SECTION OPERATIONS AND MAINTENANCE MANUALS TRACTION POWER EQUIPMENT
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1 SECTION OPERATIONS AND MAINTENANCE MANUALS TRACTION POWER EQUIPMENT PART 1 - GENERAL 1.01 DESCRIPTION OF WORK A. Furnish SEPTA with comprehensive Operations and Maintenance Manuals of all equipment and systems furnished. B. Prepare manuals uniform in presentation showing all interfaces between equipment and subsystems in sufficient detail to present a complete and clear picture of the equipment and subsystems. C. Ensure that the nomenclature, functional designations of components and their interconnections are consistent with the As-built Drawings. D. Provide all information needed for optimum and safe maintenance and repair of the equipment RELATED SECTIONS A. All Sections of Division 1 B. Section Contractor Quality Control Traction Power Equipment C. Section Delivery, Storage, and Handling Traction Power Equipment D. Section Spare Parts and Maintenance Materials E. Section Demonstration and Training Traction Power Equipment F. Section Paints and Coatings G. Section Basic Electrical Materials and Methods H. Section General Electrical Requirements Traction Power Equipment I. Section Grounding and Bonding J. Section Equipment Identification K. Section Static Frequency Converter Specification L. Section Protective Devices and Instrument Transformers M. Section Transmission and Distribution N. Section Medium Voltage (2-Pole) Breakers, Switching & Protection O. Section Surge Arresters P. Section Combined Relay and Control Switchboard Q. Section Electrical Systems Control (SCADA) R. Section Electrical Testing Traction Power Equipment 1.03 SUBMITTALS A. Submit the following Manuals for SEPTA s review and approval: 1. Operations Manual Wayne Junction SFC % Design Submittal
2 PART 2 - PRODUCTS 2. Preventive Maintenance Manual 3. Corrective Maintenance Manual 4. Heavy Repair Manual 5. Spare Parts Manual 6. Special Tools, and Test Equipment Manual 2.01 OPERATIONS MANUAL A. Provide all information needed for the optimum and safe operation of the equipment, including: 1. General system descriptions and its division into subsystems. General system and subsystems operation. Use block diagrams, as appropriate, to illustrate basic functions of equipment and interfaces between equipment. 2. General systems familiarization material, such as location, function, and operation of controls, gauges, indicators and switches. Use photos, sketches, and cut-section views for explanation. 3. Procedures to enable maintenance staff to operate the individual system components and the system as a whole in its normal and various contingency and emergency modes. 4. Explain, in detail, the operation of switchgear from SCADA, local area network controller (desktop computer), and via local control. Explain various safety interlockings between switchgear and disconnect switches. Explain function of all protective relays in detail. 5. Include step-by-step instructions for equipment energization, operation, normal shutdown, and emergency shutdown. Emphasize the safety precautions to be observed during normal operation, inspection, and before energization after a maintenance shutdown PREVENTIVE MAINTENANCE MANUAL A. Provide all information needed to enable maintenance staff to perform periodic inspection tasks to keep the system in satisfactory working order. B. Include all information needed for preventive maintenance, adjustments, and on-line trouble diagnosis of each equipment and system. C. Include step-by-step procedures for inspection, operation checks, cleaning, lubrication, and adjustments of the equipment. D. Include maintenance standards, including specifications, wear limits, settings, and tolerances. E. Provide recommended preventive maintenance schedule for all system components. F. Provide procedures for equipment removal and re-installation. Wayne Junction SFC % Design Submittal
3 2.03 CORRECTIVE MAINTENANCE MANUAL A. Provide all information needed to enable on-the-line and off-the-line troubleshooting. Include troubleshooting flow charts for diagnosis of breakdowns of all equipment and systems. B. Include description of trouble symptoms, methods for diagnosing causes of trouble symptoms, and corrective actions. C. Provide all information needed to enable maintenance staff to troubleshoot, adjust and completely repair all equipment and systems. D. Include detailed description and operation of each system, using block diagrams, flow diagrams, detailed schematics and functional wiring diagrams. E. Provide test and repair evaluation procedures. F. Include safety precautions and procedures, glossary of terms, and other relevant material HEAVY REPAIR MANUAL A. Provide all information needed to enable maintenance staff to service, maintain, repair, replace, disassemble, reassemble, rebuild, and overhaul the equipment and the system. B. Include detailed description of procedures for long-term periodic maintenance requirements of all components. Include detailed description of mid-life rehabilitation or replacement of any component, as required SPARE PARTS MANUAL A. Enumerate and describe every component with its related spare parts. B. Provide detail drawings of all spare parts. Use drawings showing cutaway isometric and exploded views of subassemblies and components to identify all parts down to the lowest level replaceable unit (LLRU). C. Include the supplier's number, the commercial equivalents, and SEPTA stock number. The inclusion of SEPTA stock number will require prior submission of the spare parts catalogs to SEPTA for coding. D. Parts common to different assemblies, such as bolts and nuts, shall bear the same Contractor's number in all assemblies, with an index reference to the other assemblies in which they are found. Each part or subassembly shall be identified as part of a next higher assembly. E. Commercially available items such as common fastenings, fuses, lamps, fittings, and relays shall be identified in a separate list in the parts catalog by the Contractor s part number and standard hardware nomenclature, sufficient for ordering these items commercially. F. Itemize all consumable parts and servicing materials, such as, oils, paints, special compounds, and greases. G. Provide, at least three supply sources (other than the Contractor) for all required consumables and servicing materials. Of the three required sources, at least two shall be in the United States. H. Provide complete list of parts and supplies, with current unit prices and sources of supply. I. Provide a list of all functional components, with manufacturer's model number and manufacturer's part number. Wayne Junction SFC % Design Submittal
4 J. Provide long-lead-time spare parts list for spare parts not readily available on the open market or for which it is anticipated ordering and deliver time will exceed 10 days. K. Provide the last date of manufacturer's warranty and guarantee date SPECIAL TOOLS AND TEST EQUIPMENT MANUAL A. Provide list of special tools and test equipment for general upkeep, inspection and maintenance of the equipment. B. Provide instructions and directions on how to use special tools and test equipment. C. Include setup and testing procedures for all special tools and test equipment and procedures needed for periodic inspection and servicing requirements including lubrication, inspection, and adjustment of all apparatus. D. Provide instructional manuals and user guides for all special tools and test equipment, including parts lists, diagrams, specifications, schematics, as well as maintenance, calibration instructions, and trouble-shooting procedures. PART 3 - EXECUTION 3.01 MANUAL FORMAT AND CONTENT A. Prepare hard copies of the Manuals in the following format: 1. Use loose leaf, 60-pound, punched 8½ x 11 paper with holes reinforced with plastic cloth. 2. Provide pocket folders for foldout diagrams and illustrations. All diagrams and illustrations shall be reproducible by dry-copy xerography method. 3. Bind Manuals in heavy duty, 3-ring vinyl-covered binders, oil-, moisture-, and wear-resistant covers identified on both the front and spine. B. Include the following in each Manual: 1. Use covers resistant to oil, moisture, and wear. 2. Title Page. Include the Manual title, name and function of the equipment, and illustration of the equipment described in the Manual. 3. Table of Contents. Provide listing of each section and subsection with page numbers. Provide list of included diagrams and drawings. 4. Index. Provide index in alphabetical order. 5. Provide manufacturer s literature describing each piece of equipment, including major assemblies and subassemblies, and giving manufacturer s model number and drawing number. 6. Provide control diagrams, sequence of operation diagrams, wiring diagrams, and interlocking diagrams. Reproduce diagrams by photographic process to a size not to exceed 11 inches by 17 inches. a) Provide only complete, clear, and legible diagrams on white paper. Vacuum-seal the diagrams in transparent plastic material impervious to moisture and oil, and resistant to abrasion. Wayne Junction SFC % Design Submittal
5 b) Other formats which are equal in clarity, sharpness, durability and permanence may be considered. c) Dimensions and lettering on drawings shall be easily legible. If reduced drawings are incorporated into manuals, the original lines shall retain their legibility after reduction. Larger drawings may be folded into manuals to page size. Any reproduction shall be of near perfect quality. C. Format all data contained in the Manuals consistently from section to section. D. Manuals consisting of catalog cuts shall not be acceptable. E. Supply hard copies of all Manuals in approved format and on CD-ROM INTERACTIVE WEB-COMPATIBLE MANUALS SYSTEM A. Provide all Manuals in Interactive Web-Compatible Manual (IWCM) system based on SGML or HTML in combination with a Web Browser. B. The IWCM shall contain all functional descriptions, repair procedures, overhaul procedures, and support information for equipment and components in a browsable format. Provide cross references by hot links. C. Users of each Manual in electronic format shall be able to read and scroll through text and illustrations just as if reading a hard copy Manual. The user shall be able to search text and illustrations based on key words, text strings, and part numbers. D. The IWCM shall be usable on conventional laptop computers, on Internet and Intranet. The system shall be compatible with commonly-available browsers, such as those developed by Microsoft and Google. Provide to SEPTA any other necessary specialized software and hardware required for the system not currently supported by SEPTA. E. Provide SEPTA Information Technology staff with instructions on development and continued maintenance of the IWCM system. END OF SECTION Wayne Junction SFC % Design Submittal
6 THIS PAGE INTENTIONALLY LEFT BLANK Wayne Junction SFC % Design Submittal
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