Facilities Instructions, Standards, and Techniques …

1 Department of the Interior Bureau of Reclamation Denver, Colorado January 2009 Facilities instructions , standards , and Techniques Volume 4-1A Revised 2009 Maintenance Scheduling for Mechanical Equipment REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188 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.

2 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. T1. REPORT DATE (DD-MM-YYYY)T September 2007 T2. REPORT TYPET Final T3. DATES COVERED (From - To)T 5a. CONTRACT NUMBER 5b. GRANT NUMBER T4. TITLE AND SUBTITLE FIST 4-1A, Maintenance Scheduling for Mechanical Equipment 5c. PROGRAM ELEMENT NUMBER 5d. PROJECT NUMBER 5e. TASK NUMBER 6. AUTHOR(S) Bureau of Reclamation Hydroelectric Research and Technical Services Group Denver, Colorado 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Hydroelectric Research and Technical Services Group Bureau of Reclamation Denver Federal Center Box 25007 Denver CO 80225-0007 8. PERFORMING ORGANIZATION REPORT NUMBER FIST 4-1A 10.

3 SPONSOR/MONITOR S ACRONYM(S) DIBR 9. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES) Power Resources Office Office of Policy Bureau of Reclamation Mail Code 84-54000 PO Box 25007 Denver CO 80225-0007 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 NOTEST 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 16.

4 SECURITY CLASSIFICATION OF: 19a. NAME OF RESPONSIBLE PERSONT Roger Cline, John Germann, Bill McStraw a. REPORT UL b. ABSTRACT UL c. THIS PAGE UL 17. LIMITATION OF ABSTRACT UL 18. NUMBER OF PAGES 19b. TELEPHONE NUMBER (include area code) 303-445-2293 SS Standard Form 298 (Rev. 8/98) P Prescribed by ANSI Std. 239-18 Department of the Interior Bureau of Reclamation Denver, Colorado January 2009 Facilities , instructions , standards , and Techniques Volume 4-1a Revised 2009 Maintenance Scheduling for Mechanical Equipment Hydroelectric Research and Technical Services Group 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.

5 Acronyms and Abbreviations A amps ac alternating current ANSI American National standards Institute ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials AWG American Wire Gauge CAL/OSHA California Occupational Safety and Health Regulations CBM condition-based maintenance CFR Code of Federal Regulations CMMS computerized maintenance management system CO2 carbon dioxide dc direct current EPSS emergency power supply systems FIST Facilities instructions , standards , and Techniques HECP Hazardous Energy Control Program Hz hertz JHA job hazard analysis MAWP maximum allowable working pressure mV millivolts NDE nondestructive examination NDT Nondestructive Testing NFPA National Fire Protection Association O&M operation and maintenance OSHA Occupational Safety and Health Administration PEB Power Equipment Bulletins PO&M power operation and maintenance PM preventive maintenance PMG permanent magnet generator psi pounds per square pvc polyvinyl chloride RCM reliability-centered maintenance Reclamation Bureau of Reclamation rpm rotations per minute rms root mean square RSHS Reclamation Safety and Health standards SSG speed signal generator SWL safe working load UNC unified coarse thread V volt

6 WECC Western Electricity Coordinating Council WISHA Washington Industrial Safety and Health Administration F degree Fahrenheit v Table of Contents Page Acronyms and Abbreviations .. iii 1. Introduction .. 1 Maintenance .. 1 General .. 1 Preventive Maintenance .. 1 Reliability-Centered 2 Condition-Based Maintenance .. 3 Combination of Condition-Based and Preventive Maintenance .. 3 standards and 4 Reclamation standards .. 4 Recommended standards and 5 Maintenance and Test 5 General .. 5 Maintenance Schedules and 6 Job Plan 6 Power O&M Forms .. 6 Power O&M Reviews .. 7 Limitations .. 7 Safety During 7 2. Turbine and Pump Maintenance .. 9 Hydraulic 9 Pumps.

7 9 Dynamic Pumps .. 9 Positive Displacement Pumps .. 13 Cavitation Erosion, Abrasive Erosion, and Corrosion .. 17 Wearing 20 Packing/Mechanical 20 Packing .. 20 Mechanical 22 22 Fluid Film 22 Antifriction 23 Shaft Couplings .. 23 Shaft Alignment .. 24 Horizontal Pump Alignment .. 24 Face and Rim Alignment Method .. 27 Reverse Indicator Method .. 32 Vibration Monitoring and 36 Proximity Probe Systems .. 36 Accelerometer Systems .. 37 Signature 37 Oil and Lubricants .. 39 FIST 4-1A Maintenance Scheduling for Mechanical Equipment vi Contents (continued) Page Oil Lubrication .. 39 Grease Lubrication .. 39 Hydraulic 40 Testing and Filtering.

8 40 Inspection Checklist .. 42 Hydraulic Turbines and Large 43 Auxiliary 48 3. Penstocks, Outlet Pipes, Piping, Gates, and 51 Penstocks, Outlet Pipes, Lines, and Piping .. 51 Gates and Valves .. 51 General .. 51 55 65 Valve and Gate Operators .. 65 Guard Gate and Valve Closure Tests .. 74 Turbine Pressure Relief 80 Auxiliary Piping 80 Inspection Checklist .. 81 Gates and Valves .. 81 Penstocks, Outlet Pipes .. 83 Gates and Valves .. 84 Gate and Valve Operators and Hoists .. 86 Guard Gate and Valve Closure Tests .. 88 Turbine Pressure Relief Valves Operational Tests .. 88 Auxiliary Piping 89 4. Mechanical Governors .. 91 General .. 91 Inspection Checklist.

9 91 5. Air 99 General .. 99 Reciprocating Air Compressors .. 99 Rotary Screw Air 99 100 Inlet Filters .. 100 Aftercoolers .. 100 Separators .. 100 100 Dryers .. 101 Pressure Regulating 101 Pressure Relief Valves .. 101 Receiver Tanks and Other Pressure Vessels .. 101 Inspection Checklist .. 102 FIST 4-1A Maintenance Scheduling for Mechanical Equipment vii Contents (continued) Page General .. 103 Reciprocating 105 Rotary Screw Compressors .. 106 6. Cranes, Hoists, Rigging Equipment, and Elevators .. 107 General .. 107 standards and 107 Reclamation standards .. 107 OSHA Regulations.

10 107 ANSI/ASME 108 New Versus Existing 109 Crane 109 109 Maintenance .. 119 Testing .. 121 Operational 121 Periodic Load Tests .. 122 Safe Operating Practices .. 123 Critical Lifts .. 125 Determination of Critical Lift .. 125 126 Designated Person .. 126 Critical Lift Plans .. 126 Critical Lift Plan 127 Prelift 128 Documentation .. 128 Overhead and Gantry Cranes .. 128 General .. 128 Modifications .. 128 Rated Load 129 Hand Signal Posting .. 129 Outdoor Cranes .. 129 General 129 Maintenance and Inspection 129 Ropes, Slings, Chains, and Rigging Hardware.