Appendix H - Wash Rack Service Matrix_2023.xlsx
XLSX spreadsheet 40 KB Posted
- Attached to
- Army Field Support Battalion (AFSBn-CHS) Facility Preventive Maintenance, Inspection & Repair Services
- Solicitation number
- FA441824Q0001
About this file
This document contains a preventive maintenance matrix for a wash rack facility and related federal contract opportunity. The matrix outlines monthly, quarterly, semi-annual and annual preventive maintenance tasks for various facility systems and equipment, including the wash pad, collection vaults, oil skimmers, hose reels, pumps, piping, plumbing, chemical dosing systems, oil water separators, clarifiers, reclaim systems, pressure washer pumps, hot water heaters, soap dispensing systems and remote stations. The federal contract opportunity is for preventive maintenance, inspection and repair services at Army Field Support Battalion facilities in support of the Department of the Air Force Air Mobility Command. The solicitation number is FA441824Q0001 and offers these services to maintain facility operations and equipment reliability.
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Table 1
| Enviremedial Services Inc. | |||||||||||||
| www.esicleanwater.com | Service Matrix | ||||||||||||
| Disclaimer: This PM matrix is based on Enviremedial Services best understanding of the customers intended usage at the time the system was ordered and manufactured. Ultimate responsibility for the systems care and longevity is the sole responsibly of the end user. Equipment may require further PM service intervals or additional care depending on the end users usage and operators adherence to the prescribed operating instruction provided by Enviremedial Services at the turnover of the equipment and in this publication. Neglect, abuse, failure to maintain equipment or substituting other than OEM parts or consumables that results in diminished performance or damage is not considered a warranty issue. | |||||||||||||
| Equipment | Notes: | Labor Hrs. | Daily | Wk | Month | Qrtr | Semi Ann. | Annual | As Required by Usage | See | |||
| Owners manual Section | Manufacturer | P/N | Notes | ||||||||||
| Wash Pad | Remove debris | Materials that can damage transfer pumps should not be washed into collection vaults | x | ||||||||||
| Remove sediment on wash pad into drum | Sediment that collects on the wash pad after washing operations are completed should be containerized rather than washed into vaults. This allows for longer vault pump outs. | x | |||||||||||
| Ensure all wands and hoses are stored properly | Prevents roll over damage | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||
| Collection Vaults | 0.2 | 0.2 | ||||||||
| Inspect vaults for oil level that would require activation of oil skimmers | x | |||||||||
| Check for debris | x | |||||||||
| Ensure all level switches are clean and secured properly | Oil and grime that adhere to switch floats can affect operation level at which switches send signals | 0.10 | x | |||||||
| Ensure all grates are in place | x | |||||||||
| Ensure sanitary sewer line leaving vaults is clear and functional | 0.10 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||||||
| Oil Skimmers | 0.3 | 2 | ||||||||||||
| Clean wipers | Wipers covered in debris may direct collected materials back into vault or outside designed containment area of skimmer | x | ||||||||||||
| Clean Belt | Belts that have sticky material on it may prevent belt from rotating completely around rollers. (Any degreaser works well to clean SS Belt) | x | ||||||||||||
| Replace belt | Replace stainless steel belt if damaged or cracked | x | Section 1 | Abanaki | 4" x 10' SS | Oil Grabber pgs 31-‐38 | ||||||||
| Guards | Ensure all guards are in place before use | x | ||||||||||||
| Motor & gear box | Ensure gear oil is at appropriate level and motor is functioning properly (minimum monthly) | 0.15 | x | x | ||||||||||
| Change gear oil | 2.00 | x | Mobilgear | 600 XP 460 | ||||||||||
| Inspect collection drum level switches for proper operation | Lift switches out of drums and touch tuning forks. Alarm light should activate and telemetry alarm should register | 0.15 | x | 1 | Flowline | LZ12 | ||||||||
| Collection drums | Properly dispose of collected POLs | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Hose Reels | 0.5 | 9 | |||||||||||
| Lubricate moving parts | Lubricate to prevent corrosion and smooth operation | 0.50 | x | WD40 or equal | |||||||||
| Inspect guide rollers | Replace rollers when worn to protect hoses | x | Cox Reels | ||||||||||
| Inspect H.P. Swivel for leaks | Replace swivel is leaking | x | Cox Reels | ||||||||||
| Inspect reel stand anchors | x | ||||||||||||
| Inspect reel stand coating | Touch up coating if damaged to prevent corrosion | x | |||||||||||
| Inspect H.P. hose | Before each use check for damage, cracking, bulging | x | |||||||||||
| Inspect H.P. trigger gun | Ensure gun operates properly without leaks | x | General | YG5000 |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||
| Test pump for proper operation | Ensure pump pumps effluent, insure suction area is clear of debris | Goulds | 3887 BHF | ||||||||
| Ensure pump LL cut-‐out switch is operational | Conery | 900 Series N/C |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||
| Exterior Piping | 0.5 | |||||||||
| Check pluming for leaks | Inspect all connections and unions for leaks. Tighten any unions as required | 0.17 | x | |||||||
| Inspect piping insulation is serviceable | 0.17 | x | ||||||||
| Inspect piping hangers and clamps for tightness to reduce vibration | 0.17 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Interior Plumbing (reclaim system) | 0.5 | ||||||||||||
| Inspect all interior plumbing for leaks | Tighten any unions or fittings as required | 0.10 | x | 4 | Harvel | ||||||||
| Clean all strainers for reclaim system | Remove strainer, clean and reinstall | 0.10 | x | 4 | Spears | ||||||||
| Inspect all check valves for proper operation | Ensure swing check flaps are in place and operational | 0.10 | x | 4 | Spears | Clear PVC Swing Check | |||||||
| Inspect all actuated and manual ball valves for proper operation | Tighten unions if required or replace o-‐rings if required | 0.10 | x | 4 | plastomatic | True Union/ ABRS |
actuators
| Inspect main 2" RPZ backflow | By others. Inspect and test annually for compliance with local, state and federal regulations. Inspect shutoff valves and test ports for proper operation & inspect relief valve for leaks. | ||
| Inspect and test all floor drains for clear flow to vaults or sanitary sewer | because main backflow is located within equipment room proper drainage is critical | 0.10 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||
| Building heating & ventilation system | |||||||||||
| Inspect building heating system | By others: Inspect and test wall mounted electric heater and thermostats to protect systems from freeze damage. | In winter months | |||||||||
| Inspect building ventilation systems | By others: Inspect and test exhaust fans and combustion air dampers for proper operation. Non functioning dampers could cause freeze issues in building if not operational. | In winter months |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Chemical Dosing System | 0.5 | 0.2 | |||||||||||
| Inspect inline mixer to ensure no blockages | Clean blockages or replace mixers if blockages can not be cleared | 0.10 | x | Mcmaster Carr | 35385K37 | ||||||||
| Inspect and Service peristolic pumps per manual | Follow OEM requirements for PM requirements. Minimum monthly inspections required by Enviremedial Services Inc. | 0.10 | x | 4 | Plusafeeder | P-S-CHEM- TECH-XP | |||||||
| Inspect all chemical injection pickup points and injection points | Inspect for blockages in pickup lines or leaks in injection points. Clear suction strainers and clean and ensure injection back check valves are operational | 0.10 | x | 4 | Plusafeeder | P-S-CHEM- TECH-XP | |||||||
| Inspect chemical levels | If dosing system active ensure appropriate amount of chemicals on site | 0.20 | x | 4 | |||||||||
| Inspect chemical level switches | Test switches to ensure local and remote alarming is operational | 0.10 | x | 4 | Flowline | LZ12 | |||||||
| Inspect chemical tubing | Check all polypropylene tubing for serviceability. Ensure no cracking, pinching or defects from animal activity | 0.10 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||||
| Inspect OWS vessel for serviceability | Inspect for leaks, damage, lid in place and serviceable, valve & actuators Serviceable. | 0.80 | x | 5 | ||||||||
| Inspect & test Tuning fork Level switch for proper operation | Ensure level switch shuts off pit pump and coagulant pump. | 0.80 | x | 5 | ||||||||
| Inspect & Test OWS Pump | Ensure pump is serviceable | 0.80 | x | 5 | Little Giant | 10E-‐CIA-‐SFS | ||||||
| Ensure Coagulant Dosing is correct | Depending on if customer choses to use dosing and what chemicals, ensure proper dosing rates and PH based on lab testing and chemical manufacturer recommendations. (ESI setup is in operations manual) | 0.20 | x | See ops manual | ||||||||
| Inspect and Clean interior of OWS | Remove any collected floating oils and containerize, if sediment levels in OWS are more than 5% of volume, drain OWS, remove and containerize solids and re-‐fill OWS. | 0.80 | x | 5 | ||||||||
| Inspect and clean coalescing media | Low pressure warm water. Rinse coalecing packs on wash pad into first stage of vaults. | 0.80 | x | 5 |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||||||
| AnJan Clarifier | 0.2 | 0.5 | 4 | |||||||||||
| Inspect OWS vessel for Serviceability | Inspect for leaks, damage, lid in place and Serviceable, valve & actuators Serviceable. | 0.17 | x | 4 | ||||||||||
| Inspect & test tuning fork Level switch for proper operation | Ensure level switch shuts off pit pump and coagulant pump. | 0.17 | x | 4 | ||||||||||
| Set Clarifier drain valves | Set timing for clarifier sediment collection drain valves per usage and amount of daily collected solids within clarifier collection cones. Collected sediment should be no more than 1/2 height of cones (See telemetry output relay control in Telemetry manual.) | x | 8 | ESI | WMID_ENVI R | Sec. 6.19-‐6.29 | ||||||||
| Ensure Coagulant Dosing is correct | Depending on if customer choses to use dosing and what chemicals, ensure proper dosing rates and PH based on lab testing and chemical manufacturer recommendations. (ESI setup is in operations manual) | 0.20 | x | See ops manual | ||||||||||
| Drain and thoroughly clean clarifier | Shut system down and thoroughly clean clarifier | 4.00 | x | |||||||||||
| Calibrate PH Probe | Conduct 2 point buffer calibration 7.01 & 4.01 buffer | 0.17 | x | 8 | ESI | WMID_ENVI R | Sec. 7.3 | |||||||
| Replace PH probe end | Annual Requirement | x | 8 | Ewing | PH-‐11 99-‐15 |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||||||
| AnJan Paper filter | 2 | 0.2 | ||||||||||||
| Inspect OWS vessel for Serviceability | Inspect for leaks, damage, lid in place and Serviceable, valve & actuators Serviceable. | 0.40 | x | 6 | ||||||||||
| Tighten dribe pulley sprockets on shafts | Requires Hex head | 0.40 | x | 6 | ESI | See Exploded view | ||||||||
| Lubricate drive chains | If required, visual inspection before lubricating | 0.20 | x | |||||||||||
| Test drive belt float switch and tank HL float switch for Serviceability. | Height of switches is set at factory. Any change in height will have downstream effects. | 0.40 | x | 6 | Dayton | 3BY71 | ||||||||
| Inspect and test paper filter transfer pump | Insure pump is is flowing properly, internal level switch is operational and inlet port is clear from any debris | 0.40 | x | 6 | Little Giant | 10E-‐CIA-‐SFS | ||||||||
| Inspect AC gear motor | Ensure sprocket is secure. Check gearbox for leaking and gear oil level | 4.00 | x | Dayton | 3M327 | |||||||||
| Check filter paper level | Ensure enough paper is always on feed side of Paper filter. Paper consumption depends on customer individual setup and wash rack usage. Remove excess spent paper from collection rollers and dispose of properly. | 0.20 | x | 0 | ESI | PF-‐BLK-‐60-‐24 CAR | Consumable List | |||||||
| Check filter paper level | Ensure enough paper is always on feed side of Paper filter. Paper consumption depends on customer individual setup and wash rack usage. Remove excess spent paper from collection rollers and dispose of properly. | 0.20 | x | 0 | ESI | PF-‐BLK-‐60-‐24 CAR | Consumable List | |||||||
| Drain and clean paper filter collection tank | 0.40 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Reclaim Skid | 6 | ||||||||||||
| Inspect and test all Level switches in Holding tanks 1,2 and Clean water tank for proper operation. | Ensure switches provide appropriate input per PLC and telemetry Codes | 0.35 | x | 8 | |||||||||
| Inspect and test pressure transducers and temperature transducers | Ensure switches provide appropriate input per PLC and telemetry Codes | 0.35 | x | 8 | |||||||||
| Clean Holding tanks 1 & 2 | Drain and clean holding tanks | 0.35 | x | ||||||||||
| Drain and clean, clean water holding tank | Recommended quarterly | 0.20 | x | ||||||||||
| Add Chlorine 4" tab to clean water tank floating chlorine diffuser | 0.35 | x | |||||||||||
| Check Disk Filter & Gigasorber pumps for leaks and proper operation. | Pump has permanently lubricated bears. No maintenance required until pump seal replacement. Replace pump seal if seal leak is detected | 0.35 | x | 8 | MDM | Advance 1000 | |||||||
| Inspect disk filters for proper operation | Ensure disk filters backwash off differential pressure switches and from control panel HMI | 0.35 | x | 8 | Netafim/ESI | 2" SpinKlin | |||||||
| Clean Disks | Remove disk filter cover and clean disks with light soap solution. Reinstall after cleaning | 0.35 | x | 8 | Netafim/ESI | 2" SpinKlin | |||||||
| Inspect Disk filter regulator | Inspect for leaks and drain water from bowl. Disk filter regulator set to 35 PSI max. | 0.35 | x | ||||||||||
| Ensure air vents on disk filters are operational | Inspect air relief valves for leaks. Ensure no debris in relief port | 0.35 | x | ||||||||||
| Inspect Gigasorber AnJan media. | AnJan media should be changed when pressure in Gigasorber vessel reaches 40 PSI. (Minimum weekly check) Telemetry has auto alarms for Gigasorber H.P. and auto switching to backup unit | 0.20 | x | ||||||||||
| Inspect Gigasorber AnJan media. | AnJan media should be changed when pressure in Gigasorber vessel reaches 40 PSI. (Minimum weekly check) Telemetry has auto alarms for Gigasorber H.P. and auto switching to backup unit | 0.20 | x | ||||||||||
| Inspect AnJan Gigasorber for leaks | Inspect all fittings, unions, valves and flanges for leaks | 0.35 | x | 8 | ESI | Gigasorber | |||||||
| Check torque on Gigasorber lid | 60 ft/lbs | 0.35 | x | 8 | ESI | Gigasorber | |||||||
| Inspect air relief valves | Ensure relief valves are not leaking and no debris is lodged in the relief port | 0.35 | x | ||||||||||
| Insure Gigasorber pressure gauges are operational | 0.35 | x | |||||||||||
| Test Gigasorber pressure transducers for Serviceability | Check transducer reading against gauge reading. Transducers require no maintenance after initial setup | 0.35 | x | 8 | No Shok | ||||||||
| Inspect all valves and actuators for serviceability | Cycle valves and view proper actuation. Inspect valves for leaks | 0.35 | x | 8 | Plastomatic | True Union / ABRS |
actuators
| Clean strainer from clean water tank to pressure washer feed valves | Remove strainer, rinse and re-‐install. Bleed all air from pressure washer system after cleaning. | 0.35 | x | Spears | 2" Y-‐Strainer |
| Wipe skid down after service | 0.35 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Control System | 0.5 | ||||||||||||
| Lubricate air solenoids | Add 10 drops of air tool oil to inlet of solenoid bank. With system E-‐Stop on, manually cycle all valves to move oil into solenoids | 0.13 | x | 8 | NVKF | ||||||||
| Inspect electrical connections | 0.13 | x | |||||||||||
| Change decadent dyer media | When media color indicates change required (Legend on body of dryer) | 0.13 | x | 8 | Grainger | 5Z613 | |||||||
| Inspect air regulator | Inspect for leaks and drain any water from collection bowl. Control system regulator to be set at 70 psi. | 0.13 | x | ||||||||||
| Inspect electrical connections within the main and sub panels | Ensure connections are tight and no charring or evidence of arcing is visible | 4.00 | x | ||||||||||
| PLC Software | Ensure technicians have RS logix 500 current version for PLC programming | 8 | Rockwell Automation | RS Logix 500 |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Compressor | |||||||||||||
| Service compressor according to OEM manual | See OEM manual for all required PM services and parts. | 10 | Speedaire | 4ME98 |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||||||
| Pressure Washer Pump Station | Use Pump Service Record Data Sheet | 0.2 | 2 | 16 | 7 | Dayton Publication | ||||||||
| Inspect belt tension | Tighten belt tension as required. | 3.20 | x | |||||||||||
| Replace belts when worn | 3.20 | x | Dayton | 6A123 | BX36 | |||||||||
| Tighten pressure pump valve cover nuts | Excessive heat from pumps running in recirculation mode causes excessive heat on pump head. Customer requested shut down timing of 20 minutes and the removal of 2 minute no flow shutdown. This will cause seal and pump wear at accelerated rates | 0.20 | x | 7 | General Pump | TS2021 | 47 Series | |||||||
| Replace pump seals & packing as required | See Pump maintenance manual | 3.20 | x | 7 | General Pump | IPK 69 | 6 Seals | |||||||
| Replace pump valves as required | See Pump maintenance manual | 3.20 | x | 7 | General | IPK201 | 6 valves | |||||||
| Inspect and adjust unloader valve | Ensure unloader is Serviceable and adjust pressure as customer requires. | 0.33 | x | 7 | General | IPYU831 | ||||||||
| Inspect oil level and clarity | Add oil as required. Maximum oil life 500 hours | 0.33 | x | 7 | General Pump Series Oil | 100 | ||||||||
| Clean pump station enclosures | Wipe down all debris and ensure inside enclosure is clean and Serviceable | 0.33 | x | |||||||||||
| Inspect all hoses for damage | Replace as required | 3.20 | x | |||||||||||
| Set recommended pressure | Enviremedial Services recommends 2500 PSI max pressure setting | 0.33 | x | |||||||||||
| Check all fittings and clamps for tightness | Vibration and heat expansion loosens clamps and other fittings. | 0.33 | x | |||||||||||
| Clean inlet strainers | 0.33 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Gas Fired Hot Water Heaters | 3 | ||||||||||||
| Inspect gas valve for damage and proper operation | Ensure all electrical connections are attached, manual gas valve knob is operational and gas connections are tight and leak free. | 0.43 | x | 7 | Robertshaw | 7000DERHC-‐ |
67B
| Check controller for any operational error codes on visual LED | Correct any Fault issues according to SYNETEK Control Manual. | 0.20 | x | 7 | SYNETEK | Model IS1143P | Fault codes are on actual controller | |
| Inspect Hot water heater for leaks | 0.43 | x | ||||||
| Inspect heat setting not to exceed 175 degree | Maximum recommended temperature setting per Enviremedial Services Inc. | 0.43 | x | |||||
| Inspect Burner flow switch for proper operation | Verify flow provides continuity through flow switch | 0.43 | x | |||||
| Inspect high temp limit switch | Ensure continuity through switch when temp is below 200 degrees | 0.43 | x | |||||
| Inspect venting condition | Ensure venting is leak free and undamaged | 0.43 | x | |||||
| Inspect all natural gas piping | Ensure connections are tight and leak free. | 0.43 | x |
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | ||||||
| Soap Dispensing System | |||||||||||||
| Inspect water fill valve for proper operation | Follow manufacturers recommendations | x | 10 | Dultmeier | DU-‐PSI HP-‐8 | ||||||||
| Inspect float bottle | Follow manufacturers recommendations | x | 10 | Dultmeier | DU-‐PSI HP-‐9 | ||||||||
| Inspect pressure pump | Follow manufacturers recommendations | x | 10 | Dultmeier | DU-‐PSI HP-‐10 | ||||||||
| Inspect solenoids | Follow manufacturers recommendations | x | 10 | Dultmeier | DU-‐PSI HP-‐11 | ||||||||
| Inspect polyethylene feed tubing | Ensure no kinks, damage or cracking in tubing | x | 10 | 1/4" |
polyethylene Inspect injection point check valves Ensure one-‐way flow x
| Labor Hrs. | Daily | Wk | Month | Qtr | Semi Ann. | Annual | As Required by Usage | |||||
| Remote Stations | 0.2 | |||||||||||
| Inspect Rotary switches | Ensure input to associated input on PLC | 0.10 | x | Dultmeier | JS10R2 | |||||||
| Check remote station box for water tightness | 0.10 | x | ||||||||||
| MANAGED BY OPERATING CONTRACTOR |
| MAN HOURS PER TASK | WEEKLY | MONTHLY | ANNUALY |
| 1.0 | 20.7 | 2.0 |
&"Arial,Bold"&12Appendix H - Wash Rack Preventive Maintenance Matrix 2023
&"Arial,Bold"&12
FOR OFFICIAL USE ONLY
NOT IN USE
http://www.esicleanwater.com/
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