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Page 48 <br />Section F: EQUIPMBNT MAINTENANCB <br />ment in each treatment plant facility. The pro- <br />gram can generate a number of reports, including <br />equipment and cost analysis, a summary of com- <br />pleted maintenance work activities, and a com- <br />plete maintenance history for any piece of equip- <br />ment for any time period. Another report can <br />provide data on all the parts used in any piece of <br />equipment in any given period. <br />The program's preventive maintenance section <br />took some time to implement, but has significantly <br />reduced maintenance costs. The most time con- <br />suming element was identifying all preventive <br />maintenance activities and frequencies, then log- <br />ging the data into the program. <br />^ MAJOR PROJECTS/ACHIEVEMENTS <br />The Equipment Maintenance section has under- <br />taken several major projects in the last six years, <br />many of which have resulted in significant cost <br />savings. Projects have included rebuilding and <br />modifying existing equipment for both planned <br />and emergency situations and designing the con- <br />structionand installation of new equipment. The <br />section also has an excellent safety record, which <br />exemplifies workers' strong commitment to excel- <br />lence. <br />The program also produces regularly scheduled <br />preventive maintenance work requests. The re- <br />quests can be produced at weekly, monthly, quar- <br />terly, semi-annual, and annual intervals. Preven- <br />tivemaintenance work requests contain nearly the <br />same information as is provided on a regular cot- <br />rective maintenance request. Requests are signed <br />by the supervisor after the jobs are completed, then <br />are routed back to the data control clerk, who logs <br />them into the maintenance managementprogram. <br />The program maintains an historical record of all <br />preventive maintenance activities for the Waste- <br />water Division. <br />The following list summarizes the major projects <br />and accomplishments of the Equipment Mainte- <br />nance work section. <br />SCREW LIFT PUMPS <br />In the first few months of operation, each of the <br />four 21-MGD influent screw lift pumps lost its top <br />bearing seal. Investigation revealedexcessive shaft <br />run out and several broken bolts on the stub shaft <br />that supports the top of the screw. Factory repre- <br />sentativesfound the bolts had sheared because an <br />improper lubricant had been applied during the <br />initial installation, allowing the bolts to over- <br />torque.The screw lift pumps were repaired and the <br />cooling system modified for the gear box oil. <br />COMIVITNUTORS <br />In thefirstyearofoperation, the new comminutors <br />broke frequently. When factory representatives <br />checked them, theyfound the cuttershadnotbeen <br />properly set during the initial installation and that <br />the gear boxes were leaking oil. The manufacturer <br />made the proper cutter adjustments and replaced <br />the bolts in the comminutor housing. <br />Maintenance staff rebuilt the two old comminutors <br />and installed them into the new plant headworks. <br />Staff machined the parts that were no longer <br />available from the manufacturer. The prof ect saved <br />a considerable amount of money and delayed the <br />need to purchase new equipment. <br />Following a number of machine failures in the <br />Screw lift pumps received modified cooling systems. <br />