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Facilities Instructions, Standards, and Techniques Volume 4-1A – Revised 2009

Maintenance Scheduling for Mechanical Equipment

U.S. Department of the Interior Bureau of Reclamation Denver, Colorado

January 2009

Form OMB No.Approved 0704-0188

REPORT DOCUMENTATION PAGE

Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing this collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS.

1. REPORT DATE (DD-MM-YYYY)T T

2. REPORT TYPE T

3. DATES COVERED (From - To)T

T

September 2007

T

Final

4. TITLE AND SUBTITLE

5a. CONTRACT NUMBER

T

FIST 4-1A, Maintenance Scheduling for Mechanical Equipment 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S)

5d. PROJECT NUMBER

Bureau of Reclamation Hydroelectric Research and Technical Services Group Denver, Colorado

5e. TASK NUMBER 5f. WORK UNIT NUMBER 8. PERFORMING ORGANIZATION REPORT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

Hydroelectric Research and Technical Services Group Bureau of Reclamation Denver Federal Center P.O. Box 25007 Denver CO 80225-0007

FIST 4-1A

9. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES)

10. SPONSOR/MONITOR’S ACRONYM(S)

Power Resources Office Office of Policy Bureau of Reclamation Mail Code 84-54000 PO Box 25007 Denver CO 80225-0007

DIBR 11. SPONSOR/MONITOR’S REPORT NUMBER(S)

12. DISTRIBUTION / AVAILABILITY STATEMENT

Available from the National Technical Information Service, Operations Division, 5285 Port Royal Road, Springfield, Virginia 22161 13. SUPPLEMENTARY NOTES T

14. ABSTRACT

This document establishes minimum recommended practices for maintenance of mechanical equipment in Bureau of Reclamation hydroelectric power and large pumping plants. Included in this document are recommended maintenance activities, maintenance interval, and references.

15. SUBJECT TERMS

Mechanical equipment, hydraulic turbines, pumps, bearings, shaft couplings, oil and lubricants, cranes, hoists, rigging equipment, elevators, ropes, chains, slings, cathodic protection, fire systems, powerplant heating and ventilating systems, mechanical drawings, engine generators 17. LIMITATION OF ABSTRACT

16. SECURITY CLASSIFICATION OF:

a. REPORT

UL

b. ABSTRACT

UL

c. THIS PAGE

UL

UL

18. NUMBER OF PAGES

19a. NAME OF RESPONSIBLE PERSON T

Roger Cline, John Germann, Bill McStraw 19b. TELEPHONE NUMBER (include area code)

303-445-2293 S Standard Form 298 (Rev. 8/98) P Prescribed by ANSI Std. 239-18

Facilities, Instructions, Standards, and Techniques Volume 4-1a – Revised 2009

Maintenance Scheduling for Mechanical Equipment

Hydroelectric Research and Technical Services Group

U.S. Department of the Interior Bureau of Reclamation Denver, Colorado

January 2009

Disclaimer

This written material consists of general information for internal use only by Bureau of Reclamation operations and maintenance staff. Information contained in this document regarding commercial products or firms may not be used for advertising or promotional purposes and is not to be construed as an endorsement or deprecation of any product or firm by the Bureau of Reclamation.

Acronyms and Abbreviations A ac ANSI ASME ASTM AWG CAL/OSHA CBM CFR CMMS CO2 dc EPSS FIST HECP Hz JHA MAWP mV NDE NDT NFPA O&M OSHA PEB PO&M PM PMG psi pvc RCM Reclamation rpm rms RSHS SSG SWL UNC V WECC WISHA °F

amps alternating current American National Standards Institute American Society of Mechanical Engineers American Society for Testing and Materials American Wire Gauge California Occupational Safety and Health Regulations condition-based maintenance Code of Federal Regulations computerized maintenance management system carbon dioxide direct current emergency power supply systems Facilities Instructions, Standards, and Techniques Hazardous Energy Control Program hertz job hazard analysis maximum allowable working pressure millivolts nondestructive examination Nondestructive Testing National Fire Protection Association operation and maintenance Occupational Safety and Health Administration Power Equipment Bulletins power operation and maintenance preventive maintenance permanent magnet generator pounds per square polyvinyl chloride reliability-centered maintenance Bureau of Reclamation rotations per minute root mean square Reclamation Safety and Health Standards speed signal generator safe working load unified coarse thread volt Western Electricity Coordinating Council Washington Industrial Safety and Health Administration degree Fahrenheit

Table of Contents Page

Acronyms and Abbreviations .......................................................................... 1. Introduction ............................................................................................... 1.1 Maintenance .................................................................................... 1.1.1 General .................................................................................. 1.1.2 Preventive Maintenance ........................................................ 1.1.3 Reliability-Centered Maintenance......................................... 1.1.4 Condition-Based Maintenance .............................................. 1.1.5 Combination of Condition-Based and Preventive Maintenance .................................................... 1.2 Standards and References................................................................ 1.2.1 Reclamation Standards.......................................................... 1.2.2 Recommended Standards and References............................. 1.3 Maintenance and Test Procedures................................................... 1.3.1 General .................................................................................. 1.4 Maintenance Schedules and Documentation................................... 1.5 Job Plan Templates.......................................................................... 1.6 Power O&M Forms......................................................................... 1.7 Power O&M Reviews ..................................................................... 1.8 Limitations ...................................................................................... 1.9 Safety During Maintenance.............................................................

iii 1 1 1 1 2 3

2. Turbine and Pump Maintenance ............................................................... 2.1 Hydraulic Turbines.......................................................................... 2.2 Pumps .............................................................................................. 2.2.1 Dynamic Pumps .................................................................... 2.2.2 Positive Displacement Pumps ............................................... 2.3 Cavitation Erosion, Abrasive Erosion, and Corrosion .................... 2.4 Wearing Rings................................................................................. 2.5 Packing/Mechanical Seals............................................................... 2.5.1 Packing .................................................................................. 2.5.2 Mechanical Seals................................................................... 2.6 Bearings........................................................................................... 2.6.1 Fluid Film Bearings............................................................... 2.6.2 Antifriction Bearings............................................................. 2.7 Shaft Couplings ............................................................................... 2.8 Shaft Alignment .............................................................................. 2.8.1 Horizontal Pump Alignment ................................................. 2.8.2 Face and Rim Alignment Method ......................................... 2.8.3 Reverse Indicator Method ..................................................... 2.9 Vibration Monitoring and Analysis................................................. 2.9.1 Proximity Probe Systems ...................................................... 2.9.2 Accelerometer Systems ......................................................... 2.9.3 Signature Analysis................................................................. 2.10 Oil and Lubricants...........................................................................

9 9 9 9 13 17 20 20 20 22 22 22 23 23 24 24 27 32 36 36 37 37 39

3 4 4 5 5 5 6 6 6 7 7 7

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FIST 4-1A Maintenance Scheduling for Mechanical Equipment

Contents (continued) Page

2.10.2 Oil Lubrication .................................................................... 2.10.3 Grease Lubrication .............................................................. 2.10.4 Hydraulic Oil....................................................................... 2.10.5 Testing and Filtering ........................................................... 2.11 Inspection Checklist ........................................................................ 2.11.1 Hydraulic Turbines and Large Pumps................................. 2.11.2 Auxiliary Pumps..................................................................

39 39 40 40 42 43 48

3. Penstocks, Outlet Pipes, Piping, Gates, and Valves................................. 3.1 Penstocks, Outlet Pipes, Lines, and Piping ..................................... 3.2 Gates and Valves............................................................................. 3.2.1 General .................................................................................. 3.2.2 Gates...................................................................................... 3.2.3 Valves.................................................................................... 3.2.4 Valve and Gate Operators ..................................................... 3.3 Guard Gate and Valve Closure Tests .............................................. 3.4 Turbine Pressure Relief Valves....................................................... 3.5 Auxiliary Piping Systems................................................................ 3.6 Inspection Checklist ........................................................................ 3.6.1 Gates and Valves................................................................... 3.6.2 Penstocks, Outlet Pipes ......................................................... 3.6.3 Gates and Valves................................................................... 3.6.4 Gate and Valve Operators and Hoists ................................... 3.6.5 Guard Gate and Valve Closure Tests .................................... 3.6.6 Turbine Pressure Relief Valves Operational Tests ............... 3.6.7 Auxiliary Piping Systems......................................................

51 51 51 51 55 65 65 74 80 80 81 81 83 84 86 88 88 89

4. Mechanical Governors .............................................................................. 4.1 General ............................................................................................ 4.2 Inspection Checklist ........................................................................

91 91 91

5. Air Compressors........................................................................................ 5.1 General ............................................................................................ 5.2 Reciprocating Air Compressors ...................................................... 5.3 Rotary Screw Air Compressors....................................................... 5.4 Accessories...................................................................................... 5.4.1 Inlet Filters ............................................................................ 5.4.2 Aftercoolers........................................................................... 5.4.3 Separators .............................................................................. 5.4.4 Traps...................................................................................... 5.4.5 Dryers .................................................................................... 5.4.6 Pressure Regulating Valves................................................... 5.4.7 Pressure Relief Valves .......................................................... 5.4.8 Receiver Tanks and Other Pressure Vessels ......................... 5.5 Inspection Checklist ........................................................................

99 99 99 99 100 100 100 100 100 101 101 101 101 102

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FIST 4-1A Maintenance Scheduling for Mechanical Equipment

Contents (continued) Page

5.6 5.7 5.8

General ............................................................................................ 103 Reciprocating Compressors............................................................. 105 Rotary Screw Compressors ............................................................. 106

6. Cranes, Hoists, Rigging Equipment, and Elevators .................................. 6.1 General ............................................................................................ 6.2 Standards and References................................................................ 6.2.1 Reclamation Standards.......................................................... 6.2.2 OSHA Regulations................................................................ 6.2.3 ANSI/ASME Standards......................................................... 6.3 New Versus Existing Cranes........................................................... 6.4 Crane Types..................................................................................... 6.5 Inspections....................................................................................... 6.6 Maintenance .................................................................................... 6.7 Testing............................................................................................. 6.7.1 Operational Tests................................................................... 6.7.2 Periodic Load Tests............................................................... 6.8 Safe Operating Practices ................................................................. 6.9 Critical Lifts .................................................................................... 6.9.1 Determination of Critical Lift ............................................... 6.9.2 Responsibility........................................................................ 6.9.3 Designated Person ................................................................. 6.9.4 Critical Lift Plans .................................................................. 6.9.5 Critical Lift Plan Approval.................................................... 6.9.6 Prelift Meeting....................................................................... 6.9.7 Documentation ...................................................................... 6.10 Overhead and Gantry Cranes .......................................................... 6.10.1 General ................................................................................ 6.10.2 Modifications ...................................................................... 6.10.3 Rated Load Marking............................................................ 6.10.4 Hand Signal Posting ............................................................ 6.10.5 Outdoor Cranes ................................................................... 6.10.6 General Construction........................................................... 6.10.7 Maintenance and Inspection Requirements......................... 6.11 Ropes, Slings, Chains, and Rigging Hardware ............................... 6.11.1 General Maintenance and Inspection Requirements........... 6.11.2 Inspections........................................................................... 6.11.3 Operating Practices ............................................................. 6.11.4 Alloy Steel Chain Slings ..................................................... 6.11.5 Wire Rope Slings ................................................................ 6.11.6 Metal Mesh Slings............................................................... 6.11.7 Natural and Synthetic Fiber Rope Slings ............................ 6.11.8 Synthetic Webbing Slings ................................................... 6.11.9 Rigging Hardware (Shackles, Eyebolts, etc.)......................

107 107 107 107 107 108 109 109 109 119 121 121 122 123 125 125 126 126 126 127 128 128 128 128 128 129 129 129 129 129 143 143 144 145 146 148 151 151 152 155 vii

FIST 4-1A Maintenance Scheduling for Mechanical Equipment

Contents (continued) Page

6.12 Shop Fabricated Lifting Devices and Rigging Hardware ............... 6.13 Below-the-Hook Lifting Devices .................................................... 6.13.1 Design.................................................................................. 6.13.2 Marking ............................................................................... 6.13.3 Modifications ...................................................................... 6.13.4 Operations ........................................................................... 6.13.5 Inspections........................................................................... 6.13.6 Repairs................................................................................. 6.13.7 Testing................................................................................. 6.13.8 Maintenance Files ............................................................... 6.14 Elevators..........................................................................................

172 172 173 173 174 174 174 175 176 176 177

7. Cathodic Protection ................................................................................... 7.1 General ............................................................................................ 7.2 What Is Corrosion ........................................................................... 7.3 What Is Cathodic Protection ........................................................... 7.4 Cathodically Protected Metalwork at Powerplants ......................... 7.5 Typical Operation and Maintenance Requirements ........................ 7.5.1 Operating Criteria.................................................................. 7.5.2 Submerged Metalwork Cathodic Protection Systems........... 7.5.3 Buried Metalwork Cathodic Protection Systems .................. 7.6 Data Analysis and Technical Assistance...................................