Exploration and Production Malaysia Inc.

GENERAL SPECIFICATION

NO. 10-6-1
DIESEL ENGINES FOR OFFSHORE SERVICE

Document Revision Record

Revision Document System System Next Review

Date Approver
No. Custodian Administrator Owner Date
3 Sep. 2002 MFAA UHT JLS GEM Sep. 2007

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• This document is for ExxonMobil Use Only. It is valid for use until next revision is available.

• Refer to Summary Data Sheet for the details of changes in this revision.

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 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................ 2

2.0 REFERENCES............................................................................................................... 2

3.0 GENERAL DESIGN REQUIREMENTS.................................................................... 2

4.0 FUEL SYSTEMS ........................................................................................................... 5

5. 0 STARTING LOADS AND EQUIPMENT................................................................... 5

6.0 LUBRICATION SYSTEMS ......................................................................................... 6

7.0 COOLING WATER SYSTEM..................................................................................... 7

8.0 AIR INLET AND EXHAUST SYSTEMS ................................................................... 7

9.0 INSTRUMENTATION AND CONTROLS ................................................................ 8

10.0 AUXILIARY EQUIPMENT......................................................................................... 9

11.0 PROTECTIVE COATINGS....................................................................................... 10

12.0 INSPECTION AND TESTING ................................................................................. 10

13.0 PREPARATION FOR SHIPMENT .......................................................................... 10

14.0 VENDOR DATA REQUIRED ................................................................................... 11

Rev. 3 - September 2002 Page 1 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

1.0 SCOPE

1.1 This specification covers the minimum requirements for the design, assembly,
inspection, and testing of skid-mounted diesel engines for driving generators, air
compressors, crane power units, etc. for offshore services.

1.2 This specification is applicable to both naturally aspirated and turbocharged engines.
This specification does not apply to diesel engines used in automotive, truck, or marine
services nor to firewater pump drivers which are covered in GS 10-1-3.

1.3 All requirements of this specification are the responsibility of the engine vendor (or
referred as Vendor) unless specifically indicated to apply to others.

2.0 REFERENCES

2.1 EMEPMI General Specifications:

GS 0-4-0, Common Requirements and Specifications

GS 6-4-1, Air-Cooled Heat Exchangers.

2.2 Diesel Engine Manufacturer's Association Standards (DEMA).

2.3 NFPA 70, National Electrical Code.

3.0 GENERAL DESIGN REQUIREMENTS

3.1 Unless otherwise specified, packaged type and skid-mounted units are required with the
engine and driven equipment mounted on a single steel skid. Skids shall be constructed
in accordance with requirements of GS 0-4-0, Common Requirements and
Specifications.

3.2 Unless otherwise specified, engine vendor shall furnish skid and all necessary engine
equipment. Engines shall be manufactured by Caterpillar, Detroit Diesel or EMEPMI
approved equal.

3.3 Driven equipment will normally be directly connected to engine via stub shaft and
flexible coupling, or bolted directly to flywheel in the case of single bearing generators.
The use of clutches and torque converters may be considered in unusual circumstances
and may be recommended for EMEPMI approval in the proposal. Couplings shall
meet the requirements of the driven equipment manufacturer in any case.

3.4 The engine shall be equipped with, but not limited to, the following equipment:

- Air intake filters and silencer

- Exhaust system and silencer
- Starting system

Rev. 3 - September 2002 Page 2 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

- Fuel injection system

- Lubrication system
- Cooling system
- Instrument panel

3.5 The engine shall be rated in accordance with the following requirements of DEMA:

3.5.1 Engine horsepower rating shall be the horsepower available at the coupling after
derating required for type of service, altitude, ambient temperature, fuel quality, and
after subtracting horsepower required by auxiliary equipment driven from the engine
shaft.

3.5.2 Vendor shall provide engine ratings for continuous and intermittent service. Engines in
continuous service will operate in excess of 8000 hours per year with interruptions for
routine maintenance (excluding overhaul) not exceeding 24 hours. Engines in
intermittent service will operate from 4000 to 8000 hours per year with uninterrupted
periods of 1000 hours as a minimum.

3.5.3 The following brake mean effective pressure (BMEP) and brake horsepower (BHP)
limits shall be used in selecting the engines. The lesser of BMEP or BHP limits shall
be used. Alternate ratings may be quoted if engine complies with GS 0-4-0. Alternate
ratings require EMEPMI's specific approval.

Percent of Max. BMEP (psi/kPa)

Mfg. Rated Continuous Intermittent
Power Service Service
- Four-cycle naturally aspirated 85 90/620 100/690
- Two-cycle blower scavenged 85 85/585 95/655
- Two-cycle turbocharged (no 95 110/760 125/860
intercooling)
- Two-cycle turbocharged (with 95 115/790 130/900
intercooling)
- Four-cycle turbocharged (no 95 130/900 145/1000
intercooling)
- Four-cycle turbocharged (with 95 150/1035 165/1140
intercooling)

3.5.4 Engines in generator service shall operate at 60% to 80% of the above ratings during
normal operation and shall not exceed 100% of manufacturers rating during transient
events such as equipment switching. Engines in compressor and pump services shall
operate at their continuous rating. Engines in crane and black start unit services shall
operate at their intermittent rating.
3.5.5 Piston speed for engines in intermittent or continuous service shall not exceed 460
meters (1500 feet) per minute. All higher piston speeds require specific approval by
EMEPMI.

Rev. 3 - September 2002 Page 3 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

3.5.6 The torsional natural frequencies of the engine including the driven equipment system,
couplings and gear units when applicable, shall have a separation margin of 20% of any
shaft speeds within the operating speed range in the rotating system. If this is
impractical, dampers shall be used to limit torsional shaft stresses to 3500 psi
throughout the operating range. Constant speed applications shall have a separation
margin of ±10%.

3.6 The engine and all its components shall be suitable for operation in the electrical area
classification specified on the data sheets.

3.7 The noise level of the engine over the entire speed range shall comply with the
requirements of specification GS 0-4-0. When compliance is not met, Vendor's
proposal shall include alternative solution for noise level attenuation.

3.8 All piping connections shall be terminated at the edge of the skid at a valve with a plug
or a blind as appropriate. All electrical control and power wiring shall be terminated at
skid mounted junction boxes. All instrument tubing shall be terminated at a single skid
mounted bulkhead.
3.9 All engine materials shall be the manufacturer's standard which shall also in full
compliance to the specification. No prototype parts or systems shall be supplied.

3.10 Piping on the engine driven equipment and auxiliaries shall meet the requirements of
GS 0-4-0 and the following requirements.

3.10.1 All lube oil and fuel piping including valves and fittings shall be seamless ASTM A312
TP317 or TP316 with 3% minimum molybdenum. All other piping shall be ASTM
A106 Grade B.

3.10.2 Teflon pipe tape shall be used on all non-welded threaded connections except for lube
oil systems where pipe thread sealant shall be used to avoid system contamination. The
pipe thread sealant shall have compatible properties with the lube oil.

3.10.3 The piping system shall be designed to allow for thermal expansion and contraction
movements. The use of flexible braided sections is not allowed. However, when there
is no alternative and with EMEPMI approval, metal type flexible braided connections
shall be specifically proposed by the Vendor, and minimum lengths and number of
these connections shall be used.

3.10.4 Stud bolts shall be used for all flanged connections. Stud bolts shall be threaded full
length with continuous threads. End threads shall be removed as required to prevent
bottoming in blind holes.
3.10.5 All piping on the skid shall be supported and clamped to maintain alignment and
withstand vibration. Piping containing flammable materials such as lube oil, fuel, etc.
shall be clamped and rigidly secured with plastic holder between the piping and clamps
to prevent direct metal to metal rubbing.

Rev. 3 - September 2002 Page 4 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

4.0 FUEL SYSTEMS

4.1 The fuel system shall consist of the following as a minimum:

- Fuel lift pump

- Fuel strainer (shall be removable/replaceable type)
- Injection pump(s)
- Priming pump (may be combined with lift pump, Vendor to indicate in the
proposal)
- Dual full-flow fuel filters (coalescing type with water drains)

4.2 Fuel injectors shall be positioned for easy access and removal without dismantling any
other engine parts.

4.3 Fuel lines between injection pumps and injectors shall be 316 stainless steel tubing and
Packer Triple Lock interconnecting fittings. Vendor shall seek EMEPMI approval for
alternative material of the fuel lines. Each run of the fuel lines shall be the same length
from injection pump to each cylinder. The tubing shall follow the contours of the
engine without direct contact with the engine hot surface and shall be sufficiently
braced for vibration and shock loads. Pressure-bleed valves and low-point drains shall
be furnished.

4.4 Fuel lift pumps shall be positive displacement engine driven types. These pumps shall
be equipped with a manual lever for priming and bleeding of fuel system at high points
or a separate priming pump shall be furnished.

4.5 Fuel injection pumps shall be self-lubricating positive displacement, multi-pump or

single cylinder (unit) types, Robert Bosch or equal. Distributor type is not acceptable.

4.6 Dual fuel filters shall be contained in accessible steel housings and located upstream of
the fuel injection pump. Filters arrangement shall allow changing of a filter element
without shutting down of the engine. Filter housings shall be built with isolation
valves.

4.7 When specified on the data sheet, Vendor shall furnish a fuel day tank with 18 hours
fuel capacity. Tank shall be equipped with fill, vent, drain, lift pump, and runback
connections. Tank shall be made of 316 L stainless steel unless EMEPMI specifies or
approves otherwise. Tank may be built into skid.

5. 0 STARTING LOADS AND EQUIPMENT

5.1 The engine shall be suitable for starting with load mechanically coupled to the engine
shaft. The load device must provide maximum unloading at the start and remain
unloaded until the engine reaches operating speed.

Rev. 3 - September 2002 Page 5 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

5.2 The starting equipment shall be supplied by engine vendor and be as specified on the
engine data sheet. Starting equipment may be pneumatic, hydraulic, and / or electric
type.

5.2.1 Pneumatic engine starting shall be by means of starting air at 860 kPag (125 psig) to a
pneumatic starter motor, TDI Turbostart Series or equal. A metal bowl lubricator, Y-
type strainer, Amot 2180 air control valve or equal, and an isolating valve shall be
installed at the supply line of the motor.

5.2.2 Hydraulic engine starting shall be by means of a Bosch hydraulic motor or equal and an
accumulator system. Hydraulic starting system shall include an engine driven charging
pump, a hand charging pump, pneumatic charging pump, and accumulator(s), the
starting motor, and all necessary instrumentation, controls, and relief systems. The
accumulator(s) shall be capable of three starting attempts of 10 seconds each
immediately one follows another. Piping shall be type 316 with a minimum
molybdenum content of 3% or tubing shall be Packer Triple lock fittings. High
pressure hose length may not exceed 18 inches.

5.2.3 Electric engine starting shall be by means of Delco electric motor or equal with an
independent storage battery unit, complete with controls and charger. Rack, intercell
connectors and terminal lugs shall be provided with each battery set. Batteries shall be
sufficient for a minimum of 90 seconds total cranking time without re-charging.

5.2.3.1 Vendor shall provide a means to prevent moisture accumulation on inter-connect

wiring when battery units and/or engine are enclosed.

6.0 LUBRICATION SYSTEMS

6.1 Pressurized lubrication system shall consisting of an engine driven oil pump with
suction strainer, supply and return piping system, an oil cooler, and full-flow with
indicating integral high pressure bypass oil filter. Low-point drain connections with
valve and cap shall be provided.

6.2 Pre/post lube pumps for engine and driven equipment shall be furnished by the Vendor.
Turbochargers, when furnished, shall require pre/post lubrication.

6.3 An oil cooler shall be provided to maintain lube oil supply temperature below the
manufacturer's maximum allowable operating temperature. A minimum of additional
15 percent excess surface shall be available for operating at maximum ambient
temperature as specified in the Data Sheets. The cooler shall be a sea water-cooled
shell and tube type, or a suitable air-cooled type as specified on the data sheets.
Coolers shall be equipped with vent and drain connections on oil and water sides.

6.4 When sea water-cooling is specified, the lubricating oil pressure at the cooler outlet
shall be greater than the specified maximum cooling water pressure. The cooler
materials, with EMEPMI approval, shall be compatible for sea water service.

Rev. 3 - September 2002 Page 6 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

6.5 A dual full-flow, 10 microns nominal, 25 microns absolute or smaller, oil filter system
shall be provided. The filters shall be located downstream of the cooler. Filter
elements shall be readily accessible for replacement without disconnecting any piping
and major components. Isolation valves shall be installed to allow change of filters
without shutting down engine. Where multi-element filters are required, single multi-
element filter cases shall be furnished rather than multi-single element cases.

6.6 Turbochargers, when furnished, shall be lubricated from the engine lubrication system.

6.7 Grease lubrication connections shall be piped to allow lubrication while engine is
operating.

6.8 Unless otherwise specified, a Kenco or equal fire-safe lube oil level controller with a
counter shall be provided for external make-up to the lube oil system.

7.0 COOLING WATER SYSTEM

7.1 The cooling water system shall be sized for maximum rated engine output. Cooling
shall be by means of an air-cooled heat exchanger or, if specified on data sheet, a
water-to-water heat exchanger.

7.1.1 A radiator cooling system shall be anti-corrosion materials suitable for tropical marine
environment and be Vendor's standard equipment.

7.1.2 The cooling system heat load shall be based on the engine maximum rated horsepower
plus a 15% reserved capacity allowed for fouling. Cooling medium shall be 50%
ethylene glycol - 50% water. Radiator shall be sized for maximum ambient
temperature as specified on Data Sheets. Maximum top tank temperature of radiator
shall be 88°C.

7.1.3 When a remote cooler is required or specified on Data Sheet, an air-cooled heat
exchanger shall be provided. The heat exchanger shall be designed in accordance with
requirements of GS 6-4-1, AIR-COOLED HEAT EXCHANGERS.

7.2 Cooling water system shall include automatic control of engine outlet water
temperature. Vendor shall quote in the proposal for the optional Manual louvers.

8.0 AIR INLET AND EXHAUST SYSTEMS

8.1 Remote or engine mounted dry-type air intake filter with replaceable elements shall be
provided. Engine mounted elements shall be readily accessible for filter change
without removal or disconnecting major components.

Rev. 3 - September 2002 Page 7 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

8.2 Vendor's standard inlet silencer shall be furnished if air filter is engine mounted. For
remote mounted air filters, furnish in-line silencer, AAF or equal.

8.3 The air inlet system shall consist of filter housing with low point drain, louvers to
prevent water entrance, and coarse 316L stainless steel metal entrance screen. Interior
of entire air inlet system shall be 316L stainless steel without coating.

8.4 The exhaust manifold shall be the water-cooled type with cooling water supplied from
the main engine cooling system.

8.5 Exhaust silencers shall be the spark arresting type, residential silencing grade or better,
Maxim SA-2 or equal. Unless otherwise specified, muffler shall be supported from
skid. Insulation shall be provided and properly secured for the exhaust piping and
silencer.

8.6 The turbocharger shall be engine mounted. The turbocharger shall be isolated from
thermal strain and vibration by means of a stainless steel expansion joint with liner in
the exhaust piping and by a flexible sliding sleeve or corrugated type coupling in the air
inlet piping. Connections and gauges shall be provided for monitoring the discharge air
pressure and temperature. Low point drains shall be provided.

8.7 Engines shall be fitted with a device that closes the air intake in the event of any
shutdown. This is in addition to the fuel cut-off shutdowns.

9.0 INSTRUMENTATION AND CONTROLS

9.1 The engine shall be supplied with the Vendor's standard control panel for tropical
marine environment which shall include all components required in these
specifications. The panel shall be mounted on the engine and visible and accessible
during starting.

9.2 The control panel shall be complete with all wiring and tubing connections to driven
equipment, engine, and engine mounted devices. The panel shall have at least the
following instruments and gauges located on the front:

- Lube oil pressure gauge

- Lube oil temperature gauge
- Jacket water temperature gauge
- Electric tachometer with built-in overspeed shutdown
- Manual start button
- Manual stop button
- Exhaust gas temperature for each power cylinder
- Scavenging air pressure (2-cycle engines)
- Inlet manifold pressure (turbocharged engines)
- Inlet manifold temperature (turbocharged engines)
- Alarm annunciator

Rev. 3 - September 2002 Page 8 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

- Shutdown annunciator
- Test switch
- Run hour meter

9.3 Automatic alarm and shutdown devices with panel indicators shall be furnished as
indicated below:

9.3.1 Alarms

- Low lube oil pressure

- High jacket water temperature
- High bearing temperature (if specified on Data Sheet)

9.3.2 Shutdowns

- Low lube oil level

- Low lube oil pressure
- High jacket water temperature
- Overspeed
- High bearing temperature (if specified on Data Sheet)

Additionally, generator drivers shall have contacts to trip switch gear when engine
shuts down.

A 316 stainless steel plate legibly labeled with all the alarm and shutdown settings shall
be furnished and attached at the panel.

9.4 Automatic shutdowns shall be normally closed design type, i.e. de-energize to trip, with
first-out annunciation.

9.5 A constant speed governor shall be furnished that is adjustable throughout the speed
range of the engine. The accuracy with which the governor holds the constant speed
shall be compatible with driven equipment. For generator service, governor shall be
Woodward UG-8 hydraulic or Woodward 2301 electronic, with EMEPMI approval.

9.6 All pressure gauges shall be equipped with isolation and bleed valves. Pressure gauges
not used for shutdown devices shall be 115 mm (4-1/2 inch) liquid filled Ashcroft or
equal with solid front and blowout back.
9.7 The panel shall be designed to allow for instrumentation testing without causing engine
shutdown.

9.8 All electrical devices shall comply with NFPA 70, National Electrical Code
requirements for the specified area classification.

10.0 AUXILIARY EQUIPMENT

Rev. 3 - September 2002 Page 9 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

10.1 A mechanical or pneumatic jacking device shall be provided for rotation of engine
during maintenance.

10.2 A flywheel locking device shall be provided when the driven equipment is an air
compressor.

10.3 When specified, engine shall be equipped with hood and side doors.

10.4 When a mechanical clutch is furnished, release lever shall be readily accessible.

11.0 PROTECTIVE COATINGS

11.1 Unless otherwise specified, the engine shall be painted with a shop coat compatible
with a polyamide epoxy paint system. The skid shall be sandblasted to white metal and
coated with inorganic zinc silicate, Mobilzinc7, or equal. Muffler and exhaust piping
shall be aluminized with Metco 120, or equal.

12.0 INSPECTION AND TESTING

12.1 Inspection and testing of the engine and auxiliary equipment shall be in accordance to
GS 0-4-0.

12.2 Engines shall receive a full load and a no-load tests at Vendor's testing facilities prior to
shipment. After the running parameters stabilized, each run test shall be conducted for
two hours minimum with operating parameters being recorded at fifteen minute
intervals.

12.3 Engines shall be tested with the contract engine panel and instruments as opposed to
Vendor's shop equipment.

12.4 The whole units shall be tested to prove the mechanical operation and performance of
the driver and driven equipment and all auxiliary systems mounted on the skid.

12.5 Generator sets shall be electrical resistive load tested with all contracted equipment.

12.6 All test procedures shall be reviewed and approved by EMEPMI six weeks prior
commencement of the tests.

12.7 When specified, certain tests shall be witnessed by EMEPMI representative.

13.0 PREPARATION FOR SHIPMENT

13.1 Vendor shall comply with all the requirements of the Preparation for Shipment section
of GS 0-4-0.

Rev. 3 - September 2002 Page 10 of 11

 GENERAL SPECIFICATION
DIESEL ENGINES FOR OFFSHORE SERVICE
Exploration and Production Malaysia Inc.
Development Projects Department GS 10-6-1

13.2 The following additional data shall be included on nameplates:

- Size and type of injectors and injection pump.

- Model and speed range of governor.
- Model and boost of turbocharger (when applicable).

14.0 VENDOR DATA REQUIRED

14.1 Vendor shall comply with all the requirements of the Vendor Proposal section of GS 0-
4-0.

14.2 In addition, Vendor shall define in the proposal all emission sources from the engine
and specify for each source the rates and compositions of the emissions. The fuel
composition on which the emissions rates are based shall be listed. Emission
measurements shall be carried out per DEMA exhaust measurement procedures. This
information shall be provided for full load, partial load and idling conditions. The unit
shall be able to be installed with the optional emission control devices. Vendor shall
quote in the proposal for the optional emission control devices.

14.3 The successful Vendor shall comply with the sections of GS 0-4-0 on Vendor
Guarantees, Maintenance and Operating Manuals, Spare Parts, and Data Required.

14.4 Specific Vendor Data Requirements will be per the Data Sheets.

Rev. 3 - September 2002 Page 11 of 11