Operating and Maintenance Instructions

The Bidder shall supply complete and detailed Operating and Maintenance manuals in English covering the operation and maintenance of the plant and equipment as required by the Contract.

The contents of the operating and maintenance instructions, together with all drawings, illustrations and diagrams shall refer specifically to the plant and equipment being supplied under the Contract, and shall be specially prepared where necessary. General instructions referring to a range of equipment is not acceptable.

Operating instructions shall detail all integrated plant normal pre-start checks, starting up, running and shutting down procedures, for the various modes of operation of the plant from cold, warm or hot conditions, emergency operating procedures and any precautions recommended to prevent plant deterioration during periods of non-operation. Operating instructions shall cover local/remote and manual modes of operation and shall also include action on receipt of alarms.

The Bidder shall prepare a comprehensive commissioning schedule for each plant item and check lists to record the completion of these activities. Copies of all settings and/or calibrations of instruments and controls, pressure switches, trips and alarm settings confirmed and recorded in the commissioning schedules shall be forwarded to be included in the Operating Instructions.

[15]sets of draft copies of the manuals shall be submitted to KNOC for review [6]

months before commissioning commences. They shall be submitted as complete texts. In the event that amendments or alterations to the draft manuals are required, the Bidder shall submit revisions for review without delay so that the final documents can be supplied within the date specified. [15]sets of the final documents shall be submitted within [4] months after the Taking Over Certificate.

The whole of the operating and maintenance instructions shall be securely bound in approved covers and provided with an index for easy reference.

The O&M manuals shall be provided in paper hard copy and in electronic copy on CD-ROM to a standard document reader format (ie Adobe Acrobat Reader).

The instruction manuals shall conform to the following format:

a. Index

The index system shall provide rapid and easy access to particular subjects, drawings and illustrations. It should include a master index and a sub-index to each main section of the manual.

b. Description

This section shall include basic data on the Plant.

i. Descriptions of the Plant both for individual items and for the systems into which items are assembled.

ii. Drawings sufficient for the understanding of descriptions.

iii. Flow sheets or single line and block diagrams which explain the functioning and logic of the system. Where related systems are shown on composite diagrams, individual systems shall be identified by colour, or coding as agreed.

iv. Schedules which assemble references to items of a like kind, eg valve schedules, piping schedule, operational limit schedule, switchboard outline schedule, etc.

v. Data sheets which assemble in a concise format relevant technical details of a plant item or system. The purpose of a data sheet is to provide quick reference to the essential facts omitting all reference to general descriptions, operating or maintaining principles and instructions.

c. Operation

This section shall include basic step-by-step instructions on how to operate the Plant both with regard to individual items and to systems under all patterns of normal and abnormal conditions. The instructions shall include reference to the applicable operation limits.

Precautions and warnings relative to the safety of life and equipment shall be included where relevant.

d. Maintenance

This section shall include the following:

i. Build-up and assembly of systems and description of plant items.

ii. Schedule of equipment giving manufacturer’s name, the make/model No/catalogue No and parts list including any special spares ordering instructions. Spare parts catalogues shall be provided for the various items of equipment supplied.

iii. Routine maintenance schedule.

iv. Preventative maintenance and schedule of inspections.

v. Details necessary to carry out overhauls.

vi. Details necessary to locate and rectify faults.

vii. Details necessary to set up, test and adjust plant systems and plant items.

To include as a minimum, fuel systems, cranage, ventilation, fire protection, water treatment plant and compressed air equipment.

viii. Spares schedule.

ix. Schedule of recommended lubricants.

x. Sectional drawings of major items of plant fired boiler, steam turbine, condensers, pumps, valves, electric generators, transformers etc with dismantling instructions.

xi. As built copies of all relevant drawings corrected as necessary to incorporate any late modifications.

xii. Plant layout drawing.

xiii. Schematic diagrams and general arrangement drawings of “as-built” control panels.

xiv. Wiring and cable diagrams.

xv. Plant equipment and performance curves.

xvi. Lifting gear register.

xvii. The final records shall include the construction and pre-commissioning data dossier with signed record sheets.

e. Spare parts

This section shall comprise the definite and optional spares as required by the KNOC and the spares as recommended by the Bidder. Details and full ordering procedures for each item of main plant, auxiliary plant, electrical and C&I equipment and vendor equipment and shall include:

i. Spare part lists together with referenced sectional drawings from which the manufacturers descriptive name and part number can be clearly identified for ordering purposes.

ii. Clear details of spare part suppliers address, spare part ordering procedure and including all appropriate plan item reference numbers including serial numbers, type reference numbers, original order numbers, etc as required for the immediate and correct supply of spare parts from various original plant suppliers.

In this context the term “suppliers address” means the sub-vendor or original equipment manufacturer. It will not be acceptable for the Bidder to nominate himself as the supplier of a spare part unless he manufactures the particular equipment, or it is manufactured by a third party in accordance with the Bidder’s own manufacturing drawings.

iii. A list of spares for each type of overhaul/inspection shall be provided.

Note: where spare parts are not available and full item replacement is necessary this fact is to be advised and the appropriate ordering details provided as defined above.

For spares that are available from a multitude of sources (eg seals, “O”

rings, gaskets, nuts, bolts, etc the Bidder shall supply details of the sizes, standards and materials used.

Details shall be provided of any special storage requirements or limitations on spare parts, lead time, shelf life, storage requirement, quantity etc.

f. Plant preservation schedule and methods

This section shall cover the procedures for shutting down plant. Preservation during hibernation and re-starting of plant.

g. Manual production

Accepted abbreviations of units of measurement are permitted in the text and illustrations. A list of the abbreviations the Bidder proposes to use in the text and schedules is to be approved before work begins on the manuals. As a guide it may be taken that abbreviations of terms will be permitted only where they are in common use and readily understood, eg ac, dc.

Drawings and diagrams shall, wherever practicable, be reduced to a convenient size, eg A3, and bound into the manual. The reduced size drawings and diagrams shall be completely legible and suitable for reproduction. Drawings which are referred to several times in the text shall be either of the “fold out”

type or visible when referring to other parts of a manual or be repeated as

necessary. Throw-clear drawings are to be included at the back of the relevant subsections, and their locations noted in the Section drawing index.

Detailed engineering drawings necessary for maintenance and mentioned in the text but not included in the manual because of size reduction difficulties, should nevertheless be listed in the drawing index. The words “NOT INCLUDED” must be entered against them. Drawings are to be identified at the bottom right corner by title and number.

Black on white line drawings should be used wherever possible, using line shading, and cross hatching as necessary for clarity. Multi-colour and half-tone drawings using shading techniques, eg air brush, should only be used in preference to line drawings where the additional information conveyed justifies the effort and cost. Isometric and perspective illustrations are preferred to engineering (orthographic) drawings, although engineering drawings may be included if they are more suitable due to the size and complexity of a particular item of equipment. Where engineering drawings are used, clarify of detail necessary to support the text shall be retained and in addition all irrelevant information such as unnecessary dimensions, manufacturing information, borders, centre lines, etc should be removed. All drawings shall be clearly marked by legend.

The manuals shall be produced as a book or books, with page size international A4, bound into strong durable covers inscribed upon the front generally in the form of the title page to the Specification, except that the references to the contents will be replaced by “Operation and Maintenance Instructions”. Bidders standard pattern covers may be used, subject to KNOC’s approval.

The name of the main Bidder but not that of any subBidder may also be inscribed upon the cover after the description of the Plant.

The name of the KNOC, the title of the project and Contract number followed by a brief description of the Plant (eg turbo-generator plant, etc) shall be inscribed upon the spine of the cover. If the text is bulky it shall be divided into conveniently sized volumes, and each shall be marked with the appropriate volume number.