50%(2)Il 50% ha trovato utile questo documento (2 voti)
1K visualizzazioni27 pagine
This document outlines ABB Lummus Global Inc.'s spares philosophy and spare parts list for the 460,000 MTA ethylene plant no. 2 project in El Ameriya, Alexandria, Egypt. It defines commissioning spares, capital spares, and two-year operational spares. Commissioning and capital spares will be procured and managed by the contractor, while two-year spares lists and pricing will be obtained from suppliers and provided to the client for review and procurement. The document also specifies procedures for spare parts identification, procurement, delivery, storage, and handling surplus parts.
This document outlines ABB Lummus Global Inc.'s spares philosophy and spare parts list for the 460,000 MTA ethylene plant no. 2 project in El Ameriya, Alexandria, Egypt. It defines commissioning spares, capital spares, and two-year operational spares. Commissioning and capital spares will be procured and managed by the contractor, while two-year spares lists and pricing will be obtained from suppliers and provided to the client for review and procurement. The document also specifies procedures for spare parts identification, procurement, delivery, storage, and handling surplus parts.
This document outlines ABB Lummus Global Inc.'s spares philosophy and spare parts list for the 460,000 MTA ethylene plant no. 2 project in El Ameriya, Alexandria, Egypt. It defines commissioning spares, capital spares, and two-year operational spares. Commissioning and capital spares will be procured and managed by the contractor, while two-year spares lists and pricing will be obtained from suppliers and provided to the client for review and procurement. The document also specifies procedures for spare parts identification, procurement, delivery, storage, and handling surplus parts.
This document is the property of ABB Lummus Global, including all patented and patentable features and/or confidential information and its use is conditioned upon the user's agreement not to reproduce the document, in whole or in part, nor the material described thereon, nor to use the document for any purpose other than as specifically permitted in writing by ABB Lummus Global.
2 Apr. 10, 2006 Approved For Design Incorporates Client Comments and Additional Requirements KDB DWG 1 Mar 16, 2006 Approved For Design 4 & 5 KDB DWG 0 Mar 9, 2006 For Approval KDB REV NO
DATE REVISION DESCRIPTION PAGES REVISED WRITTEN BY
APPROVED BY ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 2 of 27 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 6.1 IDENTIFICATION OF REQUIREMENTS 5 6.2 PROCUREMENT 5 6.3 DELIVERY TO SITE AND LOGISTICS AT SITE 5 7. TWO-YEARS SPARES 5 7.1 IDENTIFICATION OF REQUIREMENTS 5 8. TWO-YEAR SPARES - OPTIONAL 6 8.1 PROCUREMENT 6 8.2 SPARE PARTS IDENTIFICATION NUMBERING 7 9. ATTACHMENT 1 - MINIMUM REQUIREMENTS FOR TWO (2) YEARS AND CAPITAL SPARES 7 10. ATTACHMENT 2 - SPARE PARTS LISTING & INSTRUCTIONS FOR FILLING IN SPARE PARTS LISTS. 7
ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 3 of 27 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 complete replacement items that would result in extended shutdowns or adversely effect the performance of the plant. Capital spares also include such critical spares where long-lead time is required for purchase/replacement. Two-year operational spares as required by the Client to satisfy day-to-day maintenance for a period of two (2) years from Plant Acceptance. 3.2 OTHER DEFINITIONS Client: Sidi Kerir Petrochemicals Company (SIDPEC) Contractor: The turnkey Contractor for the SIDPEC 460,000 MTA Ethylene Plant No. 2 4.0 SCOPE OF SUPPLY 4.1 COMMISSIONING 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 commissioning spares for the realization of the project. ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 4 of 27 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 The Contractor shall provide a separate quotation for a program of services to be provided beyond those included in the Lump Sum Contract. These separate services shall include the following: After receipt of suppliers spare parts quotations, consult with SIDPEC to reach agreements on the final requirements for two-year spares. After consultation and agreement, the Contractor shall place purchase orders for the agreed upon spare parts and expedite their delivery in time for startup activities. Set up a spare parts inventory system based on SIDPECs existing system. Provide a spare parts storage building to house all spare parts. Receive and inventory all spare parts for the project. 5.0 COMMISSIONING SPARES 5.1 IDENTIFICATION OF REQUIREMENTS Commissioning spares shall be identified and supplied by the Contractor as defined above, based on Supplier's (Seller's) recommended list. A listing of all commissioning spares recommended by the Supplier shall be submitted to SIDPEC for information before Contractor approval and purchase. If there is any deviation from Supplier (Seller) recommendation as agreed between Supplier and Contractor, SIDPEC reserves the right to discuss these deviations. ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 5 of 27 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, "Minimum Requirements for Two (2) Years and Capital Spares". Any additional capital spares recommended by the Supplier shall be submitted to SIDPEC for information before Contractor approval and purchase. If there is any deviation from Supplier (Seller) recommendation as agreed between Supplier and Contractor, SIDPEC reserves the right to discuss these deviations. 6.2 PROCUREMENT Procurement of all capital spares shall be by the Contractor. 6.3 DELIVERY TO SITE AND LOGISTICS AT SITE Transport and logistics to and at site, including warehousing, maintenance and issue to the Client of capital 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 capital spares. 7. TWO-YEARS SPARES 7.1 IDENTIFICATION OF REQUIREMENTS Supplier (Seller) shall define, prior to purchase order placement, on the form "List of Spare Parts" (Attachment 2), his recommendations in quality and quantity for any spares including ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 6 of 27 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. 8.1.2 Packing and Marking Spare parts shall be packed separately from any other items. External packing shall be in wooden boxes or cardboard boxes, depending on the size and weight of the consignment. Each small part shall be individually packed in plastic sealed bag and identified on the bag with a label indicating, as applicable, the: Purchase order number. Item number Seller's part number and description. The main equipment tag number. All the small similar parts of a single purchase order item shall be consolidated in a plastic sealed bag with the same identification as above. Larger parts shall be protected and individually packed and sealed by Seller in order to provide effective protection for one (1) year against moisture. Use of desiccant bags is necessary with moisture indicator for regeneration. External marking shall be in accordance with approved procedures. The Contractor shall submit for approval by the Client detailed procedures. 8.1.3 Expediting Expediting shall be performed by the Contractor in accordance with approved expediting procedures. ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 7 of 27 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 SIDPECs 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. Any shortages or discrepancies identified before handover shall be documented and resolved by the Contractor. Any technical documentation related to such spares shall be handled in the same way. Suppliers (Sellers) and the Contractor shall systematically segregate the two-year spare parts from the commissioning spare parts and the capital spares, as well as all the technical and shipping documentation and invoices. 8.2 SPARE PARTS IDENTIFICATION NUMBERING Contractor shall provide, for Client approval, a spare parts identification numbering system as applicable. 9. ATTACHMENT 1 - MINIMUM REQUIREMENTS FOR TWO (2) YEARS AND CAPITAL SPARES See attached 10. ATTACHMENT 2 - SPARE PARTS LISTING & INSTRUCTIONS FOR FILLING IN SPARE PARTS LISTS. See attached. ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 8 of 27 ATTACHMENT 1 MINIMUM REQUIREMENTS FOR TWO (2) YEARS AND CAPITAL SPARES
1. INSTRUMENTATION SPARE PARTS Instrument Type Spare Part Item Required Number of Spares Analyzer Probes 5 pieces Heated Filter 1 piece Cool Unit 2 pieces Test Selector 2 pieces Valve 1 piece Pump 1 piece Tube Furnace 1 piece Membrane Filter 2 pieces Flow meter 2 pieces Transmitters 3 pieces Gaskets 28 pieces Differential Pressure (D/P) Transmitter Complete 5 percent Pressure Transmitter Complete 5 percent Level Gauge Complete 5 percent Motor-operated Valve (MOV) Actuator 3 pieces Orifice Plates Blank 1 per type Restriction Orifice Blank 1 per type Pressure Gauge Complete 5 percent Differential Pressure (D/P) Gauge Complete 1 piece Pressure regulator Complete 6 pieces Resistance Temperature Detector (RTD) element Assembly 5 percent Resistance Temperature Detector (RTD) transmitter Head 5 percent Solenoid Operated Valve (SOV) Complete 5 percent Proximity switch Assembly 10 percent Temperature gauge Complete 5 percent Thermowell Complete 5 percent ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 9 of 27 Instrument Type Spare Part Item Required Number of Spares Variable Area Meter Complete 2 per type Control Valves Bodies 0 pieces Plugs 18 pieces Stems 18 pieces Seat Ring 18 pieces Stem Packing 180 boxes Grease 10 pieces Diaphragm 9 pieces Relief Valves Bodies 0 pieces Bonnet Gasket 8 pieces Body Gasket 8 pieces Disc 8 pieces On-Off Valves Bodies 0 pieces Plugs 10 pieces Stems 10 pieces Seat Ring 10 pieces Stem Packing 100 boxes
2. DCS COMPUTER SPARE PARTS Item Description Required Number of Spares 16 Channel Input Modules 7 modules 8 Channel Output Modules 5 modules 32 Channel Input Modules 1 module 16 Channel Output Modules 1 module Controller 2 Power Supplies 2 Communication Cards 2 Termination Assemblies 2 of each type
Spare parts requirements for PLCs are not estimated since the type of PLCs to be used are not known. ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 10 of 27 3. SPECIAL EQUIPMENT SPARE PARTS DOX Unit (2-PA-101) Description Spare Part Item Required Number of Spares 1" Automatic Change-over Packing Set 3 pieces Valves Actuator Set 3 pieces Seat Plug Set 3 pieces 4" Automatic Change-over Packing Set 3 pieces Valves Actuator Set 3 pieces Seat Plug Set 3 pieces 6" Automatic Change-over Packing Set 3 pieces Valves Actuator Set 3 pieces Seat Plug Set 3 pieces --- Solenoid Valves 4 pieces --- Pressure Gauges 2 pieces PSA Unit (2-PA-303) Description Spare Part Item Required Number of Spares Control Valve Type 1 Packing Set 3 pieces Actuator Set 3 pieces Seat Plug Set 3 pieces Control Valve Type 2 Packing Set 1 piece Actuator Set 1 piece Seat Plug Set 1 piece Control Valve Type 3 Packing Set 1 piece Actuator Set 1 piece Seat Plug Set 1 piece --- Solenoid Valves 4 pieces --- Pressure Gauges 2 pieces Condensate Polisher Unit (2-PA-902) Description Spare Part Item Required Number of Spares Automatic Change-over Packing Set 3 pieces Valve Actuator Set 3 pieces Seat Plug Set 3 pieces Solenoid Valves Packing Set 2 pieces Feed Pump Impeller 1 piece Bearing Set 1 piece Gasket Set 2 pieces ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 11 of 27 Condensate Treatment Unit (2-PA-907) Description Spare Part Item Required Number of Spares Automatic Change-over Packing Set 3 pieces Valve Actuator Set 3 pieces Seat Plug Set 3 pieces Solenoid Valves Packing Set 2 pieces Feed Pump Impeller 1 piece Bearing Set 1 piece Gasket Set 2 pieces Wastewater Treatment Package (2-PA-906) Description Spare Part Item Required Number of Spares Centrifugal Pumps Impeller 10 pieces Bearing Set 10 pieces Gasket Set 15 pieces Screw Feeders Impeller 2 pieces Bearing Set 2 piece4s Gasket Set 5 pieces Submerged Pumps Impeller 4 pieces Bearing Set 4 pieces Gasket Set 10 pieces Chain Sludge Removers Bearing Set 2 pieces Gasket Set 5 pieces
Chemical Dosing Pumps Check Valve Set 10 pieces Membrane Sets 5 pieces Motor Bearing Sets 5 pieces Incinerator Start-up Burners 4 pieces Main Burners 4 pieces On/Off Valves Packing Set 8 pieces Actuator Set 8 pieces Seat Plug Set 8 pieces Control Valves Packing Set 10 pieces Actuator Set 10 pieces Seat Plug Set 10 pieces Fuel Gas Valves Packing Set 4 pieces Actuator Set 4 pieces Seat Plug Set 4 pieces ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 12 of 27 Description Spare Part Item Required Number of Spares Air Dampeners Packing Set 6 pieces Actuator Set 6 pieces Seat Plug Set 6 pieces ---- Pressure Gauges 20 pieces ---- Pressure Switches 10 pieces ---- Solenoid Valves 10 pieces ---- Flow Meters 10 pieces ---- Temperature Elements 10 pieces Offgas Incinerator Package (2-PA-004) Description Spare Part Item Required Number of Spares Control Valves Packing Set 3 pieces Actuator Set 3 pieces Seat Plug Set 3 pieces Temperature Elements Packing Set 5 pieces Solenoid Valves Packing Set 2 pieces
4. STATIC EQUIPMENT SPARE PARTS SRT Cracking Heater (2-BA-101 thru 107) Description Spare Part Item Required Number of Spares --- Sidewall Burners 3 pieces --- Hearth Burners 1 piece --- Convection Coil Materials 2% --- Thermowells 5 pieces --- Cast Peep Doors 6 pieces HP Steam Boilers (2-PA-904/905) Description Spare Part Item Required Number of Spares Evaporator Bare Tube 63.5 x 10 pieces 4.5 mm WT Bare Tubes 3 pieces Solenoid Valves Packing Set 51.0 x 10 pieces 3.6 mm WT Superheater Bare Tubes 44.5 x 10 pieces 4.5 mm WT ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 13 of 27 Description Spare Part Item Required Number of Spares Economizer Finned Tubes 51 x 10 pieces 4 mm WT Valves bore 15 mm 4 pieces Valves bore 25 mm 4 pieces Valves bore 40 mm 4 pieces Forced Draft Fan Clothing Flexible 1 set Joints Gaskets 1 set Bearings 1 set Shaft Seal 1 set Couplings 2 pieces Turbine Sleeve Bearings 1 set Ball Thrust Bearing 1 piece Carbon Rings 1 set Oil Baffles 1 set Safety Valves Discs 4 pieces Springs 4 pieces Gaskets 4 sets
Burners Sprayer Plates 8 pieces Y-jet Oil Gun 2 pieces Ignition Burner 2 pieces Flexible Hose 4 pieces Boiler Water Level Gauge Glasses 4 pieces Water Level Gauge Gaskets 4 pieces Metaflex Manhole Gaskets 4 pieces Quench Tower (2-DA-101) Description Spare Part Item Required Number of Spares --- Packing Material 10 m 3
ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 14 of 27 Cold Box (2-PA-301) Connection Size and Rating Required Number of Gaskets Required Number of Bolts and Nuts 6" - 150# 28 12 (3/4" ) 8" - 150# 20 8 (3/4" ) 10" - 150# 12 8 (7/8" ) 12" - 150# 12 8 (7/8" ) 14" - 150# 8 4 (1" )
3" - 300# 4 4 (3/4" ) 6" - 300# 32 12 (3/4" ) 8" - 300# 28 16 (7/8" ) 10" - 300# 12 10 (1" ) 5. ROTATING EQUIPMENT SPARE PARTS Pumps Item Description Spare Part Item Required Number of Spares 2-GA-901 A/B/C/D SHP Boiler Coupling 1 piece Feedwater Pump Mechanical Seal, Metallic and Carbon Face and Springs
4 pieces Gasket Sets, Packing or Mechanical Seal Nonmetallic Faces, O- Rings
4 pieces Shaft Sleeve, Bearing Set, Impeller and Case Wearing Rings, Throat Bushing, Throttle Bushing
1 piece First State Impeller and Shaft 1 piece Series Impeller 4 pieces
Revision 2 (04/10/06) Page 16 of 27 Item Description Spare Part Item Applicable Notes Required Number of Spares Gasket and O-rings 2 2 pieces Oil Pump 1 piece Timing Gear 1 piece Oil Cooler Bundle 1 piece
2-PA-302 Offgas Shaft Seals 2 3 pieces (See Note 6) Expander / Shaft Sleeve 2 1 piece Recompressor Radial Bearings 2 4 pieces Thrust Bearings 2 1 piece Thrust Collars 2, 4 1 piece Oil Filter Element 3 12 pieces Instrument Parts 2 1 pieces Labyrinths 2 3 pieces Accumulator Bladder 3 pieces Gasket and O-rings 2 6 pieces Oil Pump 1 piece Oil Cooler Bundle 1 piece Notes: 1. One (1) set for boiler feedwater supply to each individual compressor in casing. 2. Number of set(s). 3. Reduce by three (3) in case of washable elements. 4. For each individual compressor casing. 5. Spare parts for driver, see below 6. Indicated spare parts are based on three (3) machines. 7. Each type. ABB Lummus Global Inc.
Revision 2 (04/10/06) Page 18 of 27 Item Description Spare Part Item Applicable Notes Required Number of Spares
2-GG-601 Steam Turbine Diaphragms 9 1 piece for 2-GB-501 Nozzles 9 1 piece Packing/Labyrinth Glands 9 2 pieces Radial Bearings 9 2 pieces Thrust Bearings 9 1 piece Thrust Bearings Pads 9 1 piece Governor 1 piece Oil Pump 1 piece Oil Filter Elements 10 10 pieces Oil Cooler Bundle 1 piece Gaskets 9 3 pieces Trip and Throttle Valve Parts 9 1 piece Accumulator Bladder 1 piece Instrument Parts 9 1 piece Couplings 1 piece Notes: 8. One (1) each size 9. Number of set(s). 10. Reduce by three (3) in case of washable elements. 11. Spare arts for condenser, including condenser safety valve, see below.
ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 19 of 27 Condensers Item Description Spare Part Item Applicabl e Notes Required Number of Spares 2-EA-206 X Surface Condenser, Bolts 13 15 pieces Part of 2-GB-201 Gaskets 12, 14 2 pieces Packing Material 12 1 piece
2-EA-503 X Surface Condenser, Packing Material 12 1 piece Part of 2-GB-501 Bolts 13 15 pieces Gaskets 11, 14 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 One (1) for each valve size. Valve disc ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 20 of 27 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 for steam turbine 2-GG-501 One (1) complete rotor assembly with bearings for steam turbine 2-GG-601 One (1) complete rotor assembly with bearings for steam turbine 2-GG-901 One (1) complete rotor assembly with bearings for steam turbine 2-GG-902 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 One (1) complete rotor assembly with bearings for pump 2-GA-902 One (1) set of couplings for each compressor/driver One (1) complete set of mechanical (gas) seal cartridges for each compressor casing Two (2) complete sets of coils for SRT Cracking Heaters 20% set of complete wall burners for one SRT Cracking Heater 20% set of complete hearth burners for one SRT Cracking Heater ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 21 of 27 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.
ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 22 of 27 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 spares not needlessly duplicated but without unduly increasing the risk of a shortage within the two-year operation covered by the order. 1.6 Each Seller must fully analyze his scope of supply under main purchase order taking into consideration all parts of his supply, including instruments, oil filters, cooler, etc. 2. INSTRUCTIONS FOR FILLING OUT SPARE PARTS LISTS 2.1 ITEM It shows the tag number of the required equipment and/or instruments and/or accessories. 2.2 DRAWING NUMBER It shows the cross section drawing number of the equipment and/or instruments and/or accessories, with reference to the position of the various parts composing the equipment and/or instruments and/or accessories. 2.3 REFERENCE ON DRAWING It shows the position number of the part indicated on such a cross section drawing. 2.4 DESIGNATION It shows the description and designation of all the parts, which shall be given by the Seller and the quality of the material of spare part.
ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 23 of 27 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 zero (0) in the "recommended quantity" column under Seller's proposal but he must give the unit price and delivery time. 2.9 CLIENT STOCK Not to be filled out by Seller. 2.10 CONTRACTOR PROPOSAL Not to be filled out by Seller 2.11 QUANTITIES ORDERED Not to be filled out by Seller. 2.12 UNIT PRICES Quote unit prices for each spare part. 2.13 TOTAL PRICES Not to be filled out by Seller. 2.14 DELIVERY TIME It shows delivery time of spare parts. 2.15 EQUIPMENT NUMBER It shows the equipment number of the main equipment.
ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 24 of 27 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. 3.3 INSPECTION AND TESTING All inspections and tests shall conform to the conditions laid down in the general conditions attached to the purchase order for the main equipment. 3.4 PRICES The prices shall be: Quoted in currency of the country of origin. Firm and not subject to escalation and valid for six (6) months. Free of tax for import in Egypt and VAT provided that the spare parts are imported in the name of Client. Inclusive of: Any required protective device to ensure efficient protection from rust, humidity, sand, shocks, or any other risks. Inland transportation packing. Markings as required. Transport and insurance up to contractual delivery point Free Carriage to Works (FCA Works). All required spare parts for two (2) years normal operation, including running-in and starting-up period. ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 25 of 27 Supply of technical documentation as listed in subsection 3.5 hereafter. Based on the particular purchase conditions for main equipment. 3.5 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: 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. 3.6 SHIPPING DOCUMENTS At the time of delivery of the spare parts Seller shall supply: Packing list. Certificate of origin or attestation of EEC origin. Commercial invoice (quantities of copies to be specified). 3.7 PAYMENT CONDITIONS To be agreed. 3.8 PENALTIES In case of delay in delivery Seller shall pay the penalties as per the provisions of the main equipment order. 3.9 GUARANTEES 3.9.1 General The spare parts shall be adequately protected prior to release from Seller's works. The spare parts can be stored under normal conditions for a period of two (2) years or more and their preservation shall therefore be guaranteed during the same period as the guarantee period of the main equipment. Seller shall be entirely responsible for the proper protection of the spare parts from corrosion and/or degrading of materials.
3.9.2 Period of Mechanical Guarantee Seller guarantees: ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
Revision 2 (04/10/06) Page 26 of 27 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 Quantity per item Any other details regarding actual contents of a given box/package/bundle. 3.10.2 In addition to the packing list required in paragraph 3.10.1 above, the following copies shall be provided: One (1) copy of the packing list to be enclosed in each box/package/bundle. Two (2) copies of the packing list to be affixed to the outside of each box/package/ bundle in a waterproof envelope. A master packing list that summarizes the total shipment must be similarly included with the Number 1 box/package/bundle of a multiple packages shipment. 3.11 PACKING MARKING Packing and marking shall comply with the instructions given in the general conditions attached to the main purchase order(s).
LIST OF SPARE PARTS Rev. Two Year Operation Date LIST FOR: EQUIPMENT NO: DESIGNATION: VENDOR VENDOR/TYPE: REQUISITION: EQUIPMENT PO NO: QUANTITIES RECOMMENDED BY QUANTITY CODE NUMBER CONTRACTOR CLIENT REMARKS: DATE & CLIENT'S SIGNATURE: SPARE PART PO NO: TOTAL PAGE: AGGREGATE AMOUNT: DATE: VENDOR'S RECOMM. QUANTITIES ORDERED UNIT PRICES TOTAL PRICES CLIENT'S STOCK ITEM NO. DRAWING NO. REF. ON DRAW DESIGNATION CLIENT'S CODE PART REF. WEIGHT QUANTITY ON INSTALLED EQUIPMENT