Mandatory Spares Part List

Transcription

1 < Mandatory Spares Part List FOR HINDUSTAN PETROLEUM CORPORATION LTD. VISAKH REFINERY DHT Project JOB NO. : 6261 TOYO ENGINEERING INDIA LIMITED MUMBAI INDIA

2 < Security Level 2 > DOC.No. DHT Project Sheet 2 of 34 TABLE OF CONTENTS Sl. No. Title 1. Static Equipment 2. Piping 3. Instrumentation 4. Civil 5 Rotary Equipment 6 Package Equipments 8 Heaters 9 Electrical 11 Fire Fighting 12 Tools and Tackles

3 DOC.No. DHT Project Sheet 3 of Static Equipment: 1.1. Reactors, Columns, Pressure Vessels Sr No Part Description Quantity Required Bolting for each nozzle with blind / companion Flange and for each pad nozzle Gaskets for each nozzle with blind / Companion flange for each pad nozzle Bolting for internal flanges of each size / type Gasket for each internal flange of each size / type Sight / light glasses assembly complete with bolting and gasket Bolts, nuts, clamps, spares for demister of each size / type 10% (minimum two in each size) of installed fastners. Two sets for each installed gasket. One set of each size of each nozzle Two sets for each installed gaskets 4 sets for each installed glass 10% (minimum two in each size) of installed fasteners Tubular Exchangers Sr No Part Description Quantity Required 1 Gaskets 400% 2 Bolting 20% (Min 4 studs and 8 nuts per joint) 3 Lamiflex sealing strips 100%

4 DOC.No. DHT Project Sheet 4 of Air Coolers Sr No Part Description Quantity Required 1 Gasket for header cover and nozzles with blind flange 400% 2 Gaskets for plugs 200% 3 Plugs 20% 4 Belts 100% Bolts and nuts for all nozzle with BF & Cover plate Diaphragm Actuator with positioner for each type of auto variable pitch fan (for Moore fan) (Alternatively vendor recommended spares for his type of auto variable pitch fans for make other than Moore) Blade for each size / type of fan 20% One set One set (one set is total number of blades in one fan) 8 Set of pulleys (fan & motor ) a. 1 set for each type of fan / motor set not exceeding two in number. b. 2 Sets for each type of fan / motor set numbering three and more. 9 Fan clevis bolts a. 4 for each type of fan upto and including two in number b. 8 for each type of fan exceeding two in numbers but

5 DOC.No. DHT Project Sheet 5 of 34 upto and including six in number c. 12 for fans above six in number Fan Bearing set (top + bottom = 1 set) a. 2 for fans uptp including two in number 10 b. 3 for fans exceeding two in numbers but upto and including six in numbers. c. 5 for fans above six in numbers. Motor Bearings a. 2 for quantity upto including two in number 11 b. 3 for fans exceeding two in numbers but upto and including six in numbers. c. 5 for fans above six in numbers Tray and Tower Internals Sr No Part Description Quantity Required 1 2 Bolts / Nuts of each size type Clamp assemblies 10% of total for each size (minmum 10 nos of each size / type) 10% of total for each type and size (minimum 10 nos of each size)

6 DOC.No. DHT Project Sheet 6 of 34 3 Valves for trays 10% of each type 4 Gasketing or tapes 100% of each type and size 5 Sealing foils for cartridge trays 200% of each size 6 U-Clamps 10% of each type and size or 10 nos whichever is minimum 7 8 Tower packings Spray Nozzles 10% for metallic and plastic packings 15% for carbon and ceramic packaings. 25% subject to minimum 5nos of each type and size.

7 DOC.No. DHT Project Sheet 7 of Piping: Sr.no. Part Description Size Range * Quantity Required (% of as built) 1 Pipes and Fittings ½ to Pipes and Fittings Above 36 Nil 3 Valve and Flanges 1/2 to Valve and Flanges 10 and above Nil 5 Bolts, Nuts All sizes 10 6 Gaskets All sizes 10 7 Traps All sizes 2 8 Expansion Bellows All sizes Bolt torque wrenches 1 set 10 Bolt tensioning equipment 1 set 11 PMI equipment 1 set Notes: 1. % of quantity required to be left as mandatory spares is for each and every item / size / material consumed in as built including piping used in various vendor supplied packages. i.e all the items created in plant summary shall be individually considered to calculate spares requirement as per the criteria tabulated above. No substitution is allowed. 2. As a minimum one piece (one pipe length) per item shall be supplied. No substitution in size, schedule, rating and material is allowed. 3. No spare quantity is required for process traps and motor operated valves. 4. As a minimum one set of bolt/nuts to be supplied for each material, diameter and length. 5. For rating 900# and above and sizes 10 and above, minimum one valve surplus shall be supplied for each piping class and for each sze, rating, material. 6. For 8 and 900# and above, 2% or minimum 1 whichever is higher to be used.

8 Sr. No. Part Description Quantity Required Mandatory spare shall be quoted and included in base price as follows: Quoted yes/no/not applicable 1 FIELD INSTRUMENTS 1.1 Pressure Gauges 1.2 Draft Gauges 1.3 Temperature gauges Level Gauges SMART Transmitter for Pressure, Flow (DP),Level (DP) and Temperature 20% (Subject to min. of 1) of each type, range, material of construction and rating, whichever is higher 10% (Subject ti minimum of 1) of each range of Draft gauge, whichever is higher 20% ( Subject to min. of 1) of each type / range of Temperature Gauges, whichever is higher. a) For transparent gauges, 20& of illuminators with holder and reflector and 50% of bulbs b) In case of mangnetic type level gauges, 10% of bi-color rollers for each gaugeto be provided in addition to above. c) 30% subject to min one number of glass of each type, size along with pair of Gaskets( Cushion & Wet Gasket), whichever is higher. d) 20% subject to minimum one number of Gaskets for Gauge Cocks/Valves Bonnet/ Packing 10% (subject to min of 1) of each type (Transparent / Magnetic / Reflex), range, make and material of construction, whichever is higher 10% (subject to min of 1) of each type,of Electronics Transmitter card & LCD display, gasket, O-rings etc Instrument Manifold (2 Way, 3 Way & 5 Way) Servo / Float & Tape Type Level Gauges Ultrasonic / Radar Instrument 10% (subject to minimum of 1) each size and material to construction; whichever is higher. a) 10% or minimum one number of each type of electronic card whichever is higher b) 10% or minimum one number of each type of displacer / float whichever is higher c) 10% or min one number of local indicators, whichever is higher a) 1 Pair probe for each flow instrument & 1 probe / antenna for each level instrument b) 1 number electronic card of each type c) 2 number fuses of all types 1.9 Capacitance / RF type instruments 10% or minimum one number of each type of electronic card of each type whichever is higher 1.10 Hydrastep Level Measuring System a) 10% or minimum one number of each type of electronic card whichever is higher 1.11 Temperature Elements 20% (subject to minimum of 1) of each type, range, lengh and make of Thermcouple with Themowell, whichever is higher. Same philosophy to be followed for multi point thermocouples also but without thermowells RTDs 20% (subject to min of 1) of each lengh of RTD with Thermowell, whichever is higher 1.13 Skin Type Thermocouple 10% (subject to minimum of 1) of each lengh & type of skin thermocouple, whichever is higher Ceramic Thermowell 1 no. for each Tag 1.15 Temperature transmitters 10% (subject to min of 1) of each type, range, make and material of construction, whichever is higher Variable Area Flowmeter 20% or minimum one no. float & set of Packing for each type, size, rating (Rotameters) and material, whichever is higher 1.17 Averaging Pitot tube Set of Gasket, O-ring, Packing for Retract Mechanism and one no. Needle Valve with each Pitot Tube a) Power Fuses 6 no. per set 1.18 b) 10% of Sensor Assembly or min 1 Mass Flow Meter (Coriolis and c) 10% or min one number of each type of electronic cards whichever is Thermal) higher Vortex Flow Meter d) 10% or minimum 1 No. of Display module a) One set of gasket and Packing for each type and Size b) 10% or minimum one number of each type of electronic cards whichever is higher 1.20 Turbine Flow Meters a) 10% or minimum one number of each type of electronic cards whichever is higher a) One set of gasket and Packing for each type and Size 1.21 Magnetic Flow Meter b) 10% or minimum one number of each type of electronic cards whichever is higher a) Electrode - 10% or minimum 2 nos 1.22 PH & conductivity transmitter b) PCB -10% or minimum 1 no. c) Power PCB -10% or Minimum 2 nos. d) PH preamplifier card - 10% or minimum 2 nos.

9 Sr. No. Part Description Quantity Required Mandatory spare shall be quoted and included in base price as follows: Quoted yes/no/not applicable 2 IN-LINE INSTRUMENTS 2.1 Control Valves 3 a) 1 No. for qty.upto 5 and 10% or min 2 nos. for qty. above 5 of each type, size rating of Trim set consisting of seat, seat ring / seal ring, plug with stem, cage (whichever applicable), packing material b) 20% (subject to minimum of 1) of Positioners (smart or pneumatic) with links of each type and make, whichever is higher c) 15% (subject to minimum of 1) of Diaphragm, Actuator spring of each type/ range, whichever is higher d) 20% (subject to min of 1 ) of air filter regulators of each make, whichever is higher e) 10% (subject to minimum of 1) of Bonnet gaskets/ gland packings, piston O-rings, bearing & liner (of valve) f) 10% (subject to minimum of 1) of any special accessories provided along with the control valve like boosters position transmitters (whichever applicable), proximity switches, I/P converters etc whichever is higher. a) 10% or minimum 1 no. of electronic card of actuator 2.2 Motor Operated Valves b) 10% or min 2 nos. of each type, size rating of Trim set consisting of seat, seat ring / seal ring, plug with stem, cage (whichever applicable), packing material c) 20% (subject to minimum of 1) of Positioners (smart or pneumatic) with links of each type and make, whichever is higher d) 15% (subject to minimum of 1) of Diaphragm, Actuator spring of each type/ range, whichever is higher e) 20% (subject to min of 1 ) of air filter regulators of each make, whichever is higher f) 10% (subject to minimum of 1) of Bonnet gaskets/ gland packings, piston O-rings, bearing & liner (of valve) g) 10% (subject to minimum of 1) of any special accessories provided along with the control valve like boosters position transmitters (whichever applicable), proximity switches, I/P converters etc whichever is higher. a) 20% (subject to min 1) of air filter regulators, whichever is higher b) Seal kit consisting of O rings, gaskets, etc. against each valve Shutdown valve and ON-OFF vlave Pressure Relief Valves 2.5 Thermal Relief Valves Pressure control Valve (Self Actuating Valve) PRDS & De-superheater unit c) 20% (subject to min of 1) of proximity switches, whichever is higher d) 20% (subject to min of1) of solenoid valves of each types.whichever is higher e) 20% of seal kit consisting of Plunger assembly, Coil, O-ring shall be provided for solenoid valves f) 10%(subject to minimum of 1) of accessories like quick exhaust fuses, whichever is higher Disc - 10% of total quantity of identical pressure relief valves or minimum one number whichever is higher Expansion Bellow - 20% of total quantity of identical pressure relief valves or minimum one number whichever is higher Spring - 10% of total quantity of identical pressure relief valves or minimum one number whichever is higher Gasket set - 10% of total quantity of identical pressure relief valves or minimum one number whichever is higher Pilot - 10% of total quantity of identical pilot pressure relief valves or minimum one number, whichever is higher 10% of total quantity of identical thermal relief valves or minimum one number, whichever is higher a) Repair kit consisting of (orifice, plug, spring, gasket, diaphragm, o-ring for each valve) b) 20% or minimum 2 nos. of each type /size, rating etc.of Trim set consisting of seat, seat ring/seal ring, plug with stem, cage (wherever applicable), packing material for each valve to be provided as spare. Same as those of Control Valves and Shut Down valves and additionally a) Gaskets for actuator per unit b) Gaskets for valve and connections per unit (if such gaskets are special and supplied by PRDS/ De-Superheater vendor) c) Spray nozzle per unit 2.8 Breather Valves 1 Set of seal kit for each valve 2.9 Flame Arresters One no. of flame arrester element and one set Gasket for each Type, Size, Rating and material 2.10 Rupture Disc 3 Nos. of Gaskets & 3 Nos. of spare discs for each Tag 2.11 Orifice Plate, Flanges / Venturi / Flow Nozzle a) 10% or minimum 1 set of gasket and Packing for each type and Size

10 Sr. No. Part Description Quantity Required Mandatory spare shall be quoted and included in base price as follows: Quoted yes/no/not applicable 3 ANALYSER O2 Analyser Methane Analyser (Infrared) Moisture Analyser Hydrogen Analyser H2S Analyser CO+CO2 Analyser Sox/Nox Analyser Chromatograph 3.9 Sampling systems a) Furnace Assembly -1 b) Thermocouple - 1 c) Sensor board - 1 d) Zirconia Oxide Cell -1 e) Each type / rating of Fuses - 1 set f) Thermistor assembly - 1 g) Ceramic filter - 1 h) Processor card - 1 i) Any Other card - 1 a) Rings and gasket - 2 set of each type b) Sensor and Detector - 1 no. c) Rotameter - 1 no. d) Pressure Control Valve - 1 no. e) Fuses - 5 sets f) Electronic card - 1no. g) Other Aux. Cards - 1 each h) Processor card and other electronic 1 no. each. a) Sensor and etector -1 no. b) Electronic card - 1no. Each type c) Fuses - 5 sets d) Flow indicator & switch - 1no. a) Rings and gasket - 2 set of each type b) Sensor and Detector - 1 no. with each analyser c) Rotameter - 1no. d) Pressure Control Valve - 1no. e) Each type/rating of Fuses - 5 sets f) Electronic card - 1no. With each analyser g) Other Aux. Cards - 1 each a) Cadmium lamp - 2 nos. b) Cell window -2 nos. c) Window gasket - 10 nos. d) Air regulator - 1 no. e) Seal kit fro ball valve - 4nos. f) Kit-o-ring - 2 sets g) Seal kit, Air act. - 2 no. h) Fuse - 5 set each i) Realy - 1 set each j) Display Board - 1no. With each analyser k) Processor Board - 2no. l) Other Cards - 2each a) Fuses - 1 set of each type b) Ring - 2 sets of each type c) Mother board - 2nos. d) Filter assembly band pass with guard - 2no. e) Filter - 1 Set of each type f) IR/UV Lamp - 2 nos. g) Other cards - each h) Detector heaters - 1 each a) Filter of each type - 2sets b) Critical orifice - 1 no. c) Vacuum pump / Elector - 1 no. d) Ring set - 1no. Each e) Processor / Mother board - 2nos. f) Display board - 2nos. g) Optical bench - 1no h) Filter detector - 2nos i) Fuses - 1 set of each type j) Other cards - 1 each k) Ozonaotor - 1 l) Cuvette - 2 nos m) Chopper motor - 1no. n) Dessican & flow sensor - 1no each a) Filter - 2sets b) Display Board - 1no c) Processor Board - 1no. d) Chromatograph Column e) Solenoid valve (10% subject to minimum of 1 of each type f) Vaporization system if required, which includes vaporizer, thermostat, electrical tracing cable and heater etc. - 1set. g) Cooling system if required, which includes one cooler, flow conditioning system etc., - 1set h) Probe Filter - 2 nos. i) Probe Tube - 2 nos. j) Probe heater & Temp. sensores - 2 nos. For various instrument types used in sampling systems, spares philosophy shall be as per this document SWAS - Steam & water analyser system 10%(subject to minimum of 1) of all the accessories provided in SWAS

11 Sr. No. Part Description Quantity Required Mandatory spare shall be quoted and included in base price as follows: Quoted yes/no/not applicable DCS, PLC and sub systems as DON, SER, UHN, HMS ETC. A) Modules 4.2 Consumables These spares are in addition to 20 % installed spares 5% or 1 module of each type (processor module, I/O module, communication module, power supply module etc.) being used inclusive of those used in consoles. This shall include spare modules for hardwired instruments also. 10% or minimum 2 nos. of Safety Barriers, Signal Converters, trip amplifiers etc. 20% or minimum one no. of each type of Fuses, MCBs, Auxiliary relays 10%or minimum 2 nos. of communication system components such as hubs, switches, routers, etc. whichever is higher Consumable spares including Laser printer cartridges, Paper or any other consumable items supplied along with the system required for a minimum of 6 months duration after system acceptance. 5 OTHER ITEMS 5.1 Snubber, Syphon, Gauge Saver, etc. 10% (subject to minimum of 1) of each item used, whichever is higher 5.2 Loop powered indicators 20% (subject to minimum of 2) of Loop powered indicators used, whichever is higher 5.3 Solenoid Valves 20% or minimum 2 nos. of solenoid valves of each type used. 5.4 MCT Block 10% of each type of MCT Block used. 5.5 Instrument Valves/Tube Fittings/Pipe Fittings 10% subject to minimum one no. for each type, size whichever is higher 5.6 Panel mounted instruments 10% or minimum one no. Whichever is higher Cooling fans and filters for Cabinets and consoles CCTV Machine Monitoring System Gas detection system 10% of each type used A) Camera Station - 1 no. B) Camera 1 no. C) Lens with zoom -1no. D) Water tank with tube, bracket - 1 no. E) Receiver and drive - 1 no. F) Keypad including joy stick - 1 no. a) 10% or minimum 2 nos. of ech type of probes (vibration, speed, displacement etc.) and transducers / proximator / extension cables / connector protective sleeves etc. b) Electronic modules / cards : 10 % or minimum 1 no. of each type, whichever is higher Sensors : 20 % or minimum 2 sets of each type, whichever is higher Electronic cards PCB: 10 % or minimum of 1 set of each type used, whichever is higher Junction Box & Cable Glands 10% of each type used 5.12 Multiplexers 10% of each type used 5.13 Barriers 10% of each type used 5.14 Instrument Air Manifolds 10% of each type used 5.15 Push Buttons / Indication Lamps / Selector Switches 5.16 Annunciators 10% of each type used 5.17 Cables 10% of each type used Electronic cards PCB: 10 % or minimum of 1 set of each type used, whichever is higher. NOTES : Above-mentioned mandatory spares list defines the minimum requirement. In case any other item supplied by Bidder is not covered in the above list, Bidder to consider 10% or minimum 1 no. of the complete unit as Mandatory Spare.Vendor recommended mandatory spares are also acceptable in such cases. Similar philosophy shall be followed for packaged units and other items not covered in this list. Contractor to submit spares list for 2 year operation and maintenance. The prices shall be valid for atleast 2 years from date of order. Contractor shall supply all spare items required for commissioning. Next rounded figure to be considered wherever % is specified Example : For total 11 Nos. Instruments with 10 % spares basis, 2 Nos. spares shall be provided.

12 DOC.No. DHT Project Sheet 15 of Civil: 4.1. HV spary nozzles 10% of total nozzles used in each size/type with minimum Drill holes MV spray nozzles 10% of total nozzles used in each size/type with minimum Drill holes Quartzoid bulb Detector 10% of total used Notes: 1. The above no of spares are suggestive and minimum. In case the vendor feels more are required / recommended by manufacturer, same shall be provided and mentioned along the offer.

13 DOC.No. DHT Project Sheet 16 of Mechanical Rotary: Sno. Description Quantity (Insurance Spares) Remarks 1 PUMPS: 1.1 Centrifugal Pumps (Process Service) a.one set of complete replaceable inner case element consisting of all rotating and stationary hydraulic elements (diffuser or volutes etc.) (Only for multistage centrifugal barrel type pumps) b. One set of dynamically balanced complete rotor assembly including balancing drum. (Only for multi-stage centrifugal axial split type pumps) c. One set of mechanical seal in case of process service centrifugal pumps d. One Lube oil filter cartridge 1.3 Centrifugal Pumps (General Water Service) NIL 1.5 Positive Displacement Pumps NIL (Reciprocating) 1.6 Positive Displacement Pumps NIL (Controlled Volume) 1.7 Positive Displacement Pumps (Rotary) 1 set of mechanical seals

14 DOC.No. DHT Project Sheet 17 of 34 Sno. Description Quantity (Insurance Spares) Remarks 1.8 Liquid Ring Vacuum Pumps NIL 2 COMPRESSORS / FANS & BLOWERS 2.1 Centrifugal Compressors 1 set of dynamically balanced rotor + 1 set of dry gas seals + 1 set of bearings + 1 set of couplings + 1 Lube oil filter cartridge 2.5 Centrifugal Fans 1 Rotor with bearings 2.6 Induced Draft / Forced Draft Fans 1 set of dynamically balanced rotor with bearings 2.7 Packaged Integrally Geared 1 set seals + 1 set bearings+ 1 Centrifugal Air set of couplings + 1 Lube oil Compressors filter cartridge + 1 Suction air filter element 2.8 Reciprocating Compressors (Utility & Instrument Air Service) 1 Lube oil filter cartridge + 1 Suction air filter element. 2.9 Reciprocating Compressors (Process 1 set of cylinder valves Service) 1 set of LO filters 1 set of packing rings 1 set of valve gasket 2.10 Positive Displacement Compressors (Rotary) 1 set of dynamically balanced Rotor + 1 set of timing gear + 1set of shaft seals + 1 set of bearings + 1 set of couplings

15 DOC.No. DHT Project Sheet 18 of 34 Sn o Description Quantity (Insurance Spares) Remar ks 3 MECHANICAL DRIVERS / GEAR BOXES 3.4 Steam Turbines (General Purpose) NIL 3.5 Steam Turbines (Special Purpose) 1 set of dynamically balanced rotor + 1 set of each Radial & Thrust bearing + 1 set of shaft seals and labyrinths. 3.6 Special Purpose Gear Box 1 set of dynamically balanced rotor + 1 set of bearings 3.7 General Purpose Gear Box NIL 3.8 Special Purpose Coupling NIL 4 Oil mist lubrication system 1 set of filter cartridge 1 set of gaskets Remarks: (1) Spare parts shall be identical in all respects to the parts fitted in the main equipment, including dimension, material of construction and heat treatment. (2) Spare rotors shall be supplied in metal container in vertical storage and with Nitrogen blanketing. (3) Specified quantity is total for one Item (Service), which remains same even if there are many machines per Item ( for example: 90-P-01 A / B ). Same is also applicable for Commissioning spares (minimum) in below Table-3. (4) Mandatory spares for Electrical and instrumentation shall be as specified in their respective job specifications or as listed elsewhere in the tender documents. TABLE 3: Commissioning Spares (Minimum) Sno. Description 1 Centrifugal Pumps: (Qty.) 1.1 Set of Gaskets 200% 1.2 Set of seal packings 200% 1.3 Set of seal faces 100% Remarks Of Installed quantity

16 < Security Level 2 > DOC.No. DHT Project Sheet 19 of 34 2 Reciprocating Pumps: 2.1 Set of diaphragms 200% 2.2 Set of Plunger packings 200% 2.3 Suction / Discharge valve 100% 2.4 Set of all gaskets 100% Of Installed quantity 3 Vertical Pumps: 3.1 Set of intermediate bushes 100% 3.2 Set of gaskets 100% 3.3 Set of seal faces 100% Of Installed quantity 4 Reciprocating Compressors: 4.1 Set of valve cover gaskets / O-rings 100% 4.2 Set of Head gaskets 100% 4.3 Set of other gaskets 100% 4.4 Set of valve plates for all stages 100% 4.5 Set of springs for valves 100% 4.6 Rod packings & wipers 100% Of Installed quantity Note :- Specified commissioning spares herewith are minimum, and LSTK contractor shall ensure that all required erection and commissioning spares for all equipments are supplied by the vendors.

17 DOC.No. DHT Project Sheet 20 of Mechanical Package: SR.NO. DESCRIPTION QUANTITY (as per installed unit) FEED FILTER /CARTRIDGE FILTER / COALESCER 1 Sets of Filtering Element 100% 2 Gaskets 100% 3 Nuts and Bolts 10% EJECTOR / EDUCTOR 1 Gaskets 400% of each flanged joint 2 Nuts and Bolts 20% But not less than 4 studs with 8 nuts for each fanged joint 3 Steam Nozzle 100% SILENCER 1 Gaskets 100% 2 Nuts and Bolt 20% EOT CRANE 1 Brake Liner (LT,CT,Hoist) 200%

18 DOC.No. DHT Project Sheet 21 of 34 2 Bearing 200% 3 Oil seals and Gaskets 200% 4 Electrical spare refer individual electrical item spare part list STATIC MIXER 1 Gaskets 100% 2 Nuts and Bolts 20% LOADING ARM 1. Swivel Joint Kit 1 no. WEIGH BRIDGE 1. Load Cell 1 no. 2. Control PCB of Weigh Indicator 1 no. 3. PCB of Junction Box 1 No. Pastillation Unit ( Note-1) 1 Sets of Filtering Element 100% 2 Gaskets 100% 3 Nuts and Bolts 10% BAG FILTERS Filter Bags 100 %

19 DOC.No. DHT Project Sheet 22 of 34 Pulse Valves 25% Filter bag cages 25% Sequential controller (timer) Rubber Gasket 1 no. 1 set Note-1 : For Other bought out items such as pumps, motors, exchangers within package, mandatory spares shall be provided as per Mandatory spares list for respective items attached elsewhere

20 DOC.No. DHT Project Sheet 23 of Fired Heater: Sr.no Description Quantity Required Remarks 1 Gaskets 400% 2 Boltings (Pressure parts) 20% 3 Pressure parts ( including all type of 10% (min one no in each tubes and fittings) type, size and material along with special welding consumables) 4 Tube support casing / assemblies (except tubesheet / support beams) 3% (min one no in each type size & material) 5 Sight glasses 100% 6 Burners (per heater) 6.1 Oil tp assembly (including oil tip, atomizer, spud, insert and sleeve) 1 no per 3 nos (min 1 no) 6.2 Gas tip assembly (includes primary 1 set per 3 nos. (min 1 and stages gas tip / raisers) no) 6.3 Muffle block & Regen tile 1 set per 3 nos. ( min 1 no) 6.4 Gaskets 1 complete set per burner 6.5 Pilot jet / mixer, nozzle / tip spud 1 per 3 nos (min 1 no) 6.6 Ignition transformer / Power pack 1 no 6.7 Ignitor electrode 1 no per ignitor 6.8 Oil gun assembly 1 no 6.9 Gas burner assembly 1 no 6.10 Burner management system One PCB of each type 7 Dampers 7.1 Seals 100% 7.2 Boltings 20% 7.3 Actuator 1 set of each type 8 All refractories installed and 20% installation material

21 DOC.No. DHT Project Sheet 24 of Electrical: Sr.No PART DESCRIPTION QTY 1.0 Generator ( one set of spares for each rating and type ) One set a) Generator bushings One set b) Current transformer One set c) Potential transformer One set d) Diodes for exciter One set e) Generator relays One set f) Gen. Field breaker. One set g) Exciter field breaker One set h) Field discharge resistor One no. type each i) DVR- all control cards One set j) DVR.- CTs One set k)dvr- Power supply card I)DVR - Contactors, relays & control transformers One set One set 2.0 Power Transformers (one set of spares for each rating and type) a) Bushings HV & LV One set b) Gasket One set c) Buchholz relay One set

22 DOC.No. DHT Project Sheet 25 of 34 d) Neutral CT One set e) Explosion vent diaphragm Two nos KV Generator Bus switchgear (one set of spares for each rating and type) a) Spare breaker One no. for each rating and type b) Bus insulator 5% c) OT & PT ( All type & ratings) One set each d) Closing Coils 10% e) Snunt trip coil 10% f) All protection relay One set of all types g) Pane limit switches & interlock switches 10% each type h) Panel operating switches ( all type) One set each i) Control fuses ( all type & ratings ) 20% each j) Male pads One set each for all types KV switchgear distribution Bus switch - (one set of spares for each rating and type ) a) Spare breaker One no. for each rating b) Bus insulators 5% c) CT & PT (all types and ratings) One set each d) Closing coils 10% e) Snunt trip coil 10% f) All protection relays One set of all types

23 DOC.No. DHT Project Sheet 26 of 34 g) Panel limit switches & interlocking switches 10% each type h)panel operating Switches (all types) One set end i) Control fuses (all types & ratings) 20% each j) Male pads One set each for all types Sr.No. PART DESCRIPTION QTY KV AND 6.6KV switchgear distribution Bus (one set of spares for each rating and type) a) Spare Breaker One no. for each rating b) Bus insulators 5% c) CT & PT (all types & ratings) One set each d) Closing Coils 10% e) Shunt trip coil 10% f) All protection relays One set of all types g) Panel limit switches & interlocking switches 10% each type h) Panel operating switches (all types) One set each I) Control fuses (all types & ratings) 20% each j) Male pads One set each for all types k) Vaccum bottles-incomers and bus couplers 3 nos each rating I) Vaccum bottles- Outgoing feeders 3 nos each rating m) Breaker limit switches & interlocking switches 10% each type V PCC/PMCC/EPCC switch boards (one set of spares for each rating and type) a) ACB(each type & rating) One no. each

24 DOC.No. DHT Project Sheet 27 of 34 b) Bus insulators 5% c) CT/PT/Control transformer ( all types & ratings) One set each d) Closing coils 10% e) Shunt trip coil 10% f) All protection relays One set of all types g) Panel limit switches & interlocking switches 10% each type h) Panel operating switches (all types) One set each i) Control fuses (all types and ratings) 20% each j) Male pads One set each for all types k) Breaker limit switches & interlocking switches 10% each type I) Control connectors Five set each for all types V MCC/ASB/LDB Switch Boards (one set of spares for each rating and type) a) Vertical bus bars 5 nos. each type b) Bus insulators 5% c) CT One set each d) All protective relays/bimetal relays 5 nos. each type/rating e) Power fuses Five set each type & rating f) Control fuses (all types and ratings) 20% each g) Power and control connectors Five set each for

25 DOC.No. DHT Project Sheet 28 of 34 all types 8.0. Variable frequency drives(one set of spares for each rating and type) a) Transistors / GTB One set b) Control Card One set c) Power supply card One set d) Relays/Contactors One set each e) All fuses Two set each f) Man machine interface One set g) CT/PT One set each h) Cooling fans One set i) Limiters & protection devices One set Sr.No. PART DESCRIPTION QTY 9.0 Relay I Data concentrator panel / HMI (One set of spares for each rating/model type) and type a) All cards such as input and out put cards, power supply cards, processor cards etc. One set b) All control fuses One set 10. UPS (one set of spares for each rating and type) a) Power transistors/igbt One set b) Switching module with static switch One set

26 DOC.No. DHT Project Sheet 29 of 34 c) Power supply card One set d) Operating console card 20% e) All fuses One set f) Cooling fans 11 DC System (one set of spares for each rating and type) a) All fuses 20% b) All Cards One set c) Load break contactor One No d) Contactor coil One No e) Thyristors One set 12 Synchronous motors (one set of spares for each rating and type) a) Diode One set b) Bearings One set c) Pressurization system i) control unit One set ii) Valves iii) pressure switches/electrical switches iv) fuses One set One set One set v) Air filter assembly One set 13 HV induction motors (one set of spares each rating and type) a) Bearings One set

27 DOC.No. DHT Project Sheet 30 of 34 b) Terminal / bushings One set each 14 MV induction motors (one set of spares for each rating and type) a) Bearing Assembly One set b)terminal / bushings One set each c) Bearings One set 15 Telephone Exchange a) All fine cards 20% b) Processing cards One set c) Power supply cards One set d) Crone connectors 20% e) GD Tubes (If protection devices Provided)/Other line 20% f) Crone Tool 4 Nos 16 Fire Alarm System a) All cards One set b) DGFAP One No c) Fuses One set d) Break glass 100% e) Talk back hand 10 nos f) Hammer 10% g) Terminal Blocks 10%

28 < Security Level 2 > DOC.No. DHT Project Sheet 31 of 34 Sr.No. PART DESCRIPTION QTY 17 Paging System a) All cards One set b) All fuses One set c) FLP horn 10% each type d) FLP call stations 10% each type e) Power supply unit One no. each type f)switches & indication lamps One set each type

29 DOC.No. DHT Project Sheet 32 of Fire Fighting: Sr No Part Description Quantity Required 1.0 Clean agent system 1.1 Clean agent cylinders (filled), for centralized system basis (maximum of the following) a. For each installation 1 no (minimum) 5% of main cylinders. 5 nos + 2 % of main clinders b. Exceeding 1 no but not exceeding 100 nos c. Exceeding 100 nos plus for every additional 100 nos 1.2 Automatic and Manual release system One of each type / size used in the system supplied 1.3 Cylinder valve with safet pressure relief One of each type / size used in the system supplied 1.4 Clean agent nozzles 10% of total nozzles used in each size / type with minimum drill holes. 1.5 Clean agent release push buttons 10% of total used of each type 2.0 Hoses & Branch pipes As per TAC 3.0 Spray nozzles for water spray system 5% of each type 4.0 Revolving head 2 nos of each size 5.0 Foam chambers / makers 2 nos of each type / size 6.0 Quartzoid bulb detectors / sprinklers 5% of each size / type Notes: 1. Mandatory spares for any other fire fighting equipment specified else where in the bid document or recommended by the equipment manufacturer shall be

30 DOC.No. DHT Project Sheet 33 of 34 included and supplied by the contractor. 2. Start up and Commissioning spare as required are to be provided by the Contractor and are to be listed in the bid. The unutilized spares shall be the property of the owner. 3. Bidder should quote for spares for 2 years of normal operation as optional separately. a. All items consumables and non consumables required to complete the job. b. All tools tackles, plant machinery etc to complete the job.

31 DOC.No. DHT Project Sheet 34 of Tools and Tackles: Bidder to ensure supply of all tools and tackles for operation and maintanence of the entire plant and equipment and the list of the same shall be furnished along with the bid. They shall be preferably hydraulically operated tools. The price of the same shall be included in the lumpsump price Special tools: Following minimum tools shall be supplied by the vendor: Hydraulic bolt tightening bolt wrench 1 no Any other special tools which in opinion Of supplier are required including set of Non sparking tools. Hydraulic pullers (bearing/coupling) 3T wheel mounted trolleys 4 nos 3T manual operated mobile crane (360 swing) 2 nos Non sparking spanners open end and ring set full set 46 mm incl hammers General purpose maintainence tools General maintainence tools 1 set Set of open spanners 1 set Set of box spanners 1 set Torque wrench 1 no Slings, D shackles Dial gauges digital 1 no Callipers inside 12, outside 12 1 set each Vernier caliper 12 digital 1 no Diagnostic tools Portable vibration analyzer. Portable bearing temperature indicator Lube oil test kit for viscosity / sp gr Temperature calibrator.