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WASTEWATER DIVISION PAGE 5 EQUIPMENT MAINTENANCE Equipment Maintenance successfully managed the Divi- and over 340 feet of drive chain in each channel. In addi- sion's corrective maintenance (CM) and preventative main- tion to this routine work, Equipment Maintenance rede§- tenance (PM) programs for 2003. The result of this mainte- igned the out-dated and failing bearing mount system for the nance activity, in conjunction with a dedicated Operations upper drive shaft in each channel and replaced it with a staff, was that the Division experienced no permit violations modern, more reliable, less expensive, and easier to repair due to equipment failure for the year. To help accomplish system. The total mechanical maintenance cost of these two this outcome the Equipment Maintenance work section suc- projects was $71,656.00. Furthermore, during this rebuild cessfully processed (closed) 4,946 work orders as follows: cycle additional work was completed by contract through Facility Maintenance to repair extensive concrete damage 190 Priority 2 (Quick) Work Orders (4% oftotal) and re-seal each channel. 401 Priority 3 (Planned & Scheduled) Work Orders (>8%oftotal) The mechanical rebuild of each Primary and Secondary 249 Priority 4 (Planned & Scheduled w/ Due Date) Clarifier is an extensive and coordinated effort between the Work Orders (5%oftotal) Equipment Maintenance work section and a contracted 17 Priority 5 (Routine) Work Orders (<1%oftotal) (large) crane service. The Equipment Maintenance work 3,850 Priority 6 (Preventative Maintenance) Work Orders section, with assistance from Oldham Crane Service, re- (78% oftotal) moved and replaced the bridge assemblies form each clari- 180 Priority 7 (High Priority) Work Orders fier, removed and replaced the center assembly from each (3%oftotal) clarifier, and Equipment Maintenance rebuilt each of the 59 Priority 9 (Emergency) Work Orders (1% of) clarifier main gearbox drives, as well as either rebuilding or replacing the smaller gearboxes. This work included having 4,946 Total (100%) anew pinion gear assembly machined by a local machine shop for one clarifier drive (less than half the cost of an OEM part), and the extensive construction and use of safety The WWD performance goal assigned to Equipment Main- scaffolding on the Secondary Clarifier. The total mechani- tenance for planned vs. unplanned (emergency) mainte- cal maintenance cost of these two projects was $17,983.00. nance work is 90% planned work / 10% unplanned work. At 1% unplanned work (priority 9 work orders), the work In 2003 the Equipment Maintenance work section, with help section's 2003 performance was well above target. from the WWD Hazardous Waste Administrator (otherwise known as Todd Anderson) completed the transition, started Of the routine (priority 5) work orders mentioned above, two years earlier, from solvent based parts cleaners and several were large gear-drive and process-conveyance sand-blasting sand that could not pass a TCLP test fresh equipment mechanical rebuild projects routinely performed from the manufacturer, to aqueous parts cleaners and metal on about seven (7) year cycles. These were the mechanical free glass-beads for our sand-blast cabinet. The Mainte- rebuild of two (2) Pretreatment Grit Channels (WO # 47787 nance Shops are now virtually solvent-free, at least for bulk and 47788), resulting in the completion of the seven-year cleaning on a day-to-day basis. We only purchase bulk sol- cycle for all of this type equipment; the mechanical rebuild vents for parts cleaning operations on an as-needed basis, of one (1) Primary Clarifier (WO # 49990), resulting in the and then only in very small quantities (5 gallons or less). completion of the seven-year cycle for all of this type equip- Both the aqueous cleaning solutions for the parts washers merit; and the mechanical rebuild of one (1) Secondary and glass-beads for the sand-blast cabinet are changed-out Clarifier (WO # 48330), resulting in half of the seven-year on a monthly basis. This allows us to remain below pre- cycle being completed for all of this type equipment. The ferred levels of oil/grease contaminate discharges for our rebuild of each Pretreatment Grit Channel is an extensive aqueous parts cleaners, and well below required TCLP con- and coordinated effort between Equipment Maintenance taminate levels for the sand-blast cabinet. and, depending on circumstances, the Facilities Mainte- nance work section and/or contractors. The Equipment L A R R Y P E D E R S E N Maintenance work section, in conjunction with Facilities and their improved crane-truck capabilities (eliminating the need and expense for a contracted crane service for this type work), removed and replaced (with new) all of the mechani- cal parts to each of the two grit channels. This included large drive shafting and gears, 32 grit-conveyance flights,