And maintenance fire system valves and components

Table of Contents

Page

1.1.2 Preventive Maintenance........................................................ 1

1.1.3 Reliability-Centered Maintenance......................................... 2

1.2.1 Reclamation Standards.......................................................... 4

1.2.2 Recommended Standards and References............................. 5

1.6 Power O&M Forms......................................................................... 6

1.7 Power O&M Reviews ..................................................................... 7

2.2 Pumps.............................................................................................. 9

2.2.1 Dynamic Pumps .................................................................... 9

2.5.1 Packing.................................................................................. 20

2.5.2 Mechanical Seals................................................................... 22

2.8 Shaft Alignment .............................................................................. 24

2.8.1 Horizontal Pump Alignment ................................................. 24

2.9.2 Accelerometer Systems......................................................... 37

2.9.3 Signature Analysis................................................................. 37

Contents (continued)

Page

2.11 Inspection Checklist........................................................................ 42

2.11.1 Hydraulic Turbines and Large Pumps................................. 43

3.2.1 General .................................................................................. 51

3.2.2 Gates...................................................................................... 55

3.5 Auxiliary Piping Systems................................................................ 80

3.6 Inspection Checklist........................................................................ 81

3.6.5 Guard Gate and Valve Closure Tests.................................... 88

3.6.6 Turbine Pressure Relief Valves Operational Tests ............... 88

5. Air Compressors........................................................................................ 99

5.1 General ............................................................................................ 99

5.4.2 Aftercoolers........................................................................... 100

5.4.3 Separators.............................................................................. 100

5.4.8 Receiver Tanks and Other Pressure Vessels ......................... 101

5.5 Inspection Checklist........................................................................ 102

6. Cranes, Hoists, Rigging Equipment, and Elevators .................................. 107 6.1 General ............................................................................................ 107 6.2 Standards and References................................................................ 107 6.2.1 Reclamation Standards.......................................................... 107 6.2.2 OSHA Regulations................................................................ 107 6.2.3 ANSI/ASME Standards......................................................... 108 6.3 New Versus Existing Cranes........................................................... 109 6.4 Crane Types..................................................................................... 109 6.5 Inspections....................................................................................... 109 6.6 Maintenance .................................................................................... 119 6.7 Testing............................................................................................. 121 6.7.1 Operational Tests................................................................... 121 6.7.2 Periodic Load Tests............................................................... 122 6.8 Safe Operating Practices ................................................................. 123 6.9 Critical Lifts .................................................................................... 125 6.9.1 Determination of Critical Lift ............................................... 125 6.9.2 Responsibility........................................................................ 126 6.9.3 Designated Person................................................................. 126 6.9.4 Critical Lift Plans .................................................................. 126 6.9.5 Critical Lift Plan Approval.................................................... 127 6.9.6 Prelift Meeting....................................................................... 128 6.9.7 Documentation ...................................................................... 128 6.10 Overhead and Gantry Cranes .......................................................... 128 6.10.1 General ................................................................................ 128 6.10.2 Modifications ...................................................................... 128 6.10.3 Rated Load Marking............................................................ 129 6.10.4 Hand Signal Posting............................................................ 129 6.10.5 Outdoor Cranes ................................................................... 129 6.10.6 General Construction........................................................... 129 6.10.7Maintenance and Inspection Requirements......................... 129 6.11 Ropes, Slings, Chains, and Rigging Hardware ............................... 143 6.11.1 General Maintenance and Inspection Requirements........... 143 6.11.2 Inspections........................................................................... 144 6.11.3 Operating Practices ............................................................. 145 6.11.4 Alloy Steel Chain Slings ..................................................... 146 6.11.5 Wire Rope Slings ................................................................ 148 6.11.6 Metal Mesh Slings............................................................... 151 6.11.7 Natural and Synthetic Fiber Rope Slings............................ 151 6.11.8 Synthetic Webbing Slings................................................... 152 6.11.9 Rigging Hardware (Shackles, Eyebolts, etc.)...................... 155

vii

8. Fire Systems.............................................................................................. 193 8.1 General ............................................................................................ 193 8.2 Carbon Dioxide Fire Suppression Systems..................................... 194 8.3 Fire Suppression Systems for Transformers ................................... 194 8.4
Fire Suppression Systems for Paint and Oil Storage and Transfer Rooms ..................................................................... 195 8.5 Clean Agent Fire Extinguishing System......................................... 195 8.6 Life Safety Code.............................................................................. 195 8.7 References and Standards................................................................ 196 8.8 Inspection, Testing, and Maintenance of Sprinkler Systems .......... 197 8.8.1 Sprinklers .............................................................................. 198 8.8.2 Pipe and Fittings.................................................................... 198 8.8.3 Gauges................................................................................... 198 8.8.4 Alarm Devices....................................................................... 199 8.8.5 Buildings ............................................................................... 199 8.9
Inspection, Testing, and Maintenance of Fire Pumps..................... 199 8.10 Inspection, Testing, and Maintenance of Water Spray,
Fixed Systems .............................................................................. 200

viii

10. Mechanical Drawings................................................................................ 211 10.1 General ............................................................................................ 211 10.2 Maintenance Schedule for Mechanical Drawings........................... 211

11. Engine Generators..................................................................................... 213 11.1 General ............................................................................................ 213 11.2 Maintenance Schedule for Engine Generators................................ 213

Figure Number Page

1 Crane and hoist equipment inspection criteria................................ 116 2 Overhead Crane Inspection Standards ............................................ 117 3 Summary of Sprinkler System Inspection, Testing,
and Maintenance .......................................................................... 197 4
Summary of Fire Pump Testing, Maintenance, Training, and Drills...................................................................................... 199 5 Summary of Water Spray Fixed System Inspection, Testing,
and Maintenance .......................................................................... 200 6 Summary of Private Water Fire Service Main Inspection,
Testing, and Maintenance ............................................................ 201 7 Summary of Standpipe and Hose System Inspection,
Testing, and Maintenance ............................................................ 202 8 Summary of Carbon Dioxide Systems Inspection, Testing,
and Maintenance .......................................................................... 204 9 Summary of Clean Agent Extinguishing Systems
Inspection, Testing, and Maintenance.......................................... 205 10 Summary of Valve Inspection, Testing, and Maintenance ............. 206

x

Maintenance recommendations are based on industry standards and experience in Reclamation facilities. However, equipment and situations vary greatly, and sound engineering and management judgment must be exercised when applying these recommendations. Other sources of information must be consulted (e.g., manufacturer=s recommendations, unusual operating conditions, personal
experience with the equipment, etc.) in conjunction with these maintenance recommendations.

1.1.2 Preventive Maintenance
Preventive maintenance (PM) is the practice of maintaining equipment on a regular schedule based on elapsed time or meter readings. The intent of PM is to “prevent” maintenance problems or failures before they take place by following routine and comprehensive maintenance procedures. The goal is to achieve fewer, shorter, and more predictable outages.

•It is easily understood and justified.

PM does have some drawbacks:

1

FIST 4-1A Maintenance Scheduling
for Mechanical Equipment

Whether utilizing a PM, RCM, or condition-based maintenance (CBM) program, or a combination of these, scheduled maintenance should be the primary focus of the in-house maintenance staff.2 This will reduce reactive (emergency and corrective) maintenance. Scheduled maintenance should have a higher priority than special projects and should be the number one priority.

1.1.3 Reliability-Centered Maintenance
RCM programs are gaining in popularity and have been piloted in a few
Reclamation power facilities with good results. The goal of these programs is to provide the appropriate amount of maintenance at the right time to prevent forced outages while at the same time eliminating unnecessary maintenance.

•It may result in a “run-to-failure” or deferred maintenance philosophy for some equipment which may cause concern for some staff and managers.

2World Class Maintenance Management, Terry Wireman, Industrial Press Inc., 1990, pg. 32.

RCM is not an excuse to move to a “breakdown maintenance” philosophy or to eliminate critical PM in the name of reducing maintenance staff/ funding.

However, to mitigate problems associated with a PM program, maintenance managers may choose to apply a consciously chosen, effectively implemented, and properly documented RCM program.

1.1.4 Condition-Based Maintenance
This program relies on knowing the condition of individual pieces of equipment.

Some features of CBM include:

Drawbacks to CBM include it being very difficult and expensive to monitor some quantities. It requires knowledgeable and consistent analysis to be effective; and also condition monitoring equipment and systems themselves require
maintenance. Because of these drawbacks, it is nearly impossible to have an entirely CBM program.

1.1.5 Combination of Condition-Based and Preventive Maintenance A combination of CBM and PM is perhaps the most practical approach.

1.2 Standards and References

1.2.1 Reclamation Standards
Electrical and mechanical maintenance recommended practices for some
equipment are contained in other Facilities, Instructions, Standards, and
Techniques (FIST) volumes that will be referenced in this report. For equipment not covered by other FIST volumes, requirements defined in this report are the recommended practices. Manufacturer=s maintenance requirements, as defined in instruction books, also must be incorporated into a complete maintenance program. Other recommended practices are defined in Power Equipment
Bulletins (PEB).

Regional and Area Offices – Contact 86-68440, Hydropower Technical Services Group 303-445-2300. All others – contact National Technical Information Service, Operations Division, 5285 Port Royal Road, Springfield, Virginia 22161.

•Intranet access to FIST volumes: http://intra.usbr.gov Select: Quicklist; Power O&M.

1.2.2 Recommended Standards and References
Current editions of the following published standards and references should be maintained locally for mechanical engineers, mechanical foremen, mechanical supervisors, and other O&M personnel to use:

•Applicable National Fire Protection Association (NFPA) Standards

1.3 Maintenance and Test Procedures

1.3.1 General
Maintenance activities fall into three general categories:

5

FIST 4-1A Maintenance Scheduling
for Mechanical Equipment

The maintenance recordkeeping system must be kept current so that a complete maintenance history of each piece of equipment is available at all times. This is important for planning and conducting an ongoing maintenance program and provides documentation needed for the Power O&M Reviews (section 1.7). Regular maintenance and emergency maintenance must be well documented, as should special work done during overhauls and replacement.

The availability of up-to-date drawings to management and maintenance staff is extremely important. Accurate drawings are very important to ongoing
maintenance, testing, and new construction; but they also are essential during emergencies for troubleshooting. In addition, accurate drawings are important to the continued safety of the staff working on the equipment.

6

FIST 4-1A Maintenance Scheduling
for Mechanical Equipment

This program uses regularly scheduled annual (self-assessment), periodic
(regionally conducted), and comprehensive (Denver conducted) reviews. Each level of review is intended to assess compliance with accepted practices in operation and maintenance. The accepted practices for mechanical equipment maintenance are defined in this and other FIST volumes, PEBs, and in the references cited in this document. As stated above in section 1.2.1, variance from these practices is acceptable if adequate justification is provided to reviewers

1.8 Limitations