CONTRACT MM3-CBS-TVE (PHASE 1)

PART 2 – EMPLOYER’S REQUIREMENT

Section VI-A: General Specifications - Appendix 6

MUMBAI METRO LINE 3

BIDDING DOCUMENTS

Part 2

Section VI-A

EMPLOYER’S REQUIREMENTS

GENERAL SPECIFICATIONS

Appendix 6

Operation and Maintenance Documentation

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

1. Table of Contents
1. GENERAL ............................................................................................................................ 1
2. OPERATION MANUALS ....................................................................................................... 1
3. MAINTENANCE MANUALS ................................................................................................. 3
4. SUBMISSION REQUIREMENT ............................................................................................... 4
5. AS BUILT DOCUMENTATION............................................................................................... 7
6. TROUBLE SHOOTING PROCEDURES INCLUDING ................................................................. 8

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

OPERATION AND MAINTENANCE DOCUMENTATION

1. General

1.1. The Contractor shall submit a submission programme. The submission program shall
identify all submissions to be furnished, submission titles, submission numbers and
target submission dates.
1.2 The Contractor shall provide configuration management to ensure that the system is
correctly configures. The Contractor shall ensure that a configuration control program is
maintained. The programme shall ensure that the configuration of each item is recorded and
maintained at the same level during the life of the Contract and Defects Liability Period.
1.3 The Contractor shall submit a Project Management Plan to the Project Manager for review.
The Project Management Plan shall identify the persons to be responsible and the methods
and arrangement to carry out the Project Management.
1.4 The Contractor shall supply Operation and Maintenance documentation in respect of the
Railway electrical and mechanical Systems including depot equipment supplied or installed
or modified under the systems Contract in accordance with the requirements of the following
clauses, except where expressly specified otherwise in the Contract.
1.5 As well as submitting the Operation and Maintenance Manuals the Contractor shall submit a
Health and Safety Manual in accordance with Chapter 18 and Appendix 18 for the operation
and maintenance work on Site and in Depot.
1.6 Except where otherwise stated, the Contractor shall provide one electronic copy, 3 bound
copies and one unbound copy of all documentation. The unbound copy will be used by the
Employer / OMC for reproduction purposes.
1.7 All documentation shall be written in concise and plain English language. The content shall
be sufficient to provide adequate guidance on all features of the design which impact on the
operation, maintenance and repair of the railway systems including depot equipment.
1.8 The Operation and Maintenance Manuals shall fully describe the overall operation of all
Systems.
1.9 The Operation and Maintenance Manuals shall contain no irrelevant or ambiguous
information and shall relate specifically to this Contract. The Operation and Maintenance
Manuals shall be prepared in a user-friendly manner that permit finding complete sets of
information and instructions for a given system or component quickly.
1.10 Owing to the workshop type environment that the Operation and Maintenance Manuals will
be used in the manuals shall be produced using quality / heavy duty products (ie quality
paper, plastic sealed binders, opaque covers, laminated sheet).

2. Operation Manuals

2.1 The Operation Manuals shall provide detailed instructions for the operation of all types of
Railway Electrical and mechanical Systems including depot and workshop equipment, and
infrastructure maintenance vehicles provided under a separate contract. These manuals
will be produced with due regard to the qualification of personnel who shall be required to
refer to them. These documents will be issued as controlled documents and should therefore
be collated and numbered in proper order corresponding to the contents and index

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

pages. Nomenclature of equipment, diagrams and figure numbers or units shall be

consistent throughout the text. In order to comprehend the text, diagrams, drawings,
sketches and actual photographs shall be added where necessary. All manufacturers’
literature identification codes or stamp markings shall be omitted. Precautions and
warnings regarding the safety of life and equipment shall be included where applicable.

2.2 Familiarization of Operation and Maintenance manual.

The contractor shall provide instructions including

1) Basic functions
2) Operation Instructions
3) Table listing locations and quantities
4) Special options or unusual features not normally supplied.

2.3 Content Structure

The Contractor shall arrange all documentation in accordance with the following
guidelines for all Operation and Maintenance Manuals:

(1) The first Section shall be an overview of the functions provided by the
systems.
(2) All functions shall be described and all operator input clearly defined.
(3) All system operating sequences shall be explained.
(4) All indications and alarms shall be described together with the appropriate
operator response.
(5) Descriptions of indications and operator inputs shall be accompanied by pictures
or screen shots of the control interface.
(6) Lengthy technical descriptions of the systems in sections on operator input shall be
avoided and if required shall be segregated into an appendix for reference.
(7) Relevant system block diagrams, drawings, flow charts etc. shall be provided where
this assists understanding of the text and the significance of the equipment alarms
and status indications.
(8) Paper size shall be A4 and if necessary with folded A3.

2.4 Contents of Operation Manuals

The Contractor shall prepare operation manuals for all System, rolling stock, maintenance
vehicles, equipment and machines of the relevant contracts. The operation manuals shall
contain followings, but not be limited to:

(1) Safety regulations for operation excluding train operation;

(2) Instruction of operation;
(3) Explanation of the system out line, structure of the system indicating relation of each
subsystem and/or equipment, faculty of system/subsystem/equipment;
(4) List of equipment and parts with identification codes and illustration indicating
structure;
(5) Guide to failure detection;
(6) Instruction of daily cleaning, checking and adjustment;
(7) Contact address in emergency;
(8) Route.

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

3. Maintenance Manuals

3.1 The Maintenance Manuals shall provide detailed instructions for the maintenance of all
types of railway systems including depot equipment provided. These manuals shall be
produced with due regard to the qualification of personnel who shall be required to refer to
them. These documents will be issued as controlled documents and should therefore be
collated and numbered in proper order corresponding to the contents and index pages.
Nomenclature of equipment, diagrams and figure numbers or units shall be consistent
throughout the text. In order to comprehend the text, diagrams, drawings, sketches and
actual photographs shall be added where necessary. All manufacturers’ literature
identification codes or stamp markings shall be omitted. Precautions and warnings
regarding the safety of life and equipment shall be included where applicable.
Manuals shall be clearly identified as being:
(1) First line scheduled maintenance
(2) First line recovery/corrective maintenance
(3) Second line maintenance
(4) Software maintenance

3.2 Content Structure

The Contractor shall arrange all documentation in accordance with the following
guidelines for all Operation and Maintenance Manuals:
(1) The first Section shall be an overview of the functions provided by the
systems.
(2) All functions shall be described and all operator input clearly defined.
(3) All system operating sequences shall be explained.
(4) All indications and alarms shall be described together with the appropriate
operator response.
(5) Descriptions of indications and operator inputs shall be accompanied by pictures
or screen shots of the control interface.
(6) Lengthy technical descriptions of the systems in sections on operator input shall be
avoided and if required shall be segregated into an appendix for reference.
(7) Relevant system block diagrams, drawings, flow charts etc. shall be provided where
this assists understanding of the text and the significance of the equipment alarms
and status indications.
(8) Paper size shall be A4 and if necessary with folded A3.

3.3 Kinds of Maintenance Manuals

The Contractor shall prepare maintenance manuals for all Railway Systems, Depot and
Workshop Equipment, Infrastructure Maintenance Vehicles as followings, but not be limited
to:
(1) Safety regulations for maintenance work;
(2) Inspection or maintenance regulation in accordance with the I n d i a n r e g u l a t i o n s
and the Tender Documents;
(3) Inspection and repair standard and/or criteria;

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

(4) Inspection and repair methods;

(5) Operation manuals for inspection equipment, instrument, tester and tool;
(6) Data management system for logging asset status, inspection and repair record;
(7) Quality assurance system data base for tracing maintenance history.

4. Submission Requirement

4.1 Contact details for emergency maintenance during DLP period shall include;

1) Name of supplier organization for emergency maintenance

2) Name of supplier person(s) for emergency maintenance
3) Telephone number(s) for emergency maintenance
4) Email address(es) for emergency maintenance

4.2 The Contract shall include records of amendment in each submission with the following
detailed:

(1) Revision history and status of the submissions;

(2) Description on changes for each revision;
(3) The Contractor’s signature for authorization of the submission indicating proper
design check has been carried out before the submitting to the Project Manager.
(4) The revision status and date of preparation of the submission shall be clearly
indicated at the header of each page of the submission.
(5) The first submission shall be revision 0 and subsequent revision shall be A, then B,
so on and so forth.
(6) The Contractor shall maintain records of the submission and updated record shall be
included in the Monthly Progress Report. The submission record shall include the
following details;
(a) Submission number
(b) Submission title
(c) Revision history
(d) Status of Project Manager’s response for each revision
(e) Submission dates and dates of return from the Project Manager for
each revision
(f) Current status

4.3 Levels of submission

The Contract shall adopt top-down approach and submit submissions of the following
levels in a logic sequence for the review of the Project Manager;
(a) System level related submission
(b) Equipment level related submission
(c) Installation design related submission
(d) Design calculations
(e) Management plans and procedures
(f) Approval certificates
(g) Miscellaneous submission

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

4.4 System level related submission shall show the total system including the configuration
block diagrams, operating principle, system features and functions, capacity, expandability,
interconnection within the subsystem, between subsystems and between all other Interface
Contracts.
4.5 Equipment level related submission shall show the specification on electrical, mechanical
and functionality of the equipment/materials employed for the system and the
subsystems.
4.6 Installation design related submissions shall include;

(a) The installation methods and procedures for different types of installation activities
(b) Drawings showing the equipment locations and positions, subsystems coverage,
capacity, size, weight etc.
(c) Schematic and wiring diagrams
(d) Cable core plan and numbering scheme
(e) Equipment mounting details
(f) Configuration data, parameters and setting
(g) Cable route drawings
(h) Layouts in equipment racks, in equipment rooms, trackside, concourse,
platform and all other equipment locations

4.7 Design calculations shall demonstrate the performance of the system and subsystems.

4.8 The Contractor shall submit a copy of certificates from relevant parties and authorities as
required including equipment calibration certificates from manufactures and laboratories.

4.9 Preventative Maintenance Information (First Line Scheduled Maintenance)

4.9.1 Preventive maintenance information shall include but not limited to the following
column column title
A PM ACTIVITY
B SYSTEM
C SUBSYSTEM
D SUBSUBSYSTEM
E PERIODIC REQUIREMENT
F SITE LOCATION
G DETAILED LOCATION
H RELATED PART NUMBER
I MAINT MANUAL DOC NAME
J MAINT MANUAL DOC NUMBER
K MAINT MANUAL SECTION
L MAINT MANUAL PARAGRAPH
M AS-BUILT DRAWING NUMBER

4.9.2 For each equipment item requiring preventive maintenance, The Contractor shall include
preventive table(s) in each O&M Manual.

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

4.9.3 For each O&M Manual, The Contractor shall create soft copy EXCEL files, each formatted
identically, with the preventative maintenance activities listed above. The soft copy
preventative maintenance files shall be included with each O&M Manual.
4.9.4 The Contractor may provide a different list format provided the list format is the identical for
each of the STPT systems.
4.9.5 The purpose of the soft copy preventative maintenance files is import to a maintenance
management database provided by others.
4.10 Corrective Maintenance Information.

4.10.1 The Corrective Maintenance information shall contain but not limited to the following details
in Table of Replaceable Parts including the following. The Contractor shall provide a simple
text-only spreadsheet of Lowest Replaceable Units (LRU). Each row of the spreadsheet shall
list one LRU.

column column title

A MML3 PART NAME
B ASSET MGT NUMBER (APDX-14)
C SYSTEM
D SUBSYSTEM
E SUBSUBSYSTEM
F OEM NAME OF PART
G OEM PART NUMBER
H OEM NAME
I OEM PART SUPPLIER
J OEM SUPPLIER WEBSITE
K OEM SUPPLIER EMAIL
L OEM SUPPLIER TELEPHONE
M OEM SUPPLIER CITY STATE COUNTRY
N OEM SUPPLIER EST DELIVERY TIME
O ALT-1 NAME OF PART
P ALT-1 PART NUMBER
Q ALT-1 NAME
R ALT-1 PART SUPPLIER
S ALT-1 SUPPLIER WEBSITE
T ALT-1 SUPPLIER EMAIL
U ALT-1 SUPPLIER TELEPHONE
V ALT-1 SUPPLIER CITY STATE COUNTRY
W ALT-1 SUPPLIER EST DELIVERY TIME
X ALT-2 NAME OF PART
W ALT-2 PART NUMBER
Z ALT-2 NAME
AA ALT-2 PART SUPPLIER
AB ALT-2 SUPPLIER WEBSITE
AC ALT-2 SUPPLIER EMAIL
AD ALT-2 SUPPLIER TELEPHONE

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PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

AE ALT-2 SUPPLIER CITY STATE COUNTRY

AF ALT-2 SUPPLIER EST DELIVERY TIME
AG LRU LISTED IN PM ACTIVITY
AH PERIODIC REPLACEMENT REQUIREMENT
AI LRU MAINT MANUAL DOC NAME
AJ LRU MAINT MANUAL DOC NUMBER
AK LRU MAINT MANUAL SECTION
AL LRU MAINT MANUAL PARAGRAPH
AM LRU AS-BUILT DRAWING NUMBER

4.10.2 For each equipment item with replaceable parts, The Contractor shall include replaceable
parts table(s) in each O&M Manual.
4.10.3 For each O&M Manual, The Contractor shall create soft copy EXCEL files, each formatted
identically, with the replaceable part details listed above.
4.10.4 The Contractor may provide a different list format provided the list format is the identical for
each of the STPT systems.
4.10.5 In addition to the details listed above, each replaceable part shall include the assigned asset
management number per Appendix 14.
4.10.6 The soft copy replaceable part files shall be included with each O&M Manual.
4.10.7 The purpose of the soft copy replaceable part files is import to a maintenance management
database provided by others.

5. As built Documentation

5.1 The as-built documentation shall describe the system as installed and provide sufficient
information for the O&M Company staff maintainers and other users to execute their
responsibilities. All documentation shall be submitted for review by the Project
Manager , and shall include (but not be limited to):
(a) Operation and Maintenance Manuals
(b) Configuration Data Tables
(c) As-built drawings

5.2 The configuration data table shall be prepared for each individual subsystem and on an
item-by-item basis as well as on location basis.
5.3 The as-built drawings shall show the as-built details of the works and the Information
contained on the drawings shall include but not be limited to:
1) Arrangement drawings for all sub-systems and individual items of equipment;
2) Installation and fixing drawings for all sub-systems and individual items of
equipment;
3) Interface drawings for all sub-systems and individual items of equipment;
4) Schematic drawings f o r all electrical, pneumatic, hydraulic, water and drainage
systems;
5) Sizes, material and finish of all fixtures and threads;
6) Manufacturer's code, drawing and reference numbers;
7) Wiring diagrams to appropriate Standards including internal wiring of sealed unit
items;

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 CONTRACT MM3-CBS-TVE (PHASE 1)
PART 2 – EMPLOYER’S REQUIREMENT
Section VI-A: General Specifications - Appendix 6

8) Setting dimensions and tolerances; and

9) Bill of materials.

6. Trouble Shooting procedures including

1) Trouble Symptoms
2) Diagnostic Methods
3) Isolating Faults
4) Schematic and/or Block Diagrams for Fault Diagnosis
5) Diagnostic Test Equipment user manual

-- End of Appendix 6 --

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