GENERAL-PURPOSE INTERNAL COMBUSTION DIESEL ENGINES

DECEMBER 1989

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EGE 15-B-15 1989

TABLE OF CONTENTS 1. 2. 3. Scope References Design Basis 3.1 General 3.2 Rating 3.3 Allowable Speeds 3.4 Vibration and Critical Speeds 3.5 Guards 3.6 Flywheels 3.7 Engine Starting 3.8 Engine Cooling System 3.9 Engine Fuel System 3.10 Engine Lubricating System 3.11 Inlet and Exhaust System Controls 4.1 General 4.2 Instrumentation 4.3 Speed and Load Governing 4.4 Safety Devices

4.

Auxiliary Piping Support Systems Materials Couplings Inspection and Testing 9.1 General 9.2 Hydrostatic Tests 9.3 No-Load Mechanical Test 10. Preparation for Shipment 11. Drawings and Other Data 11.1 Drawings 11.2 Data Required 12. Proposals 12.1 General 12.2 Drawings and Data 12.3 Performance Data 13. Performance and Guarantee Appendix Diesel EnginePurchase Checklist

5. 6. 7. 8. 9.

1. SCOPE This Guide covers basic requirements for the design, fabrication, and testing of compression-ignition diesel engines and associated auxiliary equipment for use in petroleum refineries, petrochemical plants, and related facilities. For fire pump duty, refer to EGE 41-B-53. 2. REFERENCES The following publications form a part of this Guide. Unless otherwise specified herein, use the latest edition.
Mobil Engineering Guides EGE 00-B-5 EGE 00-C-4 EGE 33-B-19 EGE 41-B-53 Equipment Sound Levels Equipment Purchases General Engineering Requirements Electrical Stationary Batteries and Chargers Centrifugal Fire Pumps

ASME (American Society of Mechanical Engineers) Standards B1.1 Unified Screw Threads

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B31.3
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Chemical Plant and Petroleum Refinery Piping

Code of Federal Regulations 29 CFR 1910 Title 29, Part 1910: (Labor) Occupational Safety and Health Administration (OSHA) Standards

NEMA (National Electrical Manufacturers Association) Standard SM 23 Steam Turbines for Mechanical Drive Service

NFPA (National Fire Protection Association) Code 70 National Electrical Code

3. DESIGN BASIS 3.1 3.1.1 General Vendors shall comply with the requirements of EGE 00-C-4, except as modified herein.

3.1.2 Diesel engines, piping, and auxiliary equipment shall be designed for the required power rating, type of fuel, and service duty over the specified range of ambient conditions. 3.1.3 Diesel engines (and turbochargers, if provided) shall be mechanically suitable to operate up to engine overload conditions, including the overspeed trip setting. 3.1.4 All equipment covered by this Guide or any referenced specification shall meet the applicable sound levels established in EGE 00-B-5. 3.1.5 All electrical components and installations shall be suitable for the area classification and grouping specified on the data sheet and shall comply with Articles 500 and 501 of NFPA 70 and specified local codes. 3.1.6 The diesel engine vendor shall supply Mobil with all information needed to develop an arrangement having adequate clearance areas and safe access for operation and maintenance. 3.1.7 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. 3.1.8 All parts of diesel engines, auxiliary equipment, piping, and appurtenances shall be designed and constructed to prevent throwing or dripping of oil. When required, crankcase mist eliminators shall be provided. 3.1.9 All equipment shall be designed to permit rapid and economical maintenance. Major parts shall be designed (shouldered or doweled) to ensure accurate alignment on reassembly. 3.1.10 The vendor shall review and comment on Mobils equipment support drawings.

3.1.11 If special weather protection and/or winterization is required, the vendor shall clearly indicate the necessary minimum requirements in the proposal.

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3.1.12 Diesel engines shall be designed to minimize the requirement of special tools (noncatalog items) for installation or normal maintenance. One set of any such tools required, with a description and instructions for their use, shall be supplied by the diesel engine manufacturer. 3.2 3.2.1 Rating The diesel engine rating shall be as specified on the data sheet.

3.2.2 Unless otherwise specified, the diesel engine shall be rated for continuous operation at the specified power output level, over the specified speed range. 3.2.3 The diesel engine shall be sized to deliver continuously the driven equipment rated power plus any transmission losses and auxiliary takeoff equipment power requirements. 3.2.4 The engine rating shall be based on specified site ambient conditions. As a guide, the engine shall have a minimum engine brake horsepower rating at least 20 percent greater than the power required to drive the equipment at rated load and speed. On emergency generator drive applications, the engine shall be capable of starting, accelerating to full speed, and carrying full load within 10 seconds after actuation of the start signal. 3.2.5 The job-rated brake mean effective pressure at the maximum rating for the unit shall not exceed the following limits:
Naturally aspirated up to 75 kW (100 hp) Naturally aspirated over 75 kW (100 hp) 2-stroke supercharged 4-stroke supercharged 4-stroke supercharged and intercooled 6.7 barg (97.15 psig) 8.0 barg (116.00 psig) 10.0 barg (145.00 psig) 12.5 barg (181.25 psig) 14.5 barg (210.25 psig)

3.2.6 Engine ratings shall be substantiated by vendors standard published curves. Special ratings or maximum ratings are not acceptable. 3.2.7 All rotating components shall be designed to withstand overspeeds of 125 percent of rated speed. Overspeed trips shall be set at 110 percent of rated speed. 3.3 Allowable Speeds

3.3.1 Diesel engines shall be rated conservatively to operate at speeds not in excess of those shown in Table 1. 3.3.2 In general, 4-stroke engines are preferred for intermittent (1000-4000 h/yr) and continuous (4000 h/yr and up) operation, while either 2-stroke or 4-stroke engines are acceptable for emergency (standby) services less than 1000 h/yr). 3.3.3 The mean piston speed shall not exceed 9.15 m/s (30 ft/s) for engines in standby or continuous service. 3.4 Vibration and Critical Speeds

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3.4.1 The diesel engine vendor shall assume full responsibility for performing necessary torsional studies and eliminating any lateral or torsional vibrations that may hinder the operation of the complete unit within the specified operating range.
TABLE 1 MAXIMUM OPERATING SPEEDS (RPM) vs ENGINE RATINGS IN kW (hp)* Service Engine Ratings kW (hp) Up to 100 (Up to 134) 101-335 (135-449) 336-783 (450-1049) 784-1118 (1050-1499) 1119-1500 (1500-2010) 1501-2000 (2011-2680) Above 2000 (Above 2681) Emergency (0-1000 h/yr) 1800 rpm 1800 1800 1800 1200 900 Intermittent (1000-4000 h/yr) 1800 rpm 1800 1200 1200 900 720 720 Continuous (Above 4000 h/yr) 1800 rpm 1200 1200 1200 900 720 600

*Applicable to mechanical drive and electric generator drive (60 Hz) applications. Speed limits for 50 Hz generator applications are correspondingly lower than shown.

3.4.2 The torsional natural frequencies of the engine and driven equipment system (including ancillary drives) shall not be closer than 10 percent to any specified running speed. Constant speed applications shall be considered to have a speed range of 10 percent. 3.4.3 When the engine is furnished in conjunction with the driven equipment, supplier (when requested) shall furnish torsional critical speed calculations within three months of the date of purchase order. The analysis shall include, but not be limited to, the following information: (a) A complete description of the method used in the analysis.

(b) A graphic display of the shaft system torsional frequencies showing predominant forcing frequencies. (c) The torsional mode shape diagram of the shaft system.

(d) A graphic display of the shaft system showing the stations used in the analysis and the torsional stiffness and inertia constant used at each station. (e) Selection of drive coupling with torsional damping characteristics.

3.4.4 The engine shall be mounted so as to isolate any vibration from the foundations or structural steel supports.

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EGE 15-B-15 1989

3.4.5 Torsionally resilient spacer couplings shall be used for pump, compressor, or other mechanically driven equipment. Torsionally resilient close couplings shall be used for generator drives. Axial stiffness force imposed by the coupling shall not result in excessive loads on engine or driven equipment bearings. 3.5 Guards

3.5.1 Guards extending to within 12.7 mm ( in.) Of stationary housings shall be provided on all moving parts that could be hazardous to personnel. Guards shall also be provided for any flywheels furnished. Guards shall comply with specified applicable local safety codes. 3.5.2 Guards shall be easily removable and shall be built in accordance with OSHA standards (see 29 CFR 1910). 3.5.3 3.6 For outdoor installations, guards shall be weatherproofed and ventilated. Flywheels

Flywheels shall be of the solid type. The engine shall be designed to facilitate manual crankshaft rotation utilizing a barring device, ratchet wrench, or other suitable means. 3.7 Engine Starting

3.7.1 The method of engine starting shall be specified on the data sheets. When specified on the data sheet, the engine shall be capable of starting when coupled to the driven machine. Starting devices shall have enclosed rotating parts and shall, preferably, operate on the flywheel. A clutch shall be supplied as a starting aid when specified on the data sheet. When specified on the data sheet, dual starting motors shall be provided. Either motor shall be capable of starting the engine while connected to the driven equipment. 3.7.2 When specified on the data sheet, electric starter motors shall be suitable for operating on 24 volt DC batteries that have adequate capacity for at least five consecutive start attempts. 3.7.3 Batteries, battery chargers, and related equipment shall be in accordance with EGE 33-B-19 and shall be designed specifically for engine starting. 3.7.4 Battery trays (or boxes) shall be constructed of heavy-gage sheet steel of ventilated, free-draining design with a steel lid and facilities to clean surfaces beneath trays (or boxes). The interior shall be painted with acid-resistant paint. 3.7.5 Diesel engines shall not require any special preparation for startup, unless an agreement for cold starting has been reached between the vendor and Mobil. 3.8 Engine Cooling System

3.8.1 The type of cooling system shall be as specified on the data sheet. The cooling system shall provide automatic control of the engine inlet water temperature. The cooling water supply temperature shall not be less than 60C (140F). A thermostatically controlled bypass valve shall be provided and arranged so that cooling water flow cannot be shut off. An engine driven cooling water pump shall be provided. 3.8.2 When winterization is specified, or for emergency generator applications, a complete jacket water heating system shall be provided. The system shall be thermostatically controlled and designed to allow circulation by the thermosyphon principle. Provisions shall be made for complete drainage of the engine jackets and ancillary equipment containing water (including drain lines).

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3.8.3 The engine cooling system shall be of such capacity and design as to maintain satisfactory engine jacket water temperature when operating at full load at the specified maximum ambient dry bulb temperature. Jacket water temperatures over 85C (185F) are acceptable only if the cooling system is pressurized. The use of direct air-cooled engines is acceptable only with specific Mobil approval. 3.8.4 The engine cooling system shall be provided with connections for filling the system, checking coolant level, and adding makeup coolant (when necessary). 3.8.5 The engine cooling system shall vent during initial fill and shall include an expansion tank to allow for expansion volume of the engine jacket water, venting of air, and to prevent "afterboil". 3.9 3.9.1 Engine Fuel System The supplied fuel shall have specifications as noted on the data sheet.

3.9.2 The engine shall be supplied with a complete fuel oil system that shall include the following equipment (as applicable). (a) Water and sediment trap with cleanout drain.

(b) Primary fuel pump suction strainers of the duplex type with replaceable cartridge elements and full flow transfer valve. (c) (d) Fuel priming pump (when specified on the data sheet). Shaft driven fuel feed pump with pressure relief valve.

(e) Fuel pump discharge filters of the duplex type with 10-micron nominal, replaceable cartridge elements and full flow transfer valve. The clean filter pressure drop shall not exceed 0.34 bar (5 psi) at normal operating temperatures. (f) Shaft driven fuel injection pump.

(g) Fuel day tank to supply fuel for a minimum of 24 hours continuous operation at rated load (when specified by the data sheet). The tank shall be complete with suction and return connections to the engine fuel system, fill filter, and gage spout. In addition, liquid level gage, vent pipe with flash arrester, cleanout and valved drain connections, and any other controls required for automatic makeup of day tank level shall be provided. (h) An explosionproof thermostatically controlled immersion heater and low-level alarm switch on the fuel day tank (when specified by the data sheet). (I) (j) 3.10 Guards or protecting pipe for all exposed fuel lines. Flexible, braided stainless steel fuel oil inlet and return hose connections.

Engine Lubricating System

3.10.1 The engine shall be supplied with a complete pressure lubrication system, which shall include the following equipment:

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(a) Duplex type oil filters with 10-micron nominal, replaceable cartridge elements and full flow transfer valve. The clean filter pressure drop shall not exceed 0.34 bar (5 psi) at normal operating temperatures. The filters shall not be supplied with internal bypass. (b) (c) Shaft driven positive displacement oil pump with pressure relief valve. Engine-mounted oil cooler with thermostatically controlled bypass valve.

(d) A self-contained oil reservoir that is integral with crankcase and has level indication, fill filter, vent and valved drain connections, and vent mist eliminator (on indoor units). (e) Oil reservoir explosionproof electric immersion heater with thermostatic control and low-level alarm switch (when specified by the data sheet). (f) Pre- and post-lubrication positive displacement oil pump driven by a 24 volt DC motor arranged for automatic start and stop (when specified by the data sheet). 3.10.2 The lubricating oil system shall provide sufficient capacity and pressure to continuously lubricate the engine while the engine is operating at idle speed or any other operating speed. 3.10.3 The engine oil temperature shall not exceed the engine manufacturers recommendations and shall never exceed 85C (185F) for continuous operation. For short-term operation (one hour or less) at overload conditions, the oil temperature may exceed 85C but shall never exceed 107.2C (225F). 3.11 Inlet and Exhaust System

The engine shall be supplied with an inlet and exhaust system, which shall include the following equipment: (a) Dry-element intake air filter with rain hood. When minimum ambient temperature is below 0C (32F), inlet deicing features shall be provided. (b) (c) (d) (e) Intake air silencer to meet the applicable sound levels established in EGE 00-B-5. Backfire relief device (4-cycle engines) on air inlet. Automatic inlet air shutoff valve actuated by engine overspeed. Turbocharger, complete with air intercooler (when specified on the data sheet).

(f) Water-cooled exhaust manifold (and turbocharger, if provided). Maximum surface temperature shall not exceed 200C (392F). (g) Exhaust silencer to meet the applicable sound levels established in EGE 00-B-5, with flame arrester and rain cap. (h) Exhaust system insulation to maintain a surface temperature not to exceed 74C (165F) (when specified on the data sheet). (I) Inlet and exhaust flexible connections (when specified on the data sheet).

4. CONTROLS 4.1 General

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4.1.1 All electrical components shall conform with the requirements of Paragraph 3.1.5. The vendor shall state to which NEMA governing classification the equipment has been supplied. Governors for most applications shall have NEMA B, or better, control characteristics. For generator drivers, NEMA D characteristics shall be provided. 4.1.2 Controls and control panels shall be completely piped and wired, requiring only connection to Mobils external piping and wiring circuits. 4.1.3 The control signal, the type of control system (manual or automatic), the control range, and the equipment to be furnished by the vendor shall be as specified on the data sheet. 4.1.4 Panels on engines or engine skids shall be mounted on isolation mounts in such a way as to prevent vibration damage to instruments. All pressure and temperature gages shall be liquid-filled to absorb shocks. 4.1.5 To the maximum extent possible, instrumentation and control devices provided by the engine supplier should be of the same make and model as those used within the facility where the engine is installed. 4.1.6 When winterization is specified, provisions shall be made for protection against freezing of gages and small piping. 4.2 Instrumentation

4.2.1 The engine vendor shall provide a baseplate-mounted panel with all controls required for engine operation, including the following equipment: (a) Tachometer (range, 0-10 percent above trip speed), with adjustable overspeed trip setting, overspeed alarm, digital speed indicator, and test function. (b) (c) (d) (e) (f) (g) (h) (I) (j) (k) (l) Engine jacket outlet coolant temperature gage. Engine jacket outlet coolant high-temperature alarm and trip. Expansion tank low-coolant-level alarm (when specified on the data sheet). Coolant level gage. Intake manifold air temperature gage (if engine aftercooling is provided). Intake manifold high-air-temperature alarm (if engine aftercooling is provided). Exhaust gas temperature gage on each cylinder bank manifold. Fuel inlet pressure gage. Fuel inlet filter differential pressure (DP) gage. Fuel inlet filter high-DP alarm (when specified on the data sheet). Fuel tank level gage.

(m) Engine oil inlet temperature gage.

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(n) (o) (p) (q) (r) (s) (t)

Engine oil pressure gage. Engine oil filter differential pressure (DP) gage. Engine oil filter high-DP alarm (when specified on the data sheet). Engine oil low-pressure alarm and trip. Engine oil high-temperature alarm. Engine oil level gage. Engine overcrank trip (when specified on the data sheet).

(u) Battery low-voltage alarm (if engine is equipped with electronic governors or engine is electric start) (when specified on the data sheet). (v) (w) (x) (y) Fuel leakage/overflow alarm (when specified on the data sheet). Auto/manual/off-reset/stop switch. Annunciator for alarms and trips with "first out" indication. Engine accumulated-hours meter.

4.2.2 When specified on data sheet, the controls shall be actuated automatically by a remote signal or manually from a pushbutton mounted on the control panel. When remote signal is actuated, it shall cause the controller to open or close all circuits as required to start the engine automatically by performing the following minimum functions: (a) Turn on fuel supply.

(b) Crank engine in a series of crank/rest cycles, automatically alternating between dual batteries on each cycle. (c) (d) Disconnect cranking motor on engine start. Once engine is started, it shall remain in operation until manual shutdown.

(e) If engine fails to start after several cranking attempts or within a predetermined period of time, the controller shall disconnect the starting circuit and trip an alarm to indicate failure to start. 4.2.3 4.3 Separate switches shall be furnished for alarm and shutdown functions. Speed and Load Governing

4.3.1 The speed governor shall be in accordance with the relevant classification of NEMA SM23, as specified on the data sheet. 4.3.2 The speed governor shall be suitable for receiving a remote speed signal when specified on the data sheet. 4.3.3 A separate engine overspeed governor, directly driven by the engine, shall be supplied.

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A turbocharger overspeed governor shall be supplied (if a turbocharger is provided).

4.3.5 Maximum fuel pump delivery per plunger stroke shall be no more than the engine can accept without overloading. This may be achieved by selecting nonoverloading injection pumps (if applicable) or by providing a stop on the fuel pump rack to limit injection pump delivery. A suitable warning plate shall be attached to the engine stating the maximum fuel injection pump setting. 4.4 Safety Devices

Where the option exists, explosion relief devices with integral flame traps shall be fitted on the crankcase. Safety devices shall be designed and built to open quickly at an overpressure of not more than 0.19 bar (2.8 psi) in the crankcase and to close quickly and automatically in order to avoid an inrush of air into the crankcase. 5. AUXILIARY PIPING 5.1 Piping furnished by the vendor shall be prefabricated and, where possible, installed and supported on the engine unit. Piping shall provide proper flexibility and permit normal accessibility for operation, maintenance, and thorough cleaning. Piping shall be fixed firmly in a neat and orderly arrangement adapted to the contour of the machine. Piping, tubing, or conduits shall be supported and protected to prevent damage from vibration, operation, or maintenance. Piping shall be free of rust, slag, welding beads, and other foreign materials. 5.2 All components in the piping system that contain fuel or lubricating oil, including pipe, fittings, valves, control valves, strainers, and power cylinders, shall be steel. Stainless steel lines shall be furnished when specified on the data sheet. 5.3 The materials and the construction of piping and connections shall conform to ASME B31.3.

6. SUPPORT SYSTEMS 6.1 The engine vendor shall provide a skid-type baseplate for mounting the driven equipment and diesel engine. It shall be of sufficient rigidity to transport the engine without excessive crankcase deflection or misalignment. 6.2 Baseplates shall be fabricated of structural steel by continuous welding and shall have a drip pan or drain rim to contain leakage of lubricant, fuel, or coolant. A minimum NPS 1 (NPS = nominal pipe size, inches) drain connection shall be provided. 6.3 The baseplate shall be provided with 3-point mountings on marine-type spring isolators with thrust stops. All base-mounted equipment shall have suitable flexible connections. 7. MATERIALS 7.1 7.2 7.3 Crankshaft and connecting rods shall be forged steel. Instrument tubing fittings, valves, and temperature/pressure gage cases shall be stainless steel. Material certificates shall be provided as specified on data sheet, and as required by local codes.

8. COUPLINGS

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8.1 Flexible couplings shall be furnished with forged steel hubs. Flexible parts may be synthetic rubber or approved equal. Spacer couplings shall be provided if required for maintenance or to meet torsional requirements. 8.2 Couplings shall be sized to transmit twice the rated torque of the driven equipment, continuously.

9. INSPECTION AND TESTING 9.1 General

9.1.1 All engines are subject to inspection by Mobil while work or tests are being performed. If shop inspection is specified, no surfaces or parts of the engine shall be painted until inspection is completed. 9.1.2 (a) (b) (c) Unless otherwise specified, the following tests shall be performed: Hydrostatic tests as specified on the data sheet. Witnessed running test of complete unit including control panel. Tests as required by local codes.

9.1.3 Prior to any witnessed test, the vendor shall make a preliminary test run and complete all mechanical checks before the arrival of the Mobil inspector. The vendor shall submit written notice at least 10 working days before the date stated by the vendor that the equipment will be ready for testing. 9.1.4 Acceptance of shop tests shall not constitute a waiver of requirements to meet field tests under specified operating conditions, nor does inspection relieve the vendor of his responsibility in any way whatsoever. 9.1.5 Any major equipment not fabricated in the vendors shop(s) is subject to inspection in the original manufacturers plant. 9.1.6 9.2 9.2.1 9.2.2 Final acceptance of engine shall be based on field test under specified operating conditions. Hydrostatic Tests All pressure casings of the equipment shall be tested to 1.5 times the respective design pressure. The fuel oil day tanks (when provided) shall be leak tested with water.

9.2.3 Cooling passages and jackets, fuel and lube passages shall be tested to 1.5 times the maximum system operating pressure. 9.2.4 All tests shall be maintained for a sufficient period of time to permit complete examination of parts under pressure, with a minimum period of one hour. 9.3 No-Load Mechanical Test

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9.3.1 All engines shall receive a manufacturers standard no-load shop running test for a sufficient period at rated speed to verify the mechanical operability of all protective devices, to check governor response, and to set overspeed trip switches. 9.3.2 During testing, all parts of the engine and control panel shall be operated satisfactorily without excessive heating of bearings, vibration, or other unfavorable characteristics. No fuel or lubricant leaks are acceptable. 9.3.3 (a) (b) (c) (d) (e) (f) (g) (h) (I) (j) (k) 10. The following data shall be recorded during the no-load test: Vibration amplitude and velocity. Oil temperature. Fuel pressure. Water temperature. Fuel consumption. Overspeed trip setting (three times). Engine rpm. Oil pressure. Bearing temperatures (if accessible). Ambient temperature. Sound pressure level.

PREPARATION FOR SHIPMENT

All diesel engines shall be packaged, painted, preserved, and tagged in accordance with EGE 00-C-4. 11. 11.1 11.1.1 DRAWINGS AND OTHER DATA Drawings The following paragraphs are additions to requirements in EGE 00-C-4.

11.1.2 Within the time and schedule specified on the purchase order, vendor shall supply Mobil with certified drawings. 11.1.3 The following information shall be included on the outline drawings, and on other drawings and data, as applicable: (a) (b) Mobil order number. Mobil equipment item number and vendors engine serial number.

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(c) Weights of engine, gear (if any), and the heaviest piece of equipment that must be handled for maintenance and erection. (d) (e) (f) All principal dimensions, including those required for Mobils foundation and piping design. Direction of rotation. All horizontal and vertical clearances necessary for dismantling.

(g) Size, type, and location of all major and minor pipe connections, including vents, drains, fuel, coolant, instruments, and controls. The purpose of all openings, including those to be plugged, shall be identified. (h) Auxiliary piping, fittings, or equipment furnished by the vendor.

(I) Make, size, and type of couplings (if any). The location and coverage of any coupling guards shall be indicated. (j) (k) (l) List of reference drawings. Special winterization features (if any). Thermal and mechanical movements of shafts and connections.

(m) Location of center of gravity. (n) Utilities required (for example: water: temperature/pressure/flow; electricity: volts/amps/phase).

11.1.4 Schematic drawings of control systems (including wiring diagrams), fuel and cooling systems, and dimensional outline drawings for accessories and instrument panels shall be submitted. These drawings shall include and identify all components by make, type, size, capacity, materials, and the like, as applicable. 11.1.5 Cross-sectional or assembly drawings, showing all parts and design features, shall be provided for all equipment furnished. Part numbers shall be referenced to sectional drawing. 11.1.6 If the engine is to be delivered with the driven equipment or packaged, the engine vendor shall coordinate the design and manufacture with the driven equipment manufacturer and/or package fabricator regarding baseplate design and equipment alignment. 11.2 Data Required

11.2.1 Instruction manuals describing installation, operation, and maintenance procedures shall be furnished not later than the date of shipment. Manuals shall include all auxiliaries and instruments furnished by the vendor. To avoid duplication when more than one engine is included in the order, it is preferred that one manual cover all types of engines. Furthermore, the manual should be clearly indexed to distinguish between the various types of machines and to identify all component parts as to service. For each engine unit, the manual shall: (a) Be organized and indexed by principal equipment items and systems.

(b) Include written instructions covering startup, normal shutdown, emergency shutdown, operating limits, and routine operational procedures.

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(c) Include written sequence of installation and final tests and checks for equipment furnished by the vendor. (d) Describe engine construction features and the functioning of component parts or systems (governing, lubrication, overspeed protection). (e) Include outline and "as built" cross-sectional drawings, schematic, and illustrative sketches in sufficient detail to identify all parts. In addition, these shall show clearly the operation of all equipment and components and the method of inspection and repair. (f) Include instructions for erecting, piping, aligning, and preparing the engines and auxiliary equipment for use. (g) Describe rigging procedures, methods of disassembly, repair, adjustment, inspection, and reassembly of engines and auxiliaries. (h) List fits and clearances and balancing data needed for maintenance and repairs.

11.2.2 A parts list shall be furnished for all equipment supplied and shall include pattern, stock, or production drawing numbers and materials of construction. The list shall completely identify each part so that Mobil may determine part interchangeability with other equipment furnished by the same manufacturer. Antifriction bearings and other standard purchased items shall be identified by the original manufacturers number and class of fit where number alone does not provide sufficient identification. 11.2.3 The vendor shall submit a supplementary proposal for spare parts other than those included in his original quotation. This supplementary proposal shall include recommended spare parts for 24 months operation and commissioning, cross-sectional or assembly drawings, part numbers, materials, prices, and delivery date. Part numbers shall identify each part for interchangeability purposes. Antifriction bearings and other standard purchased items shall be identified by the original manufacturers number. 11.2.4 After inspection and tests have been made, the vendor shall furnish "as built" test data sheets for each engine. 11.2.5 The vendor may combine drawings and data specified in accordance with his normal practices, but the Mobil data sheets shall be completed. 11.2.6 11.2.7 12. Certified shop log of mechanical tests. Torsional analysis report.

PROPOSALS

The paragraphs in this section are additions to requirements in EGE 00-C-4. 12.1 General

The vendor shall list in the proposal any special protection (from rain, dust, cold, etc.) required for startup operation and periods of idleness under site conditions specified on the data sheet. The list shall include protection which must be provided by Mobil as well as the vendor. 12.2 Drawings and Data

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12.2.1 Each proposal shall be accompanied by a preliminary dimensional outline drawing which shows location of inlet and exhaust connections and direction of rotation when viewing the engine from the main output shaft. 12.2.2 The vendor shall submit a diagram with a description of the governing system (including interconnection with Mobils control system, if applicable). 12.2.3 Proposal shall include diagrams of the hydraulic, starting, cooling, inlet, exhaust, lube oil, and fuel oil systems. 12.2.4 The data sheets shall be completed for the engine unit and gear, if any, to the extent applicable.

12.2.5 Proposal shall include necessary cooling water quantities and quality. If radiator-cooled engine is proposed, necessary sizing data regarding air flow, friction loss limits through enclosure (if any), and radiator duty shall be provided at maximum and minimum ambient design conditions. For heat-exchanger-cooled engines, cooler duty, cooling water flow, pressure drop, materials of construction and pressure rating shall be provided. 12.2.6 12.3 Power requirements for all auxiliaries (kVA, volts, amps, phase). Performance Data

The proposal shall include: (a) (b) Potential maximum kW (hp) for continuous operation for one hour in 24 hours. Correction factors for variations in ambient conditions and elevation for the specified location.

(c) Vendors estimated installation and commissioning time for qualified erector plus costs to perform this work. 13. PERFORMANCE AND GUARANTEE

13.1 Proper operation of any speed governors and overspeed shutdown devices shall be verified. Engine performance shall be guaranteed for , , and full load at site ambient temperatures and atmospheric pressure. Engines shall be guaranteed to be capable of operation at 110 percent of full rated load for one hour per 24 hours of operation. 13.2 Each engine shall be guaranteed to deliver the rated output, at the rated speed for the specified type of service and site conditions, with no negative tolerances allowed. The actual engine fuel consumption rate shall not exceed guaranteed fuel consumption by more than 4 percent with all ancillary equipment engine driven. 13.3 All equipment and component parts shall be guaranteed in accordance with the requirements of EGE 00-C-4.

MOBIL ENGINEERING GUIDE EGE 15-B-15 1989

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APPENDIX DIESEL ENGINE PURCHASE CHECKLIST (Refer to the Guide for Requirements A-1. MANUFACTURER AND UNIT MODEL NUMBER A-2. ENGINE (a) (b) (c) (d) (e) (f) (g) (h) (I) (j) (k) (l) (m) (n) (o) Engine model number. Type of fuel to be used. Power rating at shaft. Rating based on standby or continuous duty? Speed. Number of cylinders and arrangements. Bore and stroke. Piston speed. Displacement. Brake mean effective pressure at power rating. Engine type (2- or 4-stroke)? Compression ratio. Number of main bearings. Cylinder liners. Maximum sound pressure level.

A-3. DRIVEN EQUIPMENT (a) Type (conveying, reciprocating or centrifugal pump, compressor, crane, generator, etc.). (b) Type of starting (loaded, unloaded). (c) Operation (continuous, intermittent, standby). A-4. GOVERNOR (a) Manufacturer and model number (b) Type. A-5. GENERATOR DRIVE APPLICATIONS (a) Is isochronous or droop mode of operation required? (b) Does governor require provisions for remote operation? (c) Percentage change in rated frequency from no-load to full-load generator output when in droop mode of operation. (d) Steady-state band (percentage of rated frequency) in which frequency shall remain constant at any load. (e) Frequency modulation. (f) Maximum time required to start, synchronize, and assume full load. (Applicable to emergency/standby generator sets.) A-6. FUEL INJECTOR (a) Type (b) Manufacturer and model number.

MOBIL ENGINEERING GUIDE

DECEMBER 1989 PAGE 17 OF 19

EGE 15-B-15 1989

A-7. FUEL SYSTEM (a) Fuel consumption at power rating. (b) Minimum size of fuel supply and return lines. (c) Recommended suction at transfer pump. (d) Is day tank required? Tank and tank base supplied by purchaser or vendor? Day tank size. (e) Are fuel level gage, float switch, low-fuel relay, and control panel alarm required? (f) Transfer pump supplied by purchaser or vendor? (g) Pressure regulator. A-8. LUBRICATION SYSTEM (a) Type. (b) Oil pan capacity. (c) Oil cooling supplied by purchaser or vendor? A-9. COOLING SYSTEM (a) Basic engine water capacity. (b) Jacket water flow and temperature operating range. (c) Heat rejection to jacket water at power rating. (d) Maximum static head at cooling water pump rating. (e) Driven equipment heat radiated to room or enclosure at power rating. (f) Air required for radiator. (g) Cooling water pump supplied by purchaser or vendor? (h) Is radiator or heat exchanger cooling required? If radiator cooling is to be installed, will it be engine or remote mounted? A-10. AIR AND EXHAUST SYSTEM (a) (b) (c) (d) (e) (f) (g) (h) A-11. Combustion air requirements. Maximum allowable air intake restriction. Exhaust gas flow and temperature at power rating. Maximum allowable exhaust back pressure. Exhaust outlet diameter. Is industrial, residential, or critical silencer required? Are flexible exhaust connections required? Are thimble and rain cap required?

STARTING SYSTEM (a) Is air motor or electric motor required for starting? (b) Is starting to be automatic or manual? (c) Is engine exerciser required? (d) Is a multiple crank cycle or single crank cycle required? (e) Are jacket water and crankcase heaters required as starting airs? Kilowatt and voltage ratings.

A-12.

BATTERY (a) Manufacturer and type.

MOBIL ENGINEERING GUIDE EGE 15-B-15 1989 (b) (c) (d) (e) (f) (g) (h) A-13.
PAGE 18 OF 19 DECEMBER 1989

Ampere-hour rating. Volts. Number of cells. Are lead/acid or nickel/cadmium batteries required? Is battery to be unit mounted or separately mounted? Is battery rack required? Rack supplied by purchaser or vendor? Battery cables supplied by purchaser or vendor?

BATTERY CHARGER (a) AC supply voltage, phase, and frequency. (b) Is charger to be unit mounted or separately mounted? (c) Is a two-rate charger or a trickle charger required? (d) Is charging generator/alternator required? (e) Is a DC ammeter required? (f) Are DC low-voltage relays and AC power-failure relays required for alarms? Will control panel contain these alarms?

A-14.

ENGINE INSTRUMENT AND CONTROL PANEL Is a separate unit-mounted panel required or will it be combined with driven equipment control panel?

A-15.

BASE (a) (b) (c) (d) Are engine and driven equipment to be supplied with common base? Is a skid-type base required? Foundation bolts and nuts supplied by purchaser or vendor. Are pad- or spring-type isolators required for vibration control?

A-16.

LOCATION AND ENCLOSURE (a) Average site temperature and maximum and minimum ambient temperatures. (b) Elevation. (c) Is equipment to be installed indoors or outdoors? (d) Are there severe service conditions? (e) Is equipment to be installed in a classified area? (f) Are air filters required? (g) Is weather-protected enclosure required? Will the enclosure be lighted?

A-17.

WEIGHTS AND DIMENSIONS (a) Engine net weight. (b) Combined engine and generator package net weight. (c) Approximate floor space.

A-18. INFORMATION FURNISHED BY MANUFACTURER (a) Descriptive bulletins. (b) Dimensional outline drawings. (c) Installation, operation, and maintenance instructions.

MOBIL ENGINEERING GUIDE

DECEMBER 1989 PAGE 19 OF 19

EGE 15-B-15 1989

(d) Complete parts list. (Identify major parts not manufactured by engine or package vendor.) (e) Recommended spare parts list. (Identify major parts not manufactured by engine or package vendor.) (f) Certified test report. (g) Warranty. (h) Special tools. A-19. SERVICES (a) Will vendor startup services be required? (b) Where is the nearest service organization?

MOBIL ENGINEERING GUIDE INTERNAL COMBUSTION DIESEL ENGINE DATA SHEET

SI (METRIC) UNITS
ISSUE 1 2 APPLICABLE TO: FOR SITE UNIT SERVICE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Including: Type: No. Cyls BMEP, barg Type: Engine Rating Net Power, kW Speed, rpm* Maximum Continuous Load Power, kW Speed, rpm Fuel Consumption, m3/h ENGINE Rated Normal Type Drive: Duty: Startup: DRIVEN EQUIPMENT APPROVED 3 ISSUE APPROVED JOB NO. LOCATION

EGE 15-D-15a 1989

Page 1 of 2 ITEM NO. P.O. NO.

4 PROPOSAL

PURCHASE

AS BUILT NO. OF ENGINES REQD FURNISHED BY MANUFACTURED BY SIZE SERIAL NO.

G G G

Direct Coupled Continuous Automatic

G G G

Gear Standby Manual

G G

V-Belt Emergency

*Rated speed of driven equipment.

Fuel Grade

Cetane Rating

G G G G G G G G G G G G G G G G

ACCESSORY EQUIPMENT (EACH UNIT) Engine Skid Baseplate

G G G

With Radiator Mtd

Common with Driven Equipment

Engine Enclosure with Access Doors Clutch Flex Coupling Intake Air Filter, Type Mfr Exh Silencer: Mfr Flexible Exhaust Connector Fuel Transfer Pump: Fuel Filter: Single Day Tank, Capacity, m3 Stub Shaft V-Belt Sheave

G G

Mounted by Industrial Mounted by

G G

Residential

G G G

Hand Duplex

Motor

Jacket Water Heater with Thermostat Crankcase Oil Heater with Thermostat Prelube Oil Pump: Air

Electric

Safety Shutdown System Including:

G G G

Two Cycle Turbo Charged In-Line Cyls Bore Stroke, cm Displ, cm3

G G G G
Mfr

Four Cycle Naturally Aspirated V-Cyls

G
CW

Engine-Mounted Gage Panel with: Oil Pressure Water Temp

Max. Continuous Speed, rpm Rotation Facing Flywheel: Governor Type Speed Range, rpm: Min. Ignition: Crankcase Oil Capacity, m3 Oil Filter: Full Flow

G G

CCW

G G G G G G G G

Single

Max. Dual

Low Tension

G G G

Bypass Type

Engine Weight, kg

G G G G G G G

G G G G G G G

Low Oil Pressure Trip High Water Temp Trip Overspeed Trip Pneum System

Governor Type Batteries: Nickel Cadmium

G G

G G G G G G

Electric System

Tachometer Hour Meter Manufactured by Lead Acid

Dual

With Rack & Cables

Battery Charger Rating, amperes Coupling Type

Dual

Manufactured by

COOLING SYSTEM Radiator Eng Mounted Antifreeze Coolant Jacket Water Pump Tubular Exchanger Remotely Mounted

STARTING SYSTEM Electric Starter, Voltage Air Motor, Nm3/Start Starting Air Pressure, barg

G G

Expansion Tank Rad Duct Flg

Startup Time

G
TESTS

Dual Starter Motor

Thermostatic Temp Control Full-Load Running Test:

Reqd*

Heat Rejected to System, kW Cooling Water to Exchanger, m3/h

G G

Witnessed

G G

*Certified test reports required.

MOBIL ENGINEERING GUIDE INTERNAL COMBUSTION DIESEL ENGINE DATA SHEET

SI (METRIC) UNITS
45 46 47 48 49 50 51 N O T E S Location:

EGE 15-D-15a 1989

Page 2 of 2 SITE DATA Outdoor Min. Elev, m Max. Ph Grp barg Hz Div C

Indoor

G G
V Cl

Ambient Temp, C: Electric Power: Nonhazardous:

Cooling Water Supply: Type

% Ethylene Glycol

MOBIL ENGINEERING GUIDE INTERNAL COMBUSTION DIESEL ENGINE DATA SHEET

CUSTOMARY UNITS
ISSUE 1 2 APPLICABLE TO: FOR SITE UNIT SERVICE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Including: Type: No. Cyls BMEP, barg Type: Engine Rating Net Power (bhp) (kW) Speed, rpm* Maximum Continuous Load Power (bhp) (kW) Speed, rpm Fuel Consumption, (US gal)(Btu/h) ENGINE Rated Normal Type Drive: Duty: Startup: DRIVEN EQUIPMENT APPROVED 3 ISSUE APPROVED JOB NO. LOCATION

EGE 15-D-15b 1989

Page 1 of 2 ITEM NO. P.O. NO.

4 PROPOSAL

PURCHASE

AS BUILT NO. OF ENGINES REQD FURNISHED BY MANUFACTURED BY SIZE SERIAL NO.

G G G

Direct Coupled Continuous Automatic

G G G

Gear Standby Manual

G G

V-Belt Emergency

*Rated speed of driven equipment.

Fuel Grade

Cetane Rating

G G G G G G G G G G G G G G G G

ACCESSORY EQUIPMENT (EACH UNIT) Engine Skid Baseplate

G G G

With Radiator Mtd

Common with Driven Equipment

Engine Enclosure with Access Doors Clutch Flex Coupling Intake Air Filter, Type Mfr Exh Silencer: Mfr Flexible Exhaust Connector Fuel Transfer Pump: Fuel Filter: Single Stub Shaft V-Belt Sheave

G G

Mounted by Industrial Mounted by

G G

Residential

G G G

Hand Duplex

Motor

Day Tank, Capacity, US gal

Jacket Water Heater with Thermostat Crankcase Oil Heater with Thermostat Prelube Oil Pump: Air

Electric

Safety Shutdown System Including:

G G G

Two Cycle Turbo Charged In-Line Cyls Bore Stroke, in. Displ, in.3

G G G G
Mfr

Four Cycle Naturally Aspirated V-Cyls

G
CW

Engine-Mounted Gage Panel with: Oil Pressure Water Temp

Max. Continuous Speed, rpm Rotation Facing Flywheel: Governor Type Speed Range, rpm: Min. Ignition:

G G

CCW

Crankcase Oil Capacity, US gal Oil Filter: Full Flow

G G G G G G G G

Single

Max. Dual

Low Tension

G G G

Bypass Type

Engine Weight, lb

G G G G G G G

G G G G G G G

Low Oil Pressure Trip High Water Temp Trip Overspeed Trip Pneum System

Governor Type Batteries: Nickel Cadmium

G G

G G G G G G

Electric System

Tachometer Hour Meter Manufactured by Lead Acid

Dual

With Rack & Cables

Battery Charger Rating, amperes Coupling Type

Dual

Manufactured by

COOLING SYSTEM Radiator Eng Mounted Antifreeze Coolant Jacket Water Pump Tubular Exchanger Remotely Mounted

STARTING SYSTEM Electric Starter, Voltage Air Motor, scf/Start Starting Air Pressure, psig

G G

Expansion Tank Rad Duct Flg

Startup Time

G
TESTS

Dual Starter Motor

Thermostatic Temp Control Full-Load Running Test:

Reqd*

Heat Rejected to System, Btu/h Cooling Water to Exchanger, US gpm

G G

Witnessed

G G

*Certified test reports required.

MOBIL ENGINEERING GUIDE INTERNAL COMBUSTION DIESEL ENGINE DATA SHEET

CUSTOMARY UNITS
45 46 47 48 49 50 51 N O T E S Location:

EGE 15-D-15b 1989

Page 2 of 2 SITE DATA Outdoor Min. Elev, ft Max. Ph Grp psig Hz Div F

Indoor

G G
V Cl

Ambient Temp, F: Electric Power: Nonhazardous:

Cooling Water Supply: Type

% Ethylene Glycol