NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES M.04

SPECIAL PURPOSE GEAR UNITS (API 613)

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 2 of 14
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Additions and Exceptions to API 613 (3rd Edition) 6

4.0 MATERIALS 9

4.1 API 613 Requirements 9

5.0 INSPECTION 9

5.1 Procedures 9
5.2 Scope 10
5.3 Nameplates 11

6.0 TESTING 11

6.1 Required Tests 11

6.2 Test Procedures 11
6.3 Test Certificates 11
6.4 Start-up 11

7.0 DOCUMENTATION 11

7.1 Introduction 11
7.2 Schedules and Reports 12
7.3 Data and Calculations 12
7.4 Drawings 13
7.5 Manuals 13
 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 3 of 14
Rev 0 1999

SEC TITLE PAGE

8.0 PRIOR TO SHIPMENT 13

8.1 Painting 13
8.2 Spares 13
8.3 Packing and Storage 13
8.4 Shipping 14
8.5 Warranty 14

DATA SHEETS

Special Purpose Gear Unit Data Sheets (API 613) (3)

 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 4 of 14
Rev 0 1999

1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the design, material selection, inspection, testing,
documentation and preparation for shipment of special purpose gear units.

1.1.2 The gear units shall comply with API 613, "Special Purpose Gear Units for Refinery Service", 3rd Edition,
April 1988, as amended by this specification.

1.1.3 This specification applies to gear units in onshore oil and gas production, operation and petroleum product
service.

1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any exception
must be authorised in writing by the Owner.

1.1.5 In the event of any conflict between this specification and the data sheets, or with any of the applicable codes
and standards, the Vendor/Contractor shall inform the Owner in writing, and receive written clarification from
the Owner before proceeding with the work.

1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

Where indicated in this specification, the following additional specifications shall apply and any exceptions
shall be approved in advance by the Owner:

GES A.04 Noise Level Criteria and Noise Control of Mechanical Equipment

GES J.14 Package Unit Instrumentation

GES M.05 Lubrication, Shaft Sealing and Control Oil Systems Rotating Equipment (API 614)

GES M.06 Monitoring Systems for Rotating Equipment (API 670)

GES X.01 Surface Preparation and Painting Application

GES X.02 Colour Coding of Equipment and Piping

GES X.03 External Protective Coatings

The Vendor/Contractor shall ensure all sub-contractors comply with the relevant portions of the above
specifications.

1.3 Data Sheets

The technical data supplied by the Owner for the equipment is provided on the API Specification 613 Data
Sheets which are included at the end of this specification. The Vendor/Contractor shall complete the Data
Sheets with the remaining information and return them with his proposal. Prior to shipment, the
Vendor/Contractor shall submit a complete set of "As-Built" Data Sheets.
 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 5 of 14
Rev 0 1999

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined in paragraph 1.4 of API 613, Third Edition, and as
follows:

Axially (horizontally) Split

Refers to casing joints that are parallel to the shaft centreline.

Gear

Refers to the lowest speed rotor.

Gear Rated Power

Is the maximum power specified by the Owner on the data sheet and stamped on the nameplate.

Gear Service Factor (SF)

Is the factor that is applied to the tooth pitting index and the bending stress number, depending on the
characteristics of the driver and the driven equipment, to account for differences in potential overload, shock
load and/or continuous oscillatory torque characteristics.

A Hunting Tooth Combination

Exists for mating gears when a tooth on the pinion does not repeat contact with a tooth on the gear until it has
contacted all the other gear teeth.

Normal Transmitted Power

Is the power at which usual operation is expected and optimum efficiency is desired. The normal transmitted
power may be equal to or less than the gear rated power.

Pinion

Refers to the highest speed rotor.

Rated Input Speed

Input speed of the gear unit (in revolutions per minute) is the specified (or nominal) rated speed of its driver, as
stated on the Data Sheets.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.
 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 6 of 14
Rev 0 1999

Vendor

The company supplying the equipment.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and facilities
have been designed, constructed, inspected and tested in accordance with the requirements of this specification
and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or assigned Inspection Authority, who
verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance
with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

3.1.1 The design shall comply with this specification and the following codes and standards.

API 613, "Special Purpose Gear Units for Refinery Service", Third edition, as amended by this specification.

3.1.2 With the above exception and unless specified otherwise in the Purchase Order/Contract, the current editions
of referenced codes and standards at the time of the order should be used.

3.2 Additions and Exceptions to API 613 (3rd Edition)

The following paragraph numbers refer to API 613, Third edition, April 1988 which shall be considered as
forming a part of this General Engineering Specification.

In API 613 paragraphs are marked with a bullet (·) if the Owner has to make a decision or provide information.
Where possible, these decisions have been made or alternatively guidelines provided. Such paragraphs are
marked "*" in this specification.

All requirements specified in this specification are additions to those of API 613 unless otherwise stated.
Paragraph numbers in this specification which do not appear in API 613 are new paragraphs.
 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 7 of 14
Rev 0 1999

1.1 Scope

1.1.1 Add:

"Special purpose gear units shall be supplied by vendors qualified by experience to manufacture
the units proposed. To qualify, the Vendor/Contractor must have manufactured at the proposed
point of manufacture, at least two gear units of comparable power rating, pinion speed, speed
ratio, and pitch line velocity. The Vendor/Contractor shall provide a reference list with his
proposal, proving that their gear units have been performing successfully in similar duty for a
period of more than one year.

2.1 General

2.1.3* GES A.04, shall apply, for special purpose gear units sound pressure level requirements.

2.1.7* The Owner will define the electrical area classification.

2.1.10* Where applicable the Vendor/Contractor shall review and comment on the Sub-Contractor's
baseplate and foundation drawing. The Vendor/Contractor's representative shall check the initial
alignment, and tooth contact.

2.1.11* The Owner shall specify the installation and environmental details.

2.1.13* The Owner shall specify the external loads.

2.1.18* The Owner shall specify the shaft assembly designation.

2.1.19.2* The Owner shall specify the high-speed and low-speed shaft rotational directions.

2.2 Rating

2.2.1* The unit's gear rated power shall be specified by the Owner on the Data Sheets.

After the third sentence, add:

"When electric motor drivers are equipped with `fast' transfer facilities, the gear shall also be
rated to withstand momentary high torque overloads equal to four times gear power rating. The
suitability of this rating shall be confirmed by the Owner, after the final system characteristics are
defined.

In addition, for synchronous motor drives, the gear shall also be rated to withstand the peak
oscillatory torque values predicted by the system transient torsional analysis of the motor
starting".

2.2.2.1* The minimum gear service factor (SF) shall be specified by the Owner on the Data Sheets using
Table 2 of API 613, 3rd edition as a guideline.

2.2.2.2* The Owner shall specify the usage in order for the Vendor/Contractor to make recommendation
on the hardness level of the pinion and gear.

2.2.3.4* Operating conditions other than rated shall be specified by the Owner.

2.4 Casings Connections

 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 8 of 14
Rev 0 1999

2.4.1.3* The Owner shall specify if an inlet purge connection is required.

2.4.2.1* Oil inlet and drain connections shall be flanged. The Owner shall define the orientation on the
Data Sheets.

2.5 Gear Elements

Add new paragraph:

2.5.1.8 "Double reduction gearing for reciprocating compressor drives shall use the nested arrangement,
i.e. having a conventional double helical low speed set and the high speed gearing placed so that
half the high speed gearing is on each side of the low speed set".

2.5.4.3* The requirements of paragraph 2.5.4.3.2 shall be complied with.

2.6 Dynamics

2.6.1.8* The Owner shall assign responsibility for the torsional analysis and torsional compatibility of the
train to the package Vendor/Contractor.

Add:

"The Vendor/Contractor shall also perform an independent torsional analysis using basic
equipment dimension and stiffness data. For synchronous motor drivers, the Vendor/Contractor
shall perform a system transient torsional analysis of the motor starting".

2.6.2.3.8 A residual unbalance check shall be performed and recorded in accordance with the residual
unbalance work sheet after the final balancing of each assembled rotating element has been
corrected.

2.7 Bearings and Bearing Housings

2.7.1.2* Thrust/radial bearings shall be provided with bearing metal temperature sensors complying with
GES M.06.

2.8 Lubrication

2.8.3* The oil system shall be provided by the drive or driven equipment/package Vendor/Contractor
where possible. Refer to Data Sheets. The system shall comply with GES M.05.

2.8.6* For common systems the Owner shall specify the oil's characteristics on the Data Sheets after
agreement has been reached regarding the characteristics between the gear, the driver and the
driven equipment manufacturers.

3.1 General

3.1* The following accessories shall be provided by the Vendor/Contractor:

- couplings and guards;

- controls and instrumentation;
- torque monitors (for gear drives of over 10,000 hp (7,500kW))

3.2 Couplings and Guards

 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 9 of 14
Rev 0 1999

3.2.1* Half couplings shall be mounted by the Vendor/Contractor.

3.3 Mounting Plates

3.3.1.1* The gear shall be supplied suitable for mounting a baseplate common with the drive and driven
equipment. The suitability of the base plate shall be the joint responsibility of all equipment
manufacturers involved.

3.3.1.2.5* The Owner shall specify the epoxy grout where applicable.

3.3.2.1* The Owner shall specify the extent of the baseplate, and the equipment to be mounted on it.

3.3.2.2* The baseplate shall be provided with levelling pads or targets.

3.3.2.3* The baseplate shall be suitable for column mounting.

3.3.2.5* Sub-soleplates are not required.

3.4 Controls and Instrumentation

3.4.2.1.2 Metal-case, glass-front, stem-type mercury thermometers shall be furnished.

3.4.3.1* Non-contacting probes and transducers shall be provided. The numbers and location shall be as
defined in GES M.06.

3.4.3.3 Delete: "API Standard 670" and replace by: "GES M.06".

3.4.3.4* Non-contacting vibration and axial position monitors shall be supplied in accordance with "GES
M.06"

Controls and Instrumentation shall be supplied in accordance with GES J.14.

4.0 MATERIALS

4.1 API 613 Requirements

The Vendor/Contractor shall provide materials in accordance with paragraph 2.9 of API 613.

5.0 INSPECTION

5.1 Procedures

5.1.1 The inspection requirements are covered by the Purchase Order/Contract. Additional requirements are given
below.

5.1.2 All items of plant and equipment referenced within this specification shall be subject to inspection by the
Owner or his nominated Inspection Authority.

All inspection requirements shall be incorporated in the Quality Control Plan which shall be submitted to the
Owner before commencement of manufacture for review and approval.
 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 10 of 14
Rev 0 1999

5.1.3 Inspection shall be in accordance with API 613, Third Edition and this specification. Inspection procedures
shall comply with paragraphs 4.1 and 4.2 of API 613, as amended below.

4.1 General

4.1.3.3* The Owner reserves the right to observe any inspection carried out by the Vendor/Contractor.

4.2 Inspection

4.2.1.1 (e)* Final assembly maintenance and running clearances are required.

Add new paragraph:

4.2.1.7 "Gear elements shall be demagnetised after inspection".

5.1.4 All inspection activities to be performed, including any special requirements, shall be agreed with the Owner
and shall be incorporated within the agreed Quality Control Plan provided by the Vendor/Contractor as
defined in paragraph 4.2.1.6 of API 613 prior to work commencing. The Quality Control Plan shall be co-
ordinated with and shall include the quality plan of major Sub-Contractors. The Vendor/Contractor shall
submit procedures for all applicable NDT techniques for approval by the Owner before production
commences.

5.1.5 All operators of NDT equipment shall have thorough knowledge of the operation of the equipment to be used
and shall hold an appropriate certificate of competence, which is to be agreed by the Owner. All NDT
procedures and qualifications shall be subject to approval by the Owner’s Inspector.

5.1.6 The Vendor/Contractor is to furnish the Owner's Inspector with all reasonable facilities, to satisfy himself that
the equipment, including Sub-Contractors' materials, is fabricated and tested in accordance with the relevant
code and this specification.

5.1.7 Any approvals given by the Owner's Inspector does not relieve the Vendor/Contractor of any responsibility
regarding guarantees, workmanship or compliance with the code and this specification.

5.2 Scope

Inspection shall be carried out by the Vendor/Contractor during and after manufacture of the equipment.

Inspection shall comply with the relevant parts of API 613, paragraphs 2.5.2 and 4.2, as amended below.

2.5 Gear Elements

2.5.2.1 * The results of the contact check shall be preserved.

4.2 Inspection

4.2.1.2 * The Vendor/Contractor shall specify the parts to be examined and the type of examination
required for the approval of the Owner.

4.2.1.4 * The Owner will inspect for cleanliness.

4.2.1.5 * Hardness shall be verified.

 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 11 of 14
Rev 0 1999

5.3 Nameplates

Nameplates shall be provided complying with paragraph 2.10 of API 613.

6.0 TESTING

6.1 Required Tests

Testing shall be carried out in compliance with paragraph 4.3 of API 613, as amended below.

4.3 Testing

4.3.3.1 * A full speed/full or part-load test is required. All double reduction gearing shall be full-load
tested.

4.3.3.2 * A full torque/slow roll test is required.

4.3.3.3 * A full torque/static test is not required.

4.3.3.4 * A back-to-back locked torque test is not required.

4.3.3.5 * A sound level test is required.

6.2 Test Procedures

Testing shall comply with paragraphs 4.1 and 4.3 of API 613, as amended below.

4.1 General

4.1.3 The following tests will be witnessed by the Owner:

- mechanical running;
- full speed/full or part load;
- full torque/slow roll;
- vibration testing.

6.3 Test Certificates

Test certificates shall be provided as defined in paragraph 4.2.1.1 of API 613.

6.4 Start-up

6.4.1 When stated by the Purchase Order/Contract, the Vendor/Contractor shall supply for start-up, all lubricating
fluids, including oil, grease and coolants as required by the unit. The Vendor/Contractor shall recommend the
amount and type of lubrication and cooling fluids for subsequent operation.

7.0 DOCUMENTATION

7.1 Introduction

7.1.1 This section covers the documentation requirements for design, materials, inspection, testing, installation and
operation of the oil system.
 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 12 of 14
Rev 0 1999

7.2 Schedules and Reports

7.2.1 The Vendor/Contractor shall supply with his tender, a production schedule showing submission of all
documents for review and approval, proposed Sub-Contractors and material procurement and a
production/fabrication programme. After an order is placed, this shall be updated and re-submitted at an
interval to be agreed between the Owner and the Vendor/Contractor.

7.2.2 Similarly, a progress report, as defined in paragraph 5.2.5 of API 613 shall be issued by the Vendor/Contractor
at the same intervals as the production schedule. The Vendor/Contractor shall submit with his tender a Quality
Control Plan for the Purchase Order/Contract.

7.2.3 After the Purchase Order/Contract award, monthly reports on design, material procurement and production
progress shall be submitted to the Owner.

7.2.4 A co-ordination meeting shall be held within six weeks of the placement of the Purchase Order/Contract, as
defined in paragraphs 5.2.2 of API 613, to review all engineering and manufacturing requirements of the
Purchase Order/Contract.

7.3 Data and Calculations

7.3.1 The documents detailed below shall be submitted for approval/review to the Owner and to the Inspection
Authority within the periods agreed between the Owner and Vendor/Contractor. It shall be the responsibility
of the Vendor/Contractor to ensure that the production schedule takes into account documentation submission
periods, plus a three week approval review period by the Owner and/or the Inspection Authority. The
Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

7.3.2 All calculations shall be carried out in a clear and logical manner. The source of formulae or methods shall be
clearly referenced. Computer calculations will only be accepted if all input is shown, together with calculated
values of intermediate terms and factors and the computer program has been validated to the satisfaction of the
Owner.

7.3.3 The Vendor/Contractor shall submit as a minimum, the data and drawings as defined in API 613 with the
additions/amendments below:

Proposals

Data for proposals shall be submitted by the Vendor/Contractor, as defined in paragraph 5.1 of API 613, as
amended below.

5.1 Proposals

5.1(h) * A list of spare parts for start-up and two years maintenance is required.

Contractual

Contractual data shall be provided as defined in paragraph 5.2.4 of API 613, as amended below.

5.2 Contract Data

5.2.4.2(d) Certified copies of test data shall be provided prior to shipment.

 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 13 of 14
Rev 0 1999

7.4 Drawings

Review and Approval

Review and approval of drawings shall be according to the Purchase Order/Contract.

Proposals

Drawings shall be submitted by the Vendor/Contractor, as defined in paragraph 5.1 of API 613.

Contractual

Purchase Order/Contract drawings shall be provided by the Vendor/Contractor, as defined in paragraph 5.2.3
of API 613,

7.5 Manuals

7.5.1 Data Book

2 copies of data books shall be provided containing the items specified in paragraphs 2.9.5 and 5.2.4.2 of API
613.

7.5.2 Installation, Operating and Maintenance Manual

6 copies of installation, operating and maintenance manuals shall be provided containing the information
defined in paragraph 5.2.4.5 of API 613.

8.0 PRIOR TO SHIPMENT

8.1 Painting

Surface preparation and painting shall be in accordance with GES X.01 with colour coding of equipment and
piping in accordance with GES X.02 using a system which complies with GES X.03. Vendor/Contractor may
use their own paint system, suitable for the duty, subject to the written approval of the Owner.

8.2 Spares

The Vendor/Contractor shall submit with his initial equipment proposal, a priced list of recommended spare
parts for "Commissioning", "Start-up" and for "Two Years Operation".

After review/approval of this list by the Owner, these spares shall be ordered and delivered with the main
equipment.

8.3 Packing and Storage

Paragraph 4.4 of API 613 shall be complied with, as amended below.

4.4 Preparation for Shipment

4.4.1 * The Vendor/Contractor shall recommend procedures for storage up to two years.

The equipment shall be prepared for export shipment by sea. Shipment as non-
 GENERAL ENGINEERING SPECIFICATION GES M.04
SPECIAL PURPOSE GEAR UNITS (API 613) Page 14 of 14
Rev 0 1999

containerised deck cargo is not allowed.

4.4.3.10 * The spare rotor where required, shall be crated for export shipment by sea.

8.4 Shipping

Detailed shipping arrangements are covered by the Purchase Order/Contract. The gear unit will normally be
shipped as part of a package equipment skid.

The gear unit and all furnished auxiliaries shall be shipped fully assembled on the baseplate. Components
which may sustain damage shall be carefully boxed, tagged and attached to the skid.

The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been approved
by the Owner's Inspector.

8.5 Warranty

The Vendor/Contractor shall provide manufacturer's written guarantees of the gear unit performance.

The Vendor/Contractor shall warrant all materials and services supplied against any defect for a minimum of
12 months after commissioning or 24 months from the date of delivery to site, whichever is the shorter period,
or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated with
restoring the equipment to the standard specified by the Purchase Order/Contract.