Spare Part Philosophy

ABB Lummus Global Inc. SPARES PHILOSOPHY AND SPARES LIST

ISSUED BY:

MECHANICAL ENGINEERING

APPROVED: DATE: April 10, 2006

ERIR PETROCHEMICALS COMPANY SIDI K ERIR

460,000 MTA ETHYLENE PLANT NO. 2 EL AMERIYA, ALEXANDRIA, EGYPT

REV.:

2


TABLE OF CONTENTS 1.

INTRODUCTION

3

2.

OBJECTIVE

3

3.

DEFINITIONS

3

3.1

DEFINITIONS OF SPARES

3

3.2

OTHER DEFINITIONS

3

4.0

SCOPE OF SUPPLY

3

4.1

COMMISSIONING SPARES

3

4.2

CAPITAL SPARES

4

4.3

TWO-YEAR SPARES

4

5.0

COMMISSIONING SPARES

4

5.1

IDENTIFICATION OF REQUIREMENTS

4

5.2

PROCUREMENT

5

5.3

DELIVERY TO SITE AND LOGISTICS AT SITE

5

5.4

SURPLUS

5

6.

CAPITAL SPARES

5


1.

INTRODUCTION This spare parts philosophy defines the identification of the requirements and the procurement sequence of spare parts purchased by Contractor or by Contractor on behalf of the Client.

2.

OBJECTIVE To identify the requirements and supply of spare parts in adequate quantities for their planned purpose so that commissioning, start-up and normal plant operations are not hindered.

3.

DEFINITIONS

3.1

DEFINITIONS OF SPARES Spares are components that are required for replacement due to normal or abnormal wear and tear on equipment. Three (3) categories of spares are identified as pertinent to the project: •

•

Commissioning spares as required by the Contractor to carry out all operations at site for initial operation up to acceptance of the plant, which shall include start-up, steady production and performance testing. Capital spares as required by the Client for parts of equipment, equipment assemblies or


4.2

CAPITAL SPARES As part of the Lump Sum Contract, the Contractor shall be responsible for the identification, requisitioning, procurement, delivery, storage and maintenance and all else required for the capital spares for the realization of the project. The requirements for capital spares are provided in Attachment 1, “Minimum Requirements for Two (2) years and Capital Spares”, to this spare parts philosophy.

4.3

TWO-YEAR SPARES As part of the Lump Sum Contract, the Contractor shall be responsible for obtaining from the Suppliers (Sellers) of the various items of equipment and materials on the project priced quotations for the spare parts recommended for two years of plant operation. The structure of these quotations shall include completion of the form provided as Attachment 2, “List of Spare Parts”. These quotations shall be transmitted by the Contractor to SIDPEC for their review and action. The minimum requirements for two (2) years spares are provided in Attachment 1, “Minimum Requirements for Two (2) Years and Capital Spares”, to this spare parts philosophy document. These spare parts are not part of the spare parts to be furnished by the Contractor to commission, startup and test the Plant.

4.4

TWO-YEAR SPARES - OPTIONAL


5.2

PROCUREMENT Procurement of all commissioning spares shall be by the Contractor.

5.3

DELIVERY TO SITE AND LOGISTICS AT SITE Transport and logistics to and at site, including warehousing, maintenance and issue to Contractor's commissioning team of commissioning spares, are the responsibility of the Contractor. The Contractor shall prepare and submit for approval of SIDPEC specific procedures for the control, packing, unpacking and handover to SIDPEC of any surplus commissioning spares.

5.4

SURPLUS Any surplus commissioning spares shall become the property of SIDPEC. Contractor shall, at the jobsite closure, submit a list of such surplus to SIDPEC, indicating their quantity and condition.

6.

CAPITAL SPARES

6.1

IDENTIFICATION OF REQUIREMENTS Capital spares shall be identified and supplied by the Contractor as defined in Attachment 1,


those listed in Attachment 1, "Minimum Requirements for Two (2) Years and Capital Spares" and shall indicate whether or not the part is considered necessary, and if it is, in what quantity. Supplier (Seller) shall submit his definitive list within the period defined in the material requisition for purchase. This list shall be transmitted to SIDPEC for their review and action. 8.

TWO-YEAR SPARES - OPTIONAL

8.1

PROCUREMENT

8.1.1

Purchasing Within thirty (30) days of submission of the Contractor's recommendations, the Client shall provide to Contractor his decision by returning each list reviewed and approved for purchase. Contractor shall then be authorized to place the relevant order for and on behalf of Client. These orders shall be controlled by separate account between Client and Contractor. Each order shall be typed in two (2) originals and be signed by Contractor. One (1) copy and one (1) original shall be transmitted to Client. The original shall be signed by Client for recording and payments and be returned back to Contractor. The other original shall be issued to Seller for his further supply and delivery. A complete list of equipment vendors with their contacts for spare parts shall be supplied to SIDPEC by the Contractor.


8.1.4

Inspection Inspection, if required, shall be performed by the Contractor in accordance with approved inspection procedures. Seller shall issue a certificate that shall guarantee the interchangeability of the spares and that they shall fulfill the same function as the original part. This certificate shall indicate the original part number and manufacturer's name and the corresponding spare part number and manufacturer's name.

8.1.5

Logistics Contractor shall manage the transport operations, including customs clearance operations through a freight-forwarding contract. Transport shall be in accordance with the applicable items of a shipping procedure and shipping instructions. Contractor shall prepare an inventory system, based on SIDPEC’s existing system, which shall be reviewed and approved by the Client. Contractor shall provide a spare parts warehouse based upon the approved inventory system. Immediately upon arrival at site, the Contractor shall unpack and check the contents of the consignment for and on behalf of Client and shall clarify any deficiencies as necessary. A material receiving report shall be issued and spares shall be inventoried, placed in the spare parts warehouse and formally handed over to Client. Client shall countersign the material receiving reports and inventory reports as a final acceptance of the goods. This handover shall be arranged at site in agreement between Contractor and Client or his representative.


ATTACHMENT 1 MINIMUM REQUIREMENTS FOR TWO (2) YEARS AND CAPITAL SPARES

1.

INSTRUMENTATION SPARE PARTS Required Number of Spares

Instrument Type

Spare Part Item

Analyzer

Probes Heated Filter Cool Unit Test Selector Valve Pump Tube Furnace Membrane Filter Flow meter Transmitters Gaskets

5 pieces 1 piece 2 pieces 2 pieces 1 piece 1 piece 1 piece 2 pieces 2 pieces 3 pieces 28 pieces

Differential Pressure (D/P) Transmitter

Complete

5 percent

Pressure Transmitter

Complete

5 percent


2.

Required Number of Spares

Instrument Type

Spare Part Item

Variable Area Meter

Complete

2 per type

Control Valves

Bodies Plugs Stems Seat Ring Stem Packing Grease Diaphragm

0 pieces 18 pieces 18 pieces 18 pieces 180 boxes 10 pieces 9 pieces

Relief Valves

Bodies Bonnet Gasket Body Gasket Disc

0 pieces 8 pieces 8 pieces 8 pieces

On-Off Valves

Bodies Plugs Stems Seat Ring Stem Packing

0 pieces 10 pieces 10 pieces 10 pieces 100 boxes

DCS COMPUTER SPARE PARTS


3.

SPECIAL EQUIPMENT SPARE PARTS DOX Unit (2-PA-101) Required Number of Spares

Description

Spare Part Item

1" Automatic Change-over Valves

Packing Set Actuator Set Seat Plug Set

3 pieces 3 pieces 3 pieces







-----

Solenoid Valves Pressure Gauges

4 pieces 2 pieces

PSA Unit (2-PA-303) Description

Spare Part Item

Control Valve Type 1

Packing Set

Required Number of Spares 3 pieces


Condensate Treatment Unit (2-PA-907) Required Number of Spares

Description

Spare Part Item

Automatic Change-over Valve



Solenoid Valves

Packing Set

2 pieces

Feed Pump

Impeller Bearing Set Gasket Set

1 piece 1 piece 2 pieces

Wastewater Treatment Package (2-PA-906) Required Number of Spares

Description

Spare Part Item

Centrifugal Pumps



Screw Feeders


2 pieces 2 piece4s 5 pieces



Description

Spare Part Item

Air Dampeners



----------------

Pressure Gauges Pressure Switches Solenoid Valves Flow Meters Temperature Elements

20 pieces 10 pieces 10 pieces 10 pieces 10 pieces

Offgas Incinerator Package (2-PA-004) Required Number of Spares

Description

Spare Part Item

Control Valves



Temperature Elements

Packing Set

5 pieces

Solenoid Valves

Packing Set

2 pieces


Description

Spare Part Item

Economizer

Finned Tubes 51 Ø x 4 mm WT Valves bore 15 mm Valves bore 25 mm Valves bore 40 mm

Forced Draft Fan

Required Number of Spares 10 pieces 4 pieces 4 pieces 4 pieces

Clothing Flexible Joints Gaskets Bearings Shaft Seal Couplings

1 set 1 set 1 set 1 set 2 pieces

Turbine

Sleeve Bearings Ball Thrust Bearing Carbon Rings Oil Baffles

1 set 1 piece 1 set 1 set

Safety Valves

Discs Springs Gaskets

4 pieces 4 pieces 4 sets


Cold Box (2-PA-301)

5.

Connection Size and Rating

Required Number of Gaskets

Required Number of Bolts and Nuts

6" - 150# 8" - 150# 10" - 150# 12" - 150# 14" - 150#

28 20 12 12 8

12 (3/4" Ø) 8 (3/4" Ø) 8 (7/8" Ø) 8 (7/8" Ø) 4 (1" Ø)

3" - 300# 6" - 300# 8" - 300# 10" - 300#

4 32 28 12

4 (3/4" Ø) 12 (3/4" Ø) 16 (7/8" Ø) 10 (1" Ø)

ROTATING EQUIPMENT SPARE PARTS Pumps Item

Description

Spare Part Item

2-GA-901 A/B/C/D

SHP Boiler Feedwater Pump

Coupling Mechanical Seal,

Required Number of Spares 1 piece


Centrifugal Compressors Applicable Notes


Item

Description

Spare Part Item

2-GB-201 (See Note 5)

Charge Gas Compressor

Shaft Seals Shaft Sleeve Radial Bearings Thrust Bearings Thrust Collars Couplings Oil Filter Element Instrument Parts Labyrinths Accumulator Bladder Gasket and O-rings Oil Pump Timing Gearing Oil Cooler Bundle Flushing Nozzles

2, 4 2, 4 2, 4 2, 4 2, 4

1

2 pieces 1 piece 2 pieces 1 piece 1 piece 1 piece 10 pieces 1 piece 2 pieces 1 piece 2 pieces 1 piece 1 piece 1 piece 1 piece

Shaft Seals Shaft Sleeve

2 2

2 pieces 1 piece

2-GB-501 (See Note 5)

Propane Refrigerant

3 2 2 2


Item

Description

2-PA-302 (See Note 6)

Notes:

Offgas Expander / Recompressor

Spare Part Item

Applicable Notes


Gasket and O-rings Oil Pump Timing Gear Oil Cooler Bundle

2

2 pieces 1 piece 1 piece 1 piece

Shaft Seals Shaft Sleeve Radial Bearings Thrust Bearings Thrust Collars Oil Filter Element Instrument Parts Labyrinths Accumulator Bladder Gasket and O-rings Oil Pump Oil Cooler Bundle

2 2 2 2 2, 4 3 2 2

3 pieces 1 piece 4 pieces 1 piece 1 piece 12 pieces 1 pieces 3 pieces 3 pieces 6 pieces 1 piece 1 piece

2

1.

One (1) set for boiler feedwater supply to each individual compressor in casing.

2.

Number of set(s).


Steam Turbines Item

Description

Spare Part Item

2-GG-901 A/B

Steam Turbine for Diaphragms 2-GA-901 A/B Nozzles Packing / labyrinth Glands Radial Bearings Thrust Bearings Pads Governor Oil Pump Oil Filter Elements Oil Cooler Bundle Gaskets Trip and Throttle Valve Parts Accumulator Bladder Instrument Parts Couplings

Applicable Notes


9

1 piece

9 9

1 piece 2 pieces

9

2 pieces 1 piece

10 9 9

9

1 piece 1 piece 1 piece 1 piece 3 pieces 1 piece 1 piece

1 piece


Item

Description

Spare Part Item

2-GG-601

Steam Turbine for 2-GB-501

Diaphragms Nozzles Packing/Labyrinth Glands Radial Bearings Thrust Bearings Thrust Bearings Pads Governor Oil Pump Oil Filter Elements Oil Cooler Bundle Gaskets Trip and Throttle

Applicable Notes


9 9 9

1 piece 1 piece 2 pieces

9 9 9

2 pieces 1 piece 1 piece

10 9 9

1 piece 1 piece 10 pieces 1 piece 3 pieces 1 piece


Condensers Item

Description

Spare Part Item

Applicabl e Notes

2-EA-206 X

Surface Condenser, Part of 2-GB-201

Bolts Gaskets Packing Material

13 12, 14 12

15 pieces 2 pieces 1 piece

2-EA-503 X

Surface Condenser, Part of 2-GB-501

Packing Material Bolts Gaskets

12 13 11, 14

1 piece 15 pieces 2 pieces

Notes:

12.

Number of sets per condenser

13.

Percentage of total per condenser

14.

Spare parts for condenser relief valves: Bonnet gasket Body gasket Valve disc

One (1) for each valve size.



CAPITAL SPARES The following capital spares shall be furnished: •

One (1) complete rotor assembly with bearings for steam turbine 2-GG-201

•


•


•


•


•

•

•

•

•

•

One (1) complete rotor assembly with bearings and dry gas seal for each casing of compressor 2-GB-201 One (1) complete rotor assembly with bearings and dry gas seal for compressor 2-GB-501 One (1) complete rotor assembly with bearings and dry gas seal for compressor 2-GB-601 One (1) complete rotor assembly for compressor 2-GB-110 One (1) complete centerpiece assembly with bearings for expander-compressor 2-GB-301/2-GG-301 One (1) complete rotor assembly with bearings for pump 2-GA-901


ATTACHMENT 2 SPARE PARTS LISTINGS AND INSTRUCTIONS FOR FILLING IN SPARE PARTS LISTS

INDEX

1.

GENERAL

2.

INSTRUCTION FOR FILLING OUT SPARE PARTS LISTS

3.

CONDITIONS FOR EXECUTION OF ORDER

4.

SPARE PARTS LIST ATTACHMENT: FORMAT FOR LISTING OF SPARE PARTS.


1.

GENERAL

1.1

In accordance with general purchase conditions, Seller (Supplier) shall send "Spare Parts List" plus four (4) copies, duly filled out, listing the spare parts recommended for two (2) years of normal operation of the principal supplies as well as accessories and/or instruments. The said "Spare Parts List" shall be prepared in English according to the following clarifications and instructions.

1.2

The list shall be typed to give clear presentation for ease of photocopying, reproduction, amendment, revision, etc.

1.3

Seller shall use the " Spare Parts List " to confirm his offer, the same list shall be used by Contractor to both analyze Seller's offer and, after it has been approved by Client, to place the spare parts order, on behalf and for account of Client.

1.4

Each list or set of lists must have attached the spare parts drawing(s). It can be either a cross section or an exploded view but must clearly show the location and identification of each part. If the descriptions and part numbers or other coding for the spare parts are shown on separate bills of materials, then all such bills of material relating to each spare parts, drawing must be included with the spare parts drawings. All the spare parts recorded on the " Spare Parts List " must be covered by a drawing (and bill of material if separate from the drawings) attached with the list.

1.5

If Seller is supplying a number of items, or equipment, or material, not necessarily identical, that can be serviced by the same spare part then such interchangeability must be fully taken into account when arriving at the total of such parts installed in various places within the whole installation, process plant, offsites, etc. The prime objective is to avoid overstocking and to have


2.5

PART REFERENCE It shows the reference number of spare parts, which shall be given by the Seller and the quality of the material of spare part.

2.6

WEIGHT It shows the weight of the spare part.

2.7

QUANTITY ON INSTALLED EQUIPMENT It shows the total number of same parts assembled on all the required equipment and/or instruments and/or accessories. For similar units multiply the number of units by the number of same part installed on each unit.

2.8

QUANTITY RECOMMENDED BY MANUFACTURER Seller shall recommend those parts he deems necessary to store, on the basis of his own experience and of the following criteria: a.

Wear, corrosion and erosion, during normal operation.

b.

Parts which may be damaged during maintenance of the supplied equipment and/or instruments and/or accessories.

c.

Critical parts both for origin and/or long delivery times.

d.

Interchangeability of parts.

e.

If for any reason, Seller does not recommend a spare part, then he shall indicate this by a


2.16

DESIGNATION It shows the designation of the main equipment.

2.17

VENDOR/TYPE It shows the manufacturer of the spare part.

2.18

REQUISITION It shows the requisition number of the main equipment.

2.19

EQUIPMENT PURCHASE ORDER NUMBER It shows the purchase order number of the main equipment.

3.

CONDITIONS FOR EXECUTION OF ORDER FOR SPARE PARTS

3.1

A separate order, related to the main equipment, shall be issued by Contractor. This order for spare parts shall be governed by the general and particular purchase conditions applicable for the main equipment order.

3.2

MATERIALS The spare parts procured shall be of the same type as those on the relevant equipment and/or instruments and/or accessories. Any deviation shall only be accepted with Contractor's written permission providing that the function and the interchangeability of the replacement components is guaranteed by Seller.


−

•

3.5

Supply of technical documentation as listed in subsection 3.5 hereafter.

Based on the particular purchase conditions for main equipment.

TECHNICAL DOCUMENTATION At the time of the delivery of the spare parts Seller shall supply one (1) reproducible and three (3) copies of the following documents:

3.6

•

Certificate of interchangeability

•

Certificate of conformity.

•

Material certificate showing the results of mechanical tests and chemical analysis.

•

Certificates of acceptance.

•

Tests reports.

•

Drawings (cross sections, exploded views, etc.)

•

Maintenance instructions.

•

Fitting-up instructions.

SHIPPING DOCUMENTS At the time of delivery of the spare parts Seller shall supply: •

Packing list.


•

•

The protection of the spare parts from any and all risks such as corrosion, sand storm, humidity, etc. The mechanical holding of the spare parts and their perfect performance without affecting the performances guaranteed for the main equipment during twelve (12) months after their installation.

Any spare parts found defective within this period shall be replaced or repaired at Seller's costs. In such a case the guarantee period shall again be of twelve (12) months from the date of repair or replacement of said spare parts. 3.9.3

Guarantee of Interchangeability Seller guarantees the conformity of the spare parts with the initial parts: Both shall be of the same quality and dimensions. In addition, Seller undertakes to be in a position to supply on Client's request identical spare parts during ten (10) years after the expiry of the guarantee period.

3.10

PACKING LIST

3.10.1 The packing list shall provide the following information •

Name of Seller,

•

Spare part purchase order number

•

Description of parts included

•

Item number

LIST OF SPARE PARTS

Rev.

Two Year Operation

Date

LIST FOR:

EQUIPMENT NO: DESIGNATION:

VENDOR

VENDOR/TYPE: REQUISITION: EQUIPMENT PO NO:

ITEM NO.

DRAWING NO.

REF. ON DRAW

DESIGNATION

CLIENT'S PART REF. CODE

W EI GHT

QUANTITY ON VENDOR'S INSTALLED RECOMM. EQUIPMENT

QUANTITIES CLIENT'S STOCK QUANTITY

CODE NUMBER

RECOMMENDED BY CONTRACTOR

CLI ENT

QUANTITIES ORDERED

UNIT PRICES

TOTAL PRICES

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