CHAPTER II - PUMPS AND HYDRAULIC TURBINES

1. Inspection Checklist

Inspection
Items of inspection interval
Pumps _and Turbines

Runner or impeller A
Seal rings NS A
Scrollcase or pump casing A
Wicket gates NS A
Curb plates A
Thrust collars A
Gate linkage W A
Draft tube A
Shaft and coupling W A
Shift ring and bearing surfaces NS
Bearings DANS
Servomotor cylinder, piston, and rod D NS
Packing glands DNS
Lubrication D A
Thermometers and gages D A
Controls and indicators W A
Linkage and pins W A
Pump inspection report NS A

D - Routine daily inspection when in service.

W - Routine weekly inspection when in service.

A - Annual inspection.

NS - Not scheduled, frequency as required to maintain equipment and
assure its function.


2. Foundation

Quarterly inspection. - Visual inspection for cracks, settling, and
spalling.

- Make careful check on alinement of pipe and foun-
nt or breakage of the foundation may stress the
joints beyond their breaking points.

3. Sliding Supports

Quarterly inspection. - Visual inspection for lubrication and for
obstructions.

Annual inspection. - Check lubrication. Clean all exposed bearing

surfaces of rust, scale, paint, or other material. See that slid-
ing members are not obstructed.

4. Expansion Joints

Quarterly inspection. - Visual inspection for leaks and corrosion.
Tighten adjusting bolts as necessary and clean sliding surface.

Annual inspection. - Repack as necessary. Clean and lubricate slid-
ing surface. See that line is not obstructed and is free to move at
slip joint.

5S. Welds, Rivets and Bolts

Quarterly inspection. - Visual inspection of all welds, rivets, and

bolted flanges for leaks and corrosion.

Annual inspection. - Make careful visual examination of all welds,
rivets, and bolts for leaks and corrosion. Calk rivets or replace
where necessary, spotweld leaky welds with line drained. Tighten
or renew bolts and studs where necessary.

6. Exterior Paint and Surface

Examine paint for cracking, chalking, or other deterioration. L[x-
amine surface for corrosion, paying particular attention to welded
joints, rivet heads, and bolts and nuts at flanged joints. Prepare
corroded or deteriorated surfaces with sandblasting or other recon-
mended methods and repaint with suitable materials.

25


The success of preventive maintenance will depend largely on the
alertness of the men who work around the equipment. They should be
continually on the alert for things which need attention, such as
loose bolts, vibration, leaks, wear, unusual noise, odor, etc.

2. Work Schedules

Maintenance work should be done in accordance with prearranged
schedules to make the best use of available men, to coincide with
favorable weather, and with periods in which outages of the equip-
ment can best be tolerated.

Major work should be scheduled as much as possible in the nonirri-
gation season. Better work will be produced when employees are not
compelled to work against the clock to meet immediate demands for
water delivery.

3. Maintenance Record Cards

A card system should be kept for recording equipment nameplate in-
formation. It is also recommended for calling attention to the time
when an inspection is due and for recording a brief description of
the repair work done. A 5- by 8-inch card, shown as Form PO&M-122,
"Equipment Data," Figure 1, page 3, can be used for this purpose.

The front of the card has spaces for recording the pertinent data
for the equipment to which the card applies. The back of the card
has spaces for recording the dates of inspections and repair work,
name of the inspector, a reference to the complete inspection and
repair report, and a brief description of the work done. Form
PO&M-123, "Inspection and Maintenance Record," as in Figure 2,
page 4, can be used as a continuation of the original card when
space on that card is filled.

Entries should be made on the "Inspection and Maintenance Record"
for the detailed annual inspection and repair work but not for the
routine weekly, or monthly inspections, unless some repair work is
performed.

A card should be used for each piece of equipment which is subject
to scheduled periodic inspection and maintenance. A simple rotat-
ing file system, illustrated in Figure 3, page 5S, is suggested as
appropriate for pumping plants. This entire file, including the
index tabs, rotates forward as time goes on, with cards removed
from the front as work is done being placed in the back so that for
each year (or other inspection interval) the cards come up in the
same order.


13. Servomotor

Daily inspection. - Note glands for leakage. Adjust as necessary.
Listen for "groaning" noises indicating misalinement.

Not scheduled. - Examine plunger, rings, and cylinder for scoring.
If scored, examine for possibility of misalinement and realine if
needed. Repair by reboring or polishing cylinder, renewing rings,
or machining piston. Inspect packing and repack as necessary.

14. Packing Glands

Daily inspection. - Check packing gland and seals for excessive heat
and see that a slight flow of water is coming from between the gland

and the shaft or the gland and stuffing box. Adjust gland as
necessary.

Not scheduled. - Inspect packing rings for wear. See that lantern
Ying is in proper place and cooling waterlines are clear. Repack
as necessary, staggering adjacent rings so that the points where
ends meet do not coincide. See that the lantern ring is in its
proper place and that the cooling waterlines and drains are not ob-
structed. The gland should be adjusted so that a slight leak oc-
curs rather than complete stoppage of waterflow. A gland too tight
to allow a flow of water will wear the shaft sleeve unduly. The
purpose of a gland is to control the flow rather than to stop it.

1S. Lubrication

Routine inspection. - Lubricate underwater fittings once daily where
the unit regulates frequently or every other day where load is con-
stant. Cycle gates to distribute grease if load is constant. Above-
water fittings should be lubricated twice weekly where the unit reg-
ulates frequently or once weekly otherwise. On pumps or turbines
which are fitted with babbitted bearings which are submerged in
water containing abrasive material, it may be necessary to lubricate
every 5 minutes or less with a solenoid-operated grease gun or sim-
ilar equipment. Replenish oil in reservoirs as necessary. Check
automatic greasing system to see that all fittings are receiving
grease and that system is functioning properly. See Power O&M
Bulletin No. 21.

Annual inspection. - Clean and flush out all fittings with fresh
grease. Check each fitting for adequate grease quantity where auto-
matic greasing system is used. Test oil in large bearings for acid-
ity prior to overhaul. If neutralization number is within limit

12


Section

ee
BOWDMIDaMaWUNY

WCOIANnaUNnH

CONTENTS - Continued

CHAPTER VI - SWITCHBOARDS AND CONTROL EQUIPMENT

Inspection Checklist... 2... ee ee eee
Panels and Cabinets wee

Panel Wiring and Terminal “Blocks eee eee
Relays .... ee
Control Switches Pr er
Indicating Lamps . ed
Meters and Instruments ...........--
Position Indicators

Protective Relays rs
Test Switches ... see ee ee we
Rheostats and Resistors

CHAPTER VII - MOTOR STARTERS AND CONTROLLERS

Inspection Checklist . eee

Knife Switches .... rs

Fuses and Circuit Breakers .

Contacts and Shunts . .

Blowout Coils and Arc chutes .

Solenoids ... 1... 2. eee eee ee eee
Operating Shaft .... eee
Mechanical and Electrical "Interlocks . .
Latches and Trip Devices . . rrr
Auxiliary Switches... .......2.2-
Overload Trip .. Foe ee eee

Step Starter Timers .. woe
Miscellaneous Control Devices .

Power Supplies and Wiring .. .

CHAPTER VIII - STORAGE BATTERIES

Inspection Checklist ......

Battery Electrolyte .....

Connectors we ew we we
Hydrometers .........2.-

Equipment re ee
Distilled Water 2... 1... 2. pe ee eee
Battery Charger .... 2... ee ee eee

iii



_ AIR GAP CLEARANCE (INCH) 8 NORTH
MAIN UNIT eb.
MAIN EXCITER 15.
PILOT EXCITER .-

(MEASURE OPPOSITE SAME SPOT ON ROTOR FOR EACH POSITION IF PRACTICAL)
WAS INSULATION RESISTANCE MEasuREO? ....See Form O&M-109

(REPORT DATA ON FORM O&M 109)

MAXIMUM LOADING AND TEMPERATURES OF UNIT (FROM LOG SHEETS OR TEST)

I 1
[pate 5/18 5/18 | 5/18
[Hour 3P ip | UN
[8c AMPS 410 272 | | 80
[aAcKy. 6600 6600 | 6600
KW 4900 3510 [1600
KVAR. PF 99/eq_ 95/aq_| 95/aq
FIELD AMPS. TO 55 | | to
FIELD VOLTS 133 120 [100
PILOT EXCITER AMPS. | !
PILOT EXCITER VOLTS
TURBINE GATE OPENING 8 _ 6 | i 3. j
TURBINE NET HEAD 92 . 92 ! | 92 |
STATOR TEMP. °C. 78.5 by RTD 71 by RTD 65 by RTD
INLET AIR TEMP. °C 30 22 | i 20 j
THRUST BRG. TEMP. °C, 56 50 1.50 |
_ UPPER GUIDE BRG. TEMP. °C. 50 4S 4s |
LOWER GUIDE BRG. TEMP. °C. 4g 45 4g
TURBINE GUIDE BRG. TEMP. °C. uy 4o ho |
COOLING WATER TEMP. °C. |
AMBIENT TEMP. °C. 30 22 20
|

INSPECTION MADE BY: John Jones....... --

NOTE: CROSS OUT ALL ITEMS WHICH DO NOT APPLY TO THE UNIT COVERED BY THIS INSPECTION,
23



References

Power O&M Bulletin No. 21, Lubrication of Powerplant Equipment
Power O&M Bulletin No. 24, Welding Repair to Hydraulic Equipment
Bureau Paint Manual and Field Painting of ‘etalwork

2. Runner or Impeller

Annual inspection. - Examine runners for cavitation pitting, sand,
or other forms of erosion, and cracked vanes, blades, or crowns.
Repair pitted areas, cleaning damaged area with a gouging rod and
building up steel runners with mild steel welding rod, bronze run-
ners with bronze rod, cast iron runners with 'Ferroweld" rod, and
stainless steel runners with stainless steel rod. Other approved
type rods may also be used. Bronze and stainless steel runners
should be built up to the original surface and ground smooth. Cast
iron and cast steel runners should be built up and ground to a sur-
face about 1/8 inch low to the original. Then 18-8 stainless steel
should be used as a final coating over the mild steel inlay on steel
runners and should be 1/8 inch thick. 25-12 stainless steel should
be used over ''Ferroweld"” inlays on cast iron runners.

In grinding the stainless steel coatings, a high-speed grinder should
be used, and a permanent bar magnet or a commercial copper sulphate
solution should be used to check the thickness of the stainless.
Stainless steel is nonmagnetic and too much pull on the magnet indi-
cates that the stainless has been ground away or applied too thinly.
Some work has been done with metallizing surfaces subject to cavi-
tation with stainless steel, but until further information as gath-
ered from experience is available, it is advisable to continue to
weld or braze. See Power O&M Bulletin No. 24 for details on welding.
After assembly, check vibration of unit with vibrometer and balance
if necessary.

3. Seal Rings

Annual inspection. - Check the seal ring clearances. Check to see
that seal ring cooling waterlines are clear.

Not scheduled. - Remove the runner, replace or build up with suit-

able material and machine seal rings to original clearances as list-
ed on manufacturer's blueprints.

4. Scrollcase or Pump Casing

Annual inspection. - Examine surface for corrosion and failure of
paint. Check rivets for tightness. Inspect for leaks. Calk leaks



CONDITION OF:
ore Pum!

INTAKE GATE,
LEAKAGE,.. DESCRIPTION OF LEAK aGe:_.veaKage TISN’ Nane DOCeomM sie ___________.
DISCHARGE GATE:
LEAKAGE,__£> GPM, DESCRIPTION OF LEAKAGE:

SHAFT PACKING:
LEAKAGE,.__-_ GPM, TYPI

Garlock G44

GLANDS AND LANTERN RING: Onn SS ON BOC ae

NAME, MANUFACTURER AND VISCOSITY OF OIL USED:

REMARKS AND RECOMMENDATIONS:.
Repair damage pain’

inspection wave By...JOhD Rose.

15 Form O&M 154 12-I-51 (Back



9. Draft Tube

Annual inspection. - Inspect metal liner for cavitation pitting.
Weld and grind as necessary. Inspect concrete for failure and re-
pair as necessary. Test for voids between liner and concrete by
striking the liner with a hammer. A "drummy" sound indicates a
void at that point. Grout if necessary. Inspect manhole door gas-
kets and bolts. Replace where needed. Smooth up seating surfaces
on door and case. Prepare bare or corroded surfaces and paint with
suitable material.

10. Shaft and Coupling

Weekly inspection. - Check shaft visually and by hand for wobble or
runout. Note coupling for apparent misalinement or signs of loose
coupling bolts.

Annual inspection. - Check shaft with oscillograph or dial indica-
tor for excessive runout. Check coupling for runout. Check aline-
ment of shaft at coupling and inspect coupling bolts for tightness.

Inspect shaft sleeve at packing gland. Replace or build up and
machine as necessary.

11, Shift Ring

Not scheduled. - Lift shift ring and inspect bearing surfaces for
wear and proper lubrication. Check scoring and for out-of-round
condition. If fitted, inspect patch bolts on cover plate bearing
surface for tightness. Smooth up or build up and machine bearing
surfaces as needed. Replace bearing plates on cover plates if
needed.

12, Bearings

Daily inspection. - Check bearings for overheating and to see that
an ample supply of lubrication is being furnished.

Not_scheduled. - Inspect babbit or bronze bushings for wiping or
scoring. Inspect journals for scoring, wear, and discoloration
which may be due to excessive heat, acidity of the oil, or shaft
current.

Annual inspection. - Refit or rebabbitt and machine bearings as nec-
essary. See that all oil or prease grooves are clear. Check oil

for dirt, sludge, and acidity, and filter or replace as necessary.

See that bearing temperature bulbs and alarms are functioning properly.

11



CHAPTER IV - DISCHARGE LINE

P701-100-96

1. Inspection Checklist

Inspection
_Items of inspection interval
Discharge Lines
Foundation Qa
Sliding supports QA
Expansion joints QA
Welds, rivets, and bolts Q A
Exterior paint and surface A
Interior paint and surface A

Q - Quarterly inspection.
A - Annual inspection.

Reference

24


The file should be consulted frequently to see what work is due.
After the work is completed, the card should be filled in, signed
by the man responsible for maintenance, and placed at the back of
the file.

Keeping records of the inspection, repairs, and tests is an impor-
tant part of preventive maintenance. It provides a means of recog-
nizing chronic troubles and finding their causes. It also serves
as a basis for estimating what spare parts should be kept on hand
and how often repairs will be necessary.

The PO&M-123 cards described on page 2, when used in the rotating
file system, are intended to serve primarily as an index and tick-
ler system to assist in scheduling inspections. At each inspection,
it may be desirable to record a more complete report showing briefly
what was found and what was done. The work involved in making such
reports can be greatly simplified by using forms made out for the
purpose.

4. Inspection Checklist

Fach piece of equipment should be inspected at specified intervals.
Scheduling of such inspections (and repairs) will be facilitated by
careful recordkeeping.

The inspection checklists on the following pages should be used as
a guide to proper maintenance by the operators and maintenance men.
The time intervals shown represent the average intervals which the
particular item should go without inspection. Nore or less fre-
quent inspections may be necessary as operating experience or ac-
cessibility for maintenance dictates.

The lists are intended to cover all types of equipment, including
the most complex. If the particular equinment is not provided with
all the features listed under "Items of Inspection," these items
on the checklist should be disregarded.

The routine inspections are those which normally should be made by

a roving maintenance man, a ditchrider or other responsible employee
not necessarily in constant attendance of the plant equipment. These
routine checks and inspections should be of a visual nature not re-
quiring the use of tools or equipment, and are intended to detect
troubles in their carly stages so that corrective measures can be
applied before serious trouble develops. Anything unusual should be
promptly reported to personnel responsible for maintenance for
proper action.


Section

Caonuaqaueaune

oad
Nes

13.

me
wns

CONANSTne

eee
NEO

13.

”

CONTENTS - Continued

CHAPTER XVII - TRANSMISSION LINES

Inspection Checklist
Wood Poles .

Crossarms, Pins,
Steel Towers . .

Guys .
Warning Si gns

and Braces

Footings and Guy Anchors .

Ground Wires and Connections .

Main Conductors and Overhead Ground “Wires”

Conductor Splices
Vibration Dampers
Hardware . .
Insulators wae
Right-of-way ....

Line Maintenance Tools .
CHAPTER XVIII - PUMPING PLANT BUILDING

Inspection Checklist . .

Doors and Windows .

Electric Space Heaters and Ventilating Fans
Water Supply and Drain Piping

Water Ileaters and Coolers .

Wash Basins, Sinks, Showers, Toilets, Etc.

Water Supply .
Lighting... we
Fire Protection.
Conduit and Fittings

Wiring and Wiring Devices . .
Railings and Miscellaneous Netalwork .

Stairways and Ladders

CHAPTER XIX - SEASONAL MAINTENANCE

Spring Startup .
Fall Shutdown

viii

97
99


13. Shaft and Bearings

Daily inspection. - Check bearing temperature, lubrication and oil
Tevel. (See Power O&M Bulletin No. 21.)

Annual inspection. - Check bearing clearances. Check oil for dirt,
Sludge, and acidity, and filter or replace as necessary. Check end
play on horizontal machines. Replace or refinish rough bearings.
Inspect bearing oil piping and cooling water piping for leaks. Check
shaft for wobble and alinement. Check for shaft currents through
bearings on large machines. Check insulation of insulated bearings.
Check oil film resistance occasionally with machine in operation
with ohmmeter of 6 volts or less on thrust bearings provided with
test terminals.

14. Couplings

Annual inspection. - See that keys, setscrews, and coupling bolts are
tight. Check parts of flexible couplings for wear or fatigue. Adjust
belt or silent chain tension. Flush out and renew grease in gearboxes.
Inspect belts, chains, or gears. Check alinement between driving and
driven machine.

15. Cooling Coils on Water Cooled Units

Daily inspection. - Check for water leaks in bearing cooling coils and
surface air coolers. Check cooling waterflow.

Annual inspection. - Check external supply and drain piping for leaks.
Flush out cooling coils with air and water. Test bearing cooling coils
for leaks by applying air pressure to coils and observe for air bub-
bles rising in oil and drop in air pressure with supply valve closed,
or use hydrostatic pressure test. Use hydrostatic pressure test on

air coolers. If water scale is present, circulate a solution of 25 per-
cent hydrochloric acid and water through the coils until clean. Then
flush out thoroughly. Clean external surfaces of coils if practical.

A pressure of 75 pounds per square inch is recommended.

16. Temperature I

Annual inspection. - Check bearing and stator temperature indicators
and relays for sticking, dirty contacts, etc. Check calibration if
in doubt. Check water and oil flow or pressure gages and relays for
proper operation.

icators

At each inspection, it may be desirable that a more complete report be
made showing briefly what was found and what was done. A form similar
to Form OfM-150, Figure 5, pages 22 and 23, may be used for this purpose.

21


References

Power O&M Bulletin No. 3, Testing Solid Insulation of Electrical
E ent

Power O&M Bulletin No. 9, Keeping Motor Windings Dry

Power O&M Bulletin No. 13A, Field Balancing of Large Rotating
Machinery

Power O&M Bulletin No. 21, Lubrication of Powerplant Equipment

Power O&M Bulletin No. 23, Fire--Fighting, Cause and Prevention

2. Base

Monthly inspection. - Visual inspection to see that machine founda-
tion, base, or support is in good condition.

Annual inspection. - Check concrete foundation for cracks. Check
Dase or support for broken, loose, or weakened parts. Check and
tighten anchor bolts. Check sound-absorbing base for adequacy.

3. Frame

Annual inspection. - Check for cracks, loose, or broken parts. Clean

and repaint as necessary. Check frame ground connection.

4. Laminations and Pole Pieces

Annual inspection. - Check for loose laminations and tighten clamping
bolts. If laminations vibrate and cannot be stopped by tightening
clamping bolts, force some quick-drying varnish or shellac between
the loose laminations while the machine is out of service. Check
for damaged laminations at airgap due to rubbing or objects caught

in airgap. Check and tighten field pole piece clamping bolts.

5S. Armature or Rotor

Annual inspection. - Check induction motor squirrel-cage rotor bars or
Synchronous motor amortisseur windings for loose or broken bars or end
connections. Check synchronous motor field circuit connections and
tighten if necessary. Check voltage drop across each synchronous motor
field pole by applying alternating current at the collector rings and
then measuring the voltage across each pole winding with a voltmeter.
This will show up a turn-to-turn short better than direct current. After
this test it may be necessary to "flash the field" to restore the proper
residual field polarity. Flashing the field may be performed by momen-
tarily connecting a 6- or 12-volt battery, with the proper polarity,
across the slip rings. Check pole keys for tightness. Rebalance arma-
ture or rotor if vibration is objectionable. (See Power O&M Bulletin
No. 13A.)

18



CONTENTS - Continued

Section

CWVMYUDAHEWUNY

~

Vou aAnauny

Cables or Chains .......

Lifting Beams .. 1... 1... eee eee
Counterweights .. 6. 6 ee ee ee eee
Blocks and Hooks .......-. 2 ee
Electrical Wiring .. eee eee
Hydraulic Hoist Cylinder, “Ete. a ee ewe
Hydraulic Pump . . oe
Hydraulic Control valves and Piping oe
Oil Reservoir . we ee eee
Guide Rails and Shoes we ee ee ew

Safety Devices © ss ees tres
Operation ... rr ry

Elevator Inspection eee eee

CHAPTER XI - LOW-VOLTAGE SWITCHGEAR, BUSES,

Inspection Checklist ...... .- .
Bus Bars, Joints, and Connections eee
Bus Insulators and Supports .......
Bus Enclosures and Barriers .......
Switchgear Panels and Enclosures .....
Locks and Interlocks ..........--.
Warning and Safety Signs . . . wee

Current and Potential Transformers see
Power Cables... 2... ee ee eee
Potheads .. 1... 2. ee ee ee

AND

QUAPTER XII - OIL AND AIR CIRCUIT BREAKERS

Inspection Checklist... .......4-
Foundation. .......
Frame and Tanks .... 2... 2s
Oil Valves and Plugs .......-.2.-
Oil Levels and Gages .. ~~... 1.2.4.
Breathers and Vents ........
Panels and Cabinets .........
Bushings or Insulators oe ee eee
Bushing Current Transforners and Potential
Devices ... see
Main Terminals and Ground. Connections oe
Main Contacts ... es
Contact Pressure Springs . rary
Flexible Shunts . . oe oe
Magnetic, Air, or Oil “Blowout Devices” oe
Crosshead . 2... 2. eee ee eee eee



Section

VCanauauny

VCHmUuaAKHaUne

CONTENTS - Continued

CHAPTER IX - COMPRESSORS AND MISCELLANEOUS PUMPS

Inspection Checklist ........
Foundation. ........
Frame... .. .

Drive .. or
Pulleys, Idlers, and Couplings . .
Crankshaft... 2... 2. ee ee eee
Connecting Rod . 2... 2. we ee ee
Crosshead .. 1... ee eee eee
Piston .

Cylinder .

Valves... ee
Bearings . es
Packing Gland rr
Lubricating Systen . wee ee ee
Cooling System... 1... + ee eee
Receiver Tank ......

Air Intake and Cleaner .

Gages .. . . eee
Pressure or Float “switches .

Unloader . : ee eee

Piping and Valves rr
Safety Valve... we ee ee
Guardrails or Grills . ee ee
Operation . 2... 1. ee ee eee ee
Safety Cleaning ..........0..
Impeller or Rotor .......-+..-.

Tanks 2... eee ee ee ee
Strainers ... 1... . ee eee

CHAPTER X - CRANES, HOISTS, AND ELEVATORS

Inspection Checklist . . ay
Crane Rails, Supports, and Stops we
Hoist and Bridge Framework . wee
Bumpers .. . rr
Rails and Wires” rs

Trolley Shoes ee
Catwalks . . 1. 1 ee ee ee ee
Ladders «2 1 eee ee ee ee eee
Cab... ee ee ee ee
Driving Gears, Shafts, Bearings. and Wheels
Brakes... . eee ee ew
Cable Drums and Sheaves" wee

iv


The indexed paragraphs following the checklists are intended to give
pertinent instructions on what to look for and what to do. However,
it is not intended to supersede other specific instructions already
covered in detail in other bulletins, manufacturers’ instruction
books, or other available publications, particularly Designers’
Operating Criteria or Standing Operating Procedures, if such have
been prepared.

5. Reference Material

This Irrigation Operation and Maintenance Bulletin has been prepared
from material included in the Power Operation and Maintenance Bulletin
No. 19, revised October 1965.

Power Operation and Maintenance Bulletins are prepared primarily
to assist Bureau of Reclamation power operating personnel in estab-
lishing Bureau standards for proper and safe operation of power
facilities. These booklets are referred to in many places in this

publication as reference material and a complete set consists of 27
bulletins.

The above bulletins are available for sale from our Publications and
Film Management Unit, for $25.40 a set. Requests should be directed
to:

U.S. Department of the Interior
Bureau of Reclamation
Engineering and Research Center
Building 67

Denver Federal Center

Denver, Colorado 80225

Bureau of Reclamation requisitions should also be sent to the above
address.



Section

Oud

DouaAnauAnye

CONTENTS - Continued

Lighting . . .
Oil Storage Facilities .

Conduits, Ducts, Trenches, and Tunnels .

Power Supplies and Wiring ......
CHAPTER XV - TRANSFORMERS

Inspection Checklist... ..
Foundation, Rails and Trucks .

Tanks and Radiators

Oil and Water Piping . .

Oil Levels, Gages, and Relays.
Breathers and Vents .......6.
Relief Diaphram . .
Water-cooling Coils and. Piping .

Flow Indicators and Relays .

Oil Pumps

Cooling Fans and Water Sprays .
Temperature Indicators and Relays .
Inert Gas Tanks . wee
Gas Regulator Gages and. Relays .

Gas Piping and Valves ........
Gas Analysis .............
Bushings ..............
Tap Setting .. .
Main Terminal and Ground Connections .
Core and Coils. ..........
Internal Inspection .......
Ratio Adjuster . eee eee
Insulation Resistance ........
Oil Dielectric... ......40.
Oil Acidity .. ee eee wee
Filter and Reclaim oil ew eee

CHAPTER XVI - LIGHTNING ARRESTERS

Inspection Checklist . . . .

Base and Support . .
Porcelain Shells and Insulators. .
Grading Rings ...

Arrester Units... .......
Gaps . . . soe eee
Line and Ground Connections wee

vii


specified by oil manufacturer, and has not taken a sudden increase
since the last test, centrifuge and filter oil and clean out all
bearing reservoirs and sumps. If neutralization number is above
limits set by manufacturer, discard and refill system with new oil.
In small bearings where the cost of testing is approximately equal
to or more than the cost of new oil to refill the system, the oil
should be drained and the system refilled with fresh oil.

16. Thermometers and Gages

Daily inspection. - See that gages and thermometers have no visible
Signs of breakage. See that all dial-type needles are free to move
by tapping the case gently with the fingers.

Annual inspection. - Remove all gages and thermometers and calibrate.
Reinstall.

17. Controls and Indicators

Weekly inspection. - Note daily operation of all controls and indi-
cators. Investigate any unusual conditions. Lubricate moving parts.

Annual inspection. - Check pointers on indicators for correct set-
ting. Check control moving parts for wear. Check remote controls
for proper indication. Repair or renew as necessary. Calibrate
gages.

18. Linkage and Pins

Weekly inspection. - Note linking arms and pivot pins for excessive
backlash due to wear and vibration. Lubricate as necessary.

Annual inspection. - Refit or replace bushings and pins as needed.

At each inspection, it may be desirable that a more complete report
be made showing briefly what was found and what was done. A form
similar to Form O§M-154, Figure 4, pages 14 and 15, may be used
for this purpose.

19. Pump Inspection Report

A suggested form for reporting the condition of a pump and repairs
made is given on pages 14 and 15. Copies of this form, O&M-154
(10-56) can be furnished.

13



LAST COPY - BO NOT REMOVE

Department of the Interior, Bureau of Reclamation

IRRIGATION OPERATION AND MAINTENANCE

BULLETIN NO. 60

April, May, June 1967
(REVISED January 1971)

SUPERSEDED BY #155 - March 1991

ME

7 PAAR
U WUE babii

LAST COPY - DO NOT REMOVE

7 Wu i

i

¢

LA

In This Issue:

Pumping Plant Maintenance Schedules and Records




Figure

Figure

Figure

Figure

Figure

Figure

Figure

LIST OF FIGURES

PO§M-122--Equipment Data and
Inspection and Maintenance Record

PO&M-123--Inspection and
Maintenance Record. ....

Rotating Card File System for
Maintenance Schedules

O&M-154--Pump Inspection Report

O&M-150--Motor or Generator
Inspection Report ....

O&M-152--Circuit Breaker
Inspection Report ....

PO&M-151--Transformer
Inspection Report .

ix

14

22

66

83



Photo PX-D-68175NA

9. Banding and Lashing

Annual inspection. - Check wire and string banding on direct-current

armature windings. Check end-turn lashing of alternating-current
stator coils. Apply lashing if end turns vibrate excessively.

10. Slot Wedges

Annual inspection. - Check slot wedges and replace loose ones.

Tighten coils in slots by rewedging if necessary,

11. Commutator or Collector Rings on Synchronous ‘Motors

Weekly inspection. - Check commutation or collector ring and brush

Operation. Wipe commutator or rings if needed. Ilave brushes re-
placed if worn too short.

12, Brushes on Synchronous !Motors

Annual inspection. - Turn down, stone, or polish commutator or col-
ector rings if grooved, rough, or eccentric. Undercut mica if high.
If commutator or rings have a good polish, they should not be dis-
turbed. Check brush spring tension and brush fit. Tighten bolts,
screws, and connections. Reset brush holders if not properly spaced.
Check brush neutral position. Replace and sand in new brushes if
needed. Clean up carbon or metallic dust.

20


Photo PX-D-68176NA

6. Airgap

Annual inspection. - Check airgap at four quadrature positions and re-
center rotor if necessary. On horizontal machines, the bearings may
need replacing if the bottom airgap is appreciably smaller than the

top.

7. Air Fans

Annual inspection. - Check rotor air fans for fatigue cracks. Check

and tighten holding bolts or screws.

8. Windings

Monthly inspection. - Visual inspection for damaged insulation and

dirt, oil, or moisture on winding.

Annual inspection. - Blow out dust with clean dry air at pressure not
exceeding 40 pounds per square inch. Clean exposed parts of windings
thoroughly with a noninflammable solvent, using suitable brushes for
inaccessible places. The use of carbon tetrachloride is not recom-
mended because of the toxic hazard. A number of good commercial
solvents such as ''Turco-Solv'' are satisfactory. Check for insulation
deterioration such as tape separation, cracking, brittleness, or evi-
dence of corona. Check insulation with Megger or high-voltage direct-
current method. (See Power O&M Bulletins No. 3 and 9.)


Section

16.
17.
18,

19.
20.
21.
22,
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

Cwmrn Av aane

UNE

CONTENTS - Continued

Lift Rods and Guides... . --
Operating Rods, Shafts, and Bellcranks oe
Closing Solenoid Air Cylinder, Motor, or
Spring. ... se eee .

Manual Operating Device oe

Latch and Trip Mechanism. ........-..
Tripping Solenoid ....... 2... eeu
Solenoid Valves . 2... 2. . ee ee eee
Auxiliary Switches... ......- 5580

Operation Counter ........ 24
Position Indicator . rr)
Dashpots or Snubbers ........-.4-
Mechanism Cabinet .........2. 22 eee

Cabinet Lights and Heaters . .
Power Supplies and Wiring .....
Oil Dielectric Tests . see
Filter Oil]... 2... 2... ee eee
Operation .. 1... 2... eee eee

CHAPTER XIII - DISCONNECTING SWITCHES AND FUSES

Inspection Checklist... .....-22.04.-
Base and Mounting .. 1... 2. +e ee eee
Insulators ..... we ee ee ee
Line and Ground Connections rr rrr
Blades and Contacts ... wee www wwe

Contact and Hinge Springs and Shunts ....
Arcing Horns . oe

Blade Latches and. Stops. ee er
Operating Rods, Levers, and Cranks ......
Gearboxes 2... 1. ee eee ee ee
Operating Motor .. oe

Auxiliary and Limit Switches wee

Locks and Interlocks .......-..2-+.-
Switch Sticks 2... 1. ee ee ee eee
Fuse Tubes . 1. 1 1 ee eee ee ee ee
Fuse Links... . eee eee
Multiple-shot Reclosing Fuse see

CHAPTER XIV - SWITCHYARDS

Inspection Checklist... ......

Yard and Fences .... 2... 2. ee ee eee
Ground Connections ...... 2... +e eee
Conductors and Buses... 2... 2 ee ee

vi


and rivets as necessary. Prepare surfaces and paint with a recom-
mended material. Inspect manhole door gaskets and bolts, and renew
as necessary. Smooth up seating surfaces on door and case.

5. Wicket Gates

Annual inspection: - Measure clearance between gates when nearly
closed. Adjust openings as necessary. Examine body of gates for
pitting. Examine sealing surfaces and grind or file rough or wire-

drawn portions to a smooth surface. Check clearance at stem bush-
ings by jacking.

Not scheduled. - Raise cover plate and inspect stem bushings, jour-
nals, and shaft sleeve at packing gland for scoring, improper lu-
brication, and corrosion. Clean all hard grease from grooves and
pockets. Refit bushings as necessary. Build up stem at packing
gland and at journal areas using stainless steel if they are mild
steel or repair is needed. At this time, also inspect baffle plates
for deterioration and tightness. Clean and paint baffle plates and
underside of cover plate.

6. Curb Plates

Annual inspection. - Examine facing plates for scoring and corrosion.
Check clearance between facing and wicket gates. See that the facing
plates are tight to the head cover and bottom ring.

7. Thrust Collars

Annual inspection. - Examine three or four thrust collars and plates
as examples for scoring, corrosion, and proper lubrication, taking
different ones each year until all are examined. If excessive scor-
ing or corrosion is noted, examine the remainder and repair as nec-
essary. Obtain proper clearances between wicket gates and upper and
lower curb plates with the thrust collars, placing or removing shims
as needed.

8. Gate Linkage
Weekly inspection. - Note linkage for excessive backlash.

Annual inspection. - Measure the backlash in linkage and refit pins
and bushings as needed.

10


Tea Pot Dome Irrigation District. General view of Pumping
Plant T-3, Lateral 99.4. Friant Division, Porterville,
California. Photo P214-D-58274

Tea Pot Dome Irrigation District. T-1 Pumping Plant control
board, pumps, and air chamber. Friant Division, Porterville,
California. Photo P214-N-58275

16


CONTENTS - Continued
Section Page

CHAPTER III - ELECTRIC MOTORS

1. Inspection Checklist .......... . oe 17
2. Base ww we ee ee 18
3. Frame 2 6 we ee ee hee ee he eee 18
4. Laminations and Pole Pieces .. . oe . 18
5. Armature or Rotor . oe . . 18
6. Airgap... 2 ee eee eee eee wee ee 19
7. Air Fans... ee ee ee ee ee ee eee ee 19
8. Windings .. 2... ee ee ee ee ee ee . 19
9. Banding and Lashing . A ee a ee 20
10. Slot Wedges ... . eee wee 20
11. Commutator or Collector Rings” on n Synchronous

Motors 2 6 6 wee ee ee ee ee ee 20
12. Brushes on Synchronous Motors ........+4.e-. 20
13. Shaft and Bearings... 1... 1 eee ee ee eee 21
14, Couplings ... Se ew ee eee we 21
15. Cooling Coils on Water Cooled Units ........ 21
16. Temperature Indicators .. 1... 6 eee eee ene 21

CHAPTER IV - DISCHARGE LINES

1. Inspection Checklist... ....2-5.- se 24
2. Foundation... 6... ee ee ee ee ee ee 25
3. Sliding Supports .. 1... 1. ee eee eee ee 25
4. Expansion Joints... 6... ee eee ee eee 2s
5. Welds, Rivets, and Bolts. ..........004. 2s
6. Exterior Paint and Surface... . 1... eee eee 25
7. Interior Paint and Surface . . a cee 26

CHAPTER V - GATES AND VALVES

1. Inspection Checklist... . 1... ee ee eee oe 27
2 Gates and Valves . 1. 1 6 6 ee ee eee ee ee 28
3. Seals and Guides... 1... . ee eee ee eee 28
4, Seat, Disk, etc. 2... eee ee ee ee eee 28
Ss. Stems 2. we ee ee ee ee ee ht 28
6. Lubrication .. Ce 28
7. Springs and Cushioning Mechanism... .. see 29
8. Journals, Bearings, and Bushings ......... 29
9. Wheels, Pins, and Rollers ....... wee ee 29
10. Operating Cylinder or Gear Mechanism... . . 29

1l. Control Piping. ......-.+-.-0-00000” 29
12. Packing Glands... 1. ee we ee ee ee ee 29
13. Operation Check .. 1... 1. eee ee ee eee 30

ii


POEM - 122
(5-56) rug, __LWE-5-3

Bureau of Reclamation

equine 115 kv_OCB No. 1162 SPECTION OE June
moect__ Rio Grande Location Elephant Butte Powerplant nerctios muir 1
cquipvexr ava
rmiseo or Spec. 892, Schedule 3 om __Initial operation June 1955 ___
commactor Johns Manufecturing Co.
or. Johns Manufacturing Co. Bad B20-60-115D
MODEL OR STYLE 10, SERIAL 10. 5894
Ours 115 kv nes.
Mr, TM. on, Tar
RPM, Prey. 60 od 3 Ter. ec
Ws os
INTERRUPTING RATING — KVA. 1,000,000
tne we TW oF @ETRCTION
comet S12 0 KO coacre snc

ro moses
FRONT
INSPECTION AND MAINTEMANCE RECORD
‘DATE INSPECTED BY | REPORT REFERENCE DESCRIPTION OF WORK DONE TABOR sr TATERTAL
6/9/56 AUF. ‘Annual inspection - See report of 7/1/56
6/18/57 | AIF * . TRYST
g/ek/sT | RwH Replaced open circuited trip coil 7.00 | 4.50,
6/15/58 | Rw ‘Annual inspection - See report of 6/30/50
rt aa
oF
REAR
Figure 1
3



File No. Gla -6-1

Inspection and

\
Wy }

Glb -6-1
maintenance cards --~.:
= Gie-6-I
4 HI-6-1
Index tobs--~---- 6-JUNE Al -6/12-1 |
Uy
KI-5-4
JIE-5-3
5-MAY JIW -5-2 \
YY \ |
\ /
S76 -4-4 \ /
S7EA -4-3 | /
S7EB-4-3 if ! /
4-APR SG2-4-1 i|7 |/
/ V
| / /
G2a -3-4 / 7
G2b-3-4 / /
G2c-3-4 r ]
H2-3-4 /
/
3-MAR, A2-¥o-4 /
7
7
K2-2-4
7
JTE-2-2 7
~*~
-2- ~--Cards are removed from
2-FEB. JTW 2! Yo front as work is completed
YY Z and placed at the proper
a location toward the rear of
the file.
—_— 7

FILE No.

1st. Symbol group = Equipment designation symbol as established for construction
Purposes and shown on switching diagrams. Gia = generator No! . a,b,
c, etc. represent parts such as exciters, etc. requiring separate
cords. For old plant or equipment having no official symbol use word
description such as Gen./, Line!, etc.

2nd.Symbol = Month when inspection is due.

3rd.Symbol = Week when inspection is due.

Figure 3
ROTATING GARD FILE SYSTEM FOR MAINTENANCE SCHEDULES

5



Section

UNITED STATES
DEPARTMENT OF THE INTERIOR
BUREAU OF RECLAMATION
DIVISION OF WATER OPERATION AND MAINTENANCE
Denver, Colorado 80225

Irrigation Operation and Maintenance
Bulletin No. 60

April, May, June 1967
(REVISED JANUARY 1971)

: PUMPING PLANT
MAINTENANCE SCHEDULES AND RECORDS

CONTENTS

CHAPTER I - INTRODUCTION

Preventive Maintenance... ...-+ +5050
Work Schedules .. 2... 1 ee eee etwas
Maintenance Record Cards ..........--.
Inspection Checklist... 16.6 eee ee ee
Reference Material ......... eee ee

CHAPTER II - PUMPS AND HYDRAULIC TURBINES

Inspection Checklist ....
Runner or Impeller... . .
Seal Rings .......
Scrollcase or Pump Casing
Wicket Gates... ....
Curb Plates .......
Thrust Collars ....
Gate Linkage . .
Draft Tube. .......
Shaft and Coupling. .......
Shift Ring... 1... eee eee
Bearings... 1. ee eee eee
Servomotor . . 6 6 ee ee ee ee ee wee
Packing Glands ..... 2... eee
Lubrication .. 1... eee ee eee
Thermometers and Gages ........
Controls and Indicators .......
Linkage and Pins... ... + ee ee
Pump Inspection Report ........

NONNE



7. Interior Paint and Surface

Inspect for deterioration of the paint in the form of scales, loose-
ness, tubercles, dissolution, cracks, etc. Pay particular attention
to rivet heads and welded and flanged joints. Prepare surfaces where
paint has failed by sandblasting or other recommended means and re-
paint with suitable paint.

Southern San Joaquin Municipal Utility District - Central Valley
Project, Pumping Plant S9, Lateral 127.7E. Photo P214-D-58276

26


9 aM 154
(0-56)
Bureau of Reclamation

PUMP INSPECTION REPORT

provect...CO10-

MANUFACTURER

-PUMPING PLANT.

+ MODEL NO.:..

SERIAL NO.:
neao:___186 feet _

CLEARANCES

POSITION 33%
PART a 8 ¢ D
WEARING RING, MOTOR END 015 014 014 015
WEARING RING, PUMP END 014 ous 015 014
PUMP GUIDE BEARING, MOTOR END -016 +017 .015 -017
PUMP GUIDE BEARING, INTERMEDIATE +018 +016 «017 -016
PUMP GUIDE BEARING, PUMP END +014 +016 +015 +015
IMPELLER

OTHER CLEARANCES

EXPLAIN AND GIVE REFERENCE POINTS IN 33t SHOW SKETCH
REMARKS IF NECESSARY. ,

B D
A

Discharge

CONDITION OF
PAINT ANO KIND, OR IF BARE, METAL SURFACES OF, INCLUOING LOCATION OF PITTING AND EROSION AREAS AND SIZE AND DEPTH OF

DAMAGED AREAS:

re feet in area.

BP
ous welded vanes

(See_impeller

SEAL AND WEARING RINGS

ng
_Satisfactory f Wearin

Lg coring. C
further operation. g Ting pump end OK.



On November 6, 1979, the Bureau of Reclamation was
renamed the Water and Power Resources Service in the
U.S. Department of the Interior. The new name more
closely identifies the agency with its principal
functions—supplying water and power.

The text of this publication was prepared prior to
adoption of the new name; all references to the Bureau of
Reclamation or any derivative thereof are to be con-
sidered synonymous with the Water and Power
Resources Service.

The Irrigation Operation and Maintenance Bulletin is published quar-
terly, for the benefit of irrigation project people. Its principal
purpose is to serve as a medium of exchanging operation and mainte-
nance information. It is hoped that the material herein concerning
the maintenance of pumping plant equipment and procedures, developed
by the Bureau, will result in improved efficiency and reduced costs
for those operators adapting these ideas to their needs.

The revisions made herein, include sectionalization, some rearrange-
ment of material and the addition of a section on seasonal maintenance.

te eR

Division of Water Operation and Maintenance
Engineering and Research Center
Denver, Colorado

COVER PHOTOGRAPH:

This shows the 4 pumps of
Lateral 113.7E looking west
over the Delano-Farlimart Ir-
rigation District in Califor-
nia. The system consists of
approximately 172 miles of
laterals and sublaterals uti-
lizing precast reinforced con-
crete pressure pipe, and 18
pumping plants and appurtenant
works. Photo PX-D-58270.



0.8 M-150

(9-86)
burea

MOTOR OR GENERATOR INSPECTION REPORT

Location...Black Canyon Pr. Pl.

MFR. OF UNIT.
RATING:
VOLTS 6600
HP. _
apm, 225

FRAME SIZE__._
nevolhle AMPS.
KIND OF BEARINGS.

MAIN EXCITER

PiLot Exciter: None

5-18-67

UNIT No. 3...

--. DATE OF INSPECTION

TYPE - ween eee
sees es 22 --ee------SERIAL No.
~--VOLTS.._

kw 35 vouts...250 | ames, WHO
TYPE --SERIALNo, 119500.
KW... AMPS. -

TYPE SERIAL No.

CONDITION OF UNIT AND AUXILIARY DEVICES:

cot Insucation... Clean OK

FIELD COIL RESISTANCE...
MAIN EXCITER FIELD COIL RESISTANCE

FRAME AND ROTOR...

STATOR AND ROTOR LAMINATIONS

BEARINGS...
ANY OIL LEAKS ?..
BEARING OIL._

COLLECTOR RING OPERATION.

COMMUTATION...

IF TROUBLE IS EXPERIENCED GIVE
BRUSH GRADE_____
COLLEGTOR-RING MATERIAL...
SPRING PRESSURE

MISALINEMENT OR VIBRATION ?_
DOES END PLAY FLOAT FREELY ?____
BEARING THERMOMETERS OR MXQMXOOGMES
BEARING OIL GAGE ORXKKXEN -
BEARING COOLING- WATER PRESSURE GAGE OR SWITCH. ne.
STATOR: TEMP. INDICATOR OR THERMOSTAT. RTDs on swbd indicator OK
FIRE PROTECTIVE EQUIPMENT...

MAX. AMPS,
RING OR COM, DIA

ween eee ---.. OK

Figure 5
22


CHAPTER III - ELECTRIC MOTORS

P755-100-12

1. Inspection Checklist

Inspection
Items of inspection interval
Foundation, base, or support M A
Frame A
Laminations and pole pieces A
Armature or rotor A
Airgap A
Air fans A
Windings M A
Banding and lashing A
Slot wedges A
Commutator or collector rings W
Brushes A
Shaft and bearings D A
Couplings, gears, and pulleys A
Cooling coils and air coolers D A
Temperature indicators and relays A

D - Routine daily inspection by operators when in service.
W - Routine weekly inspection when in service.

M - Routine monthly inspection when in service.

A - Annual inspection.

17


CHAPTER I - INTRODUCTION

Pumping plants on an irrigation system must be maintained in reliable
operating conditions. Such maintenance is necessary to: (1) pro-
vide required service to water users, (2) reduce emergency repairs,
and (3) lower maintenance costs. However, it is impossible to cover
the subject of preventive maintenance in anything but a very general
manner in a short publication. This bulletin will, therefore, serve
only as an outline or guide for the maintenance which should be

performed.

Much of the material in the bulletin has been written for pumping
plant maintenance; but a great deal of it has been adapted from
Power Operation and Maintenance Bulletins and where appropriate can
be applied to power and pumping plants of any size.

The supervisor or foreman should take time to review the forms and
inspection lists provided, add material as needed, and eliminate
those items which do not pertain to his particular plant.

As indicated on the inside of the cover, this is a revision of the
original Bulletin No. 60, published for April, May, and June 1967.
The revision consists of sectionalizing the original Bulletin for

more convenient reference, some rearrangement of material made nec-
essary by the sectionalization, and the addition of a section on

seasonal maintenance. This section contains suggestions for serv-
icing prior to spring startup and fall shutdown of pumping plants.

1. Preventive Maintenance

Experience has proved that a continuous program of preventive main-
tenance, combined with equipment overhaul when required, is the best
and least costly means of maintaining any plant or equipment and
will best suit the needs of irrigation pumping plants. This con-
sists of continually performing routine maintenance and adjusting
the critical items of a structure or facility in a scheduled and
organized manner so that special inspection and costly repairs are
less necessary.

Maintenance is applied more specifically to the parts which are
known to need repairs or replacement most often, the theory being
that proper lubrication, adjustment, and small repairs applied often
enough to the critical parts will make it less necessary to under-
take complete overhaul or replacement. Breakdowns are reduced,
outages shortened, and the frequency for overhaul of most facilities
is lessened when preventive maintenance is a practiced procedure.



PORM-125
(20-55)
Bureau of Reclamation FILE No

INSPECTION DUE.

EQUIPMENT.

PROJECT. - INSPECTIONS ANNUALLY. _

INSPECTION AND MAINTENANCE RECORD

INSPECTED | REPORT cost
DATE OY REFERENCE DESCRIPTION OF WORK DONE WY CLE TST
FRONT
INSPECTION AND MAINTENANCE RECORD
INSPECTED REPORT cost
DATE ey REFERENCE. DESCRIPTION OF WORK DONE LAGOA | maTERIAL

REAR

Figure 2