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Documente Profesional
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A2
11.07.14
CJP
AND
DEK
Rev
Date
Purpose of Issue
Prepared
by
Checked by
Approved By
Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
CONTENTS
TABLE OF CONTENTS
Sl. No.
Title
1.
2.
3.
Mechanical Package
4.
Piping
5.
6.
Electrical
7.
HSE
8.
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Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
The Project Spares have been divided into three major Categories:
1. Mandatory Spares
2. Start up and Commissioning Spares
3. Operation Spares
Procurement Philosophy :
Mandatory Spares : The below list mentions the minimum mandatory spares that shall be
supplied along with the individual equipment. These are the minimum spares required for the
project.
Start Up & Commissioning Spares : These spares shall be included in the EPC Contractor
scope. The list of commissioning spares as required shall be furnished by the EPC Contactor
on award of the job; however the price of it shall be included in the lumpsum offer. Start up
and Commissioning spare as required are to be provided by the Contractor. The unutilized
spares shall be the property of the owner.
Operation Spares : The vendor shall recommend in a list of spares for 5 years of operation;
EPC contractor submit the list of these spares as recommended by the vendor along with the
unit rate with a validity of 2 years from the date of Purchase order by EPC contractor on the
vendor. These spares shall be procured by CIL themselves; however the listing of Operation
Spares is a must requirement along with the other list of mandatory spares during
engineering.
Part Description
Quantity Required
A2
Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
Sr No
Part Description
Quantity Required
Sr No
Part Description
Quantity Required
2 sets
100%
Sr No
Part Description
Quantity Required
200%
Plugs
20%
Belts
100%
A2
Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
Sr No
Part Description
A2
Quantity Required
20%
One set
10
11
Motor Bearings
Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
Sr No
Part Description
Quantity Required
Clamp assemblies
Gaskets or tapes
U-Clamps
1.5 Tanks-
Sr No
Quantity Required
10% (Minimum 2 of each size)
Part Description
Bolting for each nozzle with blind/
companion flange and for each pad
nozzle
2 sets
2 sets
4 sets
2. MECHANICAL ROTARY:
Sno.
Description
PUMPS:
Quantity Required
A2
Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
1.1
1.2
COMPRESSORS
BLOWERS
2.1
Centrifugal Compressors
FANS &
2.2
Centrifugal Fans
2.3
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Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
Sno.
Description
2.4
Packaged
Quantity Required
Integrally
Geared
Centrifugal Air
Compressors
2.5
2.6
A2
Reciprocating Compressors
Service)
1 set of LO filters
1 set of packing rings
1 set of valve gasket
2.7
Positive
Displacement
Compressors
(Rotary)
MECHANICAL
GEAR BOXES
DRIVERS
3.1
3.2
NIL
3.3
3. MECHANICAL PACKAGE:
SR.NO.
DESCRIPTION
Quantity Required
100%
Gaskets
100%
10%
Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
A2
EJECTOR / EDUCTOR
1
Gaskets
400% of each
flanged joint
Steam Nozzle
100%
SILENCER
Gaskets
100%
20%
ELECTRIC HOIST
1
200%
Bearing
200%
3
4
200%
refer individual electrical item spare
part list
STATIC MIXER
1
Gaskets
100%
20%
4. PIPING:
4.1Spares to be left after commissioning of the plant shall be as given in the following
table :
Sr.no. Part Description
Size Range
to 36
Cairn Document
Number:
RGT UPGRADATION PROJECT (RGT) R230
R230TEC-RFG-PMLSP-3001
Revision
A2
Size Range
Above 36
Nil
1/2 to 8
10 and above
Nil
Bolts, Nuts
All sizes
10
Gaskets
All sizes
10 (Min. 4 Nos.)
Traps
All sizes
Expansion Bellows
All sizes
Notes:
1. % of quantity required to be left as mandatory spares is for each and every item /
size / material consumed other than normal carbon steel (Like AS , SS , NACE
,HIC,IBR,DSS,GRP ) 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.
5.
Sr.no
1
Part Description
Quantity Required
FIELD INSTRUMENTS
1.1
Pressure Gauges
1.2
Temperature gauges
1.3
Level Gauges
1.5
3Way manifold
1.6
Ultrasonic / Radar
Instrument
Capacitance / RF type
instruments
1.4
1.7
Sr.no
Part Description
1.8
Temperature Elements
1.9
RTDs
1.10
1.11
Ceramic Thermowell
1.12
1.13
1.14
1.15
1.16
2.0
2.1
Quantity Required
10% (subject to minimum of 1) of each type,
range, length and make of Thermocouple with
Thermowell, whichever is higher. Same
philosophy to be followed for multi point
thermocouples also but without thermowells.
10% (subject to min of 1) of each length of RTD
with Thermowell, whichever is higher
10% (subject to minimum of 1) of each length &
type of skin thermocouple, whichever is higher.
Control Valves
Sr.no
Part Description
Quantity Required
b) 10% (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) 10% (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.
2.2
2.3
2.4
Sr.no
Part Description
(Self Actuating Valve)
2.5
PRDS &
De-super heater unit
Quantity Required
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-Super heater vendor)
2.6
Breather Valves
2.7
Flame Arresters
2.8
Rupture Disc
ANALYSER
a) Furnace Assembly -1
b) Thermocouple - 1
c) Sensor board - 1
3.1
3.2
O2 Analyser
HydroCarbon Analyser
(Infrared)
Sr.no
3.3
3.4
Part Description
Moisture Analyser
H2S Analyser
Quantity Required
a) Sensor and Detector -1 no.
b) Electronic card - 1no. Each type
c) Fuses - 5 sets
d) Flow indicator & switch - 1no.
a) Cadmium lamp - 2 nos.
b) Cell window -2 nos.
c) Window gasket - 10 nos.
d) Air regulator - 1 no.
e) Seal kit for 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
3.5
Sampling systems
DCS/PLC system
4
4.1
4.2
4.3
Prefabricated cables
4.4
Relays
4.5
Sr.no
Part Description
Quantity Required
4.6
System Spares
4.7
Installed spares
4.8
Spare Space
4.9
MCBs
100%
4.11 Fuses
4.13 Consumables
5.0
OTHER ITEMS
5.1
5.2
5.3
5.4
Solenoid Valves
MCT Block
Sr.no
Part Description
5.5
Instrument Valves/Tube
Fittings
Panel mounted instruments
CCTV
Machine Monitoring
System
5.6
5.7
Quantity Required
Telephone Exchange
a) All fine cards
20%
b) Processing cards
One set
One set
d) Crone connectors
20%
20%
4 Nos
Sr.no
10.0
11.0
Part Description
Quantity Required
One set
b) DGFAP
One No
c) Fuses
One set
d) Break glass
100%
10 nos
f) Hammer
10%
g) Terminal Blocks
10%
Paging System
a) All cards
One set
b) All fuses
One set
c) FLP horn
6. ELECTRICAL:
Sr.No
PART DESCRIPTION
Quantity Required
1.0
One set
a) Generator bushings
One set
b) Current transformer
One set
c) Potential transformer
One set
One set
e) Generator relays
One set
Sr.No
2.0
PART DESCRIPTION
Quantity Required
One set
One set
One set
j) DVR.- CTs
One set
One set
One set
One set
b) Gasket
One set
c) Buchholz relay
One set
d) Neutral CT
One set
Two nos.
F Gauge glass)
3.0
One
b) Bus insulators
5%
d) Closing coils
10%
10%
no. for
each rating
Sr.No
PART DESCRIPTION
Quantity Required
j) Male pads
4.0
One no.
rating
for
each
b) Bus insulators
5%
d) Closing Coils
10%
10%
Sr.No
PART DESCRIPTION
Quantity Required
5.0
b) Bus insulators
5%
c) CT/PT/Control
transformer
ratings)
d) Closing coils
10%
10%
I) Control connectors
Five set each for all
types
6.0
b) Bus insulators
5%
c) CT
5 nos. each
type/rating
e) Power fuses
f) Control fuses (all types and ratings)
Sr.No
PART DESCRIPTION
g) Power and control connectors
6.6 kV Extension Panel (LHS + RHS)
Closing coil
7.0.
Closing coil
8.0
Quantity Required
Five set each for all
types
Quantity is per
switchboard.
20 % or one no
(min) of each rating
One set
g) CT/PT
h) Cooling fans
One set
One set
Sr.No
PART DESCRIPTION
Quantity Required
9.0
One set
One set
One set
One set
e) All fuses
f) Cooling fans
10.0
13.0
d) Contactor coil
One No
e) Thyristors
One set
fuse link
12.0
f) BLOCKER DIODE
11.0
One set
Two nos.
10 nos. of each rating &
type.
One set
b) Terminal / bushings
MV induction motors
(one set of spares for each rating and type)
a) Bearing Assembly
One set
b)Terminal / bushings
c) Bearings
One set
Fuses
Bearing ( DE & NDE ) (as applicable)
14.0
ECS
Interposing relays (As applicable)
7. HSE:
Sr
Part Description
Quantity Required
No
1.0
1.1
(filled),
for
1 no (minimum)
5% of main cylinders.
1.3
1.4
1.5
2.0
3.0
Sr.No
PART DESCRIPTION
Quantity Required
4.0
5.0
6.0
Fire Extinguishers
7.0
Special tools:
Following minimum tools shall be supplied by the vendor:
10.3.
10.4.
1 no
Any other special tools which in opinion of supplier are required including set of
Non sparking tools.
1 set each
Hydraulic pullers (bearing/coupling)
1 no
2 nos
1 nos
full set 46
mm incl hammers.
1 set
1 set
1 set
Torque wrench
Slings, D shackles
1 no
1 set each
1 no
1 set each
1 no
Diagnostic tools
1 no
1 no
1 no
Temperature calibrator.
1 no