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DOCUMENT NO.

PT Caltex Pacific Indonesia

REV.

SP-ME-ME-008
DATE :

1
1
OF

October 9, 2001
Nurhasan Nurhasan Shawn

SHEET :

14

SPECIFICATION

PREPARED BY CHECKED BY APPROVED BY

NHS NHS SPD

DIESEL ENGINE FOR CENTRIFUGAL FIRE PUMPS

PT. CALTEX PACIFIC INDONESIA

REV

DATE

PAGES

DESCRIPTION

PREPD

CHKD

APPD

0 1

10/9/01 15/5/02

ALL ALL

ISSUED FOR IMPLEMENTATION CPI SPEC REVIEW TEAM (TRB, TOTO, FIB, SKMT, BBA, TJG, MIRS)

NHS Team

NHS Team

SPD Team

TABLE OF CONTENT 1. GENERAL .......................................................................................................................... 3 1.1. 1.2. 1.3. 1.4. 2. Scope........................................................................................................................ 3 Terminology.............................................................................................................. 3 References................................................................................................................. 3 Conflicting Requirements ........................................................................................... 4

BASIC DESIGN .................................................................................................................. 4 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. 2.11. 2.12. 2.13. 2.14. Engine Rating............................................................................................................ 4 Engine Cycle............................................................................................................. 4 Fuel Injection System................................................................................................. 4 Combustion Chamber ................................................................................................ 5 Starting System.......................................................................................................... 5 Cooling System.......................................................................................................... 5 Fuel System............................................................................................................... 5 Engine Air Cleaner.................................................................................................... 6 Governor .................................................................................................................. 6 Lube Oil System......................................................................................................... 6 Muffler...................................................................................................................... 6 Material.................................................................................................................... 6 Noise Level............................................................................................................... 6 Interconnecting Piping and Wiring............................................................................. 7

3.

ACCESSORIES................................................................................................................... 7 3.1. 3.2. 3.3. 3.4 3.4. Gear Units................................................................................................................ 7 Instrument/controller Panels...................................................................................... 7 Instrumentation......................................................................................................... 8 Engine Drive Controllers........................................................................................... 9 Fabrication ............................................................................................................... 9

4. 5.

COATING AND PAINTING............................................................................................... 9 INSPECTION AND TEST................................................................................................... 9 5.1. 5.2. Inspection ................................................................................................................. 9 Shop Test ................................................................................................................ 10

6. 7.

PREPARATION FOR SHIPMENT................................................................................... 10 INSTALLATION AND COMMISSIONING..................................................................... 12

PT. CALTEX PACIFIC INDONESIA

Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

8. 9.

MAINTENANCE SCHEDULE ......................................................................................... 12 GUARANTEE................................................................................................................... 12 9.1. 9.2. Mechanical............................................................................................................. 12 Performance ........................................................................................................... 12

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1: Project Specific Clarifications & Requirements

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PT. CALTEX PACIFIC INDONESIA

Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

1.

GENERAL 1.1. Scope This specification covers the minimum performance requirements for heavy duty internal combustion engines for mechanical drive of fire pump for PT. Caltex Pacific Indonesia in Riau Province, Sumatra, Indonesia. 1.2. Terminology In this specification, the following words and terms shall have the meanings hereby assigned to them, unless noted otherwise. 1.2.1. COMPANY Refers to PT Caltex Pacific Indonesia as the ultimate user and owner, the authorized representative of COMPANY or COMPANY third party inspection. 1.2.2. CONTRACTOR Refers to company selected by COMPANY, which may be responsible for the detailed engineering design, material and equipment procurement, and construction as specified in Contract, Scope of Work, or Work Order. 1.2.3. Vendor Refers to the company selected by COMPANY or CONTRACTOR which is responsible for the Purchase Agreement or Purchase Order of the goods/services specified in this specification. Note : ? ? For EPC (Engineering, Procurement and Construction) project purposes: The terminology shall have the meaning as above. ? ? For Direct Procurement by COMPANY purposes: Vendor shall also be responsible as CONTRACTOR. 1.3. References 1.3.1. Related Specification :
? ? PP-PC-GG-003 ? ? PP-PC-GG-004 ? ? PP-QC-GG-003 ? ? PP-QC-GG-004 ? ? SP-ME-ME-025 ? ? PP-QC-GG-006 ? ? SP-ME-ME-007

Shipping instruction Procedure Packing and Marking Instruction Inspection and Test Plan at Shop Inspection and Test Plan at Field Coating and Painting Specification Welding Procedure Centrifugal Fire Pumps

1.3.2.

Standard Code : Engine and accessories shall conform to NFPA 20, standard for the installation of Centrifugal Fire Pump, latest edition, except as modified by this specification.

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

An exception to a referenced NFPA 20 paragraph deletes the entire paragraph. An addition to a NFPA 20 paragraph expands the requirements or select options. 1.4. Conflicting Requirements 1.4.1. In case of conflict between this Specification and its associated Specifications and the above Codes and Standards, the Vendor shall bring the matter to the COMPANYs attention for resolution and approval in writing. However, the most stringent requirement shall be applied. Should conflicts exist between this specification and other documents, the following order of precedence shall govern:
? ? Purchase Order. ? ? Data sheets. ? ? This Specification ? ? Other COMPANY Specifications ? ? Other Referenced Publications ? ? Approved for Construction Drawings ? ? Vendors Code

1.4.2.

2.

BASIC DESIGN 2.1. Engine Rating 2.1.1. (Addition to paragraph 8.2.1 of NFPA 20) Engines shall be rated at standard SAE conditions of 29.61 in Hg barometer and 77 0 F inlet air temperature by the testing laboratory (see SAE Standard J 1349). Engine service rating shall not exceed 75% of manufacturer's maximum continuous duty rating. 2.1.2. (Addition to paragraph 8.2.2.5 of NFPA 20) A deduction of 1 percent from engine horsepower rating as corrected to standard SAE conditions shall be made for diesel engines for every 10 0 F above 77 0 F ambient temperature. Design inlet air temperature is 100 0 F. 2.1.3. Engine Requirements ? ? Capable of continuous duty of required HP ? ? 1800 RPM maximum ? ? Non turbo charged

2.2.

Engine Cycle The type of engine cycle shall satisfy under continuous load of required HP.

2.3.

Fuel Injection System

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

Fuel injection type shall be the vendor responsibility to provide the optimum combustion process. 2.4. Combustion Chamber Combustion chamber shall give high efficiency of the engine. 2.5. Starting System 2.5.1. 2.5.2. Engine shall be equipped with an electric starting system as described in NFPA 20. (Addition to paragraph 8.2.6.3 of NFPA 20) 110 volt, 60 Hz alternating current power is available for the automatically controlled battery charging system. 2.5.3. 2.6. Engine skid/platform design by Vendor shall include proper battery racks per paragraph 8-2.6.5 of NFPA 20.

Cooling System 2.6.1. The engine cooling system shall be a closed circuit type, including a circulating pump driven by the engine, a heat exchanger, and a reliable engine jacket temperature regulating device as described in paragraph 8-2.7 of NFPA20. The cooling water supply for the heat exchanger shall be open type from the discharge of the circulating pump, taken of prior to the pump discharge valve.

2.6.2. 2.7.

Fuel System 2.7.1. (Addition to paragraph 8.2.6.3 of NFPA 20) A guard or protecting pipe shall be provided for all exposed fuel lines near the engine, between the engine and fuel tank, and near the fuel tank. 2.7.2. (Excepting to paragraph 8-4.4 of NFPA 20) The fuel supply tank shall be sized properly for the engines as described in paragraph 8-4.3 of NFPA 20. 2.7.3. The fuel supply tank shall be located on the structural steel platform. Fuel outlet of the bottom tank shall be at least the same level or above the engine. Vendor shall incorporate the tank into the platform design. Fuel System in Skid A diesel skid mounted fuel tank sized to provide a minimum of 12 hours of run time at full load shall be provided, complete with vent and steel body manual drain valve. It shall be permissible to use the area between the skid beams as part of the diesel tank. A 2 inch, 150 # RF, Schedule 40 or 20 bore flange connection shall be provided for pumping fuel into the tank. This flange shall be blinded off. A high-quality full-flow fuel filter shall be supplied. A low-fuel level alarm contact shall be provided and wired to the on-skid junction box. The low-fuel level alarm shall be a MURPHY EL150EX or equivalent.

2.7.4.

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

2.7.5.

The type and grade of diesel fuel shall be as specified by the engine manufacturer. Residual fuels domestic heating furnace oils and drained lubrication oils shall not be used.

2.8.

Engine Air Cleaner An engine air cleaner filter recommended by the manufacturer shall be provided.

2.9.

Governor (Addition to paragraph 8-2.4.1 of NFPA 20) In addition to the governor a manual control throttle shall be provided.

2.10.

Lube Oil System 2.10.1. The lube oil system shall be equipped with a day tank complete with level gauge. The engine shall be equip ped with a lube oil pressure gauge, and a low lube oil pressure shut down. (Murphy A 25 EX or equivalent.) Lube oil filters shall be easily replaceable. Lubricating oil type shall suitable with service condition of the diesel engine.

2.10.2. 2.11. Muffler

Engine shall be equipped with appropriate muffler mount on unit (not shipped loose). 2.12. Material 2.12.1. 2.12.2. Engine material shall comply to ASTM standard and operating condition Thermal blanket for exhaust line shall be installed of Ceramic Fiber Silicon treated glass cloth covered with a 304SS knitted mesh (good for 2300F) when surface temperature may exceed 60 degrees C. A minimum of 1-1/2 calcium silicate covered with aluminum shall be used where rigid insulation is required such as on water line.

2.13.

Noise Level COMPANY desires engines, which will not produce noise, which may cause hearing impairment, speech interference, or be a public nuisance. Engines Sound Pressure levels (SPL) at any location 3 feet from the engine and its connecting load shall not exceed the following values: Octave Band Center Frequency (Hz) 31 63 125 250 Maximum SPL dBA (ref 0.0002 microbar) 100 96 92 90

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

500 1000 2000 4000 8000 2.14. Interconnecting Piping and Wiring 2.14.1. (Addition to paragraph 8-2.4.1 of NFPA 20)

90 90 90 90 90

All connecting wires for automatic controllers shall be harnessed or flexibly enclosed, mounted on the engine, and connected in an engine junction box to terminals numbered to correspond with numbered terminals in the controller. This is to ensure ready wiring in the field between the two sets of terminals. The same method shall be used for connecting wires between: ? ? Automatic charging system and power source ? ? Automatic charging system and controller ? ? Diesel fuel tank and controller 2.14.2. All piping and tubing required for the operation of the engine, pump, and completed shall be to the fullest possible extent by the Vendor in his shop facilities. All connecting piping or tubing shall be run to the edge of the skid or partial unit as broken down for shipment. A field connection diagram shall be provided and permanently attached to the inside of the controller panel. The field connections shall be clearly marked to correspond with the field connection diagram furnished. This shall include but not be limited to the following ? ? Cooling water from pump to engine skid ? ? Fuel from diesel fuel tank to engine skid ? ? Pressure sensing lines to controllers. 3. ACCESSORIES 3.1. Gear Units 3.1.1. Gear units shall be in accordance with AGMA specifying action 420 (under 3600 rpm). Horsepower ratings of gears shall not exceed that allowed by AGMA Specifications for the service factor required by the service conditions. Gear unit housings shall be sealed against loss of lubricant or against the entrance of water or any foreign matter. The pump and gear unit shall be aligned and balanced prior to shipment. The pump and gear unit shall be fixed to prevent relative movement during shipping and installation.

3.1.2.

3.2.

Instrument/controller Panels

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

3.2.1.

Each engine/pump shall be equipped with control panel to control all functions of operation of the unit. The control panel shall be a NEMA 4X, stainless steel, enclosure and shall be permanently attached to the skid of the unit by steel supports. Control Panel shall contain all controls to automatically start, operate and shutdown the unit as required (both engine and pump). Unit shall be either automatically started via a pressure switch mounted on the control panel by Vendor or manually via a start push-button mounted on the panel and manually shutdown via a stop push-button on the panel. Automatic shutdowns shall be provided for engine alarms such as overspeed, high temperature, low oil pressure, etc. COMPANY will tube necessary pressure signal to starting pressure switch. Control system shall have incorporated a 30 minute exercise time that automatically starts the pump every seven days and then automatically shutdown the unit. Annunciation on the control panel face shall be provided for alarms listed in section 3.3 below. Two (2) sets of form C contacts shall also be provided for connection to a remote system for alarm annunciation. Starting system shall be 12VDC with an automatic deep cycle battery charger specifically designed for engine starting. Battery charger shall be installed inside control panel. COMPANY will supply 120VAC/60Hz to the control panel for operation of the charger. A separate steel enclosure shall be incorporated into the skid of the unit to house necessary starting batteries. Enclosure shall have a lid with lockable latch to prevent unauthorized access to the battery. Battery system shall be sized to allow a minimum 20 crank of the unit, with no charging voltage present. Batteries shall be deep cycle, heavy duty, lead acid type. All on-skid devices shall be pre-wired by Vendor such as batteries, charger, starter, engine shutdowns, etc. In the event of engine overspeed, the inlet air manifold shall be automatically shut to prevent engine runaway. Combination locks shall be installed on the battery compartment and the control panel. Locks shall be heavy duty with user pre-configured combinations.

3.2.2.

3.2.3.

3.2.4.

3.2.5.

3.2.6.

3.2.7. 3.2.8. 3.2.9. 3.3.

Instrumentation 3.3.1 (Addition to paragraph 9-5-2.4 of NFPA 20). The engine shall be provided with the following instrumentation. ? ? Amperemeter ? ? Tachometer ? ? Oil Pressure Gage ? ? Jacket Water Temperature Gage ? ? Low oil pressure alarm and shutdown at separate pressure settings ? ? High jacket water temperature alarm and shutdown at separate temperature settings ? ? Overspeed shutdown

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

? ? Battery and Battery charger failure alarm ? ? Failure of automatic engine start alarm

3.3.2 3.4

The diesel fuel tank shall be provided with a level indicator other than sight tube and also a low level alarm.

Engine Drive Controllers 3.4.1 (Addition to paragraph 9-5.2.3 of NFPA 20) Over remote manual control station shall be provided for each engine to manually start the engine. 3.4.2 A visible beacon-type alarm shall be used in place of an audible alarm. The beacon shall be clearly visible during daylight conditions. A separate beacon shall be provided for each pump/controlled and a method shall be provided to test the beacon lamp element.

3.4.

Fabrication 3.4.1. 3.4.2. 3.4.3. 3.4.4. No fabrication may begin until the Vendor has received written approval of detailed fabrication drawings from the COMPANY. Shop detail drawing shall be completed with all dimensions, thickness and detail of construction. No fabrication shall be sub-contracted without the prior written approval of the COMPANY. Material shall be as stated on data sheet. Alternative materials may be used if advantageous with the prior approval of the COMPANY. Proposed substitutions must be clearly defined.

4.

COATING AND PAINTING 4.1. Unless otherwise specified, Coating and Painting shall be in accordance with SP-ME-ME025 Coating and Painting Specification.

5.

INSPECTION AND TEST Unless otherwise specified, Vendor shall be responsible for all inspection and testing in accordance with PP-QC-GG-003, "Inspection and Test Plan at Shop", PP-QC-GG-004, "Inspection and Test Plan at Field". 5.1. Inspection The intent of inspection is to provide quality control during all activities rather than only final acceptance criteria. The Vendor is responsible for QA/QC within his own plant as well as assuring and coordinating that all subvendors and suppliers comply with their QA/QC requirements as specified, generally recognized or implied. Vendor shall submit all manufacturing, fabrication, inspection and testing procedures for CONTRACTOR/COMPANY approval at least three (3) weeks in advance of

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

implementing the procedure. Manufacturing and fabrication shall not proceed until Vendors material inspection has been approved by CONTRACTOR/COMPANY. Equipment will normally be inspected at the various plants. A pre-inspection meeting between the COMPANY, VENDOR and major Subvendors will be held before work starts to review all specifications and inspection requirements. The inspection program as part of the VENDORs QA/QC program will be established at that time. All hold points will be established (this meeting must be held soon after order placement so that the hold points are shown on the Schedule). Inspection may include, but not be limited to, the following: ? ? Visual examination of castings ; ? ? Witnessed repairs of castings; ? ? In-process inspection of welding; ? ? Inspection of parts before assembly; ? ? Review of material test reports and certifications; ? ? Review of weld procedure qualification records and welder Qualifications; ? ? Review of running clearances documentation; ? ? Review of gear and engine balancing documentation; ? ? Observing or witnessing of any tests; ? ? Review of documentation prior to releasing the complete unit for shipping; ? ? Inspection for conference to the Data Sheets; ? ? Visual and dimensional inspection; ? ? Checking of painting and shipping preparation; or ? ? Other inspection which is required by specifications referenced and/or included in this Specification. 5.2. Shop Test 5.2.1. Vendor shall be responsible for Factory Acceptance Test (FAT). All equipment, materials, consumables, utilities, and facilities for the test shall be furnished by Vendor. Welded piping shall be tested with a system hydrostatic test at 1.5 times MAWP. Instrumentation system shall be shop pressure tested, functional/operational tested, and calibrated. The engine shall be run at rated brake horsepower and rpm until jacket water and lube oil temperatures have leveled off and remained stable for not less than 30 minutes. Vendor shall record all essential data during the test including fuel consumption rate.

5.2.2. 5.2.3. 5.2.4.

6.

PREPARATION FOR SHIPMENT 6.1. Unless otherwise noted in the COMPANYs Request for Proposal and/or Purchase Order, Preparation for shipment shall be in accordance with PP-PC-GG-003, Transportation and Traffic Instructions, PP-PC-GG-004 Packing and Marking Instruction. All components (individual pieces, as well as packaged sets) shipped with mounted preassembled piping, tubing, or wiring shall with OSHA requirements and shall carry outside securely affixed large, red, all-weather tags stating the following in bold letters:

6.2.

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

THIS SYSTEM HAS BEEN REASSEMBLED AND TESTED FOR OPERABILITY AND SAFETY, COMPLIES WITH ALL REQUIREMENTS OF OSHA AND SHALL NOT BE DISTRIBUTED BY UNAUTHORIZED PERSONNEL. 6.3. Assembly and preparation for shipment shall be in accordance with Vendors standards and as noted herein. Vendor shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers. Each major component shall be properly identified with item and serial numbers. All material shipped separately shall be properly tagged or marked with the item and serial number for which it is intended. Immediately after final testing and prior to shipment, equipment shall be drained, dried and cleaned thoroughly of all grease, loose scale, rust, flux, weld splatter and rubble, both internally and externally. Adequate protection shall be provided against mechanical damage and atmospheric corrosion in transit, and for mutually acceptable period of outdoor storage at job site before installation. Preparation for shipment and packing will be subject to inspection and rejection by Companys inspectors. All costs occasioned by such rejection shall be to the account of the CONTRACTOR. Equipment shall be packed, securely anchored, and skid mounted when required. All items, which can be damaged by water, shall be securely wrapped in waterproof paper or plastic before placed in wooden crates. Bracing, support, and rigging connections shall be provided to prevent damage during transit, lifting, or unloading. Open end of pipe shall be capped for protection. The cap shall be removable. Female threaded connection shall be plugged with solid metal pipe plugs, and male threaded connections shall be protected with full metal pipe caps. Separate, loose and spare parts shall be completely boxed. Piece of equipment's and spare parts shall be identified by item number and service and marked with Companys order number, tag number, and weight, both inside and outside of each individual package or container. Exposed finished and machined surfaces, including bolting, shall be given a coating of rust inhibiting compound. Internal metal surfaces shall be sprayed or coated with a suitable rust preventive prior for shipment. Opening shall be suitably tagged to indicate the rust preventive applied. One complete set of the installation, operation, and maintenance instructions shall be packed in the boxes or crate with equipment. A recommended spare part list for 2 years operation shall be included also. No equipment shall be released for shipment from Vendors shop until inspection release has been issued from Contractors inspector. Vendor shall provide COMPANY the instruction that necessary to preserve the integrity of the storage preparation, after the equipment arrives at the job site and before startup.

6.4.

6.5.

6.6.

6.7.

6.8. 6.9. 6.10. 6.11. 6.12. 6.13.

6.14.

6.15.

6.16. 6.17.

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

7.

INSTALLATION AND COMMISSIONING 7.1. Well in advance of shipping, Vendor shall prepare detailed installation instructions, precommissioning checklists, and job site test agendas for COMPANY approval. These stepby-step instructions, checklists and test agendas shall be comprehensive and describe all steps necessary for: 1) COMPANY to install the complete unit to the foundation, 2) COMPANY and Vendor commissioning engineer to verify completion of all precommissioning procedures, and 3) COMPANY and Vendor commissioning engineer to verify that all hydraulic, mechanical, vibration, and electrical performance criteria are met. The preparation of these documents shall be included in the Lump Sum Amount. Vendor is responsible for any deficiencies in hydraulic, mechanical, vibration, or electrical performance at the job site. Field Acceptance Tests shall be conducted as defined in paragraph 11-2 of NFPA 20. Vendor shall be responsible for conducting the tests and shall submit a test agenda at least two months prior to testing. If specified, COMPANY will prepare a Supplemental Agreement to the Purchase Order for the services of Vendor 's commissioning engineer. The basis for this Agreement will be Vendor's proposal received with his Base Proposal. All commissioning engineers contracted under a Supplemental Agreement shall be competent, experienced (5 years minimum), factory trained, and certified. The commissioning engineer shall come equipped with all special tools and information required to expeditiously perform his work per the COMPANY approved precommissioning checklist and job site test. Special tools may include optical alignment tools, multi-channel direct readout vibration monitors, multi-channel direct readout temperature monitors, ammeters, etc.

7.2.

7.3.

7.4.

8.

MAINTENANCE SCHEDULE Vendor shall provide daily, weekly, monthly and quarterly maintenance schedule to ensure that the engine fire pump is in ready condition.

9.

GUARANTEE 9.1. Mechanical 9.1.1. All equipment and component parts shall be warranted by the Vendor against defective materials, design, and workmanship for 1 year after being placed in service (but not more than 18 months after date of shipment) If any mal-performance or defects occur during the guarantee and warranty period, the Vendor shall make all necessary alterations, repairs, and replacement free of charge, free on COMPANY warehouse. Field labor charges, if any, shall be subject to negotiation between the Vendor and the COMPANY.

9.1.2.

9.2.

Performance

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Diesel Engine for Centrifugal Fire Pumps SP-ME-ME-008 Rev. 1

Unless exception is recorded by the Vendor in his proposal, the equipment shall be guaranteed for satisfactory performance at all operating condit ions specified on the data sheet.

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