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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

DGS-MU-003 Rev- 2

SPARE PARTS

Amendment History

2 Mar 2009 AMD-MU-003-BECHTEL Clause # 2.0 &9.1 SMK/ QAM/MAY Mar 2009
MLM/ HD

1 Feb 2008 DGS-MU-003 Rev-1 Made more elaborate SMK / HD ETSDM / EPDM Feb 2008
Appendices with inputs
from MED

No Date Amendment Description Proposed Approved Incorporated

DGS History

2 Mar 2009 DGS-MU-003 Rev 2 AMD-MU-003-BECHTEL SMK/MLM/ QAM/MAY


HD

1 Feb 2008 DGS-MU-003 Rev 1 AMD-MU-003-ETSD SMK/HD QAM/MAY

0 Mar 2006 DGS-MU-003 Rev- 0 Previous Project SMK / HD ETSDM / EPDM

No Date Description Source Reviewed Approved

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

TABLE OF CONTENTS

1.0 GENERAL 4
1.1 INTRODUCTION 4
1.2 PURPOSE 4
1.3 DEFINITIONS 4
2.0 CODES AND STANDARDS 5
3.0 REFERENCE DOCUMENTS 6
4.0 DOCUMENT PRECEDENCE 6
5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL 6
6.0 QUALITY ASSURANCE/QUALITY CONTROL 6
7.0 DOCUMENTATION 6
8.0 SUBCONTRACTORS/SUBVENDORS 6
9.0 HANDLING 6
9.1 PACKAGING AND SHIPPING 6
9.2 PRESERVATION AND STORAGE 8
10.0 SPARE PARTS LIST and INTERCHANGEABILITY RECORD 8
10.1 VENDOR REQUIREMENTS 8
11.0 SELECTION OF TWO YEAR OPERATING SPARES AND QUANTITY RECOMMENDATIONS 9
11.1 SELECTION OF SPARE PARTS 9
11.2 QUANTITY OF SPARE PARTS 10
APPENDIX - 1 11
EQUIPMENT AND MATERIALS DATA ACQUISITION SYSTEM FOR TAKREER PROJECTS 11
APPENDIX 2 47
REFERENCE TO IDENTIFY TYPE OF SPARES TO BE SPECIFIED ON SPIR FORM 47
APPENDIX 3 60
INSURANCE SPARE PARTS 60
APPENDIX 4 62
PROCEDURE FOR HAND-OVER OF TWO YEARS OPERATIONAL SPARES 62
ADDENDUM SHEET 68

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

List of Authorized Signatures / Initials

DGS Discipline Committee Member, ADRD: None

DGS Discipline Committee Member, RRD: Hani Dawod (HD)

DGS Discipline Committee Member, E&PD: Megharaj L. Mane (MLM)

DGS Discipline Committee Member Leader, E&PD: Shivaji M Karade (SMK)

Engineering & Technical Services Manager, E&PD: Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD: Mohd Al Yabhouni (MAY)

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

1.0 GENERAL
1.1 INTRODUCTION
This specification is intended to assist VENDORS supplying equipment and spare parts
by giving recommendations on both:
a. The selection and quantities of spare parts in general.
b. The selection of spare parts to be maintained for two years of normal operation of
the plant after handing over.
Throughout this specification, the term spare parts is used in a broad sense, i.e. the
component parts of any piece of equipment.
1.2 PURPOSE
This specification is to advise the VENDOR of his spare parts obligations and responsi-
bilities:
a. When preparing the equipment quotation.
b. After receipt of the equipment Purchase Order.
This specification covers spare parts required for start-up and for two (2) years of con-
tinuous operation. Spare parts are required for all mechanical equipment, non-bulk elec-
trical equipment, and instruments supplied for the PROJECT. Insurance spare parts will
be purchased along with the original equipment wherever practical. Delivery of spare
parts ordered with the original equipment such as start-up and insurance spares are re-
quired concurrent with the original equipment. All other spare parts shall be delivered
prior to equipment commissioning.
1.3 DEFINITIONS
For the purposes of this specification, the following definitions shall apply:
General Definitions:
DOCUMENT Any form, letter, facsimile, contract, specification, requisition, drawing, or
record of any kind required to transmit information from one party to another. It also in-
cludes computer generated drawings, lists, charts, etc. and other data used to form a
permanent record of the Project progress.
CONCESSION REQUEST Deviation requested by the SUBCONTRACTOR or VEN-
DOR, usually after receiving the contract package or purchase order. Often, it refers to
an authorization to use, repair, recondition, reclaim, or release materials, components or
equipment already in progress or completely manufactured but which does not meet or
comply with COMPANY requirements. A CONCESSION REQUEST is subject to COM-
PANY approval.
SHALL Denotes mandatory action or requirement.
SHOULD Denotes an action or requirement which is not mandatory but which is strong-
ly recommended.
Specific Definitions:

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

EMDAS Equipment and Materials Data Acquisition System (Spare Parts Interchange-
ability Record in electronic format).
OEM SPARE PARTS The parts which are manufactured by original equipment manu-
facturer (OEM) e.g:- Pump Spare parts:- Impeller, Shaft, Wear Rings, Bushing etc..
BUY OUT SPARE PARTS The parts which are procured from other manufacturer, by
OEM.
Eg:- Mechanical Seal, Coupling, Bearing etc..
INSURANCE SPARE PARTS - parts of equipment, equipment assemblies, or complete
items of equipment having long delivery time that are required for replacement of items
not subject to deterioration by normal use but failure of which is critical for continuous
safe operation of the plant. The list of these spares to be approved by Company prior to
purchasing. When it is necessary to manufacture insurance spares at the same time as
the equipment, i.e., where fitting of the part into the equipment is necessary during manu-
facture, the original equipment requisition shall include those parts. These parts are sub-
jected to the same stringent inspection requirements as the main equipment.
Example: spare compressor or turbine rotors, stators, heat exchanger tube bundle, heater
tubes, complete spare parts, complete motors, multi stage pump rotor, fan rotor, instru-
ments, equipment without a standby.
SPARE PARTS LIST & INTERCHANGAEABILITY RECORD (SPIR)-An important tool for
a proper spare part selection is SPIR.
ELECTRONIC SPIR Five Excel worksheets in single Excel file consists of SPIR infor-
mation to be filled by the successful Vendor/Contractor to quote his recommended spare
parts. Once the Company reviewed/confirmed order quantity, the SPIR form becomes an
attachment to the spare parts Purchase Order and serves as the basic spare parts docu-
mentation for the Project.
SPIR PACKAGE - VENDOR shall submit a SPIR PACKAGE, as defined in Section 10.1
of this specification, to CONTRACTOR.
START-UP SPARE PARTS - spare parts needed to adequately cover the requirements of
day to day maintenance and any premature failures for the period of start-up and trial run
operations. Start-up spares must be ordered at such a date that they will arrive on site at
the same time as the parent equipment, but in any case prior to equipment start-up activi-
ties. Start-up spares also include parts and assemblies normally used or consumed dur-
ing installation of equipment, cleaning, flushing, and inspection.
TWO YEARS OPERATING SPARE PARTS - parts or assemblies normally used or con-
sumed on the basis of scheduled maintenance, overhauls, inspections, wear, corrosion,
erosion or deterioration in normal service for a period of two years after start-up.
2.0 CODES AND STANDARDS
The following codes and standards shall, to the extent specified herein, form a part of
this specification. The edition in force at the time of CONTRACTORs/ VENDORs pro-
posal shall apply.

ISO (International Organization for Standardization):

ISO 9001-2000 Quality Management System Requirements


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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

ISO 9004-2000 Quality Management Guidelines for Performance Improvement


System

3.0 REFERENCE DOCUMENTS


It shall be the VENDORS responsibility to be or to become, knowledgeable of the refer-
enced codes and standards and project documents.
Project Specifications
DGS-MU-002 Design General Specification Preservation and Export Pack-
ing
4.0 DOCUMENT PRECEDENCE
The VENDOR shall notify the CONTRACTOR of any apparent conflict between this spe-
cification, the related data sheets, the Codes and Standards and any other specifications
noted herein. Resolution and/or interpretation shall be obtained from the CONTRACTOR
in writing before proceeding with the design/manufacture.
In case of conflict, the order of precedence shall be stated in the AGREEMENT or other
PROJECT documents as applicable.
5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL
Any technical deviations to the Purchase Order and its attachments including, but not lim-
ited to, the Data Sheets and Narrative Specifications shall be sought by the VENDOR
only through CONCESSION REQUEST format. CONCESSION REQUESTS require
CONTRACTORS and COMPANYS review/approval, prior to the proposed technical
changes being implemented. Technical changes implemented prior to COMPANY ap-
proval are subject to rejection.
6.0 QUALITY ASSURANCE/QUALITY CONTROL
The QA/QC program used by the VENDOR for spare parts manufacture shall be the
same program, previously approved by CONTRACTOR for use on the original equipment
purchase.
7.0 DOCUMENTATION
For additional VENDOR documentation requirements specifically for spare parts, refer to
section 10.1 of this specification.
8.0 SUBCONTRACTORS/SUBVENDORS
The VENDOR shall assume unit responsibility and overall guarantee for spare parts
manufacture consistent with the original equipment purchased.
9.0 HANDLING
9.1 PACKAGING AND SHIPPING
Packaging and shipping of spare parts shall be consistent with that of the original equip-
ment purchased, and the additional requirements as indicated herein.
All spare parts shall be individually labeled by one of the following methods:

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

a. An aluminum label imprinted with lettering approximately 6mm (1/4 in) high and se-
cured to the part with S.S. wire.
b. Inscribing with an electric spark, engraving pencil.
c. Mark large items with non-fading moisture resistant marking ink, figures/letters to be
at least 25mm (1 in) high. Ink shall be Pannier Yellow Industrial or equal.
d. Items such as ball bearings which in actual storage will remain in their packing, may
be labeled with an adhesive label firmly attached to the outside of the carton.
e. Original manufacturers identification shall be retained on their original packing and
shall not be tampered/ spoiled.
f. Alternative methods which are standard industrial practice may be used provided
COMPANY approval has been obtained in writing in advance. Stamping directly
onto spare parts will not be allowed.
The following shall appear on each spare part label:
Spare Part Description
Quantity of Item
MANUFACTURERS Part Number
Spare Parts Purchase Order Number
Equipment or Main Assembly Description
Tag number of Parent Equipment - where applicable
Label shall be similar to the following example:
Coupling Assembly, Balanced
One PC
P/N SP8-650/2H
P.O. 457100-4
Feed Booster Pump
211-G-001
Preparation for shipment and packing will be subject to inspection and rejection by COM-
PANYS/CONTRACTORS inspectors. All costs occasioned by such rejection shall be to
the account of the VENDOR.
Electronic and instrument parts shall be packed in vacuum sealed clear plastic bags or in
a sealed bag along with desiccant.
Operating spare parts shall be packed separately from the main equipment and the pack-
ing container shall be clearly marked SPARES, and a bill of material shall be enclosed.
VENDOR shall provide following details as a minimum along with the Spare parts:
a. Main Equipment Tag
b. Main VENDOR
c. Sub VENDOR
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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

d. Data sheets and specification sheets


e. Part No. of original Manufacturer
f. Drawing No. of original Manufacturer
g. Material
h. Model No. /Type designation
i. Quantity required
j. Approximate dimensions
k. Weight -net and gross, maximum weight for maintenance
l. Special instructions for storage and hazardous applications
m. SPIR forms showing interchange ability, QPU (Quantity per Unit), TIQ
(Total Installed Quantity).
An ordering information sheet from the VENDOR is a mandatory requirement encom-
passing SPIR formats. The referenced drawings shall become a part of the VENDOR op-
eration and Maintenance Manual.
9.2 PRESERVATION AND STORAGE
All parts and equipment shall be preserved and export packed in accordance with Project
Preservation Specification, DGS-MU-002.
All spares are to be packed and stored in such a manner to ensure a minimum shelf life
of four years in a non air conditioned warehouse sighted in an extremely dusty location
where the maximum shade temperature may exceed 58C, and where relative humidity
reaches 96%.
VENDOR must advise COMPANY of any spare parts which can not be stored under the
conditions stated, and which require special storage conditions. VENDORS are to advise
what storage conditions they recommend and the expected shelf life of such items under
VENDORS recommended conditions.
10.0 SPARE PARTS LIST AND INTERCHANGEABILITY RECORD
An important tool for a proper spare part selection is the Spare Parts List and Inter-
changeability Record (SPIR). A sample (SPIR) and the Guide to Completion are given in
Appendix 1 & 2.
The SPIR form is designed so that duplication and interchangeability between parts of
equipment will be detected and original manufacturers identified and recorded. This will
reduce the possibilities of duplicate stockholding and over ordering in general. A SPIR
listing and selection per commodity and manufacturer for buy-out items shall be included.
The following buy-out items apply to this PROJECT:
Bearings, mechanical seals, couplings, control valves, safety relief valves, equipment
gaskets, and instruments etc.
10.1 VENDOR REQUIREMENTS
VENDOR shall submit to COMPANY via CONTRACTOR a statement that VENDOR shall
make every effort to notify COMPANY of any cessation of production of equipment/parts
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SPARE PARTS Rev- 2
March 2009

(planned or otherwise) within ten (10) years and period up to which spares supply support
could be given for the equipment/parts supplied. The statement shall also provide for no-
tification of COMPANY a minimum of one (1) year prior to unavailability of spare parts.
The VENDOR shall submit a SPIR PACKAGE to CONTRACTOR on or before the sched-
uled submittal date as indicated in the purchase order. Attention Spare Parts Coordinator.
The SPIR PACKAGE shall consist of the following:
a. Completed SPIR form in electronic spreadsheet format in accordance with Appen-
dix 1.
b. Three (3) hard copy of SPIR Form.
c. Three (3) sets of prints of the following documents: parts lists and sectional draw-
ings or equivalent showing location of parts quoted and referenced on the SPIR, da-
ta sheets, product manual/brochures, and P&IDs, copy of main equipment PO, ma-
terial requisition and buy-out items details with Manufacturer and Part Number.
d. Three (3) copies of a letter of transmittal stating:
Prices, Net or List with applicable discounts including quantity discounts
Price validity date of at least 180 days from the date of submittal of acceptable
SPIR. Show price adjustment requirement beyond 180 days through one (1)
year
Minimum order quantities
Other terms and conditions
The common objective is to establish a comprehensive spare parts database that may be
used by operating personnel of the COMPANY. Therefore, it is critical that the informa-
tion submitted by the VENDOR is complete and correct.
When the VENDOR does not recommend spare parts to be stocked, the list of such
equipments shall be submitted to the contractor addressed to Spare Parts Coordinator.
No deviation from the requirement for completing the SPIR Form(s) will be permitted
without prior authorization of COMPANY.
Incomplete SPIR PACKAGES will be returned to CONTRACTOR/VENDOR for rework
and re-submittal. The revised SPIR should be with new price validity (at least 180days)
and without any price change.
11.0 SELECTION OF TWO YEAR OPERATING SPARES AND QUANTITY RECOMMEN-
DATIONS
The basis for the selection of two year operating spare parts is the VENDORS recom-
mendation by means of the SPIR. For that purpose, the available SPIRs should be used
for recording and identifying of interchangeable parts and calculating the quantity of two
year operational spare parts to be ordered.
11.1 SELECTION OF SPARE PARTS
Appendix 2 contains separate equipment lists identifying the type of parts to be speci-
fied on the SPIR form.

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SPARE PARTS Rev- 2
March 2009

In addition to Appendix 1, the following guidelines apply:


Key operation and safety functions of the equipment.
Current delivery time and transportation time to site of items not stocked.
Possibility of damage during installation and commissioning.
Expected normal wear and tear during first two years of operation.
Service interval stated by MANUFACTURERS maintenance policy.
Possible repair/exchange items.
When spare parts need to be tested / inspected together with the equipment, it shall be
assured that they are available at the workshop during the equipment testing/inspection.
In order to reduce excessive stocking, consideration shall be given to repair kits when-
ever available. They usually contain washers, 0-rings, screws, and other small compo-
nents needing replacement when carrying out repairs or overhauls. Low-value items,
such as small 0-rings, small diaphragms, electronic components, gaskets, fuses, signal
lamps, etc. not included in the repair kits shall be ordered in standard commercial pack-
age quantities, e.g., 10, 25, 144.
Consideration shall also be given to ordering complete assemblies and instrument as-
semblies such as controllers, recorders, amplifiers, transmitters, printed circuit boards,
regulators, chart drive units, pressure gauges, temperature gauges, pressure switches.
For common valves, the spares shall be recommended only for valve size above 2 and
the complete valve shall be recommended for valve size 2 and below.
11.2 QUANTITY OF SPARE PARTS
The following additional guidelines should be used by the CONTRACTOR when making
quantity recommendations:
Minimize spares cost based on normal delivery time of spares. Non-critical
spares with less than 2 week deliveries should not be recommended for pur-
chase.

Professional judgment and experience should be exercised when determining


quantity recommendations.

In general, spare parts should not be recommended for spared (installed or


warehouse) equipment.

Minimize the purchase of slow wearing/slow moving parts (unless the equipment
is critical and spares are required to maintain plant integrity in event of failure).

Instrumentation - maximize the use of whole unit replacement items in lieu of


breakdown to component level.

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

APPENDIX - 1

EQUIPMENT AND MATERIALS DATA ACQUISITION SYSTEM

FOR TAKREER PROJECTS

CONTRACTORS VERSION

EXCEL SHEETS

USER GUIDE

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

USER GUIDE (CONTRACTOR VERSION)

1.0 INTRODUCTION
TAKREER requires electronic data for all equipment, spare parts and materials required for
any major or minor projects. This data must be submitted in electronic and hard copy format.
Contractor shall submit this data in EXCEL sheets. Contractor shall generate SPIR hard copy
reports from the EXCEL sheets (refer to sample report copies enclosed in this guide). In all
cases an electronic copy of the data is required.

1.1 SUBMITTAL OF EQUIPMENT AND MATERIALS DATA FOR NEW PROJECTS


1- TAKREER shall grant its approval to the contractor for procurement of two years spares
after submitting of electronic data in specially formatted EXCEL sheets. Each batch of
spares pertaining to a group of equipment shall be submitted in one SPIR list. A project
consists of a number of SPIR (typically the same number of spare parts purchase orders)
depending on the project size and complexity.

The contractor is required to fill and submit FIVE EXCEL WORKSHEETS IN ONE SINGLE
EXCEL file. The worksheets names are:

1- SPIR General Information


2- Equipment
3- Equipment Spec (equipment specifications - data sheets)
4- Item
5- Spare Part

2.0 EXCEL WORKSHEETS DESCRIPTION


2.1 SPIR GENERAL INFO SHEET
Contractor must start his data collection exercise by filling this sheet first. The same SPIR
number must be used and recorded in all other sheets. This sheet is required for identification
and listing of all the SPIR submitted for a project. It provides TAKREER and the contractor
with complete details about the scope of supply of each SPIR, manufacturer, delivery period
and all contractual obligations. It must be thoroughly filled. (duplicate SPIR numbers are not
allowed) in this sheet. The columns titles in this sheet are listed below:

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SPARE PARTS Rev- 2
March 2009

COLUMN Name COLUMN Details required

Serial Number of the SPIR, starts from with the site code
R for Ruwais projects and U for Umm AL Nar Projects
followed by the Project Code like ULG then a serial No.
SPIR No
Example SPIR for Unleaded Gasoline Project in Ruwais
shall start with RULG001, RULG002 etc and UULG001,
UULG002 for UAN SPIRs.

Title Title: Typically for a group of a unique equipment type

Vendor/Contractor Name of the supplier

Address of the supplier, complete address, telephone and


Vendor/Contractor. Address contact person name is required.

Main Equip. PO No Purchase Order Number of the main equipment

Delivery Period Enter period in weeks

Currency code Currency quoted

Submission Date Date when the SPIR data is submitted

Price Validity Enter validity date in the SPIR quotation

Reference Number of purchase order issued by Contrac-


SPIR PO No. tor after TAKREER approval of SPIR

Discount Percent Discount (applicable to all items in SPIR)

Total SPIR PO Cost Total SPIR PO Cost after discount if any

Project Number Project Number

Comments Specific comments in case of discount of

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

2.2 EQUIPMENT SHEET


All equipment tags in the project shall be listed in this sheet. Contractor is advised to import
equipment tag numbers from his engineering package to avoid typing mistakes. Sub-
assemblies shall be considered as equipment their respective main equipment tag number
shall be used followed by an identifier refer to the example listed below. Duplicates tag num-
bers are not allowed in this sheet.

COLUMN NAME COLUMN Details Required


Equipment Tag Number as per the P&I diagram or equipment draw-
ing (Mandatory). Do not include multiple equipment tags like 101-G-
01-A/B/C. This field must refer to a single equipment tag. In this ex-
ample the correct tag number shall be 101-G01A. Create two more
rows one for 101-G-01-B and another for 101-G-01-B.
In case of sub-assemblies the main equipment tag shall be used
followed by a period and a serial number as per the following ex-
ample. Sub-assemblies required list in included in this guide:
Pump coupling for 11-G01-A shall use the tag 11-G01-A.1 The
Tag No pump rotor assembly shall use the tag 11-G01-A.2. (Mandatory)
Service of the equipment as per the P&I Diagram example. Crude
Service Description Oil pump, Crude distillation tower etc. (Mandatory)
The unit number where the equipment is installed located. Must be
Unit No part of work breakdown structure (Mandatory)
Is Part of a package? Y or N. An indicator to flag equipment part of a package
Yes or No. Sub-assembly equipment shall be marked Yes, default
Is Sub-Assembly? value should be No. (Mandatory for equipment)
Package Tag No Required if the equipment is part of a package.
This field will be blank for main equipment like pumps, motors but
will have the equipment tag number in case of Sub-assemblies.
Filled by the tag number of the parent equipment in case of sub-
assemblies or for equipment within a package. This field establishes
the equipment hierarchy. In case of a package equipment like tur-
bine, compressor or boiler, it will contain the turbine or boiler tag
Parent Tag No number
Equipment type description, free text like Centrifugal pump, horizon-
Equipment type tal; boiler, plate heat exchanger, etc. (Mandatory).
Template ID Datasheet code of the equipment selected from a value list.
Name of the equipment manufacturer, (Mandatory). Contractor shall
Manufacturer be consistent in typing the manufacturer name.
Serial no Equipment Serial number. One number is allowed in this field.
Name of the equipment supplier. Contractor shall be consistent in
Vendor typing the vendor name.
Equipment Purchase Price as per the main equipment Purchase
Purchase price Order. Should be in the same PO currency. (Mandatory)

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March 2009

Model No Equipment model number


Drawing No General assembly Drawing
Databook Ref Volume reference where the equipment details are provided
PO No Main Equipment Purchase Order Number (mandatory)
SPIR No SPIR No (Mandatory)
Project No Project No. (Mandatory)
Additional Info Provide additional information that describes the equipment in detail

REMARKS:

Package equipment like turbines, compressors and boilers must be considered as a parent
independent hierarchy having children equipment within the package. Instrument loops should
also be considered as package (loop components and tags should use the loop tag number as
a parent tag.

All equipment in this package must have the main equipment as a parent.

Refer to the example listed below:

In specific cases, where packages are supplied as a mounted skid with the exception of pump
motor skids, Contractor may use the example illustrated below. However, this concept does
not apply to pump and motor skids. Contractor shall register each separately. The pump shall
be registered as following: Appendix 1 provides a detailed list of applicable and valid subas-
semblies for each type of equipment. Contractor/Users must strictly adhere to this model upon
registering equipment in EXCEL Sheets as valid for each type of equipment. The same princi-
ple shall be applicable to the motor.

Package Hierarchy to be submitted by Contractors

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In the example illustrated in above figure, a compressor set or a small dosing injection skid,
can be divided into Sub-functional location (TAG); a compressor, a motor, and an air receiver.
Similarly, a Sub-functional location can be divided, if required, into one or more Sub-sub-
functional locations, such as the safety valve shown here. The system is flexible, allowing as
much or as little depth in the structure as is necessary.

2.3 EQUIPMENT SPEC SHEET

Each equipment type has it own datasheet specification that describes its main characteristics
and attributes. Contractor is requested to provide an attribute value for each field in these
templates along with the unit of measure in one single cell.
All equipment tags must be assigned a valid specification template code. Contractor must not
change the code of any template. Each equipment tag must have its own set of data sheets
(specifications) attributes even if the specification is identical for a group of equipment.

Refer to a list of available templates (data sheets) at the end of this document. Contractor may
add new templates. Company shall take necessary action to incorporate in its database. The
attached excel file CMMMS tables contains a sheet named Templates SPEC listing the at-
tributes codes and description for each template. A sample of data required for this table is
provided in EXCEL sheet format sheet named Equipment Spec. It is to be noted that a com-
bination of following fields values is not allowed in this sheet (i.e. should not be duplicated):
Tag No, Template ID and Sequence.

EQUIPMENT SPEC SHEET:

COLUMN NAME COLUMN Details Required


Equipment Tag Number as per the P&I diagram or equipment
drawing (Mandatory). All Tag numbers entered in this table must
Tag No
have been entered and identified earlier in Equipment table. (Man-
datory).
Template ID Template Code for the equipment (Mandatory)
The unit number where the equipment is installed located. Must be
Sequence
part of work breakdown structure (Mandatory)
Attribute code relevant to the specific template. Refer to table
AttributeID Equipment Temp Details in the file named CMMMS tables
sheet having the same name.
Description of the Attribute code. All attributes codes and descrip-
AttributeDescr
tion are listed in EXCEL sheet named Equipment Temp Details
Unit Unit of measure of the attribute
Value of the attribute. This value should be entered by the contrac-
Attribute Value
tor.

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SPARE PARTS Rev- 2
March 2009

2.4 ITEM SHEET

An item is a spare part that is stored in the warehouse and procured as a two years operation
spare. Contractor must provide a comprehensive list of all spare parts required to maintain
and service the equipment. All items must be assigned a Unique Item Number Identifier for
keeping track and monitoring its quantity ordered in this project. An item can be used for one
or more type of equipment (accordingly the same item number shall be used for all equipment
sharing that item. However, Contractor shall not enter a new item row if the same item is used
by more than one equipment. The Item Table shall have unique ItemNo (Duplicates ItemNo
are not allowed). Contractor must also provide a list of the items that are shared between sev-
eral equipment types. In this case, the equipment tags must be identified in the EXCEL sheet
named SpareParts.

Contractor shall assign a serial number to each item. Contractor shall ensure that the same
item is not duplicated or listed more than one time in the Item EXCEL sheet named Item.
Contractor shall endeavor to provide as much detail information as possible such as material
of construction, reference to a special design, part number and proper buying description. The
purpose of this additional information is to assist Company in procurement of this item at a
later time. The item unit price shall not be listed in the Item table since the unit price may
vary for the same item during the course of the project. Refer to the table below for item in-
formation required in Item table.

COLUMN NAME COLUMN Details required


Unique serial number to identify each item. Assigned by the contrac-
ItemNo tor (Mandatory).
Description Description of the item (Mandatory)
Original Equipment manufacturer part number. General materials
like bearings should have their generic part number listed like SKF
6311 and not the main equipment part number as identified in the
ManfPartNum equipment drawing.
The part manufacturer name and not the main equipment manufac-
Manufacturer turer.
Unit of measure like piece, box, kit or set. Contractor should be con-
MeasureUnit sistent. (Mandatory)
Detail information like material of construction, reference to a special
AddlnInfo-Vendor design, part number and proper buying description.
Yes or No. (Mandatory) N or blank means that the item is a spare
part and belongs to equipment. Y means that is a general material
that is supplied in the project in bulk and has no specific tag number
attached to it. Typical example is piping material supplied for the pro-
General ? ject, insulation or sheet metal.
Project No Project Number (Mandatory)
SPIR No SPIR number (Mandatory)

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

2.5 SPARE PARTS SHEET


SpareParts sheet is required to identify the relation between each equipment tag and spare
parts required for its maintenance. It is also referred to as the Bill of Materials. It provides the
interchangeability between different equipment tags and different items. Every equipment tag
must be listed separately with its own spares.

COLUMN Name COLUMN Details required


Equip Tag No The equipment tag as per the P& I diagram (Mandatory)
The item number used for this equipment tag. Use the same num-
Item No
ber listed in Item table (Mandatory)
Installed Qty Total quantity of this item installed in this equipment (Mandatory)
Type the assembly or drawing number where this item is installed.
Drawing No
Do not use the word drawing or DRWG No. just type the number
Type the position number in above mentioned drawing. Do not use
Position No
the word position or No. just type the number
Quantity recommended by the Contractor for two years spares op-
Contr Recomm Qty
eration of this equipment. (Mandatory)
Item Unit price. Use same currency included in the SPIR table
Unit Price
(Mandatory)
Yes or No. Enter Y if this is an insurance item. Insurance means
Insurance? that this item will be supplied part of the main equipment package
and will not be procured separately in the SPIR order. (Mandatory)
Company approved Quantity approved by Company. This information will be commu-
Qty nicated to the Contractor
SPIR No SPIR number (Mandatory)
Project Number Project Number (Mandatory)

In addition to the five tables (worksheets) mentioned above which must be filled by contractor,
the EXCEL file CMMMS tables contains two more worksheets used as value lists and are
listed for information only to assist the contractor in selecting the proper Template ID or attrib-
utes codes and descriptions for an equipment . Contractor may add additional rows in both ta-
bles if there is a need to add new equipment templates. The value lists tables are listed as fol-
lowing:

1- Templates Description: List the template ID and its description. The list contains 236 tem-
plates.

2- Template Spec: List The template ID and all its related attributes codes and attributes de-
scription and unit of measure.

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March 2009

3.0 RELATIONSHIP BETWEEN WORKSHEETS IN CMMMS TABLES.XLS

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

4.0 PROCEDURES FOR SPIR DATA COLLECTION

The procedure for data entry and collection is simple. Use the process flow which is graphi-
cally illustrated in the next two flow charts.

PROJECT COLLECT Manufacturers data


SPECIFICATIONS Equipment sheets
data

Enter SPIR General


Info Data

Add New Template in


Templates Description and new
Enter/Import Equipment
Template attributes in Equip
Tags/details in Equipment
Templates Spec

No

Template ID available in
Templates Description?

Yes

Assign / Enter
Template Code
and all other
equipment details

Copy TemplateSpec
from Equip Templates
Spec Sheet in
Equipment Spec Sheet

Enter Attributes values


in Equipment Spec
Sheet

Equipment/Tags Data
A completed

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SPARE PARTS Rev- 2
March 2009

FLOW CHART FOR ITEMS & SPARE PARTS DATA


COLLECTION

Parts
COLLECT
Manufacturers
A Spare Parts
data sheets
(Items) Data

Equipment/Tag Data
completed

Enter/Import Items in
Item Sheet

Separate rows must be


Link Items to Tag created for each
Numbers in SpareParts equipment tag number
Table

Check thal all Tags have


Attributes Values in Equipment
and Equipment Spec Sheets

No

Enter missing
equipment Tags
Yes and attribute data

No
Print SPIR Report

Good Quality
data

Yes

SPIR Completed

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SPARE PARTS Rev- 2
March 2009

4.1 GENERAL SPIR INFORMATION SHEET


Start data collection by filling the GENERAL SPIR INFO sheet:
Create a new row in SPIR general Info sheet for every SPIR. Use sequential numbers starting
with the Letter R for Ruwais SPIR and U for UAN SPIRs. The prices in your SPIR quotation
should comply with the requested terms & conditions in the contract. Quote as requested, you
can adjust the prices by adding a percentage for the cost of packing and delivery FOB if your
prices are EX-Works and unpacked. Enter the complete address of the parts manufacturers
and all particular details.
4.2 EQUIPMENT SHEET

1- Create a new equipment TAG Number row. This row contains all equipment tag informa-
tion. Create a new record for each equipment. Contractor should fill all fields particularly
the Template ID field. Enter a new equipment row noting that duplicate Tag numbers
should be avoided. The template ID code can be easily searched by searching in the
sheet named Template Descriptions. The user can use the FIND function CTRL F to
search for any part of the template name. The desired equipment tag can be also
searched using the same technique. The following remarks should be observed in filling
this sheet:

a. The user must create a row (line) with a Unit No in Equipment sheet for general mate-
rials like Piping small valve or chemicals. This dummy tag is required to reflect the
cost of these materials. The cost shall be entered later in SpareParts sheet.

b. Copy the template specifications attributes from the sheet Templates Spec. Select
the number of rows for the desired template and paste these rows in the sheet
Equipment Spec. Enter the equipment Tag Number in each of the copied rows. Also
enter the datasheet specifications in the column titled Attribute Values.
c. Each equipment tag must have a complete set of templates attributes. As an example
Equipment tags 1101JA/JB must have two identical numbers of rows with the excep-
tion of tag number. In other the first set will have the tag number 1101JA and the sec-
ond set will have 1101JB. Copy and paste the complete number of rows for a particular
to duplicate those for identical equipment.

2- Next important step is to create item records in Items sheet.

4.3 ITEM SHEET


a. Each item (spare part) in the SPIR must be assigned a unique serial number in Item
sheet each in a separate row. Enter all required information including the SPIR number.
b. Enter all additional information that would provide adequate and comprehensive buying
description for this item like material of construction, specifications or standards to assist
TAKREER in future procurement.

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

4.4 CREATING THE BILL OF MATERIAL (SPARE PARTS LIST)

The bill of Materials (Spare parts List) can be created once the SPIR general information,
equipment tag number and Item records are created in the database. It is required to identify
and link all the items numbers used for each equipment listed in Equipment sheet. This can
be done using the sheet named Spare Parts.

Locate/identify all the spare parts item number from Item sheet using the FIND CTRL F
function to find the description of a particular item. Type the respective equipment tag number
against each item number. This means that item numbers must be entered before adding
rows to the SpareParts sheet. The following information is also required in this sheet:

1. Total quantity of the item installed in this equipment.


2. Drawing Number
3. Position number
4. Quantity of items recommended by contractor as two years spares for this equipment
only.
5. Unit Price: Individual unit price in the SPIR currency.
6. Insurance Spares? Type Y if the item is bought as insurance spare and is delivered
part of the equipment main purchase order. Otherwise leave blank
7. Quantity Recommended by TAKREER. Leave blank
8. SPIR No: Enter SPIR number previously defined in General Info SPIR sheet.
9. Project Number: Enter project number.

5.0 QUALITY ASSURANCE & CHECKING DATA QUALITY REPORTS


Contractor must check the data quality before submitting the SPIR otherwise it will be subject
to rejection and delay by TAKREER. Contractor is recommended to check the following pa-
rameters by designing special reports:

a) Tags without Spec Report. This report will list all equipment tag numbers which do
not have any attributes values entered at all in Equipment Spec sheet. This is an
indication that the equipment specification records have been entered but no effort
was done to enter corresponding attribute values from the equipment data sheets.
b) Tags without Templates Report. This report is essential to ensure that all equipment
listed in the database have been assigned a Template ID numbers so that necessary
specifications records are created in Equipment Spec sheet.
c) Equipment Spec by Tag Report This report will select a group of equipment tags within
a specified range of tag numbers. It will print the tag number, description, template ID and
the attribute, codes descriptions and values for the equipment template. It is useful for
random check of the specification data quality after entry.
d) Tags without Spare Parts Report. This report will list all equipment tags which do not
have spare parts linked.

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SPARE PARTS Rev- 2
March 2009

e) Template Report. The user specifies the template ID and this report will list all related
template attributes codes, descriptions and unit of measure. It allows the contractor to
know the type of information that must be collected for each equipment type.
The user should take corrective action after analysis of above mentioned reports.
6.0 PROJECT DELIVERABLES
The contractor contractual obligation towards TAKREER is to submit Maintenance and Mate-
rials which consists of two elements: Electronic data and hard copy format.
A- ELECTRONIC DATA
TAKREER shall accept the equipment and materials electronic data in EXCEL SHEETS
Contractor shall submit one EXCEL file containing five worksheets in the specified for-
mat as per attached sample CMMMS Tables sample.xls. Electronic Data shall be sup-
plied in batches. However, each batch much include previous data submitted earlier. The
purpose of this exercise is to obtain a consolidated database format for all equipment
and items submitted throughout the project. Contractor is advised that data submitted in
EXCEL worksheets is difficult to control and validate. TAKREER shall carry out quality
assurance tests. Invalid data shall be returned to the contractor for revalidation.
B- SPIR HARD COPY REPORTS
i. SPIR REPORT
This is the most important report that must be submitted by the contractor for ap-
proval of two years spares in each SPIR. It is a contractual obligation. The report
includes recommended and approved items quantities, unit and total costs by
SPIR. The contractor should generate his own SPIR reports from EXCEL work-
sheets. However, contractor must maintain the same format of the SPIR Report
as specified in the agreement and which sample is included at the end of this
manual. TAKREER will grant its approval for procurement of two years based on
the submitted SPIR reports in addition to the supporting documents mentioned in
the agreement which typically consists of two sets of drawings, P & I diagrams,
vendor manuals and manufacturers data sheets.
ii. BILL OF MATERIALS REPORT
This is the second deliverable report which must be submitted by the contractor. It
lists all the spare parts for each equipment tag number.

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

ATTACHMENT I (SAMPLE REPORTS)

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March 2009

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

ATTACHMENT II
EQUIPMENT SUBASSEMBLIES BY SPECIFICATIONS TEMPLATE (Page 1 of 3)

TEMPLATE EQUIPMENT DESCRIP- SUBASSEMBLIES


TION
1175 Blower Coupling
Gearbox
Drive motor
Control Cabinet
4001 Boiler Flame supervisory system
Burner management system
Control Panel
Economizer
4005 Compressor, Centrifugal Rotor
Casing
Lube System
Couplings
Seals
4006 Compressor, Reciprocating Crankcase
Cylinder Assembly
Lube System
Couplings
Seals
1407 Compressor, Rotary Rotor
Casing
Lube System
Couplings
Seal
1444 Conveyor Idler stroller
Motor
Gearbox
Clutch
Couplings
1604 Engine, Diesel Cylinder Head
Crankshaft Assembly
Lube System
Fuel System
Governor
Cooling Water System
Starter Motor Assembly
4095 Exchanger, Fin Fan Fan Assembly
4041 Furnace, Process Burner
Purge Control System
Flame Monitoring System
Temperature Monitoring System

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

EQUIPMENT SUBASSEMBLIES BY SPECIFICATIONS TEMPLATE (Page 2 of 3)

TEMPLATE EQUIPMENT DESCRIPTION SUBASSEMBLIES


4014 Generator, Gas Inlet Duct
Compressor
Turbine
Transmission
Lube System
Control Panel
4013 Generator, Diesel Engine Assembly
Generator Assembly
Starting System
4079 Loading Arm Swing Joint
Boom Loader
Control Box
5186 Agitator Gear Reducer
Mechanical Seal
5001 Blower, Soot Carriage Assembly
Valve Operating Mechanism
Trailing Cable Device
Control Cabinet
5002 Boiler, Waste Heat Diverter
Damper
DCS System
Combustion Control
5016 Crane, Mobile Hydraulic System
Engine Assembly
Brake system
Air Conditioning System
Outriggers
Fuel System
Pneumatic Control
Operator Cabin
5017 Crane, Overhead Electric Motor
Electric Switchgear box
5018 Crane, Pedestal Electric Motor
5020 Desecrator Motor
Mixer
Pump
Tank
5025 Desuperheater Atomizer
5099 Package Main Equipment Assembly
Control Panel
1983 Mixer Speed Reducer
Transmission Unit
2189 Pump, Centrifugal Mechanical Seal
Transmission
Rotor assembly

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DGS-MU-003
SPARE PARTS Rev- 2
March 2009

EQUIPMENT SUBASSEMBLIES BY SPECIFICATIONS TEMPLATE (Page 3of 3)

TEMPLATE EQUIPMENT SUBASSEMBLIES


DESCRIPTION
2192 Pump, Reciprocating Cylinder Assembly
Transmission
Seals
Rotor assembly
4087 Pump, Screw, Gear Mechanical Seal
Transmission
Rotor assembly
5177 Valve Hydraulic Hydraulic System
5177 Valve, Motor Operated Motor Actuator
5166 Tower, Cooling Fire Tower
Hydraulic Control Baffle
4088 Turbine, Gas Rotor
Casing assembly
Lube System
Filtration
Gas Handling System
Gas Heater
4092 Turbine, Steam Steam Chest
Rotor
Governor Valve
Lube System
Speed Control
4089 Turbine, Hydraulic Mechanical Seal
Coupling

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SPARE PARTS Rev- 2
March 2009

ATTACHMENT III TEMPLATES DESCRIPTION

template
ID Template Description
1009 ABSORBER, COLUMN
1012 ACCELERATOR
1013 ACCELEROMETER
1014 ACCUMULATOR
1015 ACTIVATOR
1016 ACTUATOR, CONTACT
1017 ACTUATOR, DIAPHRAGM
1018 ACTUATOR, ELECTRIC MOTOR
1019 ACTUATOR
1020 ACTUATOR, PISTON
1039 AERATOR
1041 AIR CONDITIONER
1042 ALARM
1043 ALTERNATOR
1044 AMPLIFIER
1051 ANEMOMETER
1056 ANNUNCIATOR
1057 ANODE
1058 ANTENNA
1063 ARM
1071 ATOMISER
1073 ATTENUATOR
1078 BAFFLE
1079 BAG, FILTER
1082 BALANCER, FLOW
1083 BALANCER
1107 BASIN
1111 BATTERY, BANK
1113 BATTERY
1114 BATTERY, PACK
1115 BATTERY, STORAGE
1154 BLADDER, ACCUMULATOR
1175 BLOWER
1176 BOARD, DISTRIBUTION
1178 BOARD
1181 BOAT

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SPARE PARTS Rev- 2
March 2009

1187 BOILER
1204 BONNET, VALVE
1205 BOOSTER, AIR
1206 BOOSTER, CHARGE
1212 BOTTLE
1222 BOX, TELEPHONE
1229 BREAKER, CIRCUIT
1230 BREAKER
1231 BREATHER
1232 BRIDGE
1248 BURNER
1249 BUS
1261 CABINET
1268 CALIBRATOR
1269 CALL POINT
1271 CAMERA
1288 CARD, COMPUTER
1307 CELL, CONDUCTIVITY
1308 CELL, LOAD
1310 CELL, PHOTOELECTRIC
1325 CHARGER, BATTERY
1326 CHARGER
1381 COALESCER
1390 COLLECTOR
1396 COMMUTATOR
1403 COMPRESSOR, AIR
1404 COMPRESSOR, EXPANDER TURBO
1405 COMPRESSOR
1406 COMPRESSOR, REFRIGERATION
1407 COMPRESSOR, ROTARY
1409 COMPUTER
1410 COMPUTER, PERSONAL
1413 CONDENSER
1440 CONTROLLER
1441 CONVERTER
1442 CONVERTER, SIGNAL
1444 CONVEYOR
1446 COOLER
1492 CYLINDER

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March 2009

1493 DAMPENER
1498 DEHUMIDIFIER
1499 DEHYDRATOR
1500 DEMAGNETISER
1506 DETECTOR, FIRE PROTECTION
1507 DETECTOR, FLAME
1508 DETECTOR, LEAK
1509 DETECTOR, LEAK, INSTRUMENT
1510 DETECTOR
1527 DIFFUSER
1534 DISC, RUPTURE
1545 DISTRIBUTOR
1552 DRAIN
1557 DRILL, POWER
1567 DRUM
1568 DRUM, PROCESS
1570 DRYER
1594 ELEMENT, HEATER
1596 ELEMENT
1597 ELEMENT, TEMPERATURE
1599 ENCLOSURE
1604 ENGINE, DIESEL
1608 EXCHANGER
1609 EXCHANGER, PLATE
1610 EXCHANGER, SHELL & TUBE
1613 EXHAUSTER
1619 EXTINGUISHER
1632 FEEDER
1640 FILTER, AIR
1642 FILTER, FUEL
1643 FILTER, GAS
1645 FILTER
1646 FILTER, OIL
1647 FILTER, PROCESS
1648 FILTER, WATER
1674 FLOAT
1679 FOAM
1705 GATE
1709 GAUGE, DIFFERENTIAL PRESSURE

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March 2009

1712 GAUGE, LEVEL


1713 GAUGE
1714 GAUGE, PRESSURE
1722 GEARBOX
1723 GENERATOR, ELECTRIC
1821 HUMIDIFIER
1823 HYDRANT, FIRE
1825 HYDROMETER
1826 HYGROMETER
1831 IGNITER
1839 INDICATOR
1840 INDICATOR, SIGHT FLOW
1864 INVERTER
1866 ISOLATOR, ELEC DC
1876 JOINT, EXPANSION
1922 LIFTER
1924 LIGHT
1928 LIMITER
1950 MAGNET, ELECTRO
1955 MANIFOLD
1979 METER, FLOW
1980 METER
1983 MIXER
1987 MODULE, POWER SUPPLY
1988 MONITOR
1989 MONITOR, VIDEO
1991 MOTOR, CHART DRIVE
1992 MOTOR, ELECTRIC
1993 MOTOR, ELECTRIC DC
1994 MOTOR, HYDRAULIC
1995 MOTOR
1998 MOTOR, VALVE ACTUATOR
2005 MUFFLER
2006 MULTIPLEXER
2053 ORIFICE
2054 ORIFICE, PLATE
2058 OVEN
2074 PAD, WRITING
2081 PANEL, CONTROL

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March 2009

2082 PANEL, ELEC POWER


2083 PANEL, FIRE ALARM
2084 PANEL
2130 PLATE, HOT
2157 POSITIONER
2161 POT, ELECTRIC
2162 POT
2165 POWER SUPPLY
2171 PRINTER
2175 PROBE
2189 PUMP, CENTRIFUGAL
2190 PUMP, DIAPHRAGM
2191 PUMP
2192 PUMP, RECIPROCATING
2193 PUMP, ROTARY
2194 PUMP, SUBMERSIBLE
2206 RADIATOR
2223 RECORDER, CHART
2226 RECTIFIER
2244 REGULATOR, PRESSURE
2255 RESERVOIR
2256 RESERVOIR, OIL
2259 RESISTOR
2299 SAMPLER
2302 SCALE, WEIGH
2309 SCREEN, VIBRATING
2318 SCRUBBER
2327 SENSOR, CONDUCTIVITY
2328 SENSOR
2329 SEPARATOR
2374 SIMULATOR
2378 SKIMMER
2406 SOLENOID
2412 SPACER
2422 SPHERE, STORAGE
2454 STABILISER
2455 STABILISER, VOLTAGE
2456 STACK, FLARE
2457 STACK

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March 2009

2480 STOPPER
2481 STRAINER
2494 STRIPPER
2505 SUPERHEATER, STEAM
2516 SWITCH, FLOW
2518 SWITCH, LEVEL
2519 SWITCH, LEVEL FLOAT
2524 SWITCH, LIMIT
2525 SWITCH
2527 SWITCH, PRESSURE
2531 SWITCH, SPEED
2533 SWITCH, TEMPERATURE
2535 SWITCHGEAR
2548 TANK
2568 TEE, TUBE REDUCER
2578 THERMOCOUPLE
2579 THERMOCOUPLE, SKIN
2580 THERMOMETER, DIAL
2585 THERMOWELL
2601 TIP
2615 TOTALIZER
2616 TRANSCEIVER
2617 TRANSDUCER
2618 TRANSDUCER, VIBRATION
2619 TRANSFORMER, IGNITION
2620 TRANSFORMER, INSTRUMENT
2621 TRANSFORMER
2622 TRANSFORMER, VARIABLE
2626 TRANSMITTER, DIFFERENTIAL PRESSURE
2627 TRANSMITTER, LIQUID LEVEL
2628 TRANSMITTER
2629 TRANSMITTER, PRESSURE
2630 TRANSMITTER, TEMPERATURE
2634 TRAP, STEAM
2636 TRAY
2672 TURBOCHARGER
2687 VALVE, BALL
2688 VALVE, BUTTERFLY
2689 VALVE, CHECK

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March 2009

2690 VALVE, CONTROL


2691 VALVE, DIAPHRAGM
2692 VALVE, GATE
2693 VALVE, GLOBE
2694 VALVE, NEEDLE
2695 VALVE
2697 VALVE, RELIEF
2698 VALVE, SOLENOID
2702 VENT
2704 VESSEL
2706 VIBRATOR
2736 WINCH
4001 BOILER, PACKAGE
4003 ELECTROLYSIS CELL
4004 CENTRIFUGE
4005 COMPRESSOR, CENTRIFUGAL
4006 COMPRESSOR, RECIPROCATING
4009 DESALINATOR
4010 DRYER, PROCESS
4012 DISTRIBUTION BOARD, LIGHTING
4013 GENERATOR, ELECTRIC, DIESEL DRIVEN
4014 GENERATOR, ELECTRIC, GAS DRIVEN
4015 HEATER, ELECTRIC
4020 CONTROL PANEL, ELECTROLYSIS CELL
4021 CONTROL PANEL, ELECTROLYSIS RECTIFIER
4023 RECTIFIER, BATTERY ELECTROSIS PLANT
4025 CONTROL CABINET, NITROGEN GENERATION
4026 CONTROL CABINET, PALLETIZING UNIT
4027 CONTROL CABINET, SALT PACKAGING UNIT
4028 TRANSFOMER, ELECTROLYSIS CELL
4029 TRANSFOMER, DISTRIBUTION
4031 SWITCH, ELECTROLYSIS CELL
4032 FAN
4034 MONITOR, FIRE
4041 FURNACE, PROCESS
4043 HEATER, PROCESS
4044 LOOP, FLOW CONTROL INSTRUMENT
LOOP, FLOW CONTROL PNEUMATIC INSTRU-
4045 MENT
4046 LOOP, HAND CONTROL INSTRUMENT

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

4047 LOOP, LEVEL CONTROL INSTRUMENT (SPL


4048 LOOP, LEVEL CONTROL
4049 LOOP, PRESSURE CONTROL INSTRUMENT (S
4050 LOOP, PRESSURE CONTROL
LOOP, TEMPERATURE INDICATOR INSTRU-
4051 MENT
4052 LOOP, FLOW CONTROL SPECIAL
4053 LOOP, FLOW INDICATOR INSTRUMENT
4054 LOOP, LEVEL INDICATOR INSTRUMENT
4055 LOOP, PRESSURE INDICATOR INSTRUMENT
4056 INDICATOR, METER
LOOP, TEMPERATURE INDICATOR INSTRU-
4057 MENT
4058 LOOP, VIBRATION INDICATOR INSTRUMENT
4059 LOOP, VIBRATION DIGITAL INSTRUMENT
LOOP, INDICATOR, WEIGHT SCALE INSTRU-
4060 MENT
4061 LOOP, LEVEL CONTROL DP
4062 LOOP, LEVEL INDICATOR, PNEUMATIC IN
4063 ANALYZER
4064 LOOP, PRESSURE CONTROL PNEUMATIC
4065 SYSTEM, FLOW ALARM AND ESD SHUTDOWN
4066 SYSTEM, LEVEL ALARM AND ESD SHUTDOWN
SYSTEM, PRESSURE ALARM AND ESD SHUT-
4067 DOW
4068 SYSTEM, TEMPERATURE ALARM AND ESD
4069 SYSTEM, VIBRATION ALARM AND ESD
4070 SYSTEM, SEQUENCIAL CONTROL FOR ESD
4071 SYSTEM, SEQUENCIAL CONTROL FOR RELAY E
4072 SYSTEM, SEQUENTIAL CONTROL FOR PLC
4073 LOOP, TEMPERATURE CONTROL PNEUMATIC
4074 SYSTEM, TEMPERATURE DIGITAL INDICATION
4075 SYSTEM, STORAGE TANK
4076 INSTRUMENT, TEMPERATURE MULTIPLEXING
4077 SYSTEM, TEMPERATURE DIGITAL INDICATION
4078 EJECTOR
4079 LOADING ARM, MARINE
4080 ELEVATOR/LIFT
4082 INCINERATOR
4084 NOZZLE
4087 PUMP, SCREW
4088 TURBINE, GAS

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

4089 TURBINE, HYDRAULIC


4090 TURBINE, EXPANSION
4091 TURBINE, AMIN RECOVERY
4092 TURBINE, STEAM
4095 EXCHANGER, FIN FAN
5002 BOILER, WASTE HEAT
5034 HOIST
5099 PACKAGE
5180 VAPRIZ
5314 SILENCER
8033 PROCURMET, FLAME ARRESTORS
8465 SYSTEM, GAS MONITORING
8469 SYSTEM
8492 VALVE, SEQUENCIAL CONTROL/ESD
8513 EXCHANGER, DOUBLE PIPE
8514 REACTOR
8515 COLUMN
8516 TANK, PROCESS, STORAGE
8517 VESSEL - DRUM
8518 MIXER, STATIC
template
ID Template Description
1009 ABSORBER, COLUMN
1012 ACCELERATOR
1013 ACCELEROMETER
1014 ACCUMULATOR
1015 ACTIVATOR
1016 ACTUATOR, CONTACT
1017 ACTUATOR, DIAPHRAGM
1018 ACTUATOR, ELECTRIC MOTOR
1019 ACTUATOR
1020 ACTUATOR, PISTON
1039 AERATOR
1041 AIR CONDITIONER
1042 ALARM
1043 ALTERNATOR
1044 AMPLIFIER
1051 ANEMOMETER
1056 ANNUNCIATOR
1057 ANODE

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

1058 ANTENNA
1063 ARM
1071 ATOMISER
1073 ATTENUATOR
1078 BAFFLE
1079 BAG, FILTER
1082 BALANCER, FLOW
1083 BALANCER
1107 BASIN
1111 BATTERY, BANK
1113 BATTERY
1114 BATTERY, PACK
1115 BATTERY, STORAGE
1154 BLADDER, ACCUMULATOR
1175 BLOWER
1176 BOARD, DISTRIBUTION
1178 BOARD
1181 BOAT
1187 BOILER
1204 BONNET, VALVE
1205 BOOSTER, AIR
1206 BOOSTER, CHARGE
1212 BOTTLE
1222 BOX, TELEPHONE
1229 BREAKER, CIRCUIT
1230 BREAKER
1231 BREATHER
1232 BRIDGE
1248 BURNER
1249 BUS
1261 CABINET
1268 CALIBRATOR
1269 CALL POINT
1271 CAMERA
1288 CARD, COMPUTER
1307 CELL, CONDUCTIVITY
1308 CELL, LOAD
1310 CELL, PHOTOELECTRIC
1325 CHARGER, BATTERY

Takreer DGS-MU-003-Rev2 Mar-2009 Printed 14-May-09 11:39:03 Initials Page 39 of 68


Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

1326 CHARGER
1381 COALESCER
1390 COLLECTOR
1396 COMMUTATOR
1403 COMPRESSOR, AIR
1404 COMPRESSOR, EXPANDER TURBO
1405 COMPRESSOR
1406 COMPRESSOR, REFRIGERATION
1407 COMPRESSOR, ROTARY
1409 COMPUTER
1410 COMPUTER, PERSONAL
1413 CONDENSER
1440 CONTROLLER
1441 CONVERTER
1442 CONVERTER, SIGNAL
1444 CONVEYOR
1446 COOLER
1492 CYLINDER
1493 DAMPENER
1498 DEHUMIDIFIER
1499 DEHYDRATOR
1500 DEMAGNETISER
1506 DETECTOR, FIRE PROTECTION
1507 DETECTOR, FLAME
1508 DETECTOR, LEAK
1509 DETECTOR, LEAK, INSTRUMENT
1510 DETECTOR
1527 DIFFUSER
1534 DISC, RUPTURE
1545 DISTRIBUTOR
1552 DRAIN
1557 DRILL, POWER
1567 DRUM
1568 DRUM, PROCESS
1570 DRYER
1594 ELEMENT, HEATER
1596 ELEMENT
1597 ELEMENT, TEMPERATURE
1599 ENCLOSURE

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

1604 ENGINE, DIESEL


1608 EXCHANGER
1609 EXCHANGER, PLATE
1610 EXCHANGER, SHELL & TUBE
1613 EXHAUSTER
1619 EXTINGUISHER
1632 FEEDER
1640 FILTER, AIR
1642 FILTER, FUEL
1643 FILTER, GAS
1645 FILTER
1646 FILTER, OIL
1647 FILTER, PROCESS
1648 FILTER, WATER
1674 FLOAT
1679 FOAM
1705 GATE
1709 GAUGE, DIFFERENTIAL PRESSURE
1712 GAUGE, LEVEL
1713 GAUGE
1714 GAUGE, PRESSURE
1722 GEARBOX
1723 GENERATOR, ELECTRIC
1821 HUMIDIFIER
1823 HYDRANT, FIRE
1825 HYDROMETER
1826 HYGROMETER
1831 IGNITER
1839 INDICATOR
1840 INDICATOR, SIGHT FLOW
1864 INVERTER
1866 ISOLATOR, ELEC DC
1876 JOINT, EXPANSION
1922 LIFTER
1924 LIGHT
1928 LIMITER
1950 MAGNET, ELECTRO
1955 MANIFOLD
1979 METER, FLOW

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

1980 METER
1983 MIXER
1987 MODULE, POWER SUPPLY
1988 MONITOR
1989 MONITOR, VIDEO
1991 MOTOR, CHART DRIVE
1992 MOTOR, ELECTRIC
1993 MOTOR, ELECTRIC DC
1994 MOTOR, HYDRAULIC
1995 MOTOR
1998 MOTOR, VALVE ACTUATOR
2005 MUFFLER
2006 MULTIPLEXER
2053 ORIFICE
2054 ORIFICE, PLATE
2058 OVEN
2074 PAD, WRITING
2081 PANEL, CONTROL
2082 PANEL, ELEC POWER
2083 PANEL, FIRE ALARM
2084 PANEL
2130 PLATE, HOT
2157 POSITIONER
2161 POT, ELECTRIC
2162 POT
2165 POWER SUPPLY
2171 PRINTER
2175 PROBE
2189 PUMP, CENTRIFUGAL
2190 PUMP, DIAPHRAGM
2191 PUMP
2192 PUMP, RECIPROCATING
2193 PUMP, ROTARY
2194 PUMP, SUBMERSIBLE
2206 RADIATOR
2223 RECORDER, CHART
2226 RECTIFIER
2244 REGULATOR, PRESSURE
2255 RESERVOIR

Takreer DGS-MU-003-Rev2 Mar-2009 Printed 14-May-09 11:39:03 Initials Page 42 of 68


Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

2256 RESERVOIR, OIL


2259 RESISTOR
2299 SAMPLER
2302 SCALE, WEIGH
2309 SCREEN, VIBRATING
2318 SCRUBBER
2327 SENSOR, CONDUCTIVITY
2328 SENSOR
2329 SEPARATOR
2374 SIMULATOR
2378 SKIMMER
2406 SOLENOID
2412 SPACER
2422 SPHERE, STORAGE
2454 STABILISER
2455 STABILISER, VOLTAGE
2456 STACK, FLARE
2457 STACK
2480 STOPPER
2481 STRAINER
2494 STRIPPER
2505 SUPERHEATER, STEAM
2516 SWITCH, FLOW
2518 SWITCH, LEVEL
2519 SWITCH, LEVEL FLOAT
2524 SWITCH, LIMIT
2525 SWITCH
2527 SWITCH, PRESSURE
2531 SWITCH, SPEED
2533 SWITCH, TEMPERATURE
2535 SWITCHGEAR
2548 TANK
2568 TEE, TUBE REDUCER
2578 THERMOCOUPLE
2579 THERMOCOUPLE, SKIN
2580 THERMOMETER, DIAL
2585 THERMOWELL
2601 TIP
2615 TOTALIZER

Takreer DGS-MU-003-Rev2 Mar-2009 Printed 14-May-09 11:39:03 Initials Page 43 of 68


Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

2616 TRANSCEIVER
2617 TRANSDUCER
2618 TRANSDUCER, VIBRATION
2619 TRANSFORMER, IGNITION
2620 TRANSFORMER, INSTRUMENT
2621 TRANSFORMER
2622 TRANSFORMER, VARIABLE
2626 TRANSMITTER, DIFFERENTIAL PRESSURE
2627 TRANSMITTER, LIQUID LEVEL
2628 TRANSMITTER
2629 TRANSMITTER, PRESSURE
2630 TRANSMITTER, TEMPERATURE
2634 TRAP, STEAM
2636 TRAY
2672 TURBOCHARGER
2687 VALVE, BALL
2688 VALVE, BUTTERFLY
2689 VALVE, CHECK
2690 VALVE, CONTROL
2691 VALVE, DIAPHRAGM
2692 VALVE, GATE
2693 VALVE, GLOBE
2694 VALVE, NEEDLE
2695 VALVE
2697 VALVE, RELIEF
2698 VALVE, SOLENOID
2702 VENT
2704 VESSEL
2706 VIBRATOR
2736 WINCH
4001 BOILER, PACKAGE
4003 ELECTROLYSIS CELL
4004 CENTRIFUGE
4005 COMPRESSOR, CENTRIFUGAL
4006 COMPRESSOR, RECIPROCATING
4009 DESALINATOR
4010 DRYER, PROCESS
4012 DISTRIBUTION BOARD, LIGHTING
4013 GENERATOR, ELECTRIC, DIESEL DRIVEN

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

4014 GENERATOR, ELECTRIC, GAS DRIVEN


4015 HEATER, ELECTRIC
4020 CONTROL PANEL, ELECTROLYSIS CELL
4021 CONTROL PANEL, ELECTROLYSIS RECTIFIER
4023 RECTIFIER, BATTERY ELECTROSIS PLANT
4025 CONTROL CABINET, NITROGEN GENERATION
4026 CONTROL CABINET, PALLETIZING UNIT
4027 CONTROL CABINET, SALT PACKAGING UNIT
4028 TRANSFOMER, ELECTROLYSIS CELL
4029 TRANSFOMER, DISTRIBUTION
4031 SWITCH, ELECTROLYSIS CELL
4032 FAN
4034 MONITOR, FIRE
4041 FURNACE, PROCESS
4043 HEATER, PROCESS
4044 LOOP, FLOW CONTROL INSTRUMENT
LOOP, FLOW CONTROL PNEUMATIC INSTRU-
4045 MENT
4046 LOOP, HAND CONTROL INSTRUMENT
4047 LOOP, LEVEL CONTROL INSTRUMENT (SPL
4048 LOOP, LEVEL CONTROL
4049 LOOP, PRESSURE CONTROL INSTRUMENT (S
4050 LOOP, PRESSURE CONTROL
LOOP, TEMPERATURE INDICATOR INSTRU-
4051 MENT
4052 LOOP, FLOW CONTROL SPECIAL
4053 LOOP, FLOW INDICATOR INSTRUMENT
4054 LOOP, LEVEL INDICATOR INSTRUMENT
4055 LOOP, PRESSURE INDICATOR INSTRUMENT
4056 INDICATOR, METER
LOOP, TEMPERATURE INDICATOR INSTRU-
4057 MENT
4058 LOOP, VIBRATION INDICATOR INSTRUMENT
4059 LOOP, VIBRATION DIGITAL INSTRUMENT
LOOP, INDICATOR, WEIGHT SCALE INSTRU-
4060 MENT
4061 LOOP, LEVEL CONTROL DP
4062 LOOP, LEVEL INDICATOR, PNEUMATIC IN
4063 ANALYZER
4064 LOOP, PRESSURE CONTROL PNEUMATIC
4065 SYSTEM, FLOW ALARM AND ESD SHUTDOWN
4066 SYSTEM, LEVEL ALARM AND ESD SHUTDOWN

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

SYSTEM, PRESSURE ALARM AND ESD SHUT-


4067 DOW
4068 SYSTEM, TEMPERATURE ALARM AND ESD
4069 SYSTEM, VIBRATION ALARM AND ESD
4070 SYSTEM, SEQUENCIAL CONTROL FOR ESD
4071 SYSTEM, SEQUENCIAL CONTROL FOR RELAY E
4072 SYSTEM, SEQUENTIAL CONTROL FOR PLC
4073 LOOP, TEMPERATURE CONTROL PNEUMATIC
4074 SYSTEM, TEMPERATURE DIGITAL INDICATION
4075 SYSTEM, STORAGE TANK
4076 INSTRUMENT, TEMPERATURE MULTIPLEXING
4077 SYSTEM, TEMPERATURE DIGITAL INDICATION
4078 EJECTOR
4079 LOADING ARM, MARINE
4080 ELEVATOR/LIFT
4082 INCINERATOR
4084 NOZZLE
4087 PUMP, SCREW
4088 TURBINE, GAS
4089 TURBINE, HYDRAULIC
4090 TURBINE, EXPANSION
4091 TURBINE, AMIN RECOVERY
4092 TURBINE, STEAM
4095 EXCHANGER, FIN FAN
5002 BOILER, WASTE HEAT
5034 HOIST
5099 PACKAGE
5180 VAPRIZ
5314 SILENCER
8033 PROCURMET, FLAME ARRESTORS
8465 SYSTEM, GAS MONITORING
8469 SYSTEM
8492 VALVE, SEQUENCIAL CONTROL/ESD
8513 EXCHANGER, DOUBLE PIPE
8514 REACTOR
8515 COLUMN
8516 TANK, PROCESS, STORAGE
8517 VESSEL - DRUM
8518 MIXER, STATIC

Takreer DGS-MU-003-Rev2 Mar-2009 Printed 14-May-09 11:39:03 Initials Page 46 of 68


Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

APPENDIX 2
REFERENCE TO IDENTIFY TYPE OF SPARES
TO BE SPECIFIED ON SPIR FORM

Takreer DGS-MU-003-Rev2 Mar-2009 Printed 14-May-09 11:39:03 Initials Page 47 of 68


Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

The following lists are guidelines illustrating the type of parts to be listed on the SPIR Form.

List No.

Furnaces/boilers (incl. flue gas ducting) 1


Heat exchangers 2
Columns/reactors/vessels 3
Rotating disc contactors/mixers 4
Centrifugal pumps/hydraulic turbines 5
Rotary positive displacement pumps 6
Reciprocating pumps 7
Centrifugal compressors 8
Rotary vane and screw compressors 9
Reciprocating compressors 10
Blowers / Fans 11
Steam turbines up to approx. 500 kW 12
Gearboxes 13
Diesel/gas engines 14
Electric asynchronous motors 15
Electric generators and synchronous motors 16
Electric variable speed drives 17
High and low-voltage switchgear 18
Power and telecommunication cables and acces- 19
sories
Lighting fittings 20
Instruments 21
Control valves 22
Safety relief valves 23
Valves (gate, globe, ball, etc.) 24
Miscellaneous equipment 25

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 1 - FURNACES/BOILERS (inclusive. flue ducting etc.)

ITEM SPARE PART


1 Return fittings (expanding type)
2 Butt-welding return bends (radiant section)
3 Butt-welding return bends (convection section)
4 Furnace tubes (radiant section)
5 Furnace tubes (convection section)
6 Boiler tubes (radiant section)
7 Superheater tubes
8 Tube caps
9 Boiler tubes (convection section)
10 Tube hangers/supports(radiant)
11 Specially formed refractory (burner throats)
12 Refractory materials
13 Fire bricks
14 Fuel guns, complete assembly
15 Fuel barrel assembly
16 Burner tip/plug combination (atomizer) for starting up
17 Burner tip/plug combination (atomizers) for design conditions
18 Burner air registers
19 Gas burner ring
20 Manhole gaskets
21 Handhole gaskets
22 Permanently installed ignition burner
23 Mobile ignition unit burner gun assembly
24 Looking glass/observation window
25 Sootblower
26 Air preheater
27 Gas tube tips

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 2 - HEAT EXCHANGERS


ITEM SPARE PART
1 Gaskets
2 Floating head internal expansion bellows
3 Tube bundles
4 Tubes
5 Ferrules
6 Plugs
7 Louver parts
8 Fan blades
9 Grease fittings
10 Vibration switches & parts for drive controls (refer to List 16)
11 Test ring with packing gland
12 Transmission belts
13 Bearings
14 Bearing housing seals (rubber)

LIST 3 - COLUMNS/REACTORS/VESSELS
ITEM SPARE PART
1 Gaskets (except compressed asbestos type)
2 Trays and tray parts
3 Demisters
4 Insulating cement
5 Erosion-resistant cement
6 Hex steel/floor steel
7 Erosion-resistant nozzles
8 Studs for hex/floor steel

LIST 4 - ROTATING DISC CONTACTORS/MIXERS


ITEM SPARE PART
1 Top bearing
2 Interstage bearing bushing
3 Bottom bearing bushing
4 Oil seal ring (Simmer)
5 Coupling
6 Mechanical seal
7 Inflatable seal assembly
8 Top header ring
9 Bottom header ring
10 Lip seal
11 V-Belts
12 Hydraulic drive

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 5 - CENTRIFUGAL PUMPS/HYDRAULIC TURBINES


ITEM SPARE PART
Stationary Parts
1 Casing wearing rings
2 Interstage bushing
3 Balancing drum/disc
4 Balancing ring/plate
5 Combined throat bushing/lantern ring
6 Metal gaskets
7 Seal rings (elastomers)
8 Sleeve bearings
9 Sleeve bearings pads
Rotating Parts
10 Rotor assembly
11 Shaft (incl. keys/nuts/washers)
12 Shaft lock nuts and washers
13 Impeller (if cast iron or other fragile material)
14 Impeller wearing ring
15 Interstage sleeve
16 Shaft sleeve (soft packing)
17 Soft packing
18 Ball/roller bearing
19 Coupling
20 Coupling membrane
21 Coupling gasket set
22 Mechanical seals

LIST 6 - ROTARY POSITIVE DISPLACEMENT PUMPS


ITEM SPARE PART
1 Pumping member and liner set
2 Oil seal ring (Simmer)
3 Timing gears
4 Special shaft packing
5 Ball/roller bearings
6 Sleeve bearings
7 Gaskets (except compressed asbestos type)
8 Coupling
9 Mechanical seal

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 7 - RECIPROCATING PUMPS


ITEM SPARE PART
1 Valves, suction assembly
2 Valves, discharge assembly
3 Piston rings
4 Piston rod/plunger packing
5 Ball/roller bearings
6 Sleeve bearings
7 Gaskets (except compressed asbestos type)
8 Coupling

LIST 8 - CENTRIFUGAL COMPRESSORS


ITEM SPARE PART
Stationary Parts
1 Labyrinth rings (gas and oil)
2 Balance bushing
3 Sleeve bearings
4 Sleeve/thrust bearings pads
Rotating Parts
5 Rotor assembly
6 Shaft lock nuts and washers
Seal Parts Contact type
7 Rotating seal face
8 Stationary seal face
9 Springs and ' O ' rings
10 Bellows
Liquid film type
11 Seal bushing and shaft sleeves
12 Distance springs
13 ' O ' rings
Restrictive type
14 Carbon rings (with garter springs)
15 ' O ' rings and shaft sleeves
General parts
16 Gaskets (except compressed asbestos types)
17 Casing sealant
18 Filter elements in seal oil and lube oil system (disposable type)
19 Coupling
Notes: 1. For auxiliary equipment refer to appropriate list.
2. For packaged integrally-geared centrifugal air compressors, a
combined approach for centrifugal compressors and gear boxes is
required.

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 9 - ROTARY VANE AND SCREW COMPRESSORS


ITEM SPARE PART
1 Matching rotating elements and liners
2 Labyrinth rings (gas and oil)
3 Sleeve bearings
4 Ball/roller bearings
5 Sleeve bearings pads
Seal parts Contact type
6 Rotating seal face
7 Stationary seal face
8 Springs and ' O ' rings
Liquid film type
9 Seal bushing and shaft sleeves
10 Distance springs
11 ' O ' rings
Restrictive type
12 Carbon rings (with garter springs)
13 ' O ' rings and shaft sleeves
General parts
14 Gaskets
15 Filter elements in seal oil and lube oil system (disposable type)
16 Coupling

LIST 10 - RECIPROCATING COMPRESSORS


ITEM SPARE PART
1 Piston wear bands/rider rings
2 Piston rings (with expander)
3 Cylinder liner
4 Main bearing
5 Connecting rod bearing (big end)
6 Connecting rod bearing (small end)
7 Crosshead pin
8 Metallic gasket/' O ' ring
9 Filter elements in lube oil system(disposable type)
10 Coupling
11 V-belts
12 Valves
13 Valve plate
14 Valve damper
15 Valve spring
16 Valve security nut
17 Valve gaskets (metal)
18 For diaphragm compressors Diaphragm assembly
19 Accumulator
20 Bladder
21 Sealing parts/gaskets

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 11- BLOWERS / FANS


ITEM SPARE PART
1 Fan
2 Shaft
3 Bearing
4 Lock Washer
5 Seal
6 O ring
7 Gasket
8 Oiler
9 Lock Washer
10 Bellows / Expansion joints
11 Pulley / Coupling
12 V- Belt
13 Filter Element

LIST 12 - TURBINES UP TO APPROX. 500 kW


ITEM SPARE PART
1 Rotor assembly
2 Sleeve bearings
3 Ball/roller bearings
4 Sleeve bearing pads
5 Carbon ring (with garter spring)
6 Labyrinth sealing strips
7 Governor
8 Rapid closing pawl
9 Valve cone
10 Valve plug
11 Valve gaskets
12 Steam nozzles
Note 1: For turbines over approx. 500 kW, gas turbines and expanders no
general recommendations have been made, in view of the variety of
design and complicated control systems sometimes applied. It is
suggested that a survey be made of all those parts which may be
taken into consideration with regard to spare part selection and that
then the items be selected on the same basis as is done for all other
running and instrument equipment.

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 13 - GEAR BOXES


ITEM SPARE PART
1 Gear set
2 Ball/roller bearings
3 Oil seal ring (simmer ring)
4 Sleeve bearings
5 Sleeve bearings pads

LIST 14 - DIESEL/GAS ENGINES


ITEM SPARE PART
1 Gaskets
2 Inlet and exhaust valves
3 Valve spring
4 Valve guide
5 Valve seat
6 Injector nozzle
7 Joint or washer for injector
8 Piston rings
9 Main bearing
10 Connecting rod bearing (big end)
11 Connecting rod bearing (small end)
12 Cam shaft bearing
13 Filter elements (disposable type)
14 Water pump seal
15 Fan belt
16 Sparking plugs
17 Governor

LIST 15 - ELECTRIC ASYNCHRONOUS MOTORS


ITEM SPARE PART
1 Ball/roller bearings
2 Oil seal ring (simmer ring)
3 Sleeve bearings
4 Sleeve bearing pads
5 Humidity detection systems for CACW cooled motors
6 Fan system/housing for auxiliary fan cooled motors
7 Auxiliary heaters

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Abu Dhabi Oil Refining Company

DGS-MU-003
SPARE PARTS Rev- 2
March 2009

LIST 16 - ELECTRIC GENERATORS AND SYNCHRONOUS MOTORS


ITEM SPARE PART
1 Ball/roller bearings
2 Oil seal ring (simmer ring)
3 Sleeve bearings
4 Sleeve bearing pads
5 Generator and exciter brushes
6 Brush holders
7 Exciter brush holders
8 Humidity detection systems for water cooled CACW machines
9 Fan system/housing for aux. fan cooled machines
10 Auxiliary heaters
11 Field coils
12 Pole insulation material for salient part of M/CS
13 Rotating diodes, mounting brackets and fixing materials
14 AVR control PCB cards
15 AVR (complete) for small M/CS
16 Control fuses, control board

LIST 17- CONVERTERS FOR ELECTRICAL VARIABLE SPEED DRIVES


ITEM SPARE PART
1 Converters
2 Controllers
3 Fuses
4 Lamps
5 Thyristors (power)

LIST 18- HIGH AND LOW-VOLTAGE SWITCH GEAR


ITEM SPARE PART
1 Terminal blocks
2 Fuse bases
3 Fuses
4 Auxiliary relays/contactors
5 Trip coils
6 Complete set of fixed and moving arcing contacts
7 HV fuses for motors/transformers
8 HV fuses for service transformer
9 Closing coil for circuit breaker
10 Contactors, to 60A incl.
11 Contactors, more than 60A
12 Contactor coil
13 LV thermal overload relays
14 Signal lamps
Note: 1. As there is a great variety in types of high voltage switchgear, it
is suggested to use the MANUFACTURERS list of recom-
mended spare parts and operating manuals.

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LIST 19 - POWER AND TELECOMMUNICATION CABLES AND ACCESSORIES


ITEM SPARE PART
1 High-voltage feeder cables
2 High-voltage motor supply cables
3 Low-voltage power cables
4 Low-voltage and auxiliary cables
5 Low-voltage lighting cables
6 Main telecommunication cables
7 Branch telecommunication cables
8 * Components for making straight-through joints in HV cable
9 * Components for making straight-through joints in LV cable
10 * Components for making straight-through joints in telecommunica-
tion cables
11 * Components for making branch-off joints in telecommunication
cables
Notes: 1. Comprising connectors, tapes, sleeves, joint boxes, bitumen/resin
compounds, etc.
2. For repair of damaged and faulty cables. Surplus stock of con-
struction materials shall be taken into account before ordering.

LIST 20 - LIGHTING FITTINGS


ITEM SPARE PART
1 Lamp fittings (complete)
2 Lamps and tubes
3 Starters

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LIST 21- INSTRUMENTS


ITEM SPARE PART
1 Gaskets (except compressed asbestos type)
2 O-rings
3 Fuses
4 Signal lamps
5 Small diaphragms
6 Small electronic components
7 Electronic amplifiers
8 Instrument assemblies such as: controllers, recorders, amplifiers, &
transmitters
9 Printed circuit board
10 Chart drive units
11 Pressure gauges
12 Temperatures gauges
13 Pressure switches
14 Pneumatic cables (with copper tubing only)
15 Thermocouple extension cables
16 Instrument signal cables
17 * Components for making straight-through and branch off joints in
instrument signal cables
18 Blank orifice plates
19 Terminal blocks
Notes: 1. Comprising connectors, tapes, sleeves, fittings, nozzles, resin
compound, etc.
2. For repair of damaged and faulty cables. Surplus stock of con-
struction materials shall be taken into account before ordering.
3. The complexity of instruments and the interchangeability of many
parts used by the same manufacturer for the various types of in-
struments makes it virtual impossible to prepare a more detailed list.

LIST 22- CONTROL VALVES


ITEM SPARE PART
1 Seats - rubber or synthetic material
2 Seats metal
3 Gaskets (except compressed asbestos type)
4 O-rings
5 Diaphragm, any material
6 Trim
7 Actuator bellows

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LIST 23- VALVES (gate, globe, ball etc.)


ITEM SPARE PART
1 Gaskets (except compressed asbestos type)
2 O-rings and seals
3 Seats - resilient
4 Seats metal
5 Wedge / Disc
6 Stem
7 Stem Packing
8 Actuator

LIST 24- SAFETY RELIEF VALVES


ITEM SPARE PART
1 Complete safety/relief valves for systems provided with locking de-
vice (without spring)
2 Nozzle, disc
3 Spring
4 Bellows
5 Gaskets (except CA F type)
6 Pilot valve assembly
7 Rupture discs holder
8 Rupture discs

LIST 25- MISCELLANEOUS EQUIPMENT


ITEM SPARE PART
1 Erosion-resistant parts of various equipment
2 Knife edges of weighbridges
3 Oil hoses for handling products on jetties, filling stations and rail/road
tankcar loading and unloading:
A. For crude oil and all finished products up to 25% aromatics con-
tent
B. For high aromatics, LPG, ethylene and chemical products
4 Oil hoses for handling products offshore:
A. Conventional buoy mooring
B. Single buoy mooring
5 Parts for loading arms
6 Ejector nozzles
7 Wire mesh for strainers
8 Filter cloth
9 Glasses for level indicators tubular type
10 Glasses for level indicators Klinger patent type
11 Fire fighting equipment

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APPENDIX 3
INSURANCE SPARE PARTS

Following Lists are Guidelines, illustrating the type of part to consider as Insurance Spares:

1. Centrifugal Pump / Reciprocating Pump


1.1 Rotor Assy. For multi stage pump only
1.2 Piston rod Assy.
2. Compressors (Centrifugal / Reciprocating)
2.1 Rotor Assy.
2.2 Cylinder Head
2.3 Piston Assy.
2.4 Piston Rod / Cross head Assy.
2.5 Connecting Rod Assy.
2.6 Dry gas seal assy.
3. Steam Turbines
3.1 Rotor Assy.
3.2 Nozzle Assy. / Set
3.3 Vanes Assy. / Set
4. Gas Turbines
4.1 Fuel Nozzle Assy.
4.2 Combustion Chamber, Cross Fire Tubes
4.3 Combustion Liners
4.4 Vane
4.5 Rotor blade
4.6 Turbine Rotor Assy.
4.7 Compressor Rotor Assy.
4.8 Load Gear Set
4.9 Burner
5. Blowers
5.1 Rotor Assy.
6. Boilers / Furnaces / Heater
6.1 Tubes 10% Inst. Qty.
7. Flare
7.1 Flare Tip Assy.
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8. Heat Exchangers
8.1 Tube Bundles
8.2 Tubes
9. Conveyors
9.1 Gear Units
9.2 Motors
9.3 Rollers

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APPENDIX 4
PROCEDURE FOR HAND-OVER OF TWO YEARS
OPERATIONAL SPARES

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INDEX

Section Description Page.No.


1 SCOPE 65
2 ABBREVIATIONS 65
3 DEFINITIONS 65
4 RESPONSIBILITIES 65
5 REQUISITE 65
6 PROCEDURE 66
7 INVOICING 67

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1. SCOPE
This procedure shall be applicable for the physical handing over of Two Year Operational
Spare Parts for the PROJECT, from CONTRACTOR to COMPANY. This procedure outlines
the scope, responsibilities and establishes sequences, modalities and the documentation
required for hand-over of the materials.
2. ABBREVIATIONS
GRN Goods Receipt Note
MDR Material Discrepancy Report
MRR Material Receiving Report
PO Purchase Order (Includes all type of Contracts)
POA Purchase Order Amendment
SPIR Spare Parts Interchangeability Record
3. DEFINITIONS
AGREEMENT AGREEMENT NUMBER
COMPANY Abu Dhabi Oil Refining Company [TAKREER]
CONTRACTOR The party who perform the works and activities.
PROJECT The nature of works involved in the Agreement.
VENDOR The Supplier selected for rendering materials.
MANUFACTURER Any firm or Company who manufactured / produced the actual
equipment / parts.

4. RESPONSIBILITIES
4.1 Materials to be handed over are part of Two-year Operational Spare Parts.
4.2 COMPANY's Materials Engineer and concerned Maintenance Engineer will inspect the ma-
terial, shall represent the COMPANY and will be responsible for acceptance of the materials
on behalf of COMPANY.
4.3 CONTRACTOR shall assign a dedicated Spare Parts Coordinator(s) at Ruwais Refinery/Abu
Dhabi Refinery site for the task of handing over of the materials.
5. REQUISITES
CONTRACTOR shall ensure that the following measures are taken prior to start any materi-
als transfer to COMPANY:
5.1 Ensure that the material received at site is packed according to the methods stated in the
Purchase order and that packages are intact.
5.2 Ensure that safe storage and preservation methods I maintenance are followed and shall be
carried out till hand over.
5.3 Ensure that proper and adequate documentation is available.

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5.4 Ensure that facilities for handling and safekeeping of the material are available and main-
tained.
Ensure that proper tag (paper) is assigned to each item of SPIR
6. PROCEDURE
6.1 CONTRACTOR shall submit a two years operational spare parts handing over schedule two
weeks in advance, to facilitate the joint inspection with the COMPANY representative and
take over the material.
The schedule shall indicate the SPIR references, number of items and date of material
availability at site, shall be issued I updated by CONTRACTOR on a weekly basis or as per
the agreed frequencies depending on the expected arrival of spares.
6.2 All operating spares shall be received, inspected, stored and maintained by CONTRACTOR.
These spares shall be segregated from other construction and installation materials. A ma-
terial Receiving report (MRR) shall be issued by CONTRACTOR as soon as spares are re-
ceived at site and checked to confirm compliance with the purchase order and to ascertain
any damage possibly incurred during Shipment. Any discrepancy shall be resolved by
CONTRACTOR prior to handing over of all SPIR items to COMPANY. Material shall be
stored with appropriate preservation methods foreseen by the specifications and stated on
the relevant packing lists.
6.3 Following documents in three sets with proper index will be submitted along with the materi-
als to be handed over for each SPIR;
Copy of COMPANY's approved SPIR forms and Purchase Order.
Copy of packing list and other shipping documents I delivery note as applicable.
Copy of test certificates I compliance certificates where applicable.
Copy of MRR with discrepancy, if any, and relevant corrective actions taken by CON-
TRACTOR.
6.4 Two year operational spares shall be delivered, along with the respective documentation, as
applicable at Companys Warehouse at Ruwais Refinery/Abu Dhabi Refinery.
6.5 CONTRACTOR shall arrange transportation and delivery of materials based on the agreed
handing over schedule.
6.6 The Contactor can avail the existing warehouse material handling equipments such as Fork-
lifts and Overhead Cranes as per the availability. If any special equipment required, the
Contractor shall arrange with their own cost.
6.7 Items such as ball bearings and mechanical seals will remain in actual storage in their origi-
nal packing, may be labeled with an adhesive label firmly attached to the outside of the car-
ton.
6.8 Original manufacturers identification shall be retained on their original packing, and shall not
be tampered / spoiled.
6.9 All two-year operational spares shall bear the original Manufacturer label I Tags indicating
following information as a minimum.
SPIR No.
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Item no, Description and Part no as per applicable SPIR


Manufacturer
Project No
TAKREER Item No (Same is to be filled up during handing over of Spares)
6.10 The Contractor representative shall unpack and display each item as per SPIR / Purchase
Order.
6.11 COMPANY's Materials Engineer shall inspect and receive the material in presence of Con-
tractors representative. Subsequently, the Companys concerned Maintenance Engineer
will verify the items and re-confirm the acceptability. Upon the satisfactory confirmation, a
Goods Receipt Note (GRN) will be released for the accepted material and the GRN shall be
duly signed by Material Engineer, concerned Maintenance Engineer and Warehouse Super-
visor. A minimum of five working days required to release the GRN.
The items not matching with SPIR description, Part Number and order quantity shall be
treated as Discrepancy / Short Supply items. The Discrepancy items will be separated and a
Material Discrepancy Report (MDR) will be issued. The delivery note will be acknowledge for
accepted material only and any MDR / Short Supply items must be resolved by CONTRAC-
TOR within 60 days from the date the MDR / Short Supply notification given by COMPANY.
In case of items to be manufactured again by the manufacturer, that might require a longer
lead time, COMPANY may, at its sole discretion, agree with CONTRACTOR an alternative
timeframe for the resolution of these items.
6.12 All MDR items shall be taken back by CONTRACTOR and item discrepancy should be re-
solved by them providing the correct material or clarifying the discrepancy with proper sup-
porting documents, to obtain the GRN for MDR / Short Supply items.
6.13 CONTRACTOR may use any material required for commissioning I start up from two year
operational spares, either before handing over of the corresponding SPIR to COMPANY, or
after hand over on a loan basis. In all cases CONTRACTOR shall replenish the items used
at his own cost and complete SPIR to COMPANY.
6.14 Coordination meeting likely to be held as per mutually agreed frequency for reviewing the
progress of the material handing over. The meeting shall be conducted at Ruwais Refin-
ery/Abu Dhabi Refinery with the participation of concerned person(s) from COMPANY and
CONTRACTOR.
7. INVOICING
The reimbursable costs of the two-year operational spare parts shall be invoiced by CON-
TRACTOR to COMPANY, as per AGREEMENT, on a monthly interval. Separate invoice will
be submitted for each approved SPIR, handed over to the COMPANY during preceding
month. Invoice will be submitted in line with the following applicable guidelines.
7.1 Invoices should cover full delivery of all items of the SPIR's included in the PO as per ap-
proved SPIR.
7.2 No invoice should be raised for partial delivery, except in exceptional circumstances and
with prior COMPANY approval, when all items of a SPIR have been received at site by
CONTRACTOR and handed-over to COMPANY, but where certain items are subject to an
MDR and are being clarified I resolved by CONTRACTOR. In this situation, the COMPANY
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may grant, on a case-by-case basis, exceptional approval for CONTRACTOR to issue a


partial invoices subject to the time requirements mentioned in para.6.11 above.
7.3 Invoices must be accompanied by the following documents;
Packing list stamped by CONTRACTOR's inspection Organization
Airway Bill I Bill of Landing I Delivery Note I Courier receipt
Copy of the relevant Purchase Orders
Good receipt Note (GRN) signed by COMPANY and CONTRACTOR representatives
Material Discrepancy Report with NIL discrepancy

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ADDENDUM SHEET
All revisions to this DGS subsequent to the issue of Rev Zero shall be recorded in this addendum
sheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks

March 2009 AMD-MU-003-BECHTEL Incorporated in


Revision 2

In Clause # 2.0: Addition/Deletion/Replacement /Modification


Modify Last sentence of 1st Paragraph as below:
The edition in force at the time of CONTRACTORs / VENDORs
proposal shall apply.
In Clause # 9.1: Addition
Add following at the end of this clause:
VENDOR shall provide following details as a minimum
along with the Spare parts:
a. Main Equipment Tag
b. Main VENDOR
c. Sub VENDOR
d. Data sheets and specification sheets
e. Part No. of original Manufacturer
f. Drawing No. of original Manufacturer
g. Material
h. Model No. /Type designation
i. Quantity required
j. Approximate dimensions
k. Weight -net and gross, maximum weight for main-
tenance
l. Special instructions for storage and hazardous
applications
m. SPIR forms showing interchange ability, QPU
(Quantity per Unit), TIQ (Total Installed Quantity).
An ordering information sheet from the VENDOR is a manda-
tory requirement encompassing SPIR formats. The referenced
drawings shall become a part of the VENDOR operation and
Maintenance Manual.

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