Review Template – OM Manual AKH-SC-OMM-RevForm-001/2020

OPERATION AND MAINTENANCE MANUAL

REVIEW TEMPLATE
SC 001

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Document Control

Version Date Authors Name Details of change

1.0 June 2020 Tibebu D. First Released SC 001

THIS PAGE TO BE DELETED PRIOR TO O&M MANUAL SUBMISSION

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Operation & Maintenance Manual for:

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1 Contact Information............................................................................................................6
1.1 Design Scope of Work............................................................................................................. 6

1.2 Construction Scope of Work.................................................................................................... 6

2 Defects Liability...................................................................................................................6
2.1 List of All Equipment Covered By Warranties..........................................................................6

2.2 List of Any Spares and Special Tools Supplied Under the Contract........................................6

3 WAC Information................................................................................................................6
3.1 WAC and Construction Drawings Location..............................................................................6

3.2 Commissioning Process.......................................................................................................... 7

4 Assets Operational and Maintenance Information...........................................................7

4.1 Description of the Assets Function.......................................................................................... 7

4.2 System Hydraulic Overview.................................................................................................... 7

5 Operation Procedures..........................................................................................................7
5.1 Description of Assets Operation.............................................................................................. 7

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5.2 Restriction on Assets Operation.............................................................................................. 7

5.3 Start Up/Shut Down Procedures............................................................................................. 7

5.4 Isolation Procedures................................................................................................................ 7

5.5 Complete List of Fault Conditions............................................................................................ 7

5.6 Emergency Procedures........................................................................................................... 8

5.7 Surcharge Information............................................................................................................. 8

5.8 Portable Generator Connection Details...................................................................................8

5.9 Process systems SOPs / SWMSs........................................................................................... 8

5.10 Safety Data Sheets (SDS) Register........................................................................................ 8

6 Asset Equipment..................................................................................................................8
6.1 Equipment Technical Data Tables........................................................................................... 8

6.2 Pump Details (Remove if Not a Pump Station)........................................................................8

6.2.1 Pump Certified Test Curves..................................................................................8
6.2.2 Motor Certified Test Curves (for non-submersible pumps)....................................8
6.2.3 Test Result Log Sheet........................................................................................... 9
6.2.4 Motor Torque/Speed/Efficiency Characteristic Curves..........................................9

6.3 Drawings................................................................................................................................. 9
6.3.1 Pumps................................................................................................................... 9
6.3.2 Motor (for non-submersible pumps)......................................................................9

6.4 PLC and Telemetry.................................................................................................................. 9

6.4.1 Operation Description........................................................................................... 9

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6.4.2 Functional Specification......................................................................................10

6.5 Peripheral Equipment (When Installed).................................................................................10

6.6 Other Installed Equipment..................................................................................................... 10

6.6.1 List of Installed Components Not in Another Part of This Manual.......................10
6.6.2 Technical and Replacement Details for Installed Components...........................10

6.7 Maintenance Information....................................................................................................... 10

6.7.1 Troubleshooting Instructions for Large Components (eg. pump and motors etc).10
6.7.2 Maintenance Scheduling.....................................................................................10
6.7.3 Drawings and Schedules....................................................................................10

7 OEM Manuals Summary..................................................................................................10

8 Risk Information Summary..............................................................................................11

9 Document Control..............................................................................................................11

Appendix 1. Warranty Certificates...................................................................................12

Appendix 2. Commissioning Procedure...........................................................................13

Appendix 3. Technical Data Tables...................................................................................14

Appendix 4. OEM Manuals...............................................................................................15

Appendix 5. Safety and Risk Information........................................................................16

TABLES
Table 1: Contact Details.............................................................................................................................. 7
Table 2: Construction and WAC Drawings Location....................................................................................7

1 Contact Information

Table 1: Contact Details

Designer/Supplier/Vendor Contractor Consultant

Name
Address
Phone

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Fax
Email
Project or Job Number

Design Scope of Work

Construction Scope of Work

2 Defects Liability

List of All Equipment Covered By Warranties

List of Any Spares and Special Tools Supplied Under the Contract

3 Documentation Information and References

Design and Construction Documents

Table 2: Construction and Design Repors and Drawings

Civil/Mechanical Description/Title Reference

1. #########
2. #########
3. #########
4. #########
Electrical 1.
#########

2. #########
3. #########
4. #########

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5. #########
Design Report 1. #########
2. #########
3. #########
4. #########
5. #########
Installation/Construction 1.
Method Statement
2.
3.
4.
Other Relevant 1.
Information

Commissioning Process

4 Assets Operational and Maintenance Information

Description of the Assets Function

System Overview

5 Operation Procedures

Description of Assets Operation

Restriction on Assets Operation

Start Up/Shut Down Procedures

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Isolation Procedures

Complete List of Fault Conditions

This includes both electrical and mechanical troubleshooting.

Emergency Procedures

Asset Variation Information

Refer to Appendix 3. Technical Data Tables.

Catalogues of all installed material, system and equipments (This shall have an accompanying summary
chart indicating approved material, system and equipment information against actually installed).

 model, types and description, and

 Unit or number installed in the project

Portable Generator/Backup Power Connection Details

Refer to Appendix 3. Technical Data Tables.

System Description and Report

Process systems SOPs / SWMSs

Principal Design Criteria and Equipment Ratings

System Operation and Control Schematics Indicating major items of equipment and parts
that are essential to the operation of the system

Brief Description of Interconnections and Interfaces With Other/Adjacent System

Records and Reports.

Keeping and compiling records is a valuable part of an efficient operation and maintenance of the
system. The following should be included in the manual:

 A general explanation of the importance of records & reports

 The system should maintain a list of complaints and identify responses made;

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 Daily logs, maintenance records, laboratory records, monthly reports, monitoring reports,annual
reports, operating cost reports, accident reports, and safety surveys.
 A listing of acceptable international/national Standards and procedures for testing and
commissioning.

Safety Data Sheets (SDS) Register

Emergency / Safety Program

An Emergency Operating Plan

An operation plan for emergencies and the procedures to be followed until normal operation can be
resumed. This plan should include personnel assignments, emergency equipment inventory, and
emergency vendors/supplier support numbers. The emergency call up list should identify, in ranked order,
the system/equpment personnel responsible for making decisions in specific situations. This list should
include the department, job title, office phone number, email address and etc. for all Supplier/Vendor or
personnel.

Contingency Plan

A Contingency Plan should also be made to insure proper operation of system even in adverse
conditions. This plan should describe conditions and procedures for putting standby and
emergency sources into active service. Procedures for notifying customers, the local safety and health
jurisdiction of noticeable health and safety problems.

Safety Procedures

Safety Procedures should identify work space hazards for the system. Potentialhazards include
mechanical equipment, electrical, explosion and fire, and any material of the system. The manual should
provide information on how to do the following tasks;

 Potential Hazard Handling

 Emergency Procedures and Emergency Equipments
 Detection of Damages/Failure and Repairing

6 Asset Equipment

Equipment Technical Data Tables

Refer to Appendix 3. Technical Data Tables for data tables at commissioning. Refer to TFMS for
approved equipment data for the subject of this Manual:

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Details

Catalogues of all installed material, system and equipments (This shall have an accompanying summary
chart indicating approved material, system and equipment information against actually installed).

 model, types and description, and

 Unit or number installed in the project

Endorse copy of all test results(includes test result log sheet) and Installation
supervision certificates (Approval letter and Certificate of accredited testing
laboratary/authority pertaining to the project)

Certified Environmental test

Certified Electrical test

Certified Mechanical test

Certified Safety Test and Audit Report

Test Result Log Sheet

Certificate of Installation Supervision

Installation and Inspection Test Report, and etc.

Drawings

As built drawings and existing information of the project if applicable. Note: All as built drwgs should be
endorsed by relevant authority.

 Architectural Drawings
 Civil and Structural Drawings
 Mechanical Services Drawings
 Electrical Services Drawings
 Equipment Layout plan & detail drawings

Equpment Detail Drawing

General Arrangements

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Sectional Arrangements

Electronic/PLC and Telemetry/Communication

Operation Description

Functional Specification

Peripheral/Auxiliary/Support Equipment (When Installed)

Refer to Appendix 3. Technical Data Tables for data tables at commissioning. Refer to detailed design
report/drawing or interface requirements for equipment data.

 a device connected to a computer to provide communication (such as input and output) or

auxiliary functions (such as additional storage) or

Other Installed Equipment

List of Installed Components Not in Another Part of This Manual

Technical and Replacement Details for Installed Components

Maintenance Information

Troubleshooting Instructions for Large Components (eg. pump and motors etc).

Maintenance Scheduling

Drawings and Schedules

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7 OEM Manuals Summary

The following is a Summary of the OEM Manuals in Appendix 4:

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8 Risk Information Summary

The following is a Summary of the Risk and Safety Information in Appendix 5:

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9 Document Control

Version Date Author Details of Approval Date Approved by Next

Change Scheduled
Review
0.1 Xxx xxxx xxx Initial Draft for xxx xxx xxx
Review

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Appendix 1. Warranty Certificates [All warranties, letter of guarantees and certifications

for product and equipment installed in the project].

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Appendix 2. Commissioning Procedure

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Appendix 3. Technical Data Tables

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Appendix 4. OEM Manuals

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Appendix 5. Safety and Risk Information

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