ESBD_401277_1748872531990_ATE6CA~1.PDF

ATTACHMENT G.J - ELLINGTON AFB (EF) OPERATION AND

MAINTENANCE DATA

PART 1 – GENERAL

1. DEFINITIONS

Maintenance Operation: Is defined to mean any routine operation required to ensure satisfactory performance and longevity of equipment. Examples of typical maintenance operations are lubrication, belt tensioning, adjustment of pump packing glands, and routine adjustments.

2. QUALITY ASSURANCE

A. Equipment manufacturer or system Supplier shall prepare manuals for equipment and systems.

3. SEQUENCING AND SCHEDULING

A. Manual Outline: Submit detailed outline of each manual prior to preparation of

Preliminary Manuals.

B. Manuals for Equipment and Systems:

a. Preliminary Manuals: Submit prior to shipment date for equipment, system, subsystem, or component. Include copy of warranties, Bonds, and service agreements if specified.

b. Final Manuals: Submit not less than thirty (30) days prior to equipment or system field-testing or startup.

C. Manuals for Materials and Finishes:

a. Preliminary Manuals: Submit at least thirty (30) days prior to request for final inspection.

b. Final Manuals: Submit within ten (10) days after final inspection.

4. GENERAL

A. Furnish for each item of equipment or system as specified in the individual

Specification sections.

B. Prepare data for use by Ellington Field personnel in the form of an instructional manual and on electronic media.

C. Manual Format:

a. Size: 8-1/2 inches by 11 inches.

b. Paper: 20-pound minimum, white for typed pages.

c. Text: Manufacturer's printed data, or neatly typewritten.

d. Three-hole punch data for binding and composition; arrange printing so that punched holes do not obliterate data.

e. Provide flyleaf for each separate product, or each piece of operating equipment, with typed description of product and major component parts of equipment and provide with heavy section dividers with numbered plastic index tabs.

f. Provide each manual with title page, and typed table of contents with consecutive page numbers. Place contents of entire set, identified by volume number, in each binder.

ELLINGTON FIELD, HOUSTON, TX 21 May 2024

g. Cover: Identify each volume with typed or printed title “FACILITY NO.

, OPERATION AND MAINTENANCE MANUAL, VOLUME NO.

OF ,” if applicable, and list:

i. Project title.

ii. Designate the system or equipment for which it is intended.

iii. Identity of separate structure as applicable.

iv. Identity of general subject matter covered in manual. Identity of equipment number and Specification section.

h. Assemble and bind material in CSI format, as much as possible.

i. Material shall be suitable for reproduction, with quality equal to original.

Photocopying of material will be acceptable, except for material containing photographs.

j. Binders:

i. Preliminary Manuals: Heavy paper covers.

ii. Final Manuals: Commercial quality, substantial, permanent, three-ring, D-ring binders with durable, cleanable, white-colored, plastic covers.

k. Table of contents neatly typewritten, arranged in CSI format:

i. Contractor, name of responsible principal, address, and telephone number.

ii. List of each product required to be included, indexed to content of each volume.

iii. List with Each Product: Name, address, and telephone number of

Subcontractor, Supplier, installer, and maintenance contractor, as appropriate.

1. Identify area of responsibility of each.

2. Provide local source of supply for parts and replacement.

iv. Identify each product-by-product name and other identifying numbers or symbols as set forth in Contract Documents.

l. Product Data:

i. Include only those sheets that are pertinent to specific product.

ii. Clearly annotate each sheet to:

1. Identify specific product or part installed.

2. Identify data applicable to installation.

3. Delete references to inapplicable information.

m. Drawings: Supplement product data with Drawings as necessary to clearly illustrate:

i. Relations of component parts of equipment and systems

ii. Control and flow diagrams

iii. Coordinate drawings with Project record documents to assure correct illustration of completed installation.

iv. Do not use Project record documents as maintenance manual drawings.

v. Provide reinforced punched binder tab, bind in with text.

vi. Reduced to 8-1/2 inches by 11 inches, or 11 inches by 17 inches folded to 8-1/2 inches by 11 inches.

vii. Where reduction is impractical, fold and place in 8-1/2-inch by 11-inch envelopes bound in text.

viii. Identify Specification section and product on Drawings and envelopes.

n. Instructions and Procedures: Within text, as required to supplement product data.

i. Handling, storage, maintenance during storage, assembly, erection, installation, adjusting, testing, operating, shutdown in emergency, troubleshooting, maintenance, interface, and as may otherwise be required

ii. Organize in a consistent format under separate heading for each different procedure.

iii. Provide a logical sequence of instructions for each procedure.

iv. Provide information sheet for Ellington Field personnel, including:

1. Proper procedures in the event of failure

2. Instances that might affect the validity of warranties or Bonds

o. Warranties, Bonds, and Service Agreements: In accordance with (Attachment

G.P).

p. Electronic Format: Microsoft Word, most current version.

5. SUBMITTAL PROCEDURE

A. Preliminary Manuals:

a. Submit three copies for the Program Manager’s review.

b. Disposition: In accordance with Attachment G.T.

c. If Accepted:

i. One copy will be returned to Contractor.

ii. One copy will be forwarded to the Program Manager.

iii. Submit five copies of Final Manual to the Program Manager.

d. If Rejected:

i. Two copies will be returned to Contractor with the Program Manager comments for revision.

ii. One copy will be retained in the Program Manager’s file.

iii. Resubmit three copies revised Preliminary copies for the Program

Manager review.

B. Final Manuals:

a. If different than accepted Preliminary Manuals, submit:

i. Three copies of any necessary supplemental material, including revised table of contents

ii. Instructions for insertion of supplemental material in unreturned sets

b. If Final Manuals are acceptable, Contractor shall be so notified.

c. If rejected, and at the Program Manager’s option:

i. All copies will be returned to Contractor for revision, or;

ii. All copies will be retained by the Program Manager and the necessary revision data will be requested from Contractor.

6. MANUALS FOR EQUIPMENT AND SYSTEMS

A. Content for Each Unit (or Common Units) and System:

a. Description of unit and component parts, including controls, accessories, and appurtenances:

i. Function, normal operating characteristics, and limiting conditions

ii. Performance curves, engineering data, nameplate data, and tests

iii. Complete nomenclature and commercial number of replaceable parts.

b. Operating Procedures:

i. Startup, break-in, routine, and normal operating instructions

ii. Test procedures and results of factory tests where required.

iii. Regulation, control, stopping, and emergency instructions

iv. Description of operation sequence by control manufacturer

v. Shutdown instructions for both short and extended durations

vi. Summer and winter operating instructions, as applicable

vii. Safety precautions

viii. Special operating instructions

ix. Installation instructions

c. Maintenance and Overhaul Procedures:

i. Routine operations

ii. Guide to troubleshooting

iii. Disassembly, removal, repair, reinstallation, and reassembly

d. Installation Instructions: Including alignment, adjusting, calibrating, and checking.

e. Original manufacturer's parts list, illustrations, detailed assembly drawings showing each part with part numbers and sequentially numbered parts list, and diagrams required for maintenance

f. Spare parts ordering instructions.

g. Where applicable, identify installed spares and other provisions for future work (e.g., reserved panel space, unused components, wiring, and terminals).

h. Manufacturer's printed operating and maintenance instructions.

i. As-installed color-coded piping diagrams.

j. Charts of valve tag numbers, with the location and function of each valve and valve position (normally open or normally closed).

B. Maintenance Summary:

a. Compile an individual Maintenance Summary for each applicable equipment item, respective unit, or system, and for components or subunits.

b. Format:

i. Use Maintenance Summary Form bound with this section, or an electronic facsimile of such.

ii. Each Maintenance Summary may take as many pages as required.

iii. Use only 8-1/2-inch by 11-inch size paper.

iv. Complete using Microsoft Word or similar word processing program.

c. Include detailed lubrication instructions and diagrams showing points to be greased or oiled; recommend type, grade, and temperature range of lubricants and frequency of lubrication.

d. Recommended Spare Parts:

i. Data to be consistent with manufacturer's Bill of Materials/Parts List furnished in O&M manuals.

ii. “Unit” is the unit of measure for ordering the part.

iii. “Quantity” is the number of units recommended.

iv. “Unit Cost” is the current purchase price.

C. Content for Each Electric or Electronic Item or System:

a. Description of Unit and Component Parts:

i. Function, normal operating characteristics, and limiting conditions

ii. Performance curves, engineering data, nameplate data, and tests

iii. Complete nomenclature and commercial number of replaceable parts.

iv. Interconnection wiring diagrams, including all control and lighting systems

b. Circuit Directories of Panel boards:

i. Electrical service

ii. Controls

iii. Communications

c. List of electrical relay settings, and control and alarm contact settings

d. Electrical interconnection wiring diagram, including control and lighting systems

e. As-installed control diagrams by control manufacturer.

f. Operating Procedures:

i. Routine and normal operating instructions

ii. Sequences required.

iii. Safety precautions

iv. Special operating instructions

g. Maintenance Procedures:

i. Routine operations

ii. Guide to troubleshooting.

iii. Adjustment and checking

iv. List of relay settings, control, and alarm contact settings.

h. Manufacturer's printed operating and maintenance instructions.

i. List of original manufacturer's spare parts, manufacturer's current prices, and recommended quantities to be maintained in storage

7. MANUALS FOR MATERIALS AND FINISHES

A. Content for Architectural Products, Applied Materials, and Finishes:

a. Manufacturer's data, giving full information on products:

i. Catalog number, size, and composition

ii. Color and texture designations

iii. Information required for reordering special-manufactured products.

b. Instructions for Care and Maintenance:

i. Manufacturer's recommendation for types of cleaning agents and methods

ii. Cautions against cleaning agents and methods that are detrimental to product.

iii. Recommended schedule for cleaning and maintenance.

B. Content for Moisture Protection and Weather Exposed Products:

a. Manufacturer's data, giving full information on products:

i. Applicable standards

ii. Chemical composition

iii. Details of installation

b. Instructions for inspections, maintenance, and repair

8. SUPPLEMENTS

Attachment G.J.1 - Ellington AFB (EF) Maintenance Summary Form