Date : 19.11.

2018
Document no : Rev: 01

O&M MANUAL SOP / GUIDELINE

Prepared By: Mr. Ashish S. Kinkar

Engineer (Boiler Commissioning – Project Management, tKII Pune)

Submitted to: Mr. Subhankar Chaudhuri

General Manager (Boiler Commissioning – Project Management, tKII Pune)

Date: 16.11.2018

Thyssenkrupp Industries India Pvt. Ltd.

Pimpri, Pune

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O&M MANUAL MAKING GUIDELINE

 OEM Manual collection form B&PP department

(From the respective project deputed person, which can be confirm from the project coordinator)

First prepare the list of OEM Manual requirement as per the scope of supply list from project coordinator and give the

list to the B&PP department so that they will provide the required data.

OEM Manual includes the brought out items, like: Feed pump, RAV, Conveyor, VFD, hammering system etc.

Follow the below link for details of OEM manual requirement:

https://drive.google.com/open?id=14Am8WJKEJWd9DCO2Duf-6e9mKAA91Pvt

Boiler O&M Manual inputs also need to collect from the B&PP department (technical data and all)

A. Following list we have to provide for details from B&PP Department

Site specific design data

Mechanical equipment description data

Electrical equipment description data

Anticipated performance data sheet

Constructional features

Alarm and trip list

Maintenance practices note

Boiler preservation note

SOP (Standard operating procedure)

Plant start-up and shutdown procedure

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Recommended water quality

Lubrication schedule (list of all the drives available)

Plant GA drawings

Plant P&IDs

Data sheet of flow nozzles.

List of technical specification requirement for various boiler mountings and auxiliaries, example: safety valve,

silencer, conveyors, RAV etc.

Follow the below link for details of Boiler O&M manual inputs requirement form B&PP department

https://drive.google.com/open?id=1KqpaMLxu741MYSGcx3ohHj3Ure9zstZW

B. Following list we have to provide for details from E&I Department

Control philosophy

Logic write-up and Logic diagram (OLCS) and CLCS

Alarm and trip list

IO List

(Make sure that all list available in updated format)

 Check the all OEM Manual as per the scope of supply.

 Divide of OEM manuals into various sections.

Example: Section A: Plant Auxiliaries, Section B: Plant control and instrumentation etc

 (First section must be Boiler O&M Manual.)

 Make index (Section vise)

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 Attached the entire OEM Manual section vise and made one common document.

 Send the manual to B&PP and respective project for final approval.

 Count the number of pages section wise (A3 and A4 count separately in each section) and number of files

requirement (add maximum 400 pages in each files).

 For A4 pages consider both side and A3 single side basis.

 Make one common document (A3 and A4) and one separate A3 and A4 size pages document for proper segregation

at last.

 Develop the cover page; follow the link for cover page format:

https://drive.google.com/file/d/1Q1MvFFx2U33sX944Ix1eyRwU77V4v-5X/view?usp=sharing

 Count the total number of pages for estimation purpose (A3 and A4 separately)

 Make one Index document which should include the number of pages section wise for final estimation submission for

purchase request and vendor submission

 For purchase order contact to respective project manager or respective project team member and forward the

estimation document to Mr. Amin Irani and Mr. Kanchisingh Kajania (BOTH Department)

 Forward the document to vendor copy to BOTH, Amin Irani, Project and commissioning department.

 Print the single copy of document first.

 Check the copy from respective department and take final approval for the remaining copies, give the comments to

vendor through mail if any changes required.

 Purchase request and purchase order should be generated by the respective project only.

 For sample O&M Manual follow the link:

https://drive.google.com/file/d/1fV22-81R3umw_Swx3EPsxHEIXnE0qxIe/view?usp=sharing

https://drive.google.com/file/d/1_9wePD-CAlKGjvEjBJUp0mkXqf9EJDOx/view?usp=sharing

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