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Contract File Reference Page

Number:P1007 1007-DISQ-0-M-SS-42008-Rev.1 1 of 26

RWE Dea

Disouq Field Development


FEED

GAS/ DIESEL ENGINE SPECIFICATION

Document number
1007-DISQ-0-M-SS-42008

1 9.1.12 Issued for Client comment K Nasr A Fawzi A Hamdan RWE

0 18.12.11 Issued for Client comment K Nasr A Fawzi A Hamdan RWE

Rev Date Description Issued By Checked By Approved Client


By Approval
Onspec Engineering Solutions
Disouq Field Development Project
Gas/ Diesel Engine Specification

Changes List
Date
Rev. prepared Prepared by Description
(dd.MM.yyyy)
1 9.1. 11 K Nasr Client comments incorporated

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Onspec Engineering Solutions
Disouq Field Development Project
Gas/ Diesel Engine Specification

Table of Contents
1 SCOPE ............................................................................................................................... 5
1.1 Background .................................................................................................................. 5
1.2 Purpose........................................................................................................................ 6
2 REFERENCE CODES AND STANDARDS ........................................................................ 6
2.1 International Codes and Standards .............................................................................. 6
2.2 Order of Precedence .................................................................................................... 6
3 NOT USED ......................................................................................................................... 7
4 SCOPE OF SUPPLY .......................................................................................................... 7
5 BASIC DESIGN REQUIREMENTS .................................................................................... 7
6 AUXILIARY SYSTEMS ...................................................................................................... 9
6.1 Cooling Systems .......................................................................................................... 9
6.2 Lubricating System ....................................................................................................... 9
6.3 Fuel Systems ............................................................................................................. 10
6.4 Starting System .......................................................................................................... 11
6.5 Instrumentation and Control System .......................................................................... 12
7 ENGINE EQUIPMENT AND ACCESSORIES .................................................................. 14
7.1 Intake Air System ....................................................................................................... 14
7.2 Exhaust System ......................................................................................................... 15
7.3 Baseplate ................................................................................................................... 15
7.4 Barring-Over And Locking Devices............................................................................. 15
7.5 Enclosure And Weather Hood .................................................................................... 15
8 SPECIAL SAFETY FEATURES ....................................................................................... 16
9 INSPECTION AND TESTING ........................................................................................... 17
9.1 General ...................................................................................................................... 17
9.2 Performance Testing Requirements ........................................................................... 18
9.3 Guarantee Figures And Tolerances............................................................................ 18
10 MATERIAL, EQUIPMENT IDENTIFICATION AND MARKING ........................................ 19
10.1 Item Number .............................................................................................................. 19
10.2 Nameplates ................................................................................................................ 19
10.3 Rotation Arrows.......................................................................................................... 19
PREPARATION FOR SHIPMENT ........................................................................................... 19
11 INSTRUCTION MANUALS .............................................................................................. 19
12 DATA BOOKS ................................................................................................................. 20
13 SPARE PARTS ................................................................................................................ 21
14 SPECIAL TOOLS ............................................................................................................. 22

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Gas/ Diesel Engine Specification

15 SUPPLIER INFORMATION.............................................................................................. 22
16 ENVIRONMENTAL REQUIREMENTS ............................................................................. 22
16.1 General ...................................................................................................................... 22
16.2 Emergency Drive Applications .................................................................................... 23
16.3 Continuous And Prime Power Applications ................................................................ 23
16.4 Noise Levels for Continuous Engine Drive ................................................................. 24
16.5 Waste heat utilisation ................................................................................................. 24
17 ENGINE FUELS ............................................................................................................... 24
17.1 General ...................................................................................................................... 24
18 GAS FUELS ..................................................................................................................... 26

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Onspec Engineering Solutions
Disouq Field Development Project
Gas/ Diesel Engine Specification

1 SCOPE

1.1 Background

RWE Dea Egypt has discovered seven natural gas reserves in the Disouq Concession within
the onshore Nile Delta, starting in 2008, as shown on the concession map below. Further
exploration in the concession is ongoing. RWE Dea Egypt is the operator of the Concession
with EGAS as a partner.

The objective of this project is to carry out front end engineering design (FEED) services and
prepare a scope of work for Engineering, Installation and Construction tenders (procurement will
be undertaken by RWE Dea) to finally install a natural gas trunk line system to be gathered, led
to a central gas treatment plant where the gas shall be treated to achieve sales gas quality and
send to the gas pipeline infrastructure at the boundaries of the Disouq Concession.
The selected development comprises a central gas treatment site near NSG-1x, where the gas
is collected, treated by means of Low Temperature Separation utilizing the Joule Thomson
effect, and compressed for export. Treated gas is exported via a 16 export pipeline directly into
the GASCO NTS pipeline.
The well fluids from the directly routed wells and the trunk line are fed to a common inlet
separator at the central plant. All gases and liquids will be separated and processed on the
central treatment site into sales gas, stabilized condensate, and free production water.
Treatment of gas is carried out in two trains, while treatment of condensate is in a single train.
Three trains of sales gas compression are installed. During FEED investigation shall clarify, if
the installation of front end booster compressors is more advantageous compared to this
concept.
Fuel gas for the gas engine drives is taken from the suction of the sales gas compressors.
To allow further increase of the production additional tailings and all necessary equipment like
valves and flanges shall foresee to allow a simple tie in of future treatment trains.

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Gas/ Diesel Engine Specification

1.2 Purpose
This specification covers the minimum requirements for the design, manufacture, construction and
materials, inspection and testing of diesel, gas and dual fuel engines intended for use in heavy duty
applications such as gas plants and refinery services including mechanical drive of process
equipment and electric generator drive. Either continuous, intermittent, or emergency service shall
be specified in the data sheets. Emergency service conditions include fire fighting pump drive and
emergency power generation.

Required heavy duty engines must be made of new parts, all made by the original engine
fabricator, assembled by the original fabricator or a licensed assembly factory which has the
original fabricator assuming the responsibility of quality control and final inspection and testing of
the equipment.

2 REFERENCE CODES AND STANDARDS

2.1 International Codes and Standards

The latest editions of international standards listed below shall apply as appropriate.

- BS 649 Diesel Engine for General Purpose.

- BS 3109 Gas and Dual Fuel Engines.

- BS 1701 Amendments No.1 and No.2, filters for Air Supply to Internal
Combustion Engines and Compressors.

- DIN 6270 Internal Combustion Engine.

- SAE J016 Diesel engines

- ASME PTC-17 For Testing.

- AGMA 420-03 & 421-05 For Gears.

- NEMA SM 23 Steam Turbines for Mechanical Drive Services.


(for definition of speed governor classes).

- NFPA 20 Centrifugal Fire Pumps "Diesel Engine Drive".

2.2 Order of Precedence


In case of conflict between the various documents, the following order of precedence shall govern:

The requirements of the material requisition, and all data sheets attached as integral part of
it.
This specification and its referenced specifications and international standards.
Other international codes and standards.

Engine models quoted shall be proven by supporting reference list of similar units in similar
services. At least 30,000 hours of reliable continuous operation of at least three units of same
model, shall be sufficient for qualifying the quoted model to be proven. Continuous uninterrupted

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Gas/ Diesel Engine Specification

operation means only short intervals of down time for normal maintenance activities such as spark
plug inspection or replacement for a gas engine.

3 NOT USED

4 SCOPE OF SUPPLY
Scope of supply shall include but not be limited to:

Engine, complete with accessories and auxiliaries, piping, valves and fittings for all services
required by engine.
Intake Filter, Silencer, Supercharger / Turbocharger and Lubricator, if required.
Engine Lubrication System Consisting of engine-driven lube oil pump, lube oil reservoir,
motor driven pre-lubrication pump or motor driven auxiliary pre-post lubrication pump as
specified in the data sheets, and replaceable external twin-oil filter with continuous-flow
change-over valve, monthly consumption storage tank of lubricating oil with automatic
topping device (for continuous service only).
12-HR fuel tank with its supporting frame, interconnecting fuel piping, hoses, valves, fittings
complete fuel system, twin fuel filters, with continuous flow change-over valve.
Complete self-contained cooling system and radiator, or heat exchanger as applicable.
Complete starting system.
Gear unit as required by speed or positioning considerations of driven equipment.
Direct drive is normally required.
Suitable coupling between engine, drive train and driven equipment, with non-sparking
guard.
Exhaust system and silencer, with their supporting steel structure.
Engine baseplate suitable for bearing on few support points, extended to mount driven unit
and auxiliaries, with sufficient number of vibration isolation dampers.
Weather hood - or - enclosure as specified.
Complete instrumentation and controls mounted on a local panel.
Fly wheel locking and barring devices.
Material and equipment inspection and testing.
Material and equipment identification and marking.
Packaging of engine, auxiliaries and accessories.
Instruction manual, test certificates, and all documents shall be in English language.

Critical speed analysis for engine and for engine-gear-driven equipment train.
Special tools.
Data and Drawings: Vendor's data and drawings as project documentation requirements.

5 BASIC DESIGN REQUIREMENTS


Gas engines drivers shall be manufacturers standard design, and may be two or four
cycle, naturally aspirated or with supercharger/turbo charger, designed for heavy duty
stationary industrial application.

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Gas/ Diesel Engine Specification

Engine shall be capable to operate continuously at site rated ambient conditions and
engine full rated load, uninterrupted for at least 2,500 hours without shut-down; during this
period only usual operating checks and minor running maintenance not requiring shutdown
are to be performed. Further, engine shall not require any major maintenance or overall
during 24,000 hours turndown interval. Engine operation shall be interrupted for less than
24 hours each 8000 hours for the purpose of conducting simple maintenance activities
such as spark plug inspection or replacement, oil replenishing, governor inspectionetc.
The engine shall deliver not less than 110% of the maximum specified BHP of driven
equipment including all losses and auxiliary power requirement, at worst site conditions at
normal speed.
Mean effective pressure at maximum power output shall not exceed 7 kg/cm2 for naturally
aspirated and 12 kg/cm2 for super charged engines, with inter cooling.
Engine speed shall not exceed 1500 RPM for prime power or continuous service. Mean
piston speed shall not exceed 10 M/Sec. Emergency drive diesel engine speed may reach
3000 RPM
Transmission of rotation from crank-shaft to the cam-shaft shall be obtained by gears.
Chains and cog belts may only be accepted, subject to written Purchaser approval, for
intermittent emergency-type service drivers.
Diesel and gas engines shall be one piece engine frame and one piece cylinder frame and
shall be fitted with individual cylinder heads, highly polished replaceable hardened exhaust
valve seat inserts, precision fitted replaceable bearing inserts, hardened and highly
polished bearing pins. Where available, cylinder heads with separate valve cage
assemblies are preferred. Hydraulic valve clearance adjustment devices are preferred to
simple adjustment threaded stud with locking nut. Frame is to be fitted with individual
cylinder explosion doors and inspection doors. Crankcase over-pressure protection
devices are required. Preference shall be given to engines characterised by simple
mechanical construction, arrangement, structure, etc, to allow easy access for fast
maintenance operation, and disassembly for complete overhaul.
Crank shaft and connecting rods shall be manufactured of forged steel, crankshaft shall be
ground.
Dynamic forces transmitted to the foundations shall be reduced to a minimum, by the
application of vibration isolators. Attenuation ratio shall be specified in the proposal.
Manufacturer shall guarantee that no significant vibrations of engine or any part of it shall
occur after start-up.
Manufacturer shall submit analysis justifying the selection of type of suspension. Also,
maximum expected seismic vibration amplitudes shall be furnished, not exceeding
20mm/sec overall vibration amplitude.
Manufacturer shall carry out the torsional analysis for the engine-gear-driven equipment
train when specified. Maximum torsional stresses at 120% of operating speed versus
percent load shall be furnished. Vibration analysis shall not be made for equipment
packaged and proven before, where their vibration performance is known. For such cases,
supplier shall issue a vibration report without conducting actual analysis.
Bearings shall be of replaceable shell type, generously sized.
For stand-by service, the engine shall be equipped with all devices for preheating and pre-
circulation of auxiliary fluids and of fuel, where required to permit quick placing on line of
engine-driven machine. Time to assume the whole rated power shall be 10 seconds for

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emergency services, 30 seconds for other services, engine shall be also equipped with an
automatic start-sequence repetition, in case of failed start-up.
Engine intended for fire fighting pump drive shall conform to NFPA 20 requirement in
design, manufacturing and testing. Engine and controller shall be UL-listed FM-approved
for fire service.

Speed Governing Systems:

Speed governing system class shall be in accordance with NEMA SM21; class C shall
be used as a minimum for mechanical drive, where the speed droop or steady state
speed regulation shall be adjustable up to 6% for parallel operation. Actual speed
range shall be specified for each individual service.
Speed governors shall be suitable for receiving remote speed set point control signal.
Hydraulic and electro hydraulic wood ward type or equivalent quality are required.
Over speed trip setting shall be in accordance with governor class. An independent
over speed protection device shall be incorporated. Governor over speed trip setting
must be testable without real engine operation at actual over speeding condition, e.g.
by reducing the set point, only, for the purpose of testing.
Normal stopping of the engine shall be by closing a solenoid operated valve in fuel
feeding system to the engine.
Emergency tripping of the engine shall be by closing the air passage into the engine
manifold in addition to closing the fuel supply solenoid valve. Emergency tripping shall
be limited to over-speeding and in response to the USD push button actuation by
operators due to any abnormal hazardous conditions.
Condition monitoring: the philosophy of Predictive Maintenance is to form the basis of
the Maintenance Program Stipulated in the IOM manual see section 12.
Instrumentations and Procedures to permit the Predictive Maintenance Program are
required.

6 AUXILIARY SYSTEMS
6.1 Cooling Systems
Closed loop cooling forced circulation system utilizing water and anti-fouling (corrosion inhibitor) or
glycol solution suitable for the specified max ambient temperature while operated at maximum
engine rating shall be complete with the following:

Coolant circulating pumps, shaft-driven, or electric motor driven.


Fin fan cooler radiator with associated fan shaft-driven or electric motor driven. For fire
water drive, a heat exchanger cooled by pumpage shall be applied.
Continuous temperature control by bypassing coolant cooler.
A surge drum complete with level indicator filling connection, overpressure, cap.
All piping, flanges, fittings, valves, strainers and gaskets required.
Supplier shall furnish coolant specifications to Purchaser including any required inhibitors if
coolant is water.

6.2 Lubricating System

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Gas/ Diesel Engine Specification

The lubricating system shall be full pressure type system. It shall consist of the following:

Wet type sump, complete with dipstick, filler and strainer, sized to contain all oil in the
system when the engine is shutdown. Dipstick and filler cap shall be secured in place by a
chain, made of non-sparking material.
Oil gear pump directly driven by engine shaft through gears.
Electric-driven pre lubrication pump to be used before start-up.
Twin oil filters, full flow type, replaceable cartridge elements, with continuous-flow
change-over valve. (only for continuous uninterrupted operation)
Manufacturer standard oil cooler.
Warm-up device thermostatically controlled by external electric immersion heater which is
energised when oil is circulated by auxiliary pump through heater, for 0.6 MW and higher
engine rating, or as deemed necessary for less ratings in critical standby services.
Stainless steel piping for all L.O. except for piping cast integral with engine casing. This
includes piping, fittings, flanges and valves.
Pressure relief valve with by-pass to L.O. Reservoir and oil pressure control valve.

6.3 Fuel Systems


For Diesel engines fuel oil distillate per specification attached to material requisition,
shall be applied fuel system shall include the following main items as a minimum:
(Fuel system design shall be per NFPA 20, for fire pump drive services).

- Off or on-skid mounted 12-HR operation daily consumption fuel tank, with level
indicator, filling openings and strainer, vent and flame arrestor, and drain. Tank
shall be made of at least 4.00mm thickness carbon steel sheets.

- Engine o electric motor driven main fuel pump.

- Twin fuel filters with continuous-flow changeover valve and a de-aerator.

- Control valve, shut-off, valves and a relief valve with return line to fuel tank; return
line shall be fitted with a check valve. Both supply and return fuel piping shall be
fitted with hoses at engine side, per NFPA 20 requirements.

For gas engines and for safety reasons, direct gas injection into the cylinders is
preferable for supercharged engines. However, for premixing systems with
carburettor, fuel system shall conform to the following main items :

- Gas-to-air ratio shall be adjustable within a wide range to accommodate for gas
fuel heat value variations.

- Automatic gas-to-air ratio adjustment using multi butterfly valves or equivalent


devices is preferable.

- A gas automatic shut-off valve shall be installed upstream the engine mounted
pressure regulator. A safety relief valve down stream of this regulator shall be
supplied.

- Natural gas specification; molal analysis, water and sulphur contents, and range
of pressure and temperature available at fuel header feeding the engine package,

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Gas/ Diesel Engine Specification

shall be specified in the data sheet. Depending on the above, Supplier shall
anticipate, size, design, and purchase any necessary additional line regulator,
scrubber tank, line filters or strainers. These shall be added to Supplier scope.

Dual fuel engines:

1st) Gasoline & gas fuelled engines:

These engines shall be low compression ratio to allow introducing either type of fuels
as one mixture with combustion air. Electronic ignition module with coil and spark plugs
for each individual cylinder shall be included.
Fully automatic adjustment of ignition timing and detonation protection for both types of
fuels shall be included.

Both fuel control and feed systems shall be fitted with a switch over control module.
Gas fuel system details shall be per p. 6.3.2. Liquid fuel system details shall be per p.
6.3.1 for diesel fuel system description.

2nd) Liquid diesel and gas fuelled engines:

These shall be high compression ratio engines to allow for auto liquid gas oil (diesel
fuel) ignition. In case gas fuel is injected; either as liquefied propane or as gaseous
natural (sales) gas under pressure, diesel fuel shall be used in small fraction as igniter
for the gas fuel. For this engine, fuel gas mixed with combustion air cannot be admitted
through inlet air manifold since this would lead to early combustion of air/gas mixture
causing severe detonation.

Fuel system details shall be similar to diesel fuel system per p. 6.3.1, in addition to gas
fuel system injection system suitable for the specified gas fuel for the project.

Gas fuelled engines with pre-combustion chamber:

This design is intended to control emissions of combustion products to atmosphere. Gas


engine is usually de-rated at high ambient air temperatures more than the normal de-rating
levels for a standard combustion chamber design.

Supplier quotation must include minimum guaranteed site rating at maximum ambient
temperature, and the guaranteed hours of operation at maximum site rating for spark plugs.
Reference list of previous installations with the accumulated number of reliable running
hours, and values of engine availability percent to be specified against each engine
application.

Definition: Availability is a statistical term based on the running experience with a large
number of similar machines. It is quantified as the average number of hours when the
machine is running in a reliable condition to the total number of hours in a long time interval
not less than 25,000 hours.

6.4 Starting System


Starting shall be accomplished by one of the following systems, as specified in the data sheet.

COMPRESSED AIR STARTING

The system shall include the following principal items:

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Gas/ Diesel Engine Specification

- Air compressor of standard type, air cooled, electric motor-or diesel engine-driven,
with filter silencer at suction, safety valve, flexible coupling or transmission belts
and pulleys, 6-hour fuel tank, spark arresting exhaust silencer, foundation bolts,
and a battery, if any is required.

- Air receiver designed, fabricated and tested according to ASME, Section VIII,
Division 1, sized for at least 6 start-ups, complete with supports, inlet and outlet
connections, vents, drains, and connections for pressure gage, safety valve, and
check valve, bottom drain automatic moisture drain trap and manual bypass.

- All piping required, complete with fittings, valves, gaskets, considering the air
compressor unit at 20 meter distance from the engine unit.

- Baseplate for the entire air compressor set.

- For engines not equipped with cylinder air starting fittings, the following shall also
be furnished :

Air starting motor with bendix meshing system, supports and anchor bolts, shrunk-
on gear ring on fly wheel, air filter and lubricator, cut-off solenoid valve, and exhaust
complete with drain.

ELECTRICAL START-UP

Consisting of D.C. motor, bendix meshing system gear ring shrunk-on fly wheel, batteries
of capacity sufficient for at least 6 consecutive start-ups, and buffer battery charge, rectifier
and devices for automatic recharge.

HYDRAULIC STARTING

Consisting of hydraulic motor complete with driving elements, hydraulic accumulator


capable of allowing at least 6-consecutive start-ups, piping, valve, fittings, instruments, and
an electric pump, for the hydraulic fluid, in addition to manual charging hydraulic pump.

6.5 Instrumentation and Control System


SPEED GOVERNING

Unit shall be equipped with governor meeting NEMA Class D for generator drive and
NEMA Class C for mechanical drive.

The following indicators shall be supplied :

RPM indicator and running hours indicator.

Load indicator, by means of pressure indicator combustion @ air intake manifold,


and/or by sensing exhaust manifold average temperature.

Pressure differential indicator across L.O. filter bank.

Oil pressure indicator downstream L.O. Filter.

Oil temperature indicator upstream cooler.

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Gas/ Diesel Engine Specification

Coolant system pressure indicator at pump discharge.

Coolant system temperature indicator at engine inlet and outlet.

Pressure indicator in fuel feeding system upstream of injection system, for either
type of fuel.

Intake air-filter differential pressure indicator, or service indicator to monitor filter


condition.

For turbo-charging/supercharged engines, temperature indicators downstream of


the turbo charger.

Also, the following safety equipment shall be supplied, for either generating set or
mechanical drive :

Local on the machine emergency shutdown Mushroom type switch.

Over speed trip device set at 110% of normal continuous speed which is completely
independent of the governor.

Alarm and shut-down for low L.O. pressure.

Alarm and shut down for high temperature of coolant at engine outlet.

Back fire protection devices in case of gas engine with premixing of fuel and air.

For all engines, spark arrestors integrated in air filter and in exhaust silencer.

Excessive engine vibration shutdown.

Pre-warming system alarm on failure, or healthy indication light.

Pre-lubrication system failure alarm.

Cooling water surge tank low level alarm.

Lube oil sump low level alarm.

Battery electrolyte low level alarm, each cell, but combined as one common alarm.

Starting air low pressure alarm.

Electric charger failure alarm.

Failed to start or over cranking, after the engine has failed to start upon the
expiration of the six start attempts.

Low diesel fuel level alarm, in the day tank.

Automatic barring device failure to disengage, alarm.

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Gas/ Diesel Engine Specification

For engines driving fire fighting pumps, only over-speed trip device independent of
governor, set at 110% speed is the required safety shutdown device.

LOCAL SKID-MOUNTED INSTRUMENT PANEL AND GAUGE BOARD

They shall be mounted on the base plate in an accessible location.

They shall be basically the manufacturer standard design.

Gauge board shall mount all local pressure and temperature gages, instrument
panel shall mount all safety equipment with their associated alarm lights and other
control switches, including manual start-up and shut-down switch. Both panels can
be integrated in one per manufacturer standard design.

REMOTE MOUNTED INSTRUMENT CONTROL PANEL

This is a project specific requirement of details to be described in project application


sheet depending on driven equipment type.

AUTOMATIC START-UP

Fully automatic sequence start-up is required.

Start-up shall be manually actuated using specified switches.

Start-up shall also be actuated by an external signal, as shall be specified in data


sheet, for fire fighting and emergency generator drive services.

Control systems shall allow for at least 6 successive start-up attempts before
announcing a start-up failure message. These attempts may be manual, or by
receiving the external start-up signal.

It is recognized that above scope of instrumentation and controls does not apply in its
entirety to all gas or diesel engine packages or all sizes or ratings. Inquiry
specification and data sheets shall define the actual project mandatory requirements.

7 ENGINE EQUIPMENT AND ACCESSORIES


7.1 Intake Air System
Air for combustion shall not be taken from inside the building or container housing the
engine
Intake filter shall be completely enclosed in a housing, generously sized to allow for
dusty sandy atmosphere, with air speed less than 1.5 M/Sec. at filter element
surface.
The first stage of filtration shall be inertia type to get rid of dust and sand particles, the
second stage shall be dry paper type.
Air intake silencers shall be integrated in air filter housing.
Filter design and dry element construction shall not allow for failing element to be
sucked inside the engine manifold. A stainless steel grid may be utilized for this
purpose.
Adequate expansion joints shall be utilized.

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Gas/ Diesel Engine Specification

Complete operating conditions, RPM, rotation direction and other technical data for
turbo charger are to be furnished by Supplier.

7.2 Exhaust System


Engine shall be fitted with a complete exhaust and silencing system comprising the
following as a minimum:

Flanged stainless steel flexible element(s).


Exhaust duct.
Hospital grade spark arresting silencer made of at least 4.0mm carbon steel sheets,
terminating with 125# FF flanges, fitted with plugged drain connection and adequately
treated against corrosion.
Final exhaust pipe outlet shall be protected by a suitable cover to prevent ingress of
birds, flying objects, or rain. Such closures shall be automatically opened upon
engine starting.
Exhaust engine manifold is recommended to be water cooled.

7.3 Baseplate

Common baseplate for engine, driven machine, and auxiliaries shall be supplied by
engine Supplier.

It shall be designed, sized and adequately braced in design (not temporary shipping
braces) for a single lift with all equipment mounted.

Base skid shall have drip pan sized to receive all engine oil charge, bottom of pan
shall be connected to skid edge and valved.

7.4 Barring-Over And Locking Devices


When deemed necessary, actuated (powered) barring device shall be provided. For
small size engines, manual barring device shall be provided.
Pneumatic barring is preferred.
When automatic powered barring devices are fitted, they shall be positively
interlocked with starting system to prevent inadvertent simultaneous use of both
systems.

7.5 Enclosure And Weather Hood


When specified on data sheet the enclosure and hood shall :
Reduce noise level @ 1.0 meter distance from enclosure to below 85 dB(A).
Have adequate access doors or completely removable panels to facilitate routine
and periodic maintenance.
Be securely locked when closed using metallic stainless steel hardware, with
rubber gaskets, with panic door handles from inside.
Contain all fire fighting equipment specified for the engine; i.e. inert gas bottles,
tubing, nozzles and fire detectors.
Have inertia type louvers for introducing cooling air and exit gravity type non-
return dampers.

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Gas/ Diesel Engine Specification

Fitted with pressurization fans to expel hazardous gases when engine is


installed in classified area.
Exhaust silencer to be mounted outside enclosure
Exhaust to be directed outside any building shelter or sunshade.

8 SPECIAL SAFETY FEATURES


7B

When the engine is specified for installation in a classified hazardous location, the following shall
be required:

Non-sparking material shall be applied for fan blades, fan guards, coupling guards.

All belts shall be made of non-sparking, anti-electrostatic charge material.

Crank case breather shall be oversized, fitted with demister and spark arrestor. Oil
vapours shall be brought to safe location.

Combustion air filter shall be fitted with spark arrestor.

Exhaust gas silencer shall be fitted with spark/flame arrestor.

Exhaust manifold shall be water cooled.

All machine surfaces exceeding 200C shall be thermally insulated to reduce surface
temperature to below 200C; this includes bare engine surfaces, exhaust pipe & silencer,
etc.

Ignition system shall be shielded; shields well earthed, all electrical devices and
components shall be suitable for the classified area.

Over-speed tripping of both gas engine and diesel engines shall be associated with intake
manifold closure, to prevent inhalation of high gas concentration in air which would cause
hot engine to keep on running. This system shall be manually reset before restarting.

Emergency post tripping lubrication for turbocharger and critical rotating elements which
operate at elevated temperature.

Lube oil filling connection and oil level measuring dip stick shall be connected to engine
base frame using strong chains to secure them in place upon crank case explosion.

Crank case shall be fitted with over pressure safety relief doors which open at high
pressure and close at vacuum condition to prevent atmospheric air from entering to hot
engine internal spaces.

Engine shall be contained inside an enclosure provided with the following features:

Pressurization fans with filters mounted on top of enclosure, elevated enough to suck
air from a non-classified area. Fans shall maintain at least 5.0mm water gauge
pressure inside to expel gases and keep safe unclassified area within enclosure.

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Gas/ Diesel Engine Specification

Gas detectors installed inside gas engine enclosure shall prevent starting of the
engine when hazardous gas mixture with air is detected. Ventilation fans of explosion
proof motor shall keep on running to exhaust air and gas mixture.

U/V flame detectors shall be installed inside enclosure to detect fire condition. This
will cause all fans to stop, all opening to be isolated by motorized dampers, then
extinguishing gas released. Type of extinguishing gas shall be specified by purchaser.

9 INSPECTION AND TESTING


9.1 General
All equipment and materials shall be subjected to inspection witnessed by Purchaser. Al
machinery and equipment shall be subjected to functional, mechanical and running test as
applicable and depending upon the workshop facilities. Some of the packaged equipment
inspections and testing may be conducted at packager factory after the engine has been
tested per the engine manufacturer standard procedures, at the original engines
manufacturer factory. This has to be agreed with purchaser at contract clarification stage.

During these tests, supplier shall demonstrate to the applicable extent and to the
satisfaction of inspectors the operation and performance of contract equipment in
accordance with the specified duty and guarantees.

All pertinent auxiliary equipment shall also be tested, starting systems, governing systems
and instrumentation performance shall be demonstrated to the extent practicable in
accordance with functional diagrams and automatic sequences, as approved during
detailed engineering review by purchaser.

If necessary, off-line simulation panels shall be provided for testing of shutdown circuits
and sequential controller.

If tear down/dismantling of machinery component is required for modification/replacement


for improvement of mechanical operation, the initial tests will not be accepted and the final
shop tests must be repeated after such corrections are made.

All jackets, radiators, pressure vessels, heat exchangers, pumps, etc. shall be subjected to
hydrostatic test in accordance with the applicable code or specification. Prefabricated
piping systems including all fittings and systems parts shall be also subjected to
hydrostatic test at suppliers workshop. Test pressure shall be at least 1.5 times system
design pressure.

Water with high chlorides contents shall not be used for testing austenitic stainless piping
and equipment.

Water of moderate chloride contents (50-to-100ppm) may be used, provided 2%-to-4%


sodium nitrate is added.

Test certificates with detailed logs shall be prepared by supplier and delivered to the
inspectors.

During all tests all equipment shall be checked to operate in accordance with the
requirements of suppliers instruction and maintenance book.

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Supplier shall list in his proposal the type and duration of standard tests to be carried out in
engine fabrication shop, and the other tests which can be conducted at supplier (packager)
shop. Purchaser shall review and agree with Supplier on the details of scope of testing
and place of execution.

Acceptance of shop tests does not relieve the supplier of his responsibilities in supplying
machinery satisfying the intent of all applicable specifications.

Supplier shall specify the scope of all non-destructive testing to be done on all parts of the
equipment in his proposal for purchaser review and comments.

9.2 Performance Testing Requirements


Testing of engine in accordance with B.S.649 shall be witnessed and shall include:

Six (6) plus four (4) starts in the worst conditions, with 50% discharged batteries or with
50% charged compressed air reservoir, or as applicable.

Load test according to B.S 649 as follows:

One hour at 1 / 3 load


One hour at 1 / 2 load
One hour at 3 / 4 load
Two hours at full load
One hour at 10% overload (as applicable)

These ratings are referred at testing workshop ambient conditions. The above duration of load
conditions is to be calculated after steady conditions (pressure, temperatures of oil, water, air, etc.)
have been reached after each running condition change.

Dismantling after a running test is required on 25% or 2 minimum (whichever is greater) on


all parts listed on B.S 649 clause 7 appendix D.

Specific fuel consumption at 1/3, 1/ 2, 3 /4, 1/ 1, load and 10% overload shall be recorded
together with total lube oil consumption.

During testing, the whole specified speed range shall be checked. Each engine shall run
at least one hour at minimum specified speed for checking of mechanical and thermal
behaviour.

Engine frame inlet air manifold and gas discharges manifold shall be tested for leakage
with low pressure air (100mm H2O).

Certified copies of all test records shall be furnished to purchaser.

Physical and metallurgical data of main materials relevant to major parts of engine unit
shall be available for purchaser review.

9.3 Guarantee Figures And Tolerances


In General BS649 or ASME PTC-17 tolerances shall be applicable in addition to the
following measured at 100% load condition:

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Shaft power +3, - 0%


Fuel consumption +3%
Lube oil consumption +4%
Casing vibration levels shall not exceed 20 mm/sec in the overall seismic scale.

10 MATERIAL, EQUIPMENT IDENTIFICATION AND MARKING


10.1 Item Number
The Purchaser will assign item numbers to the different pieces of equipment furnished including
instruments. Supplier shall attach a stainless steel metal tag to each of these items showing order
number, and item number. These tag numbers shall be cross referenced by the Supplier's bill of
material. For standard equipment and devices of the engine, Supplier may use standard catalogue
(instruction manual) nomenclature.

10.2 Nameplates
Suitably engraved nameplates shall be provided to properly identify all equipments, controls and
instruments. Nameplates shall be made of 18Cr-8Ni stainless steel. Purchaser item number,
manufacturer serial number, engine technical data and all design limits for all equipments shall be
shown on nameplates.

10.3 Rotation Arrows


Either cast in or attached to all rotating parts shall be furnished.

PREPARATION FOR SHIPMENT


Painting shall be in accordance with manufacturer standard subject to Purchaser review.

Engine interior spaces shall be sprayed with rust preventative removable by solvent
flushing.

All machined and threaded exterior surfaces shall be coated with a suitable rust
preventative.

Flanged nozzles shall be covered with gasketed air tight, 1/2-inch steel blanks that shall
not protrude beyond the edge of the flange outer diameter.

All threaded connections shall be fitted with steel barstock plugs.

Engine shall be packaged or crated for overseas transportation and for six month storage
in worst site conditions. Any special instructions for extended storage times shall be
marked clearly on machinery parts and components in such a visible way in clear
wordings to tell the site personnel the procedure of preservation/moving/rotating of
parts/recharging with preservatives, renewing desiccant bagsetc. without reverting them
to other instruction manuals.

11 INSTRUCTION MANUALS
These shall be furnished not later than the date of shipment. The manuals shall describe
installation, operation, and maintenance procedures for engine and auxiliaries, and instruments for
items furnished by supplier.

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The manual shall be organized and indexed by principal equipment items and systems. It shall
include as a minimum:

Written instruction, covering start-up, normal shutdown, emergency shutdown,


operating limits, and routine operational procedures.

A written sequence of assembly and final tests and checks for equipment within the unit.

A description of equipment construction features and of functioning component parts or


systems. The recommended clearances and maximum and minimum design clearances
shall be clearly stated.

All outline drawings (schematic and illustrative sketches in sufficient detail to identify all
parts) clearly showing the operation of equipment and components and the method of their
inspection and repair. All running fits, clearances, and balancing data required for erection
and maintenance shall be clearly stated.

Rigging procedures, methods of disassembly, repair, adjustment, inspection, and


reassembly of compressor, driver, and auxiliaries. Include torque values for nut tightening
as required.

Completed data sheets and performance curves.

All sub supplier data and instructions.

All main equipment and auxiliaries catalogues and brochures.

Erection, grouting, pre-commissioning and start up procedures, preservation, packaging


and shipment instructions.

Spare parts and special tools information including drawings, part number, etc.

Lubrication schedule for all components. Recommendation for lube oil analysis program
including applicable limits for Condition Monitoring

All detailed engineering approved drawings and data sheets; not limited to: certified
dimensional outline, auxiliary system schematics, material safety data sheets.

Bill of material of all supplied material and equipment.


Recommended Condition Monitoring techniques and program to facilitate Predictive
Maintenance.

12 DATA BOOKS
Data books shall be issued upon completion of manufacturing and final testing. A draft copy shall
be issued to purchaser for review during final testing. Data book shall include but not limited to:

Purchaser purchase order and any variations or changes

Copies of all purchase orders issued by supplier to his sub suppliers.

All order and sub orders relevant correspondences.

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As-built copy of data sheets, all drawings, and manufacturer data sheets.

Material certification, NDT reports, hydrostatic test reports, balancing reports.

Mechanical test and performance test procedures and test reports.

All purchaser inspection reports.

Manufacturer quality plan as executed.

Detailed bill of material associated with brief technical specifications of all items in supplier
scope.

13 SPARE PARTS
A spare parts list for commissioning, start up and two year operation shall be proposed to
purchaser.

Pre-commissioning and start up spares shall include as a minimum:

Three sets of all filter elements in oil, fuel, air or cooling water systems.

One pressure indicator of each type.

One temperature indicator of each type.

One switch of each type.

Three panel light bulb of each type.

Set of fuses.

Set of belts.

Engine gasket and O-ring sets.

Packing and mechanical seal spare parts for all pumps, repair kits for starting air
compressors, governors, actuators, chargers, etc.

Two year spare parts quotation after order, using same SPIL form A-5444 shall include as
a minimum:

Insurance type spares such as: main PLC unit, governor, water pump.

Spark plugs, coils, injection pumps, starting system spares, automatic temperature
control devices, fuel solenoids.

Repair kits not limited to fuel regulators, etc... per above description.

Consumables such as filter elements, etc as a minimum.

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14 SPECIAL TOOLS
As a minimum, the following set of special tools shall be part of the main scope of supply:

Barring device related wrenches.

All special size spanners of open, socket box head, etc.

Piston ring compression tool.

Compression Tester

Exhaust Gas Analyser.

Adjustable torque wrench with meter covering the range of torque wrench values
encountered in engine overhaul.

All special size hub pullers required for engine major overhauls.

A metallic container moving on wheels which includes a complete set of special and
standard tool set to enable complete teardown and overhaul of the engine.

15 SUPPLIER INFORMATION
Purchaser material requisition shall define in details the minimum documentation contents
required to be submitted by supplier during detailed engineering.

A complete detailed dimensional, structural and functional description of the gas or diesel
unit shall be supplied with the proposal together with pertinent appropriate technical
bulletins, drawings etc.

Following information shall also be supplied with the proposal:

Rate of combustion air sucked by engine per hour, engine exhaust gas analysis at
different loading conditions.

Rate of cooling air circulated by radiator fan per hour, rate of heat emission to cooling
water and to ambient air.

Minimum capacity of batteries or air bottles for starting the engine six times.

Maximum skid weight for transportation.

Maximum maintenance weight lifted for normal or overhaul maintenance.

16 ENVIRONMENTAL REQUIREMENTS
16.1 General
Engine construction and design must fulfil the objectives of environmental laws and
regulations of the country of origin and the country of end used, which shall not be limited
to:

Maximization of engine efficiency.

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Reducing heat emissions to atmosphere to the minimum levels.

Waste heat utilisation, which requires liaison with purchaser to know possible
application of this system, and to identify the process to be adopted.

Provisions in design for recycling of effluents or parts, such as: collection of oils or
coolants, definition of consumed filter elements proper recycling.

Application of material or liquids which when disposed in the soil or drain system shall
decompose to products which are friendly with environment.

Application of preservatives, paints, insulations, coatings which are not harmful to


man or environment, such as asbestos.

Reducing noise level.

16.2 Emergency Drive Applications


Fire water pump and emergency electric generation are typical emergency diesel engine
applications. Such applications are characterised by short weekly running of the unit for testing
purpose, and only few hours operation at duty call conditions. Another characteristic is clear for
fire water pump diesel engine drive, which has to be UL-listed, FM-approved per NFPA 20
standard requirements. Vendor to recommend an assurance program testing the start initiation
instrumentation, with minimised running of the engine.
For such services, manufacturer standard design proven for the specified service shall be applied,
trusted to fulfil most of the requirements of p. 17.1, without special additional design improvements
or additional accessories. Short duration of engine operation shall limit total negative impact on the
environment.

16.3 Continuous And Prime Power Applications


Egyptian law No. 4/1994 for environment protection and its executive memorandum issued by the
Prime Ministerial instructions No. 338/1995:

The following limits shall not be exceeded in the exhaust gases from the engine:

For carbon monoxide CO @ engine idling speed shall be less than 4.5% by volume.

Unburnt hydrocarbon gas @ idling speed shall be less than 900 PPM,W.

Smoke shall not cause overall gas opacity to reach 50% (as defined by ASTM
standard) @ full load ramp; (maximum rate of increase of load from 0% to 100% as
specified by the engine manufacturer).

For steady engine operating conditions, the following limits shall not be exceeded:

CO; carbon monoxide 50 PPM


CO2; carbon dioxide 5000 PPM
Hydrocarbon gases/vapours 100 PPM
NO2; nitrogen dioxide 150 PPM
SO2; sulphur oxide 60 PPM, intermittent
2 PPM continuous

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Unburnt mineral oil mist/vapours 5 PPM


Opacity 10% of maximum level

Supplier shall quote required fuel treatment units, or exhaust gas treatment units to
improve exhaust gas emissions to within above specified limits, or better, to conform
to more local or international environmental regulations.

Quoted systems shall be optimized for the specified fuels and available mineral base
lubricating oils.

16.4 Noise Levels for Continuous Engine Drive


The maximum allowable noise level @ one meter contour line from the engine shall be
specified based on the specific job application. If the engine is installed inside a building
by the purchaser, standard noise level shall be accepted provided that:

Air intake filter silencer is fitted.

Hospital type exhaust silencer is utilized.

Engine is mounted on acoustic & vibration attenuation pads/isolators.

All and every details proven by the standard manufacturer design to produce low
noise energy shall be applied.

Purchaser building shall be so designed to limit the outside noise level to within area
noise level requirements. Normally this limit is 85 dB (A).

When specified, engine and driven equipment may be required packaged within
acoustic enclosure which shall satisfy the external noise limits required for the project;
which would be form 85-to-90 dB (A).
16.5 Waste heat utilisation
For continuous operation or prime power generation engine drive, supplier should quote in the
proposal systems which can be integrated as standard proven ancillaries to the quoted engines for
best utilisation of jacket water and exhaust system heat. Purchaser shall evaluate the various
optional applications quoted to select the most suitable for the specific project. The waste heat
utilisation may be of the following:

Producing chilled water utilizing absorption chiller system.

Desalination of water for the purpose of utility/potable water application.

Hot water generation, for building heating or other applications.

Drying or any other process applications.

17 ENGINE FUELS
17.1 General
The intent of this section is to establish a clear understanding between supplier and the purchaser
regarding different types of fuel and the conditions of their application.

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Diesel Engine Fuels


The following are the specifications of the main two types of Egyptian diesel fuels:

Property Gas Oil Diesel Oil


Specific gravity 0.82 0.87 0.84
Colour, ASTM max. 4.5 --
Flash point P.M. closed C min. 55 min. 65
Viscosity, CP @ 38C min. 1.64
max. 6.3 max. 10.66
Pour point C, winter max. 4.5 max. 13 (1)
Summer max. 10 max. 16 (1)
Sediment, wt max 0.01 0.1
Water content % volume, max 0.15 0.25
ASH content % wt, max 0.01 0.03
Conradson carbon % wt., max 0.1 2.0 (2)
Total sulphur content % w, max. 1.5 1.5
Inorganic acids & bases Nil Nil
Distilled @ 350C %, min 80 80
Diesel index min. 48 23
Hot filtration @ 100C:
- Before storage, max - 0.1
- After 24 hours storage, max - 0.1
Solid asphalt, max - 1.0
Copper strip test @ 100C, max Div I -
Calorific value gross, kcal/kg, min 10550 10230

Notes: (1) Winter: Nov 1 to Mar 31


Summer: Apr 1 to Oct 30
(2) On 10% residue from distillation

Gas oil is the commonly available diesel fuel, however, supplied diesel engine fuel system
must be able to operate engine on either types of fuel. Method of engine tuning on a
specific fuel analysis must be described in supplier proposal.

It is common practice in gas plants to mix diesel fuels with naphtha or stabilized
hydrocarbon condensate, resulting in the following:

- Reducing diesel fuel viscosity

- Reducing pour point, because fuel shall be thinner and less viscous

- Increasing the diesel fuel index and the gross calorific value

Supplier shall advise the maximum mixing ratios, the resulting effect on engine overall rating,
operating engine temperatures, operating exhaust gas temperature and the method of optimum
tuning of engine for the specified condensate analysis.

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18 GAS FUELS
Sales gas rich in methane is the most commonly available and applied for gas engines.
Molecular weight ranges from MW17.0 to MW23 and of low value of calorific value of
11,500 kcal/kg and self ignition temperature not less than 250 to 300C which allows to
apply a reasonably high engine compression ratio without possibility of detonation. Exact
fuel analysis and degree of superheating shall be advised to engine supplier in the inquiry
specification.

In unstabilised process condition, gas fuel may be sourced out of other sections of the
process where it may not be true sales gas, where gas may be richer of heavier
components, resulting in higher values of molecular weights and lower values of self-
ignition temperatures.

Supplier in his proposal shall investigate all possible types of fuels specified in purchaser
inquiry specification, evaluating for each fuel the equivalent methane number, calculating
standard engine performance ratings for each fuel type, and reporting to purchaser the
maximum possible range of gas fuels the machine can safely utilize. The required
minimum degree of superheat of fuels above their dew point shall also be specified by the
supplier.

Fuel ignition system shall be electronically controlled, individual high tension coils and
spark plugs shall be fitted for each cylinder, system shall be rated for classified area
because presence of fuel piping, filters and other system component render the area a
hazardous classification. Fuel control system shall always optimize both fuel to air ratio
and ignition timing for fuel economy and to prevent detonation.

In case detonation condition appears to tend to catastrophic condition, engine shall be


automatically tripped with control system clearly displaying the original cause of the
shutdown.

Supplier shall select fuel control system including gas fuel regulators, governor, and
ignition electronic control module, such that a very wide range of gas fuels can be
applied, per above description.

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