SECTION 01730 OPERATION AND MAINTENANCE MANUALS

This spec was part of the Des Plaines, IL River WRF project that bid Feb 26, 2015.


SECTION 01730

OPERATION AND MAINTENANCE MANUALS



PART 1 GENERAL

1.1 SECTION INCLUDES

A. Format and content of manuals.

B. Equipment data form.

C. Operation and maintenance manual submittal checklist.

1.2 QUALITY ASSURANCE

A. Prepare instructions and data by personnel experienced in maintenance and operation of described products.

1.3 FORMAT

A. Prepare data in the form of an instructional manual.

B. Binders: Commercial quality, 8-1/2 x 11 inch three-ring binders with hardback, cleanable, plastic covers; two inch maximum ring size.  When multiple binders are used, correlate data into related consistent groupings.

C. Cover:  Identify each binder on the cover and spine with typed or printed title OPERATION AND MAINTENANCE MANUAL; list title of Project and subject matter of contents.

D. Provide a Cover Page that provides the following information:
1. Title of project.
2. Specification number and title.
3. Manufacturer.
4. General Contractor.
5. Subcontractor.
6. Supplier.

E. Arrange content by systems under section numbers and sequence of Table of Contents of this Project Manual.

F. Provide tabbed flyleaf for each separate product and system, with typed description of product and major component parts of equipment.  All tabs shall be legible with permanent smudge resistant lettering.
A.
G. Text:  Manufacturer's printed data, or typewritten data on 20 pound paper. Manufacturer's printed data must be originals or copies of good quality and clearly legible.  Fax copies of material are not acceptable and will be rejected.

H. Drawings 11 X 17 inch or smaller: Provide with reinforced punched binder tab.  Bind in with text; fold 11 x 17 inch drawings to size of text pages.

I. Drawings larger than 11 X 17 inch:  Provide clear plastic holder the size of the test pages, punched and bound in binder with the enclosed folded drawing.

1.4 CONTENTS, EACH VOLUME

A. Table of Contents:  Provide title of Project; names, addresses, and telephone numbers of Engineer, and Contractor with name of responsible parties; schedule of products and systems, indexed to content of the volume.

B. For Each Product or System:  List names, addresses and telephone numbers of Subcontractors and suppliers, including local source of supplies and replacement parts.

C. Product Data: Mark each sheet to clearly identify specific products and component parts, and data applicable to installation. Delete inapplicable information.  Clearly mark the selected product by use of arrows, underlines, or circles where more than one product is shown.  Use of highlighters to identify the selected product is unacceptable.

D. Drawings:  Supplement product data to illustrate relations of component parts of equipment and systems, to show control and flow diagrams.

E. Type Text:  As required to supplement product data. Provide logical sequence of instructions for each procedure, incorporating manufacturer's instructions specified in Section 01400.

1.5 MANUAL FOR MATERIALS AND FINISHES

A. Building Products, Applied Materials, and Finishes: Include product data, with catalog number, size, composition, and color and texture designations. Provide information for re-ordering custom manufactured products.

B. Instructions for Care and Maintenance:  Include manufacturer's recommendations for cleaning agents and methods, precautions against detrimental agents and methods, and recommended schedule for cleaning and maintenance.

C. Moisture Protection and Weather Exposed Products: Include product data listing applicable reference standards, chemical composition, and details of installation. Provide recommendations for inspections, maintenance, and repair.

D. Additional Requirements: As specified in individual product specification Sections.

E. Provide a listing in Table of Contents for design data, with tabbed fly sheet and space for insertion of data.
A.
1.6 MANUAL FOR EQUIPMENT AND SYSTEMS

A. Each Item of Equipment and Each System:  Include description of unit or system, and component parts. Identify function, normal operating characteristics, and limiting conditions.  Include performance curves, with engineering data and tests, complete nomenclature and commercial number of replaceable parts, complete nameplate data, and P&ID numbers as set forth in the Drawings.

B. Panelboard Circuit Directories:  Provide electrical service characteristics, controls and communications.

C. Include color-coded wiring diagrams as installed.

D. Operating Procedures:  Include start-up, break-in, and routine normal operating instructions and sequences. Include regulation, control, stopping, shut-down, and emergency instructions. Include summer, winter, and any special operating instructions.

E. Maintenance Requirements:  Include routine procedures and guide for trouble-shooting; disassembly, repair, and reassembly instructions; and alignment, adjusting, balancing, and checking instructions.

F. Provide servicing and lubrication schedule, and list of lubricants required.

G. Include manufacturer's printed operation and maintenance instructions.

H. Include sequence of operation by controls manufacturer.

I. Provide original manufacturer's parts list, illustrations, assembly drawings, and diagrams required for maintenance.

J. Provide control diagrams by controls manufacturer as installed. These shall be ladder diagrams, instrument loop diagrams, and electrical schematics as appropriate.

K. Provide Contractor's coordination drawings, with color-coded piping diagrams as installed.

L. Provide charts of valve tag numbers, with location and function of each valve, keyed to P&ID numbers as set forth in the Drawings.

M. Provide list of original manufacturer's spare parts, predicted life, current prices, and recommended quantities to be maintained in storage.

N. Bill of material.

O. Completed typewritten equipment data form included with this section. Manufacturer's standard form will not be acceptable.

P. Manufacturer's safety instructions.

Q. Include test and balancing reports as specified in Division 15.
A.
R. Additional Requirements: As specified in individual product specification Sections.

S. Provide a listing in Table of Contents for design data, with tabbed flysheet and space for insertion of data.

1.7 SUBMITTALS

A. Submit four copies for review within 60 days after time Contractor receives approved Shop Drawings for equipment/systems from Engineer.

B. Progress payments for equipment delivered, stored, or installed under these Contract Documents will not be made beyond 50% of the scheduled value until copies of the O&M data are delivered to and approved by Engineer. Progress payments for control systems packaged with equipment will not be made beyond 50% of the scheduled value until O&M data revisions are incorporated into equipment and control system manuals delivered and approved by Engineer.

C. Operation and maintenance manual submittals shall be accompanied by the checklist attached to this section indicating that the requirements of this section have been met in its entirety.  Engineer will reject submittals without completed checklist.  Pages for all submittals shall be numbered.

D. Engineer's review and acceptance of operation and maintenance manuals will be only for conformance with requirements of this section, for form of submittal and organization of data and completeness of information provided, but not for technical content or coordination between individual suppliers of equipment or system(s).

E. Provide four hard copies of the final approved O&M manuals and one electronic version as described herein.

F. Contractor is responsible for producing an electronic version of the Equipment Operations and Maintenance (O&M) Manuals Manual. The Electronic Equipment O&M Manual shall be delivered in Portable Document Format (PDF). The entire manual may be converted to PDF via scanning or other method of conversion. Drawings or other graphics must be converted to PDF format and made part of the PDF document. The Contractor shall provide all Equipment O&M Manuals in the electronic format as described herein.

G. The filename for the Equipment O&M Manual submittal will be provided with the request for final Equipment O&M Manuals. Filenames use the "eight dot three" convention (XXXXX_YY.PDF) where XXXXX is the specification section number and YY is an ID number. No one file shall be larger than 10 MB. If technical problems require that the submittal be divided into more than one file, a letter extension shall be added to the end of each filename. (Example: 19876_01a.pdf).

H. The number of files shall be kept to a minimum. Equipment O&M Manuals that span more than one file shall have the final Bookmark "Return to Table of Contents" which shall take the User to the first file on the Equipment O&M Manual.
A.
I. All text (word processed), spreadsheets, and electronic graphics shall be delivered in portable document form (*.PDF). The resolution of all scanned images shall be a minimum of 300 dpi unless otherwise requested by Engineer. Scanned images shall be processed with the "original image with hidden text" option (Adobe Acrobat 8 or higher). This results in a clear image and provides for optical character recognition (OCR) and word search functionality. Graphical files shall be fully searchable. All submittals must be indexed with the Adobe Catalog feature. Placement and structure of index files shall be  in accordance with Adobe's recommendations to minimize problems when transferring files. Successful searches for words or strings in the PDF document shall demonstrate proof of OCR.

J. Rotate pages viewed in landscape to the appropriate position for easy reading on a computer monitor.

K. Bookmarks shall be created in the navigation frame for each entry in the Table of Contents. Three levels deep is usually enough (i.e., "Chapter", "Section", "Subsection"); however, complex submittals like instrumentation and electrical may be required at the discretion of Engineer. When setting bookmarks for Chapter level heading, the page shall be displayed at Full Page. Section and Subsection level heading pages shall be displayed as a magnified view. Bookmarks shall be displayed as subordinate to other bookmarks in their hierarchy set so that only the Chapter level headings are displayed.

L. Thumbnails shall be generated and embedded in each PDF file.

M. Files shall be delivered without Security features activated. Password protected files will be unacceptable.

N. The opening view for PDF files shall be set as follows:
1.
Initial View:
Bookmarks and Page
2.
Magnification:
Fit In Window
3.
Page Layout:
Single Page

O. The file shall open to the cover page of the Equipment O&M Manual with bookmarks to the left. The first bookmark shall be the name of Equipment O&M Manual.

P. The submittal shall be delivered on CD after all Equipment O&M Manuals have been received and approved. Each CD shall be labeled, at a minimum, as follows, including:
1) CD-ROM disks, 2) jewel cases, and 3) hard copies.
1. Manufacturer name, point of contact, telephone number, facsimile number, and e-mail address as appropriate
2. Equipment name and/or O&M title spelled out in complete words
a. Example “Operations and Maintenance Manual - Horizontal Centrifugal Nonclog Pumps”
3. Specifications section number
4. Project name
5. Date and File Name:  Example "12-20-15",  "19876_01.pdf"

Q. Contractor shall reprocess any portion of the document that does not view or print to Owner's satisfaction.
A.
R. Contractor shall obtain all copyright permissions associated with conversion of O&M manual information into electronic format.


PART 2 PRODUCTS

Not used.


PART 3 EXECUTION

Not used.


END OF SECTION

EQUIPMENT DATA FORM (Page 1 of 3)


PROJECT                                                                                                                        NAME   CONTRACT NO.   CONTRACTOR  
EQUIPMENT                                                                                                                  NO.   DESCRIPTION   LOCATION  
MANUFACTURER   PURCHASED FROM PURCHASE DATE   VENDOR ORDER NO. PURCHASE PRICE  
LOCAL SUPPLIER PHONE   ADDRESS   MODEL NO. SHIPPING WT/UNIT   NO. OF UNITS SERIAL NOS.  
NAMEPLATE DATA

ELECTRIC MOTOR PUMP/HVAC UNIT DRIVE/REDUCER OTHER (I&C)

MANUFACTURER: MANUFACTURER: MANUFACTURER: MANUFACTURER:


 


TYPE: []AC []DC TYPE

TYPE: []GEAR TYPE []V-BELT

HP RPM

SIZE  CAPACITY_

[]CHAIN SIZE []VARIDRIVE
CAPACITY
SERVICE

VOLTAGE

PRESSURE_

FACTOR

RANGE



AMPERAGE

ROTATION

RATIO



PHASE

IMPELLER: SIZE



FRAME

MATERIAL

EQUIPMENT DATA FORM (Page 2 of 3)

MAINTENANCE SUMMARY



EQUIPMENT NO.  

DESCRIPTION  


MAINTENANCE OPERATION FREQUENCY

List briefly each maintenance operation List required frequency
required and refer to specific information of each maintenance
in Manufacturer's Maintenance Manual, if operation. applicable. Refer by symbol to "Lubricant
List" for Lubrication Operation.


 


 


 


 


 


 


 


 


 


 


 


 


 


 

EQUIPMENT DATA FORM (Page 3 of 3)

LUBRICANT/RECOMMENDED SPARE PARTS LIST


EQUIPMENT NO.  

DESCRIPTION  

LUBRICANT LIST



LUBRICANT

LUBRICANT TYPE RECOMMENDED

REFERENCE SYMBOL (MILITARY STANDARD) AND MANUFACTURER

List symbol in List general lubricant type List specific lubricant name, "maintenance operation” viscosity and manufacturer


 


 


 


 


RECOMMENDED SPARE PARTS LIST



UNIT

PART NO. DESCRIPTION UNIT QUANTITY COST


 


 


 


 

NOTE:  Identify parts provided by this Contract with two asterisks. ADDITIONAL DATA AND REMARKS









O&M MANUAL SUBMITTAL CHECKLIST (Page 1 of 5)



PROJECT NAME  

CONTRACT NO.  

CONTRACTOR  

EQUIPMENT/SYSTEM  

SECTION NO.  

MANUFACTURER/VENDOR  







FORMAT


Size: 8-1/2 x 11 or 11 x 17
Paper: 20-pound minimum
Text: Printed data/neatly typed
Drawings: Standard size bound in text; in text-size labeled envelopes Tabbed Section Dividers
Cover Label: Title
Project Name Building/Structure ID Equipment Name Specification Section

Binders: Plastic Cover

O&M MANUAL SUBMITTAL CHECKLIST (Page 2 of 5)


GENERAL CONTENTS


Not
Page
Provided
Applicable
No.


One Specification Only Title Page:
Title Project title
Building/structure ID Equipment name Specification section number Contractor ID
Subcontractor ID Purchase order data Manufacturer ID Service/parts supplier ID Product List
Table of Contents Tabbed Sections: Pertinent data sheets Annotated as needed Text:
Pertinent to project Annotated Drawings:
Illustrate product and components Control and flow diagrams Special Information: Interrelationships of equipment and components
Instructions and procedures Instructions organized in Instructions in logical Glossary
Warranty, Bond, Service Contract

O&M MANUAL SUBMITTAL CHECKLIST (Page 3 of 5)


MANUAL FOR MATERIALS AND FINISHES


Not Page
Provided Applicable No.

Building Products: Product data Catalog number Size
Composition
Color and texture designations Care and Maintenance Instructions Recommended cleaning agents and methods
Cleaning precautions
Cleaning and maintenance schedule Moisture Protection Products: Product data listing
Chemical composition Installation details Inspection recommendations Maintenance and repair Additional Data as Required

O&M MANUAL SUBMITTAL CHECKLIST (Page 4 of 5)


MANUAL FOR EQUIPMENT AND SYSTEMS

Not Page
Provided Applicable No.

Description of Unit and Components: Equipment functions
Normal operating characteristics Limiting conditions Performance curves  Engineering data
Test data
Replaceable parts list (with numbers) P&ID numbers
Operating Procedures: Startup
Break-in
Routine/normal operation Regulation and control Stopping and shutdown Emergency
Seasonal operation Special instructions Maintenance Procedures:
Routine/normal instructions Troubleshooting guide Disassembly/reassembly/repair Alignment/adjusting/balancing Servicing and Lubrication:  List of lubricants
Lubrication schedule Maintenance schedule Safety Precautions/Features
Sequence of Operation of Controls Assembly Drawings
Parts List and Illustrations: Predicted life
Recommended spare parts list and prices Control Diagrams/Schematics
Bill of Materials

O&M MANUAL SUBMITTAL CHECKLIST  (Page 5 of 5)


Not Page
Provided Applicable No.

Completed Equipment Data Form per Specification
Valves
Catalog Cuts and Tag Numbers Maintenance Instructions Panelboard Directories: Electrical
Controls Communications Instrumentation Loops: Diagrams
Components list each circuit/loop Additional Data As Required