01 78 23.pdf

Monongahela River, Remote Gate Control System Upgrades

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 78 23

OPERATION AND MAINTENANCE MANUALS

PART 1 GENERAL

1.1 SUBMITTALS

1.2 SUBMISSION OF OPERATION AND MAINTENANCE DATA

1.2.1 General

1.2.2 Hardcopy Requirements

1.2.3 Electronic Format Requirements

1.2.4 Schedule of Equipment and Operations and Maintenance Data

1.2.5 Delivery

1.2.6 Changes to Submittals

1.3 TYPES OF INFORMATION REQUIRED

1.3.1 General

1.3.2 Operating Instructions

1.3.2.1 Safety Precautions

1.3.2.2 Operator Prestart

1.3.2.3 Startup, Shutdown, and Postshutdown Procedures

1.3.2.4 Normal Operations

1.3.2.5 Emergency Operations

1.3.2.6 Operator Service Requirements

1.3.2.7 Environmental Conditions

1.3.3 Preventive Maintenance

1.3.3.1 Preventive Maintenance Plan and Schedule

1.3.4 Corrective Maintenance (Repair)

1.3.4.1 Troubleshooting Guides and Diagnostic Techniques

1.3.4.2 Wiring Diagrams and Control Diagrams

1.3.4.3 Maintenance and Repair Procedures

1.3.4.4 Removal and Replacement Instructions

1.3.4.5 Spare Parts and Supply Lists

1.3.5 Corrective Maintenance Work-Hours

1.3.6 Appendices

1.3.7 Parts Identification

1.3.7.1 Warranty Information

1.3.7.2 Personnel Training Requirements

1.3.7.3 Testing Equipment and Special Tool Information

1.3.7.4 Contractor Information

PART 2 PRODUCTS (Not Applicable)

PART 3 EXECUTION (Not Applicable)

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SECTION 01 78 23 Page 1 W911WN-09-B-0033 Revised by Amendment 0003

SECTION 01 78 23

OPERATION AND MAINTENANCE MANUALS

PART 1 GENERAL

1.1 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01330 SUBMITTAL PROCEDURES:

SD-10 Operation and Maintenance Data

Schedule of Equipment; G, ED

The Contractor shall submit a draft schedule of equipment and operations and maintenance data prior to submission of draft operation and maintenance manuals.

Operation and Maintenance Manuals; G, RE

The Contractor shall furnish to the Contracting Officer four draft copies (hardcopy) and four final approved copies (hardcopy and electronic) of operation and maintenance manuals in accordance with paragraph "SUBMISSION OF OPERATION AND MAINTENANCE DATA", above.

1.2 SUBMISSION OF OPERATION AND MAINTENANCE DATA

1.2.1 General

The Contractor shall submit Operation and Maintenance (O&M) manuals which are specifically applicable to this contract and provide a complete and concise depiction of the provided equipment or product and shall include operation and maintenance instructions and other pertinent data for each piece of equipment or system furnished under this contract. The manuals shall be organized and present information in sufficient detail to clearly explain O&M requirements at the system, equipment, component, and subassembly level. The format specified in the following paragraphs applies to manuals prepared specifically for the work under this contract.

Manufacturer's stand operation and maintenance manuals may be incorporated by reference in to project specific manuals and shall be furnished with each copy of the specified operation and maintenance manuals. Each manual shall include the information specified in paragraph "TYPES OF INFORMATION REQUIRED" below. In addition to those requirements, the manuals shall include manufacturer's name, model number, service manual, parts list, and brief description of all equipment and their basic operating features, with copies of approved catalog cuts, and copies of APPROVED equipment shop drawings and installation drawings and wiring diagrams. Photographs of components may be included for identification. Each manual shall be labeled with the equipment or system name and location, and contain a table of contents. Each O&M manual shall contain (but not be limited to) sections on containing the information specified in paragraph "TYPES OF INFORMATION REQUIRED" below, and other pertinent information as required or specified

SECTION 01 78 23 Page 2 in other Sections of the Specifications. Each O&M manual shall contain subsections on field testing and adjustments including recommended procedures and results. All information contained in the operating and maintenance instructions shall be as built and tested. Each O&M manual shall contain a "Warranty" section that includes the following information:

1. Name of item.

2. Model and serial numbers.

3. Location where installed.

4. Name and phone numbers of manufacturers or suppliers.

5. Names, addresses and telephone numbers of sources of spare parts.

6. Warranties and terms of warranty. This shall include one-year overall warranty of construction. Items which have extended warranties shall be indicated with separate warranty expiration dates.

7. Cross-reference to warranty certificates as applicable.

8. Starting point and duration of warranty period.

9. Summary of maintenance procedures required to continue the warranty in force.

10. Organization, names and phone numbers of persons to call for warranty service.

11. Typical response time and repair time expected for various warranted equipment.

1.2.2 Hardcopy Requirements

Hardcopies of each manual shall be approximately 8-1/2 inches by 11 inches, printed on good quality paper and bound. Drawings incorporated in the manual and parts lists may be reduced to page size, provided they are clear and easily legible, or may be folded into the manual to page size.

Photographs shall be neatly organized and clearly labeled, with callouts to identify individual items. Hardcopy of each manual may consist of more than one volume, and each volume shall be labeled as to its contents.

1.2.3 Electronic Format Requirements

Electronic format of final O&M manuals shall be provided in Microsoft Word.

Text and graphics shall be incorporated into the Microsoft Word format file. Drawings, catalog cuts, copies of warranty certifications, photographs, handwritten items and other information not readily available in electronic format shall be scanned and converted to a suitable graphics format, such as JPG (Joint Photographic Experts Group), TIFF (Tagged Image File Format) or BMP (Windows Bitmap). Graphics smaller than legal size (11"x14") shall be directly inserted into the Microsoft Word 2000 file.

Graphics larger than legal size (11"x14") shall provided as separate files.

All file names shall clearly and concisely identify the contents of the file. All electronic format files shall be provided on compact disk.

1.2.4 Schedule of Equipment and Operations and Maintenance Data

Prior to submission of draft operation and maintenance manuals, the Contractor shall submit a draft schedule listing all equipment and O&M data proposed to be furnished in the the Operations and Maintenance manuals.

The schedule shall list all items requiring an O&M manual, a tabulation of previously submitted O&M data, including: item description, model number and serial number; transmittal number for the approved equipment;

tabulation of as-built shop drawings and other approved submittals for the approved equipment; and a listing of other information to be provided as

SECTION 01 78 23 Page 3 listed in paragraph "TYPES OF INFORMATION REQUIRED," herein.

1.2.5 Delivery

Four copies of draft (hardcopy) O&M manuals shall be furnished for review and approval. After approval of the initial four copies, four final copies (hardcopy and electronic format) shall be furnished for a given item within 30 calendar days after the item is installed at the contract site. In the event the Contractor fails to deliver the final O&M manuals within the time limits set forth, the Contracting Officer may withhold from progress payments 50 percent of the price of the items with which such O&M manuals are associated.

1.2.6 Changes to Submittals

Manufacturer-originated changes or revisions to submitted data shall be furnished by the Contractor if a component of an item is so affected subsequent to acceptance of the O&M Data. Changes, additions, or revisions required by the Contracting Officer for final acceptance of submitted data, shall be submitted by the Contractor within 30 calendar days of the notification of this change requirement.

1.3 TYPES OF INFORMATION REQUIRED

1.3.1 General

Information required to be submitted in Operation and Maintenance manuals shall generally include (but not be limited to) the following items, as applicable:

a. Safety precautions

b. Operator prestart

c. Startup, shutdown, and postshutdown procedures

d. Normal operations

e. Emergency operations

f. Operator service requirements

g. Environmental conditions

h. Troubleshooting guides and diagnostic techniques

i. Wiring diagrams and control diagrams

j. Maintenance and repair procedures

k. Removal and replacement instructions

l. Spare parts and supply list

m. Corrective maintenance man-hours

n. Parts identification

o. Warranty information

SECTION 01 78 23 Page 4

p. Personnel training requirements

q. Testing equipment and special tool information

r. Contractor information

1.3.2 Operating Instructions

Include specific instructions, procedures, and illustrations for the following phases of operation:

1.3.2.1 Safety Precautions

List personnel hazards and equipment or product safety precautions for all operating conditions.

1.3.2.2 Operator Prestart

Include procedures required to set up and prepare each system for use.

1.3.2.3 Startup, Shutdown, and Postshutdown Procedures

Provide narrative description for each operating procedure including control sequence for each.

1.3.2.4 Normal Operations

Provide narrative description of normal operating procedures. Include control diagrams with data to explain operation and control of systems and specific equipment.

1.3.2.5 Emergency Operations

Include emergency procedures for equipment malfunctions to permit a short period of continued operation or to shut down the equipment to prevent further damage to systems and equipment. Include emergency shutdown instructions for fire, explosion, spills, or other foreseeable contingencies. Provide guidance on emergency operations of all utility systems including valve locations and portions of systems controlled.

1.3.2.6 Operator Service Requirements

Include instructions for services to be performed by the operator such as lubrication, adjustment, inspection, and gage reading recording.

1.3.2.7 Environmental Conditions

Include a list of environmental conditions (temperature, humidity, and other relevant data) which are best suited for each product or piece of equipment and describe conditions under which equipment should not be allowed to run.

1.3.3 Preventive Maintenance

Include the following information for preventive and scheduled maintenance to minimize corrective maintenance and repair.

SECTION 01 78 23 Page 5

1.3.3.1 Preventive Maintenance Plan and Schedule

Include manufacturer's schedule for routine preventive maintenance, inspections, tests and adjustments required to ensure proper and economical operation and to minimize corrective maintenance and repair. Provide manufacturer's projection of preventive maintenance work-hours on a daily, weekly, monthly, and annual basis including craft requirements by type of craft. For periodic calibrations, provide manufacturer's specified frequency and procedures for each separate operation.

1.3.4 Corrective Maintenance (Repair)

Include manufacturer's recommendations on procedures and instructions for correcting problems and making repairs.

1.3.4.1 Troubleshooting Guides and Diagnostic Techniques

Include step-by-step procedures to promptly isolate the cause of typical malfunctions. Describe clearly why the checkout is performed and what conditions are to be sought. Identify tests or inspections and test equipment required to determine whether parts and equipment may be reused or require replacement.

1.3.4.2 Wiring Diagrams and Control Diagrams

Wiring diagrams and control diagrams shall be point-to-point drawings of wiring and control circuits including factory-field interfaces. Provide a complete and accurate depiction of the actual job specific wiring and control work. On diagrams, number electrical and electronic wiring and pneumatic control tubing and the terminals for each type, identically to actual installation numbering.

1.3.4.3 Maintenance and Repair Procedures

Include instructions and list tools required to restore product or equipment to proper condition or operating standards.

1.3.4.4 Removal and Replacement Instructions

Include step-by-step procedures and list required tools and supplies for removal, replacement, disassembly, and assembly of components, assemblies, subassemblies, accessories, and attachments. Provide tolerances, dimensions, settings and adjustments required. Instructions shall include a combination of text and illustrations.

1.3.4.5 Spare Parts and Supply Lists

Include lists of spare parts and supplies required for maintenance and repair to ensure continued service or operation without unreasonable delays. Special consideration is required for facilities at remote locations. List spare parts and supplies that have a long lead time to obtain.

1.3.5 Corrective Maintenance Work-Hours

Include manufacturer's projection of corrective maintenance work-hours including craft requirements by type of craft. Corrective maintenance that requires participation of the equipment manufacturer shall be identified and tabulated separately.

SECTION 01 78 23 Page 6

1.3.6 Appendices

Provide information required below and information not specified in the preceding paragraphs but pertinent to the maintenance or operation of the product or equipment. Include the following:

1.3.7 Parts Identification

Provide identification and coverage for all parts of each component, assembly, subassembly, and accessory of the end items subject to replacement. Include special hardware requirements, such as requirement to use high-strength bolts and nuts. Identify parts by make, model, serial number, and source of supply to allow reordering without further identification. Provide clear and legible illustrations, drawings, and exploded views to enable easy identification of the items. When illustrations omit the part numbers and description, both the illustrations and separate listing shall show the index, reference, or key number which will cross-reference the illustrated part to the listed part. Parts shown in the listings shall be grouped by components, assemblies, and subassemblies. Parts data may cover more than one model or series of equipment. components, assemblies, subassemblies, attachments, or accessories, such as a master parts catalog, in accordance with the manufacturer's standard commercial practice.

1.3.7.1 Warranty Information

List and explain the various warranties and include the servicing and technical precautions prescribed by the manufacturers or contract documents to keep warranties in force. Include warranty information for primary components such as the compressor of air conditioning system.

1.3.7.2 Personnel Training Requirements

Provide information available from the manufacturers to use in training designated personnel to operate and maintain the equipment and systems properly.

1.3.7.3 Testing Equipment and Special Tool Information

Include information on test equipment required to perform specified tests and on special tools needed for the operation, maintenance, and repair of components.

1.3.7.4 Contractor Information

Provide a list that includes the name, address, and telephone number of the General Contractor and each subcontractor installing the product or equipment. Include local representatives and service organizations most convenient to the project site. Provide the name, address, and telephone number of the product or equipment manufacturers.

PART 2 PRODUCTS (Not Applicable)

PART 3 EXECUTION (Not Applicable)

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