Spare Part Philosophy - XX PDF

ABB Lummus Global Inc.
SPARES PHILOSOPHY AND SPARES LIST
ISSUED BY: MECHANICAL ENGINEERING
APPROVED:
DATE: April 10, 2006 REV.: 2
SIDI KERIR PETROCHEMICALS COMPANY
460,000 MTA ETHYLENE PLANT NO. 2
EL AMERIYA, ALEXANDRIA, EGYPT
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, Approved For Design – Incorporates Client KDB DWG

2006 Comments and Additional Requirements
1 Mar 16, Approved For Design 4&5 KDB DWG

2006
0 Mar 9, For Approval KDB

2006
PAGES
REV REVISION WRITTEN BY APPROVED
REVISED
NO DATE DESCRIPTION BY
Revision 2 (04/10/06) Page 1 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
6.2 PROCUREMENT 5
6.3 DELIVERY TO SITE AND LOGISTICS AT SITE 5
7. TWO-YEARS SPARES 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

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.

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 SIDPEC’s 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.

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

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

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
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.
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.
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.

ATTACHMENT 1
MINIMUM REQUIREMENTS FOR TWO (2) YEARS AND CAPITAL SPARES
1. INSTRUMENTATION SPARE PARTS
Instrument Type Required Number of Spares

Spare Part Item
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) Complete 5 percent
Transmitter
Pressure Transmitter Complete 5 percent
Level Gauge Complete 5 percent
Motor-operated Valve Actuator 3 pieces
(MOV)
Orifice Plates Blank 1 per type
Restriction Orifice Blank 1 per type
Pressure Gauge Complete 5 percent
Differential Pressure (D/P) Complete 1 piece
Gauge
Pressure regulator Complete 6 pieces
Resistance Temperature Assembly 5 percent
Detector (RTD) element
Resistance Temperature Head 5 percent
Detector (RTD) transmitter
Solenoid Operated Valve Complete 5 percent
(SOV)
Proximity switch Assembly 10 percent
Temperature gauge Complete 5 percent
Thermowell Complete 5 percent

Required Number of Spares

Instrument Type Spare Part Item
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 PLC’s are not estimated since the type of PLC’s to be used are not
known.

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

Spare Part Item
1" 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
Control Valve Type 1 Packing Set 3 pieces
Actuator 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)

Spare Part Item
Automatic Change-over Packing Set 3 pieces
Valve Actuator Set 3 pieces
Solenoid Valves Packing Set 2 pieces
Feed Pump Impeller 1 piece
Bearing Set 1 piece
Gasket Set 2 pieces

Condensate Treatment Unit (2-PA-907)

Automatic Change-over Packing Set 3 pieces
Valve Actuator Set 3 pieces
Feed Pump Impeller 1 piece
Bearing Set 1 piece
Gasket Set 2 pieces
Wastewater Treatment Package (2-PA-906)

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
Control Valves Packing Set 10 pieces
Fuel Gas Valves Packing Set 4 pieces


Air Dampeners Packing 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)

Control Valves Packing Set 3 pieces
Temperature Elements Packing Set 5 pieces
4. STATIC EQUIPMENT SPARE PARTS

SRT Cracking Heater (2-BA-101 thru 107)
--- 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)

Evaporator Bare Tube 63.5 Ø x 10 pieces
4.5 mm WT
Bare Tubes 3 pieces
Solenoid Valves Packing Set 51.0 Ø x 10 pieces
3.6 mm WT
Superheater Bare Tubes 44.5 Ø x 10 pieces
4.5 mm WT


Economizer Finned Tubes 51 Ø x 10 pieces
4 mm WT
Valves bore 15 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 4 pieces
Glasses
Water Level Gauge 4 pieces
Gaskets
Metaflex Manhole 4 pieces
Gaskets
Quench Tower (2-DA-101)

Spare Part Item
--- Packing Material 10 m3

Cold Box (2-PA-301)

Connection Size Required Number Required Number
and Rating of Gaskets of Bolts and Nuts
6" - 150# 28 12 (3/4" Ø)
8" - 150# 20 8 (3/4" Ø)
10" - 150# 12 8 (7/8" Ø)
12" - 150# 12 8 (7/8" Ø)
14" - 150# 8 4 (1" Ø)
3" - 300# 4 4 (3/4" Ø)

6" - 300# 32 12 (3/4" Ø)
8" - 300# 28 16 (7/8" Ø)
10" - 300# 12 10 (1" Ø)
5. ROTATING EQUIPMENT SPARE PARTS

Pumps
Required Number
Item Description Spare Part Item
of Spares
1 piece
2-GA-901 A/B/C/D SHP Boiler Coupling
Feedwater Pump Mechanical Seal,
Metallic and Carbon 4 pieces
Face and Springs
Gasket Sets, Packing
or Mechanical Seal 4 pieces
Nonmetallic Faces, O-
Rings
Shaft Sleeve, Bearing
Set, Impeller and Case 1 piece
Wearing Rings, Throat
Bushing, Throttle
Bushing
First State Impeller 1 piece
and Shaft
Series Impeller 4 pieces

Centrifugal Compressors
Applicable Required Number
Item Description Spare Part Item Notes of Spares
2-GB-201 Charge Gas Shaft Seals 2, 4 2 pieces
(See Note 5) Compressor Shaft Sleeve 2, 4 1 piece
Radial Bearings 2, 4 2 pieces
Thrust Bearings 2, 4 1 piece
Thrust Collars 2, 4 1 piece
Couplings 1 piece
Oil Filter Element 3 10 pieces
Instrument Parts 2 1 piece
Labyrinths 2 2 pieces
Accumulator Bladder 1 piece
Gasket and O-rings 2 2 pieces
Oil Pump 1 piece
Timing Gearing 1 piece
Oil Cooler Bundle 1 piece
Flushing Nozzles 1 1 piece
2-GB-501 Propane Shaft Seals 2 2 pieces

(See Note 5) Refrigerant Shaft Sleeve 2 1 piece
Compressor Radial Bearings 2 2 pieces
Thrust Bearings 2 1 piece
Thrust Collars 2 1 piece
Couplings 1 piece
Oil Pump 1 piece
Timing Gearing 1 piece
2-GB-601 Ethylene Shaft Seals 2, 4 2 pieces

(See Note 5) Refrigerant Shaft Sleeve 2, 4 1 piece
Compressor Radial Bearings 2, 4 2 pieces
Thrust Bearings 2, 4 1 piece
Couplings 1 piece

Oil Pump 1 piece
Timing Gear 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
Instrument Parts 2 1 pieces
Accumulator Bladder 3 pieces
Oil Pump 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.

Steam Turbines
2-GG-901 Steam Turbine for Diaphragms 9 1 piece
A/B 2-GA-901 A/B
Nozzles 9 1 piece
Packing / labyrinth 9 2 pieces
Glands
Radial Bearings 9 2 pieces
Thrust Bearings 1 piece
Pads
Governor 1 piece
Oil Pump 1 piece
Oil Filter Elements 10 1 piece
Gaskets 9 3 pieces
Trip and Throttle 9 1 piece
Valve Parts 1 piece
Accumulator
Bladder
Couplings
2-GG-201 Steam Turbine for Diaphragm 9 1 piece

2-GB-201
(See Note 11) Nozzles 9 1 piece
Packing / labyrinth 9 2 pieces
Glands
Thrust Bearings 1 piece
Thrust Bearings 9 2 pieces
Pads
Governor 1 piece
Oil Pump 1 piece
Oil Filter Elements 10 10 pieces
Gaskets 9 3 pieces
Valve Parts 9 1 piece
Accumulator
Bladder
Couplings Ejector 8,9 1 piece
Nozzles / Diffusers


2-GG-601 Steam Turbine Diaphragms 9 1 piece

for 2-GB-501 Nozzles 9 1 piece
Packing/Labyrinth 9 2 pieces
Glands
Pads
Governor 1 piece
Oil Pump 1 piece
Oil Filter Elements 10 10 pieces
Gaskets 9 3 pieces
Valve Parts
Accumulator 1 piece
Bladder
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.

Condensers
Applicabl Required Number
Item Description Spare Part Item e Notes 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

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
• 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

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
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.

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
2.12 UNIT PRICES
Quote unit prices for each spare part.
2.13 TOTAL PRICES
2.14 DELIVERY TIME
It shows delivery time of spare parts.
2.15 EQUIPMENT NUMBER
It shows the equipment number of the main equipment.

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.
− 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:
• 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
QUANTITY CLIENT'S STOCK RECOMMENDED BY
REF.
ITEM DRAWING CLIENT'S ON VENDOR'S QUANTITIES
ON DESIGNATION PART REF. WEIGHT CODE UNIT PRICES TOTAL PRICES
NO. NO. CODE INSTALLED RECOMM. QUANTITY CONTRACTOR CLIENT ORDERED
DRAW NUMBER
EQUIPMENT
REMARKS: DATE & CLIENT'S SIGNATURE: SPARE PART PO NO: TOTAL PAGE:
AGGREGATE AMOUNT:
DATE:

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ABB Lummus Global Inc.

SPARES PHILOSOPHY AND SPARES LIST

ISSUED BY: MECHANICAL ENGINEERING

DATE: April 10, 2006 REV.: 2

SIDI KERIR PETROCHEMICALS COMPANY

460,000 MTA ETHYLENE PLANT NO. 2

EL AMERIYA, ALEXANDRIA, EGYPT

2 Apr. 10, Approved For Design – Incorporates Client KDB DWG

1 Mar 16, Approved For Design 4&5 KDB DWG

0 Mar 9, For Approval KDB

Revision 2 (04/10/06) Page 1 of 27

SPARES PHILOSOPHY AND SPARES LIST

Revision 2 (04/10/06) Page 2 of 27

SPARES PHILOSOPHY AND SPARES LIST

3.1 DEFINITIONS OF SPARES

3.2 OTHER DEFINITIONS

4.0 SCOPE OF SUPPLY

4.1 COMMISSIONING SPARES

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SPARES PHILOSOPHY AND SPARES LIST

4.2 CAPITAL SPARES

4.3 TWO-YEAR SPARES

4.4 TWO-YEAR SPARES - OPTIONAL

5.0 COMMISSIONING SPARES

5.1 IDENTIFICATION OF REQUIREMENTS

Revision 2 (04/10/06) Page 4 of 27

SPARES PHILOSOPHY AND SPARES LIST

5.3 DELIVERY TO SITE AND LOGISTICS AT SITE

6.1 IDENTIFICATION OF REQUIREMENTS

6.3 DELIVERY TO SITE AND LOGISTICS AT SITE

7.1 IDENTIFICATION OF REQUIREMENTS

SPARES PHILOSOPHY AND SPARES LIST

8. TWO-YEAR SPARES - OPTIONAL

SPARES PHILOSOPHY AND SPARES LIST

8.2 SPARE PARTS IDENTIFICATION NUMBERING

9. ATTACHMENT 1 - MINIMUM REQUIREMENTS FOR TWO (2) YEARS AND CAPITAL

Revision 2 (04/10/06) Page 7 of 27

SPARES PHILOSOPHY AND SPARES LIST

1. INSTRUMENTATION SPARE PARTS

Instrument Type Required Number of Spares

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SPARES PHILOSOPHY AND SPARES LIST

Required Number of Spares

2. DCS COMPUTER SPARE PARTS

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SPARES PHILOSOPHY AND SPARES LIST

3. SPECIAL EQUIPMENT SPARE PARTS

DOX Unit (2-PA-101)

Description Required Number of Spares

PSA Unit (2-PA-303)

Description Required Number of Spares

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SPARES PHILOSOPHY AND SPARES LIST

Condensate Treatment Unit (2-PA-907)

Wastewater Treatment Package (2-PA-906)

Centrifugal Pumps Impeller 10 pieces

Chemical Dosing Pumps Check Valve Set 10 pieces

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SPARES PHILOSOPHY AND SPARES LIST

Required Number of Spares

Air Dampeners Packing Set 6 pieces

Offgas Incinerator Package (2-PA-004)