6261 - 4803 - 029 - Attachment-20 - Mandatory Spare Part List - XX PDF

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Mandatory Spares Part List
FOR
HINDUSTAN PETROLEUM CORPORATION LTD.

VISAKH REFINERY
DHT Project
JOB NO.: 6261
TOYO ENGINEERING INDIA LIMITED

MUMBAI INDIA
< Security Level 2 >
Manadatory Spare Part list
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED :
DOC.No. DHT Project Sheet 2 of 34
TABLE OF CONTENTS
Sl. No. Title
1. Static Equipment
2. Piping
3. Instrumentation
4. Civil
5 Rotary Equipment
6 Package Equipments
8 Heaters
9 Electrical
11 Fire Fighting
12 Tools and Tackles

ISSUED :
1. Static Equipment:
1.1. Reactors, Columns, Pressure Vessels
Sr No Part Description Quantity Required
Bolting for each nozzle with blind 10% (minimum two in each size)
1 / companion Flange and for each of installed fastners.
pad nozzle
Gaskets for each nozzle with Two sets for each installed
blind / gasket.
2
Companion flange for each pad
nozzle
Bolting for internal flanges of One set of each size of each

3
each size / type nozzle
Gasket for each internal flange of Two sets for each installed
4
each size / type gaskets
Sight / light glasses assembly 4 sets for each installed glass

5
complete with bolting and gasket
Bolts, nuts, clamps, spares for 10% (minimum two in each size)
6
demister of each size / type of installed fasteners.
1.2. Tubular Exchangers
1 Gaskets 400%
Bolting 20% (Min 4 studs and 8 nuts per

2
joint)
3 Lamiflex sealing strips 100%

ISSUED :
1.3. Air Coolers
Gasket for header cover and 400%

1
nozzles with blind flange
2 Gaskets for plugs 200%
3 Plugs 20%
4 Belts 100%
Bolts and nuts for all nozzle with 20%

5
BF & Cover plate
Diaphragm Actuator with One set

positioner for each type of auto
variable pitch fan (for Moore fan)
6 (Alternatively vendor
recommended spares for his type
of auto variable pitch fans for
make other than Moore)
Blade for each size / type of fan One set (one set is total number
7
of blades in one fan)
Set of pulleys (fan & motor ) a. 1 set for each type of fan /
motor set not exceeding two in
number.
8
b. 2 Sets for each type of fan /
motor set numbering three and
more.
Fan clevis bolts a. 4 for each type of fan upto and

including two in number
9
b. 8 for each type of fan
exceeding two in numbers but
ISSUED :
upto and including six in

number
c. 12 for fans above six in

number
Fan Bearing set (top + bottom = 1 a. 2 for fans uptp including two in
set) number
b. 3 for fans exceeding two in

10 numbers but upto and
including six in numbers.

numbers.
Motor Bearings a. 2 for quantity upto including

two in number
b. 3 for fans exceeding two in

11 numbers but upto and
including six in numbers.

numbers.
1.4. Tray and Tower Internals
Bolts / Nuts of each size type 10% of total for each size
1 (minmum 10 nos of each size /
type)
Clamp assemblies 10% of total for each type and

2 size (minimum 10 nos of each
size)
ISSUED :
3 Valves for trays 10% of each type
4 Gasketing or tapes 100% of each type and size
5 Sealing foils for cartridge trays 200% of each size
U-Clamps 10% of each type and size or 10

6
nos whichever is minimum
Tower packings 10% for metallic and plastic

packings
7
15% for carbon and ceramic
packaings.
Spray Nozzles 25% subject to minimum 5nos of

8
each type and size.
ISSUED :
2. Piping:
Sr.no. Part Description Size Range * Quantity Required (% of as built)
1 Pipes and Fittings ½” to 36” 2
2 Pipes and Fittings Above 36” Nil
3 Valve and Flanges 1/2” to 8” 2
4 Valve and Flanges 10” and above Nil
5 Bolts, Nuts All sizes 10
6 Gaskets All sizes 10
7 Traps All sizes 2
8 Expansion Bellows All sizes 100
9 Bolt torque wrenches 1 set
10 Bolt tensioning 1 set

equipment
11 PMI equipment 1 set

Notes:
1. % of quantity required to be left as mandatory spares is for each and every item /
size / material consumed in as built including piping used in various vendor supplied
packages. i.e all the items created in plant summary shall be individually considered
to calculate spares requirement as per the criteria tabulated above. No substitution
is allowed.
2. As a minimum one piece (one pipe length) per item shall be supplied. No
substitution in size, schedule, rating and material is allowed.
3. No spare quantity is required for process traps and motor operated valves.
4. As a minimum one set of bolt/nuts to be supplied for each material, diameter and
length.
5. For rating 900# and above and sizes 10” and above, minimum one valve surplus
shall be supplied for each piping class and for each sze, rating, material.
6. For 8” and 900# and above, 2% or minimum 1 whichever is higher to be used.
ISSUED :
3. Instrumentation:
Sr.no Part Description Quantity Required

1 FIELD INSTRUMENTS
20% ( Subject to min. of 1) of each type, range,
1.1 Pressure Gauges material of construction and rating, whichever is
higher.
10% (Subject ti minimum of 1) of each range of
1.2 Draft Gauges
Draft gauge, whichever is higher
20% ( Subject to min. of 1) of each type /
1.3 Temperature gauges range of Temperature Gauges, whichever is
higher.
a) For transparent gauges, 20& of illuminators
with holder and reflector and 50% of bulbs
b) In case of mangnetic type level gauges,
10% of bi-color rollers for each gaugeto be
provided in addition to above.
c) 30% subject to min one number of glass of
each type, size along with pair of Gaskets(
1.4 Level Gauges
Cushion & Wet Gasket), whichever is higher.
d) 20% subject to minimum one number of
Gaskets for Gauge Cocks/Valves Bonnet/
Packing
10% (subject to min of 1) of each type, range ,
make and material of construction, whichever is
higher
SMART Transmitter for
10% (subject to min of 1) of each type,of
Pressure, Flow (DP),Level
1.5 Electronics Transmitter card & LCD display,
(DP)
gasket, O-rings etc.
and Temperature
10% (subject to minimum of 1) each size and
1.6 3Way manifold
material to construction; whichever is higher.
a) 10% or minimum one number of each type
of electronic card whichever is higher
b) 10% or minimum one number of each type
1.7 Servo Type Level Gauges
of displacer whichever is higher
c) 10% or min one number of local indicators,
whichever is higher
Ultrasonic / Radar a) 1 Pair probe for each flow instrument & 1
1.8
Instrument probe / antenna for each level instrument
b) 1 number electronic card of each type
ISSUED :
c) 2 number fuses of all types

Capacitance / RF type 10% or minimum one number of each type of
1.9
instruments electronic card of each type whichever is higher
20% (subject to minimum of 1) of each type,
range, lengh and make of Thermcouple with
Themowell, whichever is higher. Same
1.10 Temperatur Elecments
philosophy to be followed for multi point
thermocouples also but
without thermowells.
20% (subject to min of 1) of each lengh of RTD
1.11 RTDs
with Thermowell, whichever is higher
10% (subject to minimum of 1) of each lengh &
1.12 Skin Type Thermocouple
type of skin thermocouple, whichever is higher.
1.13 Ceramic Thermowell 1 no. for each Tag
10% (subject to min of 1) of each type, range,
1.14 Temperature transmitters make and material of construction, whichever is
higher.
20% or minimum one no. float & set of Packing
Variable Area Flowmeter
1.15 for each type, size, rating and material,
(Rotameters)
whichever is higher
Set of Gasket, O-ring, Packing for Retract
1.16 Averaging Pitot tube Mechanism and one no. Needle Valve with
each Pitot Tube
a) Power Fuses 6 no. per set
Mass Flow Meter (Coriolis b) 10% of Sensor Assembly or min 1
1.17 and c) 10% or min one number of each type of
Thermal) electronic cards whichever is higher.
d) 10% or minimum 1 No. of Display module
a) One set of gasket and Packing for each type
and Size
1.18 Vortex Flow Meter
b) 10% or minimum one number of each type of
electronic cards whichever is higher
a) Electrode - 10% or minimum 2 nos
b) PCB -10% or minimum 1 no.
PH & conductivity
1.19 c) Power PCB -10% or Minimum 2 nos.
transmitter
d) PH preamplifier card - 10% or minimum 2
nos.
2.0 IN-LINE INSTRUMENTS
a) 10% or min 2 nos. of each type, size rating
of Trim set consisting of seat, seat ring / seal
2.1 Control Valves
ring, plug with stem, cage (whichever
applicable), packing material
ISSUED :
b) 20% (subject to minimum of 1) of

Positioners (smart or pneumatic) with links of
each type and make, whichever is higher
c) 15% (subject to minimum of 1) of
Diaphragm, Actuator spring of each type/
range, whichever is higher
d) 20% (subject to min of 1 ) of air filter
regulators of each make, whichever is higher
e) 10% (subject to minimum of 1) of Bonnet
gaskets/ gland packings, piston O-rings,
bearing & liner (of valve)
f) 10% (subject to minimum of 1) of any special
accessories provided along with the control
valve like boosters position transmitters
(whichever applicable), proximity switches, I/P
converters etc
whichever is higher.
a) 20% (subject to min 1) of air filter regulators,
whichever is higher
b) Seal kit consisting of O rings, gaskets, etc.
against each valve.
c) 20% (subject to min of 1) of proximity
Shutdown valve and ON- switches, whichever is higher
2.2 OFF d) 20% (subject to min of1) of solenoid valves
vlave of each types.whichever is higher
e) 20% of seal kit consisting of Plunger
assembly, Coil, O-ring shall be provided for
solenoid valves
f) 10%(subject to minimum of 1) of accessories
like quick exhaust fuses, whichever is higher
Disc - 10% of total quantity of identical pressure
relief valves or minimum one number
whichever is higher
Expansion Beloow - 20% of total quantity of
identical pressure relief valves or minimum one
number whichever is higher
2.3 Pressure Relief Valves
Spring - 10% of total quantity of identical
pressure relief valves or minimum one number
whichever is higher
Gasket set - 10% of total quantity of identical
pressure relief valves or minimum one number
whichever is higher
2.4 Pressure control Valve
a) Repair kit consisting of (orifice, plug, spring,
ISSUED :
gasket, diaphragm,
o-ring for each valve)
b) 20% or minimum 2 nos. of each type /size,
(Self Actuating Valve) rating etc.of Trim set consisting of seat, seat
ring/seal ring, plug with stem, cage (wherever
applicable), packing material for each valve to
be provided as spare.
Same as those of Control Valves and Shut
Down valves and additionally
a) Gaskets for actuator per unit
PRDS & b) Gaskets for valve and connections per unit (if
2.5
De-superheater unit such gaskets are special
and supplied by PRDS/ De-Superheater
vendor)
c) Spray nozzle per unit
2.6 Breather Valves 1 Set of seal kit for each valve
One no. of flame arrester element and one set
2.7 Flame Arresters Gasket for each Type, Size, Rating and
material
3 Nos. of Gaskets & 3 Nos. of spare discs for
2.8 Rupture Disc
each Tag
3 ANALYSER
a) Furnace Assembly -1
b) Thermocouple - 1
c) Sensor board - 1
d) Zirconia Oxide Cell -1
3.1 O2 Analyser e) Each type / rating of Fuses - 1 set
f) Thermistor assembly - 1
g) Ceramic filter - 1
h) Processor card - 1
i) Any Other card - 1
a) Rings and gasket - 2 set of each type
b) Sensor and Detector - 1 no.
c) Rotameter - 1 no.
d) Pressure Control Valve - 1 no.
Methane Analyser
3.2 e) Fuses - 5 sets
(Infrared)
f) Electronic card - 1no.
g) Other Aux. Cards - 1 each
h) Processor card and other electronic 1 no.
each.
3.3 Moisture Analyser a) Sensor and etector -1 no.
b) Electronic card - 1no. Each type
c) Fuses - 5 sets
ISSUED :
d) Flow indicator & switch - 1no.

a) Rings and gasket - 2 set of each type
b) Sensor and Detector - 1 no. with each
analyser
c) Rotameter - 1no.
3.4 Hydrogen Analyser
d) Pressure Control Valve - 1no.
e) Each type/rating of Fuses - 5 sets
f) Electronic card - 1no. With each analyser
g) Other Aux. Cards - 1 each
a) Cadmium lamp - 2 nos.
b) Cell window -2 nos.
c) Window gasket - 10 nos.
d) Air regulator - 1 no.
e) Seal kit fro ball valve - 4nos.
f) Kit-o-ring - 2 sets
3.5 H2S Analyser g) Seal kit, Air act. - 2 no.
h) Fuse - 5 set each
i) Realy - 1 set each
j) Display Board - 1no. With each
analyser
k) Processor Board - 2no.
l) Other Cards - 2each
a) Fuses - 1 set of each type
b) Ring - 2 sets of each type
c) Mother board - 2nos.
d) Filter assembly band pass with guard - 2no.
3.6 CO+CO2 Analyser
e) Filter - 1 Set of each type
f) IR/UV Lamp - 2 nos.
g) Other cards - each
h) Detector heaters - 1 each
3.7 Sox/Nox Analyser a) Filter of each type - 2sets
b) Critical orifice - 1 no.
c) Vacuum pump / Elector - 1 no.
d) Ring set - 1no. Each
e) Processor / Mother board - 2nos.
f) Display board - 2nos.
g) Optical bench - 1no
h) Filter detector - 2nos
i) Fuses - 1 set of each type
j) Other cards - 1 each
k) Ozonaotor - 1
l) Cuvette - 2 nos
m) Chopper motor - 1no.
ISSUED :
n) Dessican & flow sensor - 1no each

a) Filter - 2sets
b) Display Board - 1no
c) Processor Board - 1no.
d) Chromatograph Column
e) Solenoid valve (10% subject to minimum of 1
of each type
f) Vaporization system if required, which
3.8 Chromatograph
includes vaporizer, thermostat, electrical tracing
cable and heater etc. - 1set.
g) Cooling system if required, which includes
one cooler, flow conditioning system etc., - 1set
h) Probe Filter - 2 nos.
i) Probe Tube - 2 nos.
j) Probe heater & Temp. sensores - 2 nos.
For various instrument types used in sampling
3.9 Sampling systems systems, spares philosophy shall be as per this
document.
SWAS - Steam & water 10%(subject to minimum of 1) of all the
4
analyser system accessories provided in SWAS
DCS, PLC and sub
4.1 These spares are in addition to 20 % installed
systems as DON, SER,
spares
UHN, HMS ETC.
5% or 1 module of each type (processor
module, I/O module, communication module,
power supply module etc.) being used inclusive
of those used in consoles. This shall include
spare modules for hardwired instruments also.
10% or minimum 2 nos. of Safety Barriers,
4.2 A) Modules
Signal Converters, trip amplifiers etc.
20% or minimum one no. of each type of Fuses,
MCBs, Auxiliary relays
10%or minimum 2 nos. of communication
system components such as hubs, switches,
routers, etc. whichever is higher
Consumable spares including Laser printer
cartridges, Paper or any other consumable
4.3 Consumables items supplied along with the system required
for a minimum of 6 months duration after
system acceptance.
5.0 OTHER ITEMS
Snubber, Syphon, Gauge 10% (subject to minimum of 1) of each item
5.1
Saver, etc. used, whichever is higher
ISSUED :
20% (subject to minimum of 2) of Loop powered

5.2 Loop powered indicators
indicators used, whichever is higher
20% or minimum 2 nos. of solenoid valves of
5.3 Solenoid Valves
each type used.
5.4 MCT Block 10% of each type of MCT Block used.
Instrument Valves/Tube 10% subject to minimum one no. for each type,
5.5
Fittings size whichever is higher
Panel mounted
5.6 10% or minimum one no. Whichever is higher
instruments
Cooling fans and filters for
5.7 10% of each type used
Cabinets and consoles
A) Camera Station - 1 no.
B) Camera 1 no.
C) Lens with zoom -1no.
6 CCTV
D) Water tank with tube, bracket - 1 no.
E) Receiver and drive - 1 no.
F) Keypad including joy stick - 1 no.
a) 10% or minimum 2 nos. of ech type of
probes (vibration, speed, displacement etc.)
and transducers / proximator / extension cables
Machine Monitoring
7 / connector protective sleeves etc.
System
b) Electronic modules / cards : 10 % or
minimum 1 no. of each type, whichever is
higher
Sensors : 20 % or minimum 2 sets of each type,
whichever is higher
8 Gas detection system
Electronic cards / PCB : 10 % or minimum of 1
set of each type used, whichever is higher.
Notes:
1. Above-mentioned mandatory spares list definess the minimum requirement.
Contractor to provide any additional items as recommended by manufacturer.
Contractor to submit mandatory spares list to Owner / PMC for approval.
2. Similar philosophy shall be followed for packaged units and other items not covered
in this list.
3. Contractor to submit spares list for 2 year operation and maintenance. The prices
shall be valid for atleast 2 years from date of order.
4. Contractor shall supply all spare items required for commissioning.
5. Next rounded figure to be considered wherever % is specified.Example : For total
11 Nos. Instruments with 10 % spares basis, 2 Nos. spares shall be provided.
ISSUED :
4. Civil:
4.1. HV spary nozzles 10% of total nozzles used in each size/type with
minimum
Drill holes.
4.2. MV spray nozzles 10% of total nozzles used in each size/type with
minimum
Drill holes.
4.3. Quartzoid bulb Detector 10% of total used
Notes:
1. The above no of spares are suggestive and minimum. In case the vendor
feels more are required / recommended by manufacturer, same shall be
provided and mentioned along the offer.
ISSUED :
5. Mechanical Rotary:
Sno. Description Quantity (Insurance Spares) Remarks
1 PUMPS:
1.1 Centrifugal Pumps (Process Service) a.One set of complete
replaceable inner case
element consisting of all
rotating and stationary
hydraulic elements (diffuser or
volutes etc.) (Only for multi-
stage centrifugal
barrel type pumps)
b. One set of dynamically

balanced complete rotor
assembly including balancing
drum.
(Only for multi-stage
centrifugal
axial split type pumps)
c. One set of mechanical seal

in case of process service
centrifugal pumps
d. One Lube oil filter cartridge

1.3 Centrifugal Pumps (General Water NIL
Service)
1.5 Positive Displacement Pumps NIL
(Reciprocating)
1.6 Positive Displacement Pumps NIL
(Controlled
Volume)
1.7 Positive Displacement Pumps (Rotary) 1 set of mechanical seals
ISSUED :
Sno. Description Quantity (Insurance Spares) Remarks

1.8 Liquid Ring Vacuum Pumps NIL
2 COMPRESSORS / FANS &
BLOWERS
2.1 Centrifugal Compressors 1 set of dynamically balanced
rotor
+ 1 set of dry gas seals
+ 1 set of bearings
+ 1 set of couplings
+ 1 Lube oil filter cartridge
2.5 Centrifugal Fans 1 Rotor with bearings

2.6 Induced Draft / Forced Draft Fans 1 set of dynamically balanced
rotor with bearings
2.7 Packaged Integrally Geared 1 set seals + 1 set bearings+ 1
Centrifugal Air set of couplings + 1 Lube oil
Compressors filter cartridge +
1 Suction air filter element
2.8 Reciprocating Compressors 1 Lube oil filter cartridge +
(Utility & Instrument Air Service) 1 Suction air filter element .
2.9 Reciprocating Compressors (Process 1 set of cylinder valves
Service) 1 set of LO filters
1 set of packing rings
1 set of valve gasket
2.10 Positive Displacement Compressors 1 set of dynamically balanced

(Rotary) Rotor + 1 set of timing gear +
1set of shaft seals + 1 set of
bearings + 1 set of couplings
ISSUED :
Sn Description Quantity (Insurance Spares) Remar

o ks
3 MECHANICAL DRIVERS / GEAR
BOXES
3.4 Steam Turbines (General Purpose) NIL
3.5 Steam Turbines (Special Purpose) 1 set of dynamically balanced
rotor + 1 set of each Radial &
Thrust bearing + 1 set of shaft
seals and labyrinths.
3.6 Special Purpose Gear Box 1 set of dynamically balanced
rotor + 1 set of bearings
3.7 General Purpose Gear Box NIL
3.8 Special Purpose Coupling NIL
4 Oil mist lubrication system 1 set of filter cartridge
1 set of gaskets
Remarks:
(1) Spare parts shall be identical in all respects to the parts fitted in the main equipment,
including dimension, material of construction and heat treatment.
(2) Spare rotors shall be supplied in metal container in vertical storage and with Nitrogen
blanketing.
(3) Specified quantity is total for one Item (Service), which remains same even if there are
many machines per Item ( for example: 90-P-01 A / B ). Same is also applicable
for ‘Commissioning spares (minimum)’ in below Table-3.
(4) Mandatory spares for Electrical and instrumentation shall be as specified in their
respective job specifications or as listed elsewhere in the tender documents.
TABLE – 3: Commissioning Spares (Minimum)
Sno. Description Remarks

1 Centrifugal Pumps: (Qty.)
1.1 Set of Gaskets 200%
1.2 Set of seal packings 200% Of Installed quantity
1.3 Set of seal faces 100%
ISSUED :
2 Reciprocating Pumps:
2.1 Set of diaphragms 200%
2.2 Set of Plunger packings 200%
Of Installed quantity
2.3 Suction / Discharge valve 100%
2.4 Set of all gaskets 100%
3 Vertical Pumps:
3.1 Set of intermediate bushes 100%
3.2 Set of gaskets 100% Of Installed quantity
3.3 Set of seal faces 100%
4 Reciprocating Compressors:
4.1 Set of valve cover gaskets / O-rings 100%
4.2 Set of Head gaskets 100%
4.3 Set of other gaskets 100%
Of Installed quantity
4.4 Set of valve plates for all stages 100%
4.5 Set of springs for valves 100%
4.6 Rod packings & wipers 100%
Note :- Specified commissioning spares herewith are minimum , and LSTK contractor shall ensure that
all required erection and commissioning spares for all equipments are supplied by the vendors.
ISSUED :
6. Mechanical Package:
SR.NO. DESCRIPTION QUANTITY (as per

installed unit)
FEED FILTER /CARTRIDGE FILTER /

COALESCER
1 Sets of Filtering Element 100%
2 Gaskets 100%
3 Nuts and Bolts 10%
EJECTOR / EDUCTOR
1 Gaskets 400% of each flanged

joint
2 Nuts and Bolts 20% But not less than 4

studs with 8 nuts for each
fanged joint
3 Steam Nozzle 100%
SILENCER
1 Gaskets 100%
2 Nuts and Bolt 20%
EOT CRANE
1 Brake Liner (LT,CT,Hoist) 200%

ISSUED :
2 Bearing 200%
3 Oil seals and Gaskets 200%
4 Electrical spare refer individual electrical

item spare part list
STATIC MIXER
1 Gaskets 100%
LOADING ARM
1. Swivel Joint Kit 1 no.
WEIGH BRIDGE
1. Load Cell 1 no.
2. Control PCB of Weigh Indicator 1 no.
3. PCB of Junction Box 1 No.
Pastillation Unit ( Note-1)
1 Sets of Filtering Element 100%
2 Gaskets 100%
BAG FILTERS
Filter Bags 100 %

ISSUED :
Pulse Valves 25%
Filter bag cages 25%
Sequential controller (timer) 1 no.
Rubber Gasket 1 set
Note-1 : For Other bought out items such as pumps , motors , exchangers within package ,
mandatory spares shall be provided as per Mandatory spares list for respective items
attached elsewhere
ISSUED :
7. Fired Heater:
Sr.no Description Quantity Required Remarks

1 Gaskets 400%
2 Boltings (Pressure parts) 20%
3 Pressure parts ( including all type of 10% (min one no in each
tubes and fittings) type, size and material
along with special
welding consumables)
4 Tube support casing / assemblies 3% (min one no in each
(except tubesheet / support beams) type size & material)
5 Sight glasses 100%
6 Burners (per heater)
6.1 Oil tp assembly (including oil tip, 1 no per 3 nos (min 1
atomizer, spud, insert and sleeve) no)
6.2 Gas tip assembly (includes primary 1 set per 3 nos. (min 1
and stages gas tip / raisers) no)
6.3 Muffle block & Regen tile 1 set per 3 nos. ( min 1
no)
6.4 Gaskets 1 complete set per
burner
6.5 Pilot jet / mixer, nozzle / tip spud 1 per 3 nos (min 1 no)
6.6 Ignition transformer / Power pack 1 no
6.7 Ignitor electrode 1 no per ignitor
6.8 Oil gun assembly 1 no
6.9 Gas burner assembly 1 no
6.10 Burner management system One PCB of each type
7 Dampers
7.1 Seals 100%
7.2 Boltings 20%
7.3 Actuator 1 set of each type
8 All refractories installed and 20%
installation material
ISSUED :
8. Electrical:
Sr.No PART DESCRIPTION QTY
1.0 Generator ( one set of spares for each rating One set
and type )
a) Generator bushings One set
b) Current transformer One set
c) Potential transformer One set
d) Diodes for exciter One set
e) Generator relays One set
f) Gen. Field breaker. One set
g) Exciter field breaker One set
h) Field discharge resistor One no. type
each
i) DVR- all control cards One set
j) DVR.- CTs One set
k)DVR- Power supply card One set
I)DVR - Contactors, relays & control transformers One set
2.0 Power Transformers (one set of spares for

each rating and type)
a) Bushings HV & LV One set
b) Gasket One set
c) Buchholz relay One set

ISSUED :
d) Neutral CT One set
e) Explosion vent diaphragm Two nos.
3.0 33KV Generator Bus switchgear (one set of

spares for each rating and type)
a) Spare breaker One no. for each

rating and type
b) Bus insulator 5%
c) OT & PT ( All type & ratings) One set each
d) Closing Coils 10%
e) Snunt trip coil 10%
f) All protection relay One set of all types
g) Pane limit switches & interlock switches 10% each type
h) Panel operating switches ( all type) One set each
i) Control fuses ( all type & ratings ) 20% each
j) Male pads One set each for all

types
4.0 33KV switchgear distribution Bus switch -

(one set of spares for each rating and type )
a) Spare breaker One no. for each

rating
b) Bus insulators 5%
c) CT & PT (all types and ratings) One set each
d) Closing coils 10%
e) Snunt trip coil 10%
f) All protection relays One set of all types

ISSUED :
g) Panel limit switches & interlocking switches 10% each type
h)Panel operating Switches (all types) One set end
i) Control fuses (all types & ratings) 20% each

types
Sr.No. PART DESCRIPTION QTY
5.0 11KV AND 6.6KV switchgear distribution Bus

(one set of spares for each rating and type)
a) Spare Breaker One no. for each

rating
c) CT & PT (all types & ratings) One set each
d) Closing Coils 10%
e) Shunt trip coil 10%
h) Panel operating switches (all types) One set each
I) Control fuses (all types & ratings) 20% each

types
k) Vaccum bottles-incomers and bus couplers 3 nos each rating
I) Vaccum bottles- Outgoing feeders 3 nos each rating
m) Breaker limit switches & interlocking switches 10% each type
6.0 415V PCC/PMCC/EPCC switch boards (one

set of spares for each rating and type)
a) ACB(each type & rating) One no. each

ISSUED :
c) CT/PT/Control transformer ( all types & One set each

ratings)
d) Closing coils 10%
e) Shunt trip coil 10%
h) Panel operating switches (all types) One set each
i) Control fuses (all types and ratings) 20% each

types
k) Breaker limit switches & interlocking switches 10% each type
I) Control connectors Five set each for all

types
7.0 415V MCC/ASB/LDB Switch Boards (one set

of
spares for each rating and type)
a) Vertical bus bars 5 nos. each type
c) CT One set each
d) All protective relays/bimetal relays 5 nos. each
type/rating
e) Power fuses Five set each
type & rating
f) Control fuses (all types and ratings) 20% each
g) Power and control connectors Five set each for

ISSUED :
all types
8.0. Variable frequency drives(one set of spares
for each rating and type)
a) Transistors / GTB One set
b) Control Card One set
c) Power supply card One set
d) Relays/Contactors One set each
e) All fuses Two set each
f) Man machine interface One set
g) CT/PT One set each
h) Cooling fans One set
i) Limiters & protection devices One set
9.0 Relay I Data concentrator panel / HMI
(One set of spares for each rating/model type)

and type
a) All cards such as input and out put cards, One set
power supply cards, processor cards etc.
b) All control fuses One set
10. UPS (one set of spares for each rating and

type)
a) Power transistors/IGBT One set
b) Switching module with static switch One set

ISSUED :
c) Power supply card One set
d) Operating console card 20%
e) All fuses One set
f) Cooling fans
11 DC System (one set of spares for each rating

and type)
a) All fuses 20%
b) All Cards One set
c) Load break contactor One No
d) Contactor coil One No
e) Thyristors One set
12 Synchronous motors (one set of spares for

a) Diode One set
b) Bearings One set
c) Pressurization system
i) control unit One set
ii) Valves One set
iii) pressure switches/electrical switches One set
iv) fuses One set
v) Air filter assembly One set
13 HV induction motors (one set of spares
a) Bearings One set

ISSUED :
b) Terminal / bushings One set each
14 MV induction motors
(one set of spares for each rating and type)
a) Bearing Assembly One set
b)Terminal / bushings One set each
c) Bearings One set
15 Telephone Exchange
a) All fine cards 20%
b) Processing cards One set
c) Power supply cards One set
d) Crone connectors 20%
e) GD Tubes (If protection devices 20%

Provided)/Other line
f) Crone Tool 4 Nos
16 Fire Alarm System
a) All cards One set
b) DGFAP One No
c) Fuses One set
d) Break glass 100%
e) Talk back hand 10 nos
f) Hammer 10%
g) Terminal Blocks 10%

ISSUED :
17 Paging System
a) All cards One set
b) All fuses One set
c) FLP horn 10% each type
d) FLP call stations 10% each type
e) Power supply unit One no. each type
f)Switches & indication lamps One set each type

ISSUED :
9. Fire Fighting:
Sr Part Description Quantity Required

No
1.0 Clean agent system
1.1 Clean agent cylinders (filled), for 1 no (minimum)

centralized system basis 5% of main cylinders.
(maximum of the following) 5 nos + 2 % of main clinders
a. For each installation
b. Exceeding 1 no but not exceeding

100 nos
c. Exceeding 100 nos plus for every

additional 100 nos
1.2 Automatic and Manual release system One of each type / size used in the system
supplied
1.3 Cylinder valve with safet pressure One of each type / size used in the system
relief supplied
1.4 Clean agent nozzles 10% of total nozzles used in each size /
type with minimum drill holes.
1.5 Clean agent release push buttons 10% of total used of each type
2.0 Hoses & Branch pipes As per TAC
3.0 Spray nozzles for water spray system 5% of each type
4.0 Revolving head 2 nos of each size
5.0 Foam chambers / makers 2 nos of each type / size
6.0 Quartzoid bulb detectors / sprinklers 5% of each size / type

Notes:
1. Mandatory spares for any other fire fighting equipment specified else where in
the bid document or recommended by the equipment manufacturer shall be
ISSUED :
included and supplied by the contractor.

2. Start up and Commissioning spare as required are to be provided by the
Contractor and are to be listed in the bid. The unutilized spares shall be the
property of the owner.
3. Bidder should quote for spares for 2 years of normal operation as optional
separately.
a. All items consumables and non consumables required to complete the
job.
b. All tools tackles, plant machinery etc to complete the job.
ISSUED :
10. Tools and Tackles:

10.1. Bidder to ensure supply of all tools and tackles for operation and maintanence
of the entire plant and equipment and the list of the same shall be furnished along
with the bid. They shall be preferably hydraulically operated tools. The price of the
same shall be included in the lumpsump price.
10.2. Special tools:
Following minimum tools shall be supplied by the vendor:
• Hydraulic bolt tightening bolt wrench 1 no
• Any other special tools which in opinion
Of supplier are required including set of
Non sparking tools.
• Hydraulic pullers (bearing/coupling)
• 3T wheel mounted trolleys 4 nos
• 3T manual operated mobile crane (360 swing) 2 nos
• Non sparking spanners open end and ring set full set 46 mm incl
hammers.
10.3. General purpose maintainence tools
• General maintainence tools 1 set
• Set of open spanners 1 set
• Set of box spanners 1 set
• Torque wrench 1 no
• Slings, D shackles
• Dial gauges digital 1 no
• Callipers inside 12”, outside 12” 1 set each
• Vernier caliper 12” digital 1 no
10.4. Diagnostic tools

• Portable vibration analyzer.
• Portable bearing temperature indicator
• Lube oil test kit for viscosity / sp gr
• Temperature calibrator.

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Mandatory Spares Part List

HINDUSTAN PETROLEUM CORPORATION LTD.

JOB NO.: 6261

TOYO ENGINEERING INDIA LIMITED

Manadatory Spare Part list

HPCL, Visakh TOYO ENGINEERING INDIA LTD.

Sl. No. Title

12 Tools and Tackles

Manadatory Spare Part list

HPCL, Visakh TOYO ENGINEERING INDIA LTD.

Sr No Part Description Quantity Required

Bolting for internal flanges of One set of each size of each

Sight / light glasses assembly 4 sets for each installed glass

1.2. Tubular Exchangers

Sr No Part Description Quantity Required

Bolting 20% (Min 4 studs and 8 nuts per

3 Lamiflex sealing strips 100%

Manadatory Spare Part list

HPCL, Visakh TOYO ENGINEERING INDIA LTD.

1.3. Air Coolers

Sr No Part Description Quantity Required

Gasket for header cover and 400%

2 Gaskets for plugs 200%

Bolts and nuts for all nozzle with 20%

Diaphragm Actuator with One set

Fan clevis bolts a. 4 for each type of fan upto and

Manadatory Spare Part list

HPCL, Visakh TOYO ENGINEERING INDIA LTD.

upto and including six in

c. 12 for fans above six in

b. 3 for fans exceeding two in

c. 5 for fans above six in

Motor Bearings a. 2 for quantity upto including

b. 3 for fans exceeding two in

c. 5 for fans above six in

1.4. Tray and Tower Internals

Sr No Part Description Quantity Required

Clamp assemblies 10% of total for each type and

Manadatory Spare Part list

HPCL, Visakh TOYO ENGINEERING INDIA LTD.

3 Valves for trays 10% of each type

4 Gasketing or tapes 100% of each type and size

5 Sealing foils for cartridge trays 200% of each size

U-Clamps 10% of each type and size or 10

Tower packings 10% for metallic and plastic

Spray Nozzles 25% subject to minimum 5nos of

Manadatory Spare Part list

HPCL, Visakh TOYO ENGINEERING INDIA LTD.

Sr.no. Part Description Size Range * Quantity Required (% of as built)

1 Pipes and Fittings ½” to 36” 2

2 Pipes and Fittings Above 36” Nil

3 Valve and Flanges 1/2” to 8” 2

4 Valve and Flanges 10” and above Nil

5 Bolts, Nuts All sizes 10

6 Gaskets All sizes 10

7 Traps All sizes 2

8 Expansion Bellows All sizes 100

9 Bolt torque wrenches 1 set

10 Bolt tensioning 1 set

11 PMI equipment 1 set

Manadatory Spare Part list

HPCL, Visakh TOYO ENGINEERING INDIA LTD.