1. SCOPE ……………………………………………….2. REFERENCES 3. DEFINITIONS 4. GENERAL……………………………………………5. BASIC DESIGN 5.1 General 5.2 Lube Oil System ………………………………5.3 Combustion Air Intake 5.4 Exhaust Systems 5.5 Cooling System ……………………………….
5.6 Fuel System 5.7 Starting System 5.8 Instrumentation and Controls ……………5.9 Flameproofing 5.10 Special Tools 6. PAINTING ……………………………………………7. INSPECTION AND TESTING 8. DOCUMENTATION 8.1 Proposals ………………………………………8.2 Contract Data 8.3 Curves and Tabulations 8.4 Parts Lists and Recommended Spares 8.5 Nameplates
9. PREPARATION FOR SHIPMENT 10. MAINTENANCE …………………………………..
1. Scope
This specification, together with the data sheets, covers industrial type stationary diesel (compression
ignition) engines, and auxiliaries, for use in mechanical drive, firewater pump, and electric generator drive
applications. It does not cover automotive and marine diesel applications.
2. References
Reference is made in this specification to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
E02-E02 Hazardous Area Classification
E07-S01 Stand-By Diesel Generators, 480 and 4160 V
E16-S01 Batteries and Chargers
S20-G01 Plant Equipment Noise Limits
X01-S03 Instrumentation for packaged units
Engineering Equipment and Material Users Association (EEMUA)
107 Recommendations for the Protection of Diesel Engines for Use in Zone 2 Hazardous Areas
National Electrical Manufacturers Association (NEMA)
SM 23 Steam Turbines for Mechanical Drive Services
National Fire Protection Association (NFPA)
20 Standard for the Installation of Centrifugal Fire Pumps
Society of Automotive Engineers (SAE)
J1349 Engine Power Test Code-Spark Ignition and Diesel
3. Definitions
For the purpose of understanding this specification, the following definitions apply.
Auxiliaries.
Equipment necessary for the operation of the engine but not an intrinsic part of the engine.
Auxiliaries are usually manufactured by a different vendor.
Continuous Rating.
Maximum effective output which the engine, according to its application, is capable
of delivering continuously, with the limit of output being sufficient to permit an overload rating.
Continuous Service.
Service where operation exceeds 8,000 h per year with uninterrupted periods of
1000 h minimum. Except for annual overhauls, shutdowns for maintenance shall not exceed 24 h.
Critical Service.
Large, unspared equipment essential for reliable operation, or services essential to
maintain a safe environment, for example fire pumps and generators.
Hazardous Area.
An area in which an explosive gas mixture is or may be expected to be present in a
quantity sufficient to require special precautions for the construction, installation and use of electrical
apparatus.
Intermittent Service.
Service where operation exceeds 4,000 h but does not exceed 8,000 h per year
with uninterrupted periods of 1,000 h minimum.
Maximum Rating.
Maximum effective output which the engine is capable of delivering for 15 min without
mechanical thermal overload.
Minimum Rating.
Minimum continuous output under worst site conditions of temperature, altitude and
humidity which does not require any design changes.
Overloading Rating.
Maximum effective output which the engine is capable of delivering continuously for
one hour, or intermittently for a total of one hour, within a period of 13 h. The overload rating shall be
considered 110 percent of the continuous rating unless otherwise specified by vendor.
Package.
The complete assembly of the engine, its auxiliaries, the driven machine and controls, with or
without a baseplate.
Rated Power.
The rated power output of the engine at the most severe design ambient conditions.
Rating.
All effective ratings as defined below are outputs available at the crankshaft under SAE J1349
standard inlet air conditions of:
a. Inlet air pressure (absolute) 100 kPa abs (14.5 psia)
b. Inlet air temperature 25
°
C
c. Dry inlet air pressure (absolute) 99 kPa abs (14.4 psia)
Site Rating.
Available output at either continuous or overload maximum rating when the engine is running
under actual site conditions of maximum temperature, altitude and humidity.
De-rating for site conditions shall be calculated in accordance with SAE J1349.
Note: The terminology ‘Service’ and ‘Rating’ should be clearly distinguished. Service definitions
differentiate engines on the basis of accumulated running hours.
Standby Service.
Service where operation does not exceed 4000 h per year with uninterrupted periods of
1000 h maximum.
Start.
A start is defined as a minimum of seven complete crankshaft revolutions at the engine firing speed.
4. General
4.1 Diesel engines shall be supplied by vendors qualified by experience in manufacturing the proposed
equipment. In order to qualify, vendor shall have manufactured, at the proposed point of manufacture, at
least two engines of comparable rating, brake mean effective pressure, and speed. These engines shall
have been in service and performing satisfactorily for at least one year. Vendor shall provide, upon request,
a detailed user list of engines in service in similar applications.
4.2 Where the vendor qualification requirements prevent the application of the latest technology, vendor
may submit a second or alternative proposal incorporating the latest technology features for evaluation by
SABIC. This alternative proposal shall specifically identify the undemonstrated by experience features and
state their advantages.
4.3 Engine performance shall be guaranteed for
1
/
4
,
1
/
, and full load operation at the combination of
ambient temperatures and atmospheric pressure(s) specified on the data sheets.
2
4.4 Vendor shall have unit responsibility for meeting noise requirements. The complete installation shall
conform to SES S20-G01.
4.5 The guaranteed specific fuel consumption at these rated conditions shall be stated. The rated power of
the engine shall be adjusted for site conditions.
4.6 On certain installations, the application of NFPA 20, or other national standards specified by SABIC,
shall apply to engines driving fire pumps.
4.7 Stand-by diesel generators shall comply with SES E07-S01.
5. Basic Design
5.1 General
5.1.1 Engines shall be suitable for continuous unattended baseload operation for 24 h per day at the
extremes of ambient conditions. Engine and auxiliaries shall be designed and constructed for the rating,
type of service, fuel, installation and environmental conditions specified on the data sheets. Unless
otherwise specified, the engine shall be designed for outdoor installation.
5.1.2 The design service life for this equipment shall be 20 years. The design time between major
overhauls shall be at least 25,000 running hours for engines in continuous duty.
5.1.3 Fuel requirements for running conditions shall be stated on the data sheets, along with the
accompanying fuel properties. Vendor shall certify that the available fuel is suitable for the engine at the
service conditions.
5.1.4 Engine and auxiliary equipment shall be mechanically suitable to operate upto engine overload
conditions, including the overspeed trip setting.
5.1.5 The crankcase and all mechanical and control component enclosures shall be designed to keep out
moisture, dust and other foreign matter during both operation and idleness.
5.1.6 All equipment shall be designed to permit rapid and economical maintenance. Major parts shall be
shouldered or doweled.
5.1.7 Any special tools required for installation or normal maintenance shall be supplied with the engine,
together with instructions for their use.
5.1.8 Engine with its auxiliaries and instruments shall be suitable for hazardous area classification
specified on the data sheets. See SES E02-E02.
5.1.9 The direction of rotation shall be permanently marked on the engine in a prominent position.
5.1.10 Each cylinder head shall be fitted with provisions for performing a compression check on each
combustion cylinder.
5.1.11 Vendor shall perform a torsional analysis of the quoted engine and the driven equipment, to ensure
that torsional stresses in the system throughout the full speed range, including 110 percent overspeed, do
not exceed acceptable limits. If the vendor has recent experience with similar equipment, they may, with
SABIC approval, submit data for that equipment for review. SABIC and vendor shall mutually decide upon
the definition of similar equipment and acceptable limits.
5.2 Lube Oil System
5.2.1 The engine shall have a pressure lubrication system supplying oil to all areas requiring pressure
lubrication. Main lube oil supply shall be by means of a positive displacement, engine-driven oil pump,
equipped with a suction strainer and a pressure regulator. The pump shall be easily accessible for
maintenance.
5.2.2 The lubrication system shall include a dual, full flow oil filter equipped with differential oil pressure
taps to monitor oil filter differential pressure; an oil reservoir; and a series-connected oil cooler.
5.2.3 Oil filters shall be full flow, replaceable cartridge type. Filter(s) shall be readily accessible to allow for
cartridge replacement. Filter cartridges filtration shall be 10
µ
m, maximum.
5.2.4 Pumps shall be fitted with a removable suction strainer with 316 stainless steel screens of 20 mesh
or finer.
5.2.5 The oil sample point with isolation drain valve, positioned before oil filters, shall be provided for oil
collection/analysis.
5.3 Combustion Air Intake
5.3.1 An air intake filter suitable for the environmental conditions specified shall be provided together with
ducting between the filter and engine. Unless otherwise specified, the filtration system shall be designed
for a desert environment with high concentrations of windblown sand.
5.3.2 Unless otherwise specified, intake air filters shall be two stage, renewable dry type, provided with a
weather hood.
5.3.3 An air inlet restriction gage shall be provided, to indicate when the filter is dirty and requires
servicing.
5.4 Exhaust Systems
5.4.1 Vendor shall supply a complete exhaust system. The exhaust system shall be designed to mount on
the engine skid.
5.4.2 The engine exhaust system shall consist of a residential-type spark arrestor and silencer, a flexible
exhaust expansion joint, all necessary exhaust piping, and support racks for mounting the exhaust system
on the engine.
5.4.3 Unless otherwise specified, exhaust silencers shall be supplied by vendor, and shall attenuate the
engine exhaust to a maximum of 85 dB(A) at 1 m. See SES S20-G01.
5.4.4 Silencers shall be properly sized for the engine and be complete with companion flanges, mounting
brackets, and rain cap.
5.4.5 For exhaust ducting, vendor shall provide an expansion bellows at the termination of the engine for
SABIC connection, when specified. Vendor shall also furnish the allowable loads on this connection.
5.4.6 The routing and sizing of the exhaust ducting from the SABIC connection to final termination shall be
mutually agreed upon between SABIC and vendor.
5.5 Cooling System
Engine cooling system shall have sufficient capacity to maintain stable operating temperatures at the
maximum engine output and under the worst site conditions of temperature, altitude and humidity.
5.6 Fuel System
5.6.1 The diesel fuel system shall be sized to deliver the required amount of fuel to be consumed by the
engine and any other required uses, for example injector cooling, in accordance with vendor’s standard
scope of supply.
5.6.2 Engine fuel systems shall be supplemented by a day tank and fuel transfer pump when specified.
5.6.3 The fuel storage tank shall be supplied complete with the following equipment:
a. Armored type gage glass for level indication
b. Valved fuel supply outlet with a lockable valve
c. One inch (minimum) valved drain
d. Fittings for tank vent fill and fuel return from engine. Vendor shall supply vent and fill caps for
installation by others.
5.6.4 For engines in continuous service, fuel filters shall be of the duplex, full flow, cartridge type having a
filter mesh not exceeding 10
µ
m. The duplex filters shall have a cross over valve.
5.7 Starting System
5.7.1 The method of engine starting will be specified on the data sheets.
5.7.2 The starting system shall be capable of handling a minimum of 3 consecutive starts without
recharging the batteries or re-pressurizing the air receiver.
5.7.3 For DC electric starting system:
a. System shall be 24 V or higher, as recommended by vendor
b. System shall include starting motor, batteries, battery rack, cables, ac powered battery charger,
and necessary controls for automatic start and stop from a remote signal. See SES E16-S01.
c. The battery charger shall restore a fully discharged battery to 100 percent of the battery’s
ampere-hour rating within 24 h
d. Dual sets of batteries shall be provided for engines driving fire pumps, unless two methods of
starting are supplied. Each set of batteries shall provide the performance specified herein. Start
attempts shall alternate between battery sets.
5.7.4 For starting air supply system, if specified:
a. System shall consist of an air receiver, safety relief valves, and start and stop switches
b. The air supply shall be adequate for replenishing the air receivers to full starting air pressure from
the minimum allowable starting air pressure in not more than 15 min
c. The air receiver shall be sized for 3 consecutive starts of any engine served by the system,
including any turbocharger starting air assistance
5.8 Instrumentation and Controls
5.8.1 Vendor shall provide the necessary control and instrumentation for proper operation, and adequate
monitoring and safeguarding of the engine. See the data sheets.
5.8.2 Controls and control panels shall be completely piped and wired, requiring only connection to
external piping and wiring circuits.
5.8.3 Engines shall have an adjustable governor as specified on the data sheets. Governors for all
mechanical drives, with the exception of firewater pumps, shall be in accordance with NEMA SM 23,
Class C. Speed governors shall accept the SABIC control signal when remote control is specified.
5.8.4 Vendor shall submit complete specifications and drawings of all controls and instrumentation.
5.9 Flameproofing
5.9.1 Diesel engines located in a Class I, Div 2 area shall be flameproofed as noted in this sub-section, in
accordance with EEMUA 107.
5.9.2 Air-cooled engines shall not be permitted when flameproofing is required.
5.9.3 External metallic parts, for example fan blades, which may cause sparking by contact with other
parts, shall be manufactured from non-sparking materials.
5.9.4 Drive belts shall be anti-static and fire resistant.
5.9.5 The starter shall be either an ac mains operated electrical type, or a non-electrical type. Gasoline
engines shall not be permitted.
5.9.6 The exhaust manifold shall be water-cooled. An exhaust gas heat exchanger, a flame trap and a
spark arrestor shall be installed downstream of the exhaust manifold. The flame trap and spark arrestor
may be combined.
5.9.7 The inlet manifold shall be equipped with a flame trap downstream of the air filter.
5.9.8 The exhaust gas temperature, or the surface temperature of any part of the entire system, shall not
exceed 250 °C when the engine is running at the site overload rating.
5.9.9 The inlet manifold shall be equipped with an automatic shutoff valve to stop the engine at
overspeed.
5.9.10 The length of the flame path through or across any joint shall be minimum 13 mm.
5.9.11 Suitable metal clad jointing or other SABIC approved material shall be used between all joint faces,
to ensure that no leakage occurs.
5.9.12 No screw, stud or bolt hole shall pass through the wall of any component of the exhaust and inlet
system.
5.9.13 Crank casings having a volume larger than 0.5 m
3
shall be provided with relief devices and shall be
equipped with flame traps. Alternatively, the crank case relief valves may discharge into the intake system
downstream of the intake flame trap and upstream of the intake shut-off valves, if installed. Dip sticks and
oil filler caps shall be screwed or effectively secured by other means.
5.9.14 The engine nameplate shall be marked to show the Class, Division and Group for which it is
qualified.
5.10 Special Tools
Special tools necessary for routine maintenance shall be supplied with the engine, in particular the
following items:
a. A fuel line sight gage for air leak checking
b. A belt tension gage
c. An injector dial indicator
d. A barring device. For engines larger than 500 kW, an electric or pneumatic barring device shall be
6. Painting
provided.
6.1 Unless otherwise specified, painting shall be in accordance with vendor’s standard for conditions
specified on the data sheets.
6.2 Vendor shall submit their standard painting specification for SABIC review and approval.
6.3 Specification shall include language to define surface preparation, paint materials, application, film
thickness and paint vendor’s data sheets.
6.4 Stainless steel components shall not be painted.
7. Inspection and Testing
7.1 SABIC retains the right to inspect all materials, fabrication, and documentation.
7.2 Vendor shall be responsible for all testing. Documentation of all inspection results shall be maintained
during fabrication, and upon job completion they shall be supplied to SABIC in the vendor data books.
7.3 Vendor shall test the engine at 100 percent load on an engine dynamometer for a period of at least 4 h
after reaching steady-state conditions with no load. When steady-state conditions have been reached and
held for 15 min, the load shall be applied and test data shall be recorded at 15 min intervals. Test data shall
include the following information:
a. RPM
b. Specific fuel consumption
c. Fuel pressure
d. Oil pressure
e. Oil temperature
f. Water temperature
7.4 Immediately following the 100 percent load test, an overload test of 110 percent full load shall be run
for 30 min. Overload test data shall also be recorded. Operation of the engine governor shall be checked
under various engine loads to ensure that the governor is capable of regulating engine speed within the
range specified on the data sheets.
7.5 Following engine shutdown from the overspeed shutdown device, the engine shall be restarted and
loaded to 100 percent full load. Certified test data shall be provided by vendor from data obtained during
the performance test of the purchased engine.
7.6 Approval or release of equipment for shipment shall not relieve vendor of any responsibility or
guarantee. Acceptance of shop tests shall not constitute a waiver of field performance requirements under
specified operating conditions, nor shall shop inspection by SABIC relieve vendor of responsibilities in case
of later discovery of defective material or workmanship.
8. Documentation
8.1 Proposals
Vendor’s proposal shall include the following information:
a. A copy of the vendor drawing and data requirements form, indicating the schedule according to
which vendor agrees to furnish the data requested by SABIC
b. Copies of the data sheets complete with vendor’s information required for the proposal
c. Typical outline and arrangement drawings. Auxiliary system schematic diagrams shall be
marked to show which portions of the system are internal with or mounted on the major equipment,
and which are separate
d. A specific statement that the system and all its components are in strict accordance with this
specification
e. A list of spare parts recommended for normal maintenance purposes. SABIC will specify any
special requirements for long term storage
f. An itemized list of the special tools included in the package
g. A full description of the standard shop tests required. Special tests as specified shall also be fully
described.
8.2 Contract Data
8.2.1 SABIC will state in the inquiry and in the purchase order the number of prints and reproducibles
required, and the times within which they shall be submitted by vendor.
8.2.2 SABIC will review vendor’s drawings, but such review shall not constitute permission to deviate from
any requirements in the purchase order unless specifically agreed upon in writing. After the drawings have
been reviewed, vendor shall furnish certified copies in the quantity specified.
8.2.3 The following information shall be included in the drawings (typical drawings shall not be
acceptable):
a. SABIC order number (on every drawing)
b. SABIC equipment item number (on every drawing)
c. Lists of reference drawings
8.2.4 Vendor shall supply schematic diagrams of each system in their scope of supply. Vendor shall also
supply outline (general arrangement) drawings, bills of material, and specifications for the components for
SABIC review.
8.2.5 Vendor shall supply cross-sectional or assembly-type drawings specifically made for all equipment
furnished, showing all parts, running fits, clearances, crankshaft web deflections, and balancing data
required for erection or maintenance.
8.2.6 Vendor shall provide full information to enable completion of the data sheets, first for ‘as purchased’,
and then ‘as built’.
8.2.7 If specified, vendor shall submit the data required for an independent torsional vibration analysis.
Also, if specified, sufficient data shall be provided for independent computation of primary and secondary
shaking forces and couples.
8.3 Curves
Curves of speed versus torque shall be furnished for the engine. All curves shall be scaled in finite values.
Percentages shall not be acceptable.
8.4 Parts Lists and Recommended Spares
8.4.1 Vendor shall submit complete parts lists for all equipment and accessories supplied. These parts lists
shall include pattern, stock or production drawing numbers, and materials of construction. The list shall
completely identify each part to allow SABIC to determine the interchangeability of parts with other
equipment furnished by the original vendor.
8.4.2 Vendor shall indicate on the parts lists specified in 8.4.1, which parts are recommended spares for
start-up and normal two-year maintenance.
8.5 Nameplates
A corrosion resistant metal nameplate shall be permanently attached to the equipment (not baseplate) and
shall contain the following information using specified units:
a. Equipment item number
b. Supplier’s name
c. Serial number
d. Rated capacity
e. Date manufactured
f. Type/No. of cylinders/displacement
9. Preparation for Shipment
Preparation for shipment shall be suitable for the type of shipment and storage conditions specified in the
purchase order. Shipping preparation details shall be subject to SABIC approval.
10. Maintenance
An operating and maintenance instructional manual shall be included as part of the package. This manual
shall provide sufficient written instructions, including a cross referenced list of all drawings, to enable
SABIC to correctly install, operate and maintain the unit. The manual shall contain the following
information:
a. Instructions covering start-up, normal shutdown, emergency shutdown, operating limits and
routine operational procedures
b. A description of the constructional features and the functioning of the component parts and
systems, for example controls, and the lube oil, turbocharger, fuel injection, and cooling systems
c. Outline and sectional arrangement drawings, schematics and illustrative sketches, to identify all
parts, and to clearly show the operation of all equipment and components and the methods of
inspection and repair. Standardized sectional arrangement drawings shall be acceptable only if they
represent the actual construction of the engine being supplied.
d. As built data sheets containing all required information
e. The following maintenance data:
(i) Maximum and minimum bearing and seal clearances
(ii) Instructions for measuring and adjusting cold clearances
(iii) Crankshaft float allowance
(iv) Crankshaft dimensions and regrind allowance, if applicable
(v) Interference fits on parts required to be removed or replaced
(vi) Runout and concentricity tolerances
(vii) Cylinder bore dimensions
(viii) Piston ring clearance and wear data
f. Re-assembly data, including bolting sequence and torque values for cylinder head bolts, crank and
main bearing bolts, piston and connecting rod bolts, exhaust manifold bolts, and all other bolts that vendor
considers to be critical