J.17_Guide_card.pdf
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- Solicitation number
- 47PM0719R0014
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A-01 Air Dryer
Annual P.M. Guide Sheet Estimated Man hours: 8
Priority Level 2
Work Performed By: _______________________________________________________
Maximo Equipment ID Number: _______________________________________________
Special Instructions
Schedule this maintenance in conjunction with the Operations.
De-energize, lock and tag electrical circuits.
Review manufacturer’s instructions.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
PM Tasks
Lubricate valves and replace packing if necessary.
Check dryer operating cycle.
Inspect and clean heat exchanger.
Check outlet dew point.
Clean and lubricate blower.
Check automatic Blowdown devices.
Inspect and replace or reinstall inlet filters.
Desiccant Type:
o Replace filter cartridge, both pre-filter and after-filter.
o Check the inlet flow pressure, temperatures, and purge rate.
o Check the desiccant and replace if necessary.
o Inspect and clean solenoids, purge valve, and strainers.
Tools Required
• Miscellaneous hand tools
Special Notes
A-06 AC Machine/Package Unit Annual P.M. Guide Sheet
Estimated Man hours: 3 Priority Level 2
Work Performed By: _______________________________________________________
Safety Notes
Remove all jewelry (rings, watches, necklaces, etc.) prior to working on unit.
No smoking or open flames permitted.
Wear safety goggles.
Use of work gloves may be necessary.
Review the Standard Operating Procedure for “Confined Space Entry”. If required.
Review the Standard Operating Procedure for “Selection, Care, and use of Respiratory Protection”. If required.
Ensure proper PPE is utilized during the disconnection and grounding.
Ensure proper PPE is utilized during the reconnection.
Schedule shutdown with operating personnel, as needed.
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Schedule PM of motor per Guide Card M-03 in conjunction with this PM.
Comply with the latest provision of the Clean Air Act and Environmental Protection Agency regulations as they apply to the protection of stratospheric ozone.
No intentional venting of refrigerants is permitted during the servicing, maintenance, and repair of refrigeration equipment. The refrigerant must be recovered.
Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.
Recover, recycle, or reclaim the refrigerant as appropriate.
If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the equipment.
If materials containing refrigerants are discarded comply with EPA regulations as applicable.
Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.
Closely follow all safety procedures described in the MSDS for the refrigerant and all labels on refrigerant containers.
Check with Operations or area personnel for deficiencies.
De-energize, tag out, and lockout electrical circuit(s).
Check and tighten any loose unit electrical terminals, disconnect switches, or connections.
Remove panels and thoroughly inspect and clean interior and exterior of machine with vacuum cleaner.
Clean drain pan and note excessive corrosion. Prepare metal and spray paint as necessary.
On units larger than window units, check for refrigerant leaks using an electronic leak detector and liquid soap. If any leaks are detected address them with supervisor.
Check condition of cooling and reheat coils. Use fin comb if needed to straighten fins.
Clean coils, use coil cleaner detergent solution and high pressure water.
Drain and clean humidifier drain pan, if applicable. Remove corrosion, prime, and paint as needed.
A-06 AC Machine/Package Unit Annual P.M. Guide Sheet
Estimated Man hours: 3 Priority Level 2
Lubricate motor and fan bearings, if not sealed.
Replace pre-filters if necessary. (if applicable) Replace final filters if necessary. (if applicable) Check compressor oil level, if compressor has a sight glass.
Remove lockout, tag out and start unit.
Run unit check action of controls, relays, switches, etc. to see the following:
o Compressor runs at proper setting.
o Reheat coils activate properly.
o Humidistat activates humidifier.
o Suction and discharge pressures are proper.
o Document refrigerant pressures (low and high). As well as return and discharge air temperatures, and running load amps.
Low Pressure:_________________ High Pressure: ________________ Return Air: ___________________ Discharge Air: ________________ R.L.A.: ______________________
Clean up area and dispose of any debris properly.
Lot all items shown above on inspection sheet.
• Voltmeter
• Grease gun and oiler
• Vacuum
• Fin comb
• Cleaning tools and materials
• Electric leak detector
A-11 Air Handling Unit
Monthly P.M. Guide Sheet Estimated Man hours: 5
Priority Level 2
Work Performed By: _______________________________________________________
Wear safety goggles.
Use of work gloves may be necessary.
Review the Standard Operating Procedure for “Confined Space Entry”. If required.
Review the Standard Operating Procedure for “Selection, Care, and use of Respiratory Protection”. If required.
Schedule shutdown with operating personnel, as needed.
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Schedule PM of motor per Guide Card M-03 in conjunction with this PM.
Comply with the latest provision of the Clean Air Act and Environmental Protection Agency regulations as they apply to the protection of stratospheric ozone.
No intentional venting of refrigerants is permitted during the servicing, maintenance, and repair of refrigeration equipment. The refrigerant must be recovered.
Whenever refrigerant is added or removed from equipment, record the quantities on the appropriate forms.
Recover, recycle, or reclaim the refrigerant as appropriate.
If disposal of the equipment item is required, follow regulations concerning removal of refrigerants and disposal of the equipment.
If materials containing refrigerants are discarded comply with EPA regulations as applicable.
Refrigerant oils to be removed for disposal must be analyzed for hazardous waste and handled accordingly.
Closely follow all safety procedures described in the MSDS for the refrigerant and all labels on refrigerant containers.
De-energize, tag out, and lockout electrical circuit(s).
Check fan blades for dust build-up and clean with shop vacuum.
Check fan blades and moving parts for cracks and excessive wear.
Check fan RPM against design specifications.
Check bearing collar set screws on fan shaft to make sure they are tight.
Check dampers for dirt accumulations and clean as necessary.
Check damper actuators and linkage for proper operation. Adjust linkage on dampers if out of alignment.
Lubricate mechanical connections of dampers sparingly.
Clean coils by brushing, blowing, vacuuming, or pressure washing.
Use a fin comb to straighten coil fins if necessary.
A-11 Air Handling Unit
Monthly P.M. Guide Sheet Estimated Man hours: 5
Priority Level 2 Check coils for leaks, tightness of fittings.
o On direct expansion units check for refrigerant leaks on all lines, valves, fittings, coils, etc. using an electronic leak detector and liquid soap.
o If leaks are not able to be stopped or corrected report leak status to supervisor.
Flush and clean condensate pans and drains, remove all rust, prepare metal, and paint.
Hose down coils and drain pans and wash with appropriate EPA approved solution. Treat condensate pans with EPA approved biocide.
Check belts for wear and tear, adjust tension and alignment, and replace as necessary. Multi belt drives shall only be replaced with matched sets.
Check rigid couplings for alignment on direct drives and for tightness of assembly. Check flexible couplings for alignment and wear.
Vacuum interior of unit.
Lubricate grease bearings in fan motor and fan shaft.
Replace associated filters.
Remove lockout tag out and start unit.
Check temperature of suction and discharge air and record readings below.
Check temperatures of supply and return chilled water temperatures and record readings below.
Clean all strainers, traps, anti-seize stems on all valves, check operation of pneumatics, etc. associated with the equipment.
Inspect all gauges and insure they are properly functioning.
Clean up area of debris and dispose of properly.
Log all items shown above on inspection sheet.
• Tachometer
• Grease gun and oiler
• Pressure washer
• Vacuum
• Fin comb
• Cleaning tools and materials
• Electric leak detector
B-02 Industrial water tube steamboiler
Annual P.M. Guide Sheet Estimated Man hours: 350
Priority Level 2
Work Performed By: _______________________________________________________
Wear safety goggles.
Use of work gloves may be necessary.
Review the Standard Operating Procedure for “Confined Space Entry”. If required.
Review the Standard Operating Procedure for “Selection, Care, and use of Respiratory Protection”. If required.
Schedule this maintenance in conjunction with Building Operations.
Schedule this maintenance in conjunction with the maintenance of associated equipment. Non-Return valves must be VR recertified every year and the safety relief valves are VR recertified every other year.
Review equipment maintenance history.
Review manufacturer’s instructions.
Schedule shutdown with Operations personnel.
Drain boiler and perform Lock-out Tag out procedure to entire boiler.
Never attempt to remove a manhole or handhole cover without first properly venting the water or steam side of boiler to the atmosphere.
Prior to opening or entering a boiler it must be at atmospheric pressure.
To protect the boiler from unnecessary stresses, the boiler water temperature should be allowed to reach ambient temperature before draining the boiler.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Comply with the latest provisions of the Clean Air Act and Environmental Protection Agency regulations as they apply to the protection of stratospheric ozone.
Ensure proper PPE is utilized during the disconnection and grounding.
Reference NETA, NFPA 70E, and NEC for proper safety and disconnect.
After confirming vacuum is broken. Open, inspect, and wash all loose scale accumulation form water-side of unfired generator.
Remove approximately 50 designated handholes for inspection at GSA’s discretion.
Brush plate surfaces clean. (use vacuum cleaner) Vacuum, sweep fireboxes, and re-gasket firebox doors.
Check refractory and brick work. If damaged notify supervisor and enter data in boiler log with PM sheets.
Examine all steam and water lines to controls to determine that they are clear of scale and arranged to insure proper control operations.
Annual P.M. Guide Sheet Estimated Man hours: 350
Priority Level 2 Dismantle and clean low water cut offs, fuel oil cut offs, and water feeders to insure freedom from obstructions and proper functioning of the working parts. Always replace old gaskets before reassembling.
Inspect connecting lines to the boiler for accumulations of mud, scale, etc. Clean as required.
Clean or replace sight glass and mica film.
Schedule preventative maintenance on all related equipment during the time the boiler is down for PM’s.
o FD Fan o ID Fan o Economizer o Safety Valves (if required) o Non Return Valves o All miscellaneous feed water and other valves PM’s o Air Damper o Boiler Blowdowns o Special Boiler 5 PM’s
Cooling Tower 9 Exhaust Fans Turbine Heat Exchangers o Special Boiler 6 PM Air Pre-heater
After Non-return is repacked and safety valves are recertified by specialist install new gaskets, close the steam and mud drums. Fill and perform a hydrostatic test.
Check operation of all gas controls and valves including manual gas shutoff, petal gas regulator, safety shutoff valve (solenoid), automatic gas valve, petal solenoid valve, butterfly gas valve, safety petal solenoid (if used).
Check flue connections for tight joints and minimum resistance to air flow. (Combustion chamber, flues, breaching, and chimney are clear before firing).
Check burner, pilot, and main flame ignition. Also, verify and calibrate for smooth and reliable light.
After walk down inspection is completed and water side of boiler is closed, refill boiler with water and perform a hydrostatic “squeeze” test. At this time the manholes on the drums may need to be re-tightened on the yolks.
Walk down again and check for leaks. If hydrostatic test is successful, remove all lock out tag out.
Turn completed boiler back over to GSA.
Clean all areas where work has been performed.
• Miscellaneous pipe wrenches
• Large 24” adjustable wrench
• Power tools (grinder, pencil grinder, wire wheel, impact drill, etc.)
• Blowdown packing puller
• Shop Vacuum
Annual P.M. Guide Sheet Estimated Man hours: 350
Priority Level 2
C-09 Cooling Tower Cell
Annual P.M. Guide Sheet Estimated Man hours: 200
Priority Level 2
Work Performed By: _______________________________________________________
Schedule this maintenance in conjunction with the maintenance on associated equipment.
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Ensure proper PPE is utilized during the disconnection and grounding.
Reference NETA, NFPA 70E, and NEC for proper safety and disconnect procedures.
Check with operations or area personnel for deficiencies.
Lockout/ Tag out all associated equipment.
Drain the common basin.
Use fire hose to remove loose scale that is built up in tower fill.
Shovel out the scale/debris and properly dispose of.
Rinse basin clean with large fire hose. (Stand pipe located behind north door) Remove drift eliminators, stack neatly on the top deck of the cell.
Lay plywood/masonite over the fill to better distribute weight.
Check all of the distribution nozzles. Replace if missing and make sure to use proper replacement nozzle.
Check all brackets, hanger rods, etc. and clean using wire wheel and paint if corroded.
Check and tighten all brackets in the cell.
Check and replace any broken or corroded wood supports.
Check and replace any broken panels.
Drain oil from gear box and refill with new proper weight oil.
Check the pitch of the fan blades and tightness of all bolts.
Remove plugs from fan blades and drain any built up condensation.
Check and record info on the clearance between the tip of the impeller and the shroud.
Wire-wheel all of the gearbox housing and paint.
Check the backlash rotation and anti-reverse assembly. Repair or replace when needed.
Check alignment and shaft coupling hardware. Replace bolts and nuts if removed four times or more. Record data.
Clean and properly dispose of all debris in work area.
Record all as-found readings.
Record all as-left readings.
Use all attached forms to record all data readings.
Cooling Tower Cell
Annual P.M. Guide Sheet Estimated Man hours: 200
Priority Level 2
Special Notes
D-20 Air Dampers
Annual P.M. Guide Sheet Estimated Man hours: 6
Priority Level 2
Work Performed By: _______________________________________________________
Check for confine space requirements.
De-energize, Lock-out Tag-out all associated equipment.
Review manufacturer’s instructions
Inspect breaching for cracked or missing insulation.
Inspect access door for leaking gaskets.
Remove access door (Two men required) Enter breaching and inspect for strength, corrosion, and cracking.
Inspect alignment and interference of damper linkage.
Inspect stuffing box for leakage around each damper leaf shaft.
Tighten stuffing box nuts and replace packing as necessary.
Inspect all fasteners and tighten if necessary.
Lubricate all damper shaft bearings and fittings. Replace if needed Check travel of actuator and linkage versus damper leaf and linkage travel. Adjust as necessary. Coordinate with the government.
Lubricate universal joints as needed.
Replace access door gaskets as needed.
Close access door (Two men required)
Required Tools
• Adjustable Wrench
• Flashlight
• Grease Gun
• PPE. For confine space requirements.
E-48 Economizer
Annual P.M. Guide Sheet Estimated Man hours: 4
Priority Level 2
Work Performed By: _______________________________________________________
Schedule this maintenance in conjunction with the maintenance of associated equipment.
Review maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources” Comply with the latest provisions of the Clean Air Act and Environmental Protection Agency regulations as they apply to the protection of stratospheric ozone.
Ensure proper PPE is utilized during the disconnection and grounding.
Remove inspection covers, re-gasket.
Vacuum and sweep the tubes.
Inspect economizer tubes for leaks and cleanliness.
Do not re-install the inspection covers until the boiler has passed a hydrostatic test.
Inspect alignment of braces, brackets, and expansion joints. Check for cracking and tightness. Repair or replace damaged parts if necessary.
Inspect access doors seals and bolts.
Inspect exterior insulation.
Clean up area and dispose of trash properly.
• Impact Drill
E-50 Emergency Pumps and Ventilators
Annual P.M. Guide Sheet Estimated Man hours: 3
Priority Level 2
Work Performed By: _______________________________________________________
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Schedule PM of motor per Guide Card M-03 in conjunction with this PM.
Comply with the latest provision of the Clean Air Act and Environmental Protection Agency regulations as they apply to the protection of stratospheric ozone.
Ensure proper PPE is utilized during the disconnection and grounding.
If applicable, check the engine oil level.
Test the unit operation.
Observe operation, repair of any defects or malfunctions.
De-energize, lockout, and tag out all associated equipment.
Change crankcase oil.
Clean air and fuel filters, replace when necessary.
Tune the engine.
Remove lockout and start unit.
Operate engine and increase RPM until governor operates. Adjust if necessary.
Check for proper operation of speed controller.
Check for proper alignment and for unusual or excessive vibration.
Perform other work prescribed by manufacturer.
Electric motor- refer to appropriate guide.
Pneumatic motor- refer to manufacturer’s instructions.
Pump- refer to appropriate pump guide.
Ventilating Blower o Clean unit.
o Perform required lubrication.
o Check condition of housing, blades, and ventilating tube.
Clean up area and dispose of trash properly.
DG-01
Emergency Generators
Annual P.M. Guide Sheet Estimated Man hours: 4
Priority Level 2
Work Performed By: _______________________________________________________
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Ensure proper PPE is utilized during the disconnection and grounding.
Cooling system
I. Visual inspection of radiator or heat exchanger for leaks, damage, and obstruction.
II. Check radiator coolant level, replenish as required.
III. Test coolant for proper antifreeze percentage.
IV. Test corrosion inhibitor concentration, record.
V. Check jacket water heater for proper operation and adjust thermostat setting as needed.
VI. Inspect condition of radiator cap, gasket and sealing surface.
VII. Visual inspection of water pump and cooling system gaskets for leaks.
VIII. Check belt tension and inspect for cracking and fraying if accessibility without disassembly.
IX. Inspect pulleys for excessive wear and lubricate hub bearings as needed.
X. Inspect flexible water connections for cracking, leaks, and pliability
XI. Tighten hose clamps as needed.
Lubrication System
I. Check oil, replenish as required.
II. Check for excessive crankcase blow-by with unit running.
III. Visual inspection of front and rear crankshaft seals and lubrication system gaskets for leaks.
IV. Inspect oil hose and connections for cracking, leaks, and pliability.
Fuel System –Diesel
I. Inspect flexible fuel lines for cracking, leaks and pliability.
II. Check day tank/base tank level and test day tank pump for proper operation.
III. Operate fuel-priming pump, check for proper operation and leaks.
IV. Drain water from water separator(s).
V. Check fuel system for leaks.
VI. Check electronic governor connections and actuator.
VII. Inspect steel fuel lines for cracks, leaks and proper line bracket support.
Annual P.M. Guide Sheet Estimated Man hours: 4
Starting System
I. Record battery cells' electrolyte specific gravity (accessible batteries only).
II. Top off electrolyte level in accessible lead-acid batteries with distilled water.
III. Check and record battery charger/alternator for proper charge rate.
IV. Check for proper cranking termination upon starting.
V. C, lean and apply corrosion inhibitor to the terminals of lead acid batteries as needed.
VI. Tighten battery cable connections as needed.
VII. Inspect and tighten starter moto r(s) connections as needed
Exhaust System
I. Inspect flexible exhaust coupling for cracks, excessive leakage, broken, or missing hardware.
II. Inspect Exterior of exhaust manifold s for oil/fuel slobbering (signs of wet stacking).
III. Inspect exhaust rain protection and exhaust outlet screening.
IV. Drain water in exhaust moisture traps.
Air Intake System
I. Inspect air fi1ters for plugging and deterioration, clean if required.
II. Check all air intakes piping for damage and loose connections.
III. Inspect air cleaner seal for pliability and scaling and clean if necessary.
IV. Inspect turbocharger for excessive endplay clearance (if accessible) and seal leakage.
Installation
I. Walk around inspection of complete installation.
II. Inspect generator set vibration isolators.
III. Check for abnormal noise or vibration.
IV. Re-check for oil and coolant leaks with unit running.
V. Check for proper operation of remote fan motors, thermostats, circulating pumps, and solenoid valves.
VI. Check inlet and discharge louvers for proper operation with unit running and stopped
Control Panel
I. Operational check of illumination and safety lamps.
II. Check electronic control panels for fault codes, notify customer of any codes that need to be addressed.
III. Check proper operation of instruments with unit running.
IV. Adjust governor control for optimum performance and frequency.
V. Adjust voltage regulator for proper voltage.
VI. Inspect for excessive dirt accumulation and clean as needed.
VII. Test emergency stop.
Annual P.M. Guide Sheet Estimated Man hours: 4
Upon Completion of Service
I. Reset all controls to automatic.
II. Set circuit breaker to correct position.
III. Check that fuel valves are in correct position.
IV. Check that battery charger is on.
V. Check that day tank controls are on.
VI. Check that Louver controls arc on. .
VII. Check that Jacket water heater is on.
Change unit oil and filters, take oil sample for analysis.
Change primary and secondary fuel filters.
Properly dispose of waste oil and filters.
Lubricate fan drive if accessible.
Lubricate governor linkage.
Clean or Replace inlet filter for day tank.
Annual P.M. Guide Sheet Estimated Man hours: 4
Check inlet and discharge louvers for proper operation with unit running and stopped
Annual P.M. Guide Sheet Estimated Man hours: 4
Priority Level 2
Evapco cooling Tower Cell
Annual P.M. Guide Sheet Estimated Man hours: 20
Priority Level 2
Work Performed By: _______________________________________________________
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Ensure proper PPE is utilized during the disconnection and grounding.
Lockout/ Tag out all associated equipment.
Drain the common basin.
Pressure wash to remove loose scale that is built up in tower fill.
Shovel out the scale/debris and properly dispose of.
Rinse basin clean with hose or pressure washer.
Remove drift eliminators, clean with scale remover and brush, rinse.
Check all of the distribution nozzles. Replace if missing and make sure to use proper replacement nozzle.
Check all brackets, hanger rods, etc. and clean using wire wheel and paint if corroded.
Check and tighten all brackets in the cell.
Check and replace any broken or corroded supports.
Install the drift eliminators.
Check and replace any broken panels.
Grease fan bearings, motor bearings.
Check pulleys and sheaves, for wear and alignment. Replace if needed.
Replace fan belts.
Check squirrel cage for debris.
Check all drain lines, make up water lines for cracks and freeze ups. Repair if necessary.
Fill tower check operation.
Remove all locks and turn back over to OP’S.
Clean and properly dispose of all debris in work area.
Evapco cooling Tower Cell
Annual P.M. Guide Sheet Estimated Man hours: 20
Priority Level 2
Special Notes
F-27 Fan, Centrifugal
Annual P.M. Guide Sheet Estimated Man hours: 4
Priority Level 2
Work Performed By: _______________________________________________________
De-energize, lockout and tag out all associated equipment.
Review Manufacturer’s instructions.
Inspect fan blades. Clean dust build up and clean with degreaser.
Inspect fan blades and moving parts for excessive wear. Repair or replace if necessary.
Make sure fan RPM meets design specifications.
Inspect bearing collar. Test tightness of screws on fan shaft.
Vacuum interior unit and clean exterior.
Lubricate fan shaft bearings. 5-8 pumps from grease gun only. Do not over lubricate. Remove old or excess lubricant.
Inspect structural members, vibration eliminators, and flexible connections.
Start fan, record amps, volts, and RPM’s below.
Remove all trash and clean area around fan and fan room.
• Tachometer
• Grease gun
F-39 Control Air Filters
Quarterly P.M. Guide Sheet Estimated Man hours: .5
Priority Level 2
Work Performed By: _______________________________________________________
Review manufacturer’s instructions and recommendations.
Comply with the latest provisions of the Clean Air Act and Environmental Protection Agency regulations as they apply to the protection of stratospheric ozone.
Note these filters are obsolete. New part number is DFNT-50-10UN manufactured by Pall Corp.
Valve filter out of service.
Remove and discard old cartridge.
Clean exterior and interior of housing.
Install new cartridge and housing gaskets.
Open inlet valve and check for leaks.
Open outlet valve.
Clean area of any debris and dispose of properly.
Place equipment back into service.
F-42 ID&FD. Fan
Annual P.M. Guide Sheet Estimated Man hours: 24
Priority Level 2
Work Performed By: _______________________________________________________
Remove access cover and check condition of gasket.
Clean dust accumulations from the inside of the fan housing. Pay special attention to fan blades.
Inspect internal structure, structural members, fan blades, and damper blades for cracks or deterioration.
Tighten all bolts as needed.
Check that all base bolts are secure and all guards are in place.
Grease fan linkage on dampers as necessary.
Inspect external shaft bearings and couplings for wear, leakage, and alignment. Disassemble and clean coupling. Inspect for wear and misalignment issues if applicable.
Flush bearing cooling water jacket, both sides. Circulate chemicals. If applicable.
Inspect speed reducer or transmission for leaks and proper alignment (if applicable). Check oil level and add or replace as necessary.
Visually inspect unit for leaks and signs of metal fatigue.
Drain oil and check for contamination.
Separate bearing housing. Support the shaft so the bottom bearing may be removed and inspected.
At this point follow manufacturer’s instructions. Split bearings shall be separated and the clearance shall be verified using plastic gage. When tolerance is greater than factory specifications, this shall be brought to the attention of the contract COR.
After splitting the case, check for wear and damage to the bearings. Check for contaminants in sump.
Check shaft clearance between top of shaft and top of bearing cap. (ID Tolerances are .005-.009) Replace inspection cover using new gasket.
Refill gearbox with proper oil to proper level.
Check for leaks.
Check alignment if driven and slave units.
Check tightness of all associated bolts.
Clean area of debris
• Torque Wrench
• Hydraulic Bottle Jack
• Plasticgauge
• Miscellaneous Hand tools
F-42 ID&FD. Fan
Annual P.M. Guide Sheet Estimated Man hours: 24
Priority Level 2 Special Notes
FFS-01
Fire foam suppression System
Annual P.M. Guide Sheet Estimated Man hours: 5
Priority Level 3
Work Performed By: _______________________________________________________
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Ensure proper PPE is utilized during the disconnection and grounding.
Foam Fire Alarm System
Check control panel functions Conduct system performance test Check detection device functions (smoke, duct, and thermal detectors) Check manual device functions Inspect standby power General test of batteries Inspect alarm notification appliances (audible, speakers, and ,visible devices) Verify transmission and receiving of alarm signal Cleaning of smoke detectors (as needed) Apply inspection tag to system
Foam Sprinkler Systems Visual inspection of each sprinkler for proper spacing/ location, and obstruction or damage Full flow test by the inspector to determine proper flow and alarming Inspection of all valves for proper position Close and then reopen each water supply valve to determine its condition, test the tamper switch and adjust as necessary Trip each dry pipe valves, clean and then reset, checking alarm operation and air compressor Flow every inspectors test connection for access and proper arrangement Visually inspect Fire Department connection for access and proper arrangement Test each water motor alarm going for proper operation
FFS-01
Fire foam suppression System
Annual P.M. Guide Sheet Estimated Man hours: 5
Priority Level 3
G-01 Fuel Oil Filter/Strainer
Annual P.M. Guide Sheet Estimated Man hours: 2
Priority Level 2
Work Performed By: _______________________________________________________
Drain housing, bowl, etc. for filter/ strainer.
Remove covers, housing, bowls, etc. to filter/strainer.
Remove filter/strainer. Inspect gasket and replace if necessary.
Clean housing, bowl, etc. with EPA approved solvent.
Clean filter/strainer with EPA approved solvent.
Replace cover bowl and clean any spillage from the outside. Anti-seize all bolts.
Open inlet valve and vent air.
Open isolation valves.
Inspect filter/ strainer for leaks.
• Bucket
H-13 Air Pre-heater
Annual P.M. Guide Sheet Estimated Man hours: 16
Priority Level 2
Work Performed By: _______________________________________________________
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”
Change oil. (Do not add oil above indicated mark) Check coupling alignment.
Use No. 2 NLGI grease on LSS bearings.
Lubricate gear couplings twice a year.
Check rotor seals and replace if excessive thinning or corrosion has occurred.
Make sure that the cleaning jet is working properly to remove buildup from heating element surface.
M-03 Electric motors
Annual P.M. Guide Sheet Estimated Man hours: 2
Priority Level 2
Work Performed By: _______________________________________________________
Check ventilation ports for soil accumulation, clean ventilation ports.
Clean exterior of motor surface.
Lubricate bearings according to horsepower ratings.
Remove filler and drain plugs. (Use zerk fittings in place of filler plug if not installed) Use wire to free drain hole of any hard grease.
Add grease- use high grade lithium base grease unless otherwise indicated.
Run motor at operating temperature for 15 minutes, remove excess grease from drain hole and reinstall drain.
Check motor windings for accumulation of soil. Vacuum with long bottle type brush then blow out with dry air.
(Air pressure must not exceed 30 PSIG) Inspect bolts and groundings for tightness. Replace worn or broken ground strips.
Check slip with tachometer.
Check voltage and amps on motor and record readings below.
o Voltage: ___________________________________ o Amps: _____________________________________
• Tachometer
• Vacuum
V-08.1 Minimum Flow Valves
Annual P.M. Guide Sheet Estimated Man hours: 3
Priority Level 2
Work Performed By: ____Revise to 16 man hours, two men 8 hrs.
Isolate check valve, secure and tag associated valves and equipment.
Isolate the pump; if electric secure the power.
Secure the discharge valve and suction valve on pump.
Isolate the minimum flow valve.
Using the drain valve on the pump, drain the pump.
Remove the minimum flow valve and disassemble.
Inspect lever, valve stem guide, and spring.
Replace the o-ring and/or gasket. And all internal parts Check disc and seat on main body; re-lap if necessary.
Reassemble minimum flow valve and reinstall.
Check for leaks.
• Wrenches and Sockets
P-04.1 Chilled Water/Condenser Water Pumps
Annual P.M. Guide Sheet Estimated Man hours: 48
Priority Level 2
Work Performed By: _______________________________________________________
Schedule this maintenance in conjunction with the Building Operations.
De-energize, lock out and tag out all associated equipment.
Visually inspect the energized pump and motor o Look for fluid leaks in the mechanical seals o Replace grease bearing if vibration problems. Replace mechanical seal, if only leaking slightly.
o Look for fluid leaks from other areas (EX. Flanges, gaskets, pressure gauges, fittings, bypass, tubes, piping, and air release valves) o Look for bearing oil or grease leaks o Listen for excessive noise or obvious misalignment o Log fluid temperature, pressures, and bearing temperatures where thermometers and pressure gauges are present ______________________________________________________________
Observe pump and motor during shutdown. Vibration and bearing problems tend to become more noticeable during a coasting slowdown.
Close suction and any bypass valves. Bleed off pressure but do not drain pump. Observe pressure gauges for signs that discharge check valve is not closing tightly
Close discharge valve. Bleed off pressure but do not drain pump. Observe pressure gauges for signs that the discharge and suction valves are not closed tightly
Inspect and clean suction strainers, heat exchangers and blow down valves.
Disconnect and remove pump/motor coupling from pump shaft Clean shaft and housing. When asked by COR the pump casing top shall be removed for further inspection.
Remove bearing housing. Then remove mechanical seal assembly (When Applicable) After seal has been removed, clean surfaces of shaft sleeve. Replace the shaft sleeve if it is galled or damaged. Shaft sleeve must be made of proper material. If the shaft sleeve is not damages perform next instruction.
Replace O-rings on Mechanical Seal and visually inspect Carbon Rings. Replace if needed.
Re-install Mechanical Seal per manufacturer’s recommendations.
Check Bearings for wear. Replace if necessary. Clean Bearing Housing and fill.
Lubricate pump and motor bearings. DO NOT OVER LUBRICATE Inspect coupling. Check pump/motor-coupling alignment. Laser Align pump for most accurate alignment results. Record readings before and after.
Examine both suction and discharge pressure gauges, replace if they do not register 0-PSI.
Slowly open suction and discharge valves, vent air from pump housing. Perform pressure test.
Start pump motor, log pump operating suction and discharge pressures. Log pump motor voltage and operating amps. ________________________________________________________________________
Investigate any unusual noises and correct them.
P-04.1 Chilled Water/Condenser Water Pumps
Annual P.M. Guide Sheet Estimated Man hours: 48
Priority Level 2 Use a torque wrench to check the tightness of all bolts. Including base bolts.
Clean pump and motor surfaces.
Paint pump and motor.
Recommended Biannual Overhaul as per Flowserve Manufacturer
For 2 years operation:
o 1 – Set of bearings (line and thrust) o 2 – Sets of gland packings o 2 – Shaft sleeves o 2 – Sets of gaskets and seals o 2 – Lantern rings o 2 – Casing wear rings o 1 – Impeller (Manufacture advise replacing impeller) o (Optional: 2 – Mechanical seals; 2 – Impeller wear rings)
• Open ended spanners (wrenches) to suit up to M 48 screws/nuts.
• Socket spanners (wrenches), up to M 48 screws.
• Allen Keys, up to 10 MM (A/F)
• Range of screwdrivers
• Soft mallet:
• Bearing pullers.
• Bearing induction heater
• Laser alignment tool.
• C-spanner (wrench) – for removing shaft nut. (If difficulties in sourcing are encountered, consult Flowserve.)
P-04.2 Boiler Feed Water Pumps Annual P.M. Guide Sheet Estimated Man hours: 64
Priority Level 2
Work Performed By: _______________________________________________________
Do not over torque the studs on the stuffing box end of case.
Only torque these studs too 250 ft lbs.
o Rebuild or replace seal even if leaking only slightly o Look for fluid leaks from other areas (EX. Flanges, gaskets, pressure gauges, fittings, bypass, tubes, piping, and air release valves) o Look for bearing oil or grease leaks o Listen for excessive noise or obvious misalignment o Log fluid temperature, pressures, and bearing temperatures where thermometers and pressure gauges are present ______________________________________________________________
Observe pump and motor during shutdown. Vibration and bearing problems tend to become more noticeable during a coasting slowdown.
Close suction and any bypass valves. Bleed off pressure but do not drain pump. Observe pressure gauges for signs that discharge check valve is not closing tightly
Close discharge valve. Bleed off pressure but do not drain pump. Observe pressure gauges for signs that the discharge and suction valves are not closed tightly
Inspect and clean suction strainers and blow down valves Disconnect and remove pump/motor coupling from pump shaft Clean shaft and housing Split cases and inspect internal parts for wear. Clean internals as needed, check clearances on bushings, wear rings, etc. Document shaft rotation at all points.
Chemically clean all heat transfer devices. Bearing housings and heat exchangers for seals.
Install new pump housing gasket, re-install pump housing. Insure that all bolts and nuts are properly rated and bolts have at least three threads past the face of the nut.
Inspect coupling. Check pump and motor coupling alignment. To align the coupling, shim the motor and pump as necessary. Use laser alignment tool for most accurate results.
Examine both suction and discharge pressure gauges, replace if they do not function properly.
After static fill and vent of all air in the pump; start the pump and log pump suction and discharge pressures.
Log pump motor voltage and operating amperage.
o Suction Pressure: _______________________________________________________________ o Discharge Pressure: _____________________________________________________________ o Motor Voltage: __________________________________________________________________ o Motor Amperage: ________________________________________________________________
P-04.2 Boiler Feed Water Pumps Annual P.M. Guide Sheet Estimated Man hours: 64
Priority Level 2 Lubricate pump and motor bearings. Do not over lubricate.
Use a torque wrench to check the tightness of all bolts including base bolts.
Restore pump to service.
• Allen Keys, up to 10 MM (A/F)
• Range of screwdrivers
• Soft mallet:
• Bearing pullers.
• Bearing induction heater
• Laser alignment tool.
• Miscellaneous hand tools
• Voltmeter
• Dial indicator
• Torque wrench
P-04.3 Treated Water Pumps
Annual P.M. Guide Sheet Estimated Man hours: 32
Priority Level 2
Work Performed By: _______________________________________________________ o Repack stuffing box and replace bearings.
o Look for fluid leaks from other areas (EX. Flanges, gaskets, pressure gauges, fittings, bypass, tubes, piping, and air release valves) o Look for bearing oil or grease leaks o Listen for excessive noise or obvious misalignment o Log fluid temperature, pressures, and bearing temperatures where thermometers and pressure gauges are present ______________________________________________________________
Observe pump and motor during shutdown. Vibration and bearing problems tend to become more noticeable during a coasting slowdown.
Close suction and any bypass valves. Bleed off pressure but do not drain pump. Observe pressure gauges for signs that discharge check valve is not closing tightly
Close discharge valve. Bleed off pressure but do not drain pump. Observe pressure gauges for signs that the discharge and suction valves are not closed tightly
Inspect and clean suction strainers and blow down valves Disconnect and remove pump/motor coupling from pump shaft Disassemble inboard & outboard stuffing box, clean & paint parts.
Clean shaft and housing Split cases and inspect internal parts for wear. Clean internals as needed, check clearances on bushings, wear rings, etc. Document shaft rotation at all points.
Install new pump housing gasket, re-install pump housing. Insure that all bolts and nuts are properly rated and bolts have at least three threads past the face of the nut.
Reassemble stuffing box with new stuffing.
Inspect coupling. Check pump and motor coupling alignment. To align the coupling, shim the motor and pump as necessary. Use laser alignment tool for most accurate results.
Examine both suction and discharge pressure gauges, replace if they do not function properly.
After static fill and vent of all air in the pump; start the pump and log pump suction and discharge pressures.
Log pump motor voltage and operating amperage.
o Suction Pressure: _______________________________________________________________ o Discharge Pressure: _____________________________________________________________ o Motor Voltage: __________________________________________________________________ o Motor Amperage: ________________________________________________________________
P-04.3 Treated Water Pumps
Annual P.M. Guide Sheet Estimated Man hours: 32
Priority Level 2 Lubricate pump and motor bearings. Do not over lubricate.
Use a torque wrench to check the tightness of all bolts including base bolts.
• Allen Keys, up to 10 MM (A/F)
• Range of screwdrivers
• Soft mallet:
• Bearing pullers.
• Bearing induction heater
• Laser alignment tool.
• Miscellaneous hand tools
• Voltmeter
• Dial indicator
P-07 Gear and Reciprocating Pump
Annual P.M. Guide Sheet Estimated Man hours: 8
Priority Level 2
Work Performed By: _______________________________________________________
Schedule this maintenance in conjunction with the Operations.
De-energize, lock and tag electrical circuits.
Inspect base bolts and make sure they are secure.
Observe pump in operation, noting unusual noise and vibration, pressure and leakage.
After shutdown, inspect suction and discharge valves for holding. Inspect all pressure indicators.
Remove cover and inspect internal drive components, looking for proper clearances and wear or corrosion.
Lubricate all fittings and inspect all check valves.
Clean strainer and replace any cartridge type filters.
Inspect packing and adjust or replace as necessary.
Inspect drive shaft coupling and motor/pump alignment, if applicable.
W-03 Zeolite Tanks
Annual P.M. Guide Sheet Estimated Man hours: 64
Priority Level 2
Work Performed By: _______________________________________________________
Maintenance shall be coordinated with required inspections.
Lock out and tag out all associated equipment and valves.
All floor strainers must be checked for centering, sealing gap and tightness.
Drain the tank Examine the exterior of tank, including fittings, gauges, manholes, sight glasses, and hand holes for signs of leaks or corrosion; correct as needed Inspect structural supports and insulation or coverings for defects or deterioration Open tank and remove rust or chemical deposits from interior surfaces Thoroughly inspect interior of tank for pitting, cracking, and other defects Thoroughly inspect the centering, and sealing gap of the floor strainers. Use feeler gauge, and no more that -
.006 of an inch space.
Check filter bed for proper level Take sample of anthrasite resin in accordance with manufacturers instructions, send to a lab for analysis.
When the sample comes back negative, the anthrasite will be replaced.
Perform maintenance on all associated manual and automatic valve Manually check the operation of each automatic valve Upon maintenance completion and GSA inspection, put softener back in service and verify proper operation
R-06 Cooling Tower PM
Annual P.M. Guide Sheet Estimated Man hours: 32
Priority Level 2
Work Performed By: _______________________________________________________
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”
Clean distribution system.
Inspect and clean pump suction screen.
Adjust water flow to design conditions.
Reduce the water flow; install water diverter shelf inside tower at top of louver intakes where required.
Restore water flow to design conditions; replace or clean nozzles.
Repair broken drift eliminators.
Drain the cold-water basin; replace or repair warped or cracked members.
Caulk loose joints with water resistant caulking compound.
Seal leak points with water resistant caulking compound.
Check pump pressure; do not exceed design pressure.
Repair pipe joints.
Perform leak test.
Check shim pack; replace and adjust to specifications.
Replace motor and gear bearings or shafts as necessary.
Replace belts.
Clean surrounding area around the cooling tower.
Log motor voltage and amps.
o Motor Voltage: _____________________________ o Motor Amps: _______________________________
RO-01
Reverse Osmosis System (RO)
Annual P.M. Guide Sheet Estimated Man hours: 4
Priority Level 3
Work Performed By: _______________________________________________________
Review equipment maintenance history.
Review the Standard Operating Procedure for “Controlling Hazardous Energy Sources”.
Ensure proper PPE is utilized during the disconnection and grounding.
16 RO membranes 4 individual membrane vessels A water tank, piping 2 membrane storage tanks Conduits and wiring Replace bag filters as needed Replace bag filters as needed, and clean fouled bags as needed per manufacturer's specifications.
Replace RO pre-filters as needed.
Check UV wiper equipment Check Receiver and distribution tanks Check System strainers Check all associate electrical starters, disconnects Variable Frequency Drive (VFD) per Guide cards outlined in the Contract Calibrate and replace the following instruments as needed per manufacturer specifications o All Gauges o 4 pH Transmitters o 4 Conductivity Temperature Transmitters o 4 Flow Transmitters o 2 Low Pressure Switches o 5 Onicon Flow Transmitters
RO-01
Reverse Osmosis System (RO)
Annual P.M. Guide Sheet Estimated Man hours: 4
Priority Level 3
S-06 Sewage Ejector Pump
Annual P.M. Guide Sheet Estimated Man hours: 16
Priority Level 2
Work Performed By: _______________________________________________________
Visually inspect the energized pump and motor.
o Look for fluid leaks. (i.e. flanges, gaskets, pressure gauges, etc.)
o Look for bearing oil or grease leaks.
o Listen for excessive noise or obvious issues.
Observe pump and motor during shutdown. Vibration and bearing problems tend to become more noticeable during a coasting slow down.
Close suction and any bypass valves. Bleed off pressure, but do not drain pump. Observe pressure gauges for signs the discharge check valve is not closing tightly.
Close discharge valve. Bleed off pressure, but do not drain pump. Observe pressure gauges for signs that the discharge and suction valves are not closing tightly.
Inspect and clean suction strainers and Blowdown valves.
Disconnect and remove pump/motor coupling from pump shaft.
Clean shaft and housing.
Examine both suction and discharge pressure gauges and replace if they are not operating properly.
Slowly open suction and discharge valves, vent air from pump housing. Log suction static pressure.
o Suction Static Pressure: _______________________________________ Start pumps motor. Log pumps operating suction and discharge pressures. Log motor voltage and amps.
o Suction Pressure: _________________________________ o Discharge Pressure: _______________________________ o Motor Voltage: ____________________________________ o Motor Amperage: __________________________________
Investigate any unusual noises and correct them.
Lubricate pump and motor bearings. Do not over lubricate.
Use a torque wrench to check the tightness of all bolts.
S-06 Sewage Ejector Pump
Annual P.M. Guide Sheet Estimated Man hours: 16
Priority Level 2 Special Notes
S-08 Y Type Strainer
Annual P.M. Guide Sheet Estimated Man hours: 1
Priority Level 2
Work Performed By: _______________________________________________________
Secure strainer isolation valves.
Drain strainer housing.
Back flush if possible or remove and clean strainer cage, if applicable.
Replace cartridge and clean out strainer housing, if applicable.
Reassemble unit or replace drain plug and open isolation valve.
Check unit for leaks.
S-14 Dual Type Strainer
Annual P.M. Guide Sheet Estimated Man hours: 2
Priority Level 2
Work Performed By: _______________________________________________________
Secure strainer isolation valves.
Drain strainer housing.
Open both strainer lid covers and remove baskets.
Clean inner housing, baskets, and screens.
Replace lid hatch.
Check sliding door seals and replace if necessary.
Check for pitting and corrosion; Paint where necessary with rust inhibitor.
Check strainer baskets, repair or replace as necessary.
Remove packing on gland and replace.
Install baskets, close lids, open valves, and check for leaks.
Clean outside casing and touch up pitted or corroded areas with rust inhibitor.
Clean surrounding area.
T-01 Tanks
Triennial P.M. Guide Sheet Estimated Man hours: 8
Priority Level 2
Work Performed By: _______________________________________________________
Maintenance shall be coordinated with required inspections. This applies to hot water, cold water, and expansion tanks, etc., but not to hot water converter (steam) tanks.
Lock out and tag out all associated equipment and valves.
Examine exterior of tank including fittings, manholes, and hand-holes for leaks, signs of corrosion, and correct as indicated.
Drain and flush tank.
Open tank and remove rust, scale, and buildup by scraping, wire brushing or shot cleaning.
Inspect thoroughly the interior of tank; record size and depth of pits,…
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