated in detail O&M cost data which can serve as starting
points in constructing a guideline for a wastewater treatment plant budget.

13


In creating a PMMS for sucha 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

57


Table A-9 (Continued)

MPS No,

Equipment

Maintenance

6533 Al
6533 A2

6611 Al
6612 Q1

6612 Q2
6612 S1
6613 S1
6614 Al
6614 A2

6622 Ql

6622 Q2
6622 Q3
6623 S1
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



SELECTED WATER 7 Rept Wo.) 3. Accession No,
RESOURCES ABSTRACTS

INPUT TRANSACTION FORM 'W
4. Tite A PLANNED MAINTENANCE MANAGEMENT Revert De April 1973
SYSTEM FOR MUNICIPAL WASTEWATER 6
_TREATMENT PLANTS ” 8. Performine Orean ation
7. Author(s) Revore HeFR 90060
Sargent, Donald H., Rudich, David A. 10. Project No..
11010 GWI

9. Organization

EnviroPlan, Incorporated, College Park, Maryland [!% “outract/Granz No.
and County of Fairfax, Fairfax, Virginia

ice repoy

15. Supplementary Notes

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 b’
a steady downward trendinthe 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.

17a, 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

18, , vailabilizy is. a. Send To:
. owe | WATER RESOURCES SCIENTIFIC INFORMATION CENTER
z mice U.S. DEPARTMENT OF THE INTERIOR
WASHINGTON. D.C, 20240
Abstractor Donald H, Sargent Lissvuntion EnviroPlan, Inc.
WASIE 103 (REV. JUNEI97N

# U, 8, GOVERNMENT PRINTING OFFICE : 1974 731-937/344


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.


MAINTENANCE PROCEDURE SHEET

Page lof 1 |MPS No, 7700 Q1
EQUIPMENT NAME Average Time
Alarm Annunciators S-1 —60 min,
Plant Area RB £,G,J,K Level [Eecation S-2 min,
Oo S-3 min.
MAINTENANCE DESCRIPTION
Test Annunciator Operation,
SAFETY PRECAUTIONS
Observe standard safety precautions
TOOLS, PARTS, MATERIALS, TEST EQUIPMENT
PROCEDURE
To test annunciator operation:
Push Annunciator Test Buttons and check for proper operation of both horn
and light. The following annunciators are to be checked:
No. of
LD. Area| Level | Location] Annunciators
77200 B U ll 2
77300 E u sw 30 3
77400 G vu s 4 2
77500 J u 2 _
77600 kK u s 8
77700 K M s 10 5
&
Zz
°
~
3
3
8
2
Figure A-16

89

‘
&



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't side of Form M3 or Form M4 has been received
by the Maintenance Department. Form M5, a5 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, whichis an 8-1/2 x 1l-inch form, is used to record
the labor, parts and materials used, descriptions and recommendations,
equipment status and spare parts availabiljty, 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


Table A-1/ EQUIPMENT TYPE CLASSIFICATION

10] Tanks and Tank Equipment
11] Tanks, Channels, Bins

12 | Slide Gates, Sluice Gates
13 | Sludge and Scum Collectors
14| Weirs

20| Pumps, Compressors, Blowers
21 | Centrifugal Pumps

22 | Piston Pumps

23 | Gear, Vane, Screw, Diaphragm Pumps
24 | Air Compressors

25 | Air Blowers

26 | Sump Pumps

27 | Submersible Pump/Drive Assemblies
28| Vacuum Pumps

30] Electrical Equipment

31 | Motors, Motor and Drive Assemblies
32 | Supply Panels and Boxes

33 | Controls

34] Transformers, HV Power Supplies
35| Delays, Relays, Timers

40] Mechanical Equipment
41 | Drives and Bearings
42 | Hoists and Cranes

43 | Conveyors

44] Special Equipment

50| Hydraulic and Pneumatic Components
51]| Strainers, Filters, Screens

52| Heat Exchangers, Evaporators

53 | Diffusers, Injectors, Nozzles

54] Valves, Dampers

55] Pressure Reducers, Relief Devices
56| Silencers, Scrubbers

57] Mixers, Agitators, Vibrators

58| Chlorinators, Feeders

59] Hydraulic Power Components

60 | Measurement and Control

61 | Flowrate Transducers

62 | Pressure Transducers

63 | Level Transducers and Controls

64| Analyzers

65] Scales

66] Meters, Alarms, Recorders

67] Float, Pressure, and Limit Switches

70 | Plant Service Equipment
71| Fire Extinguishers

72 | Heaters, Ventilators

73 | Laboratory Equipment

96


Fairfax County Lower Potomac Pollution Control Plant
MAINTENANCE SUMMARY REPORT FOR WEEK ENDING

WORK LOAD SUMMARY

Number Estimated Manhours
Line Item of

Actions | Skill! | Skill 2 | Skill 3 | Total

Preventive Maintenance
Backlog irom previous week
Regularly scheduled ror ths week i
Total outstandinu work (AKB) —~ [
‘Accomplished this week
Backlog for next week (C-D)

wala} ts] >|

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)

bea tea) tad

La

Total backlog for next week (E&J) L

WORK ACCOMPLISHED SUMMARY

Item Preventive Corrective Total
Maintenance Maintenance Maintenance

Number of Actions Completed

Actual manhours expended
Skil 1
Skill 2
Skill 3
Total

Labor costs
Regular
O.T.
Total

Outside contractor costs

Cost of parts and materiale

Total costs

Form M7-5/72

Figure 10. Form M7, Weekly Maintenance Summary Report

37