NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES M.03

GENERAL PURPOSE GEAR UNITS (API 677)

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

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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 5

3.1 Codes and Standards 5

3.2 Additions and Exceptions to API 677 6

4.0 MATERIALS 8

4.1 API 677 Requirements 8

5.0 INSPECTION 8

5,1 Procedures 8
5.2 Scope 9
5.3 Nameplates 9

6.0 TESTING 10

6.1 Required Tests 10

6.2 Test Procedures 10
6.3 Test Certificates 10
6.4 Fluids 10

7.0 DOCUMENTATION 10

7.1 Introduction 10
7.2 Schedules and Reports 11
7.3 Data and Calculations 11
7.4 Drawings 12
7.5 Manuals 12
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SEC TITLE PAGE

8.0 PRIOR TO SHIPMENT 12

8.1 Painting 12
8.2 Spares 12
8.3 Packing and Storage 12
8.4 Shipping 13
8.5 Warranty 13

DATA SHEETS

General Purpose Gear Unit (API 677) Data Sheet (3 sheets)

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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 general purpose gear units.

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

1.1.3 This specification does not apply to Special Purpose Gear Units which are covered by GES M.04.

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/or standards, the Vendor/Contractor shall inform the Owner in writing, and
receive written clarification from the purchaser 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.04 Special Purpose Gear Units

GES M.05 Lubrication Shaft Sealing and Control Oil Systems for 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 Standard 677 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.
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2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are as defined in paragraph 1.4 of API 677.

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.

Vendor

The company supplying the equipment and material.

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 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 the 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 677 "General Purpose Gear Units for Refinery Service" as amended by this specification.

3.1.2 Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and
Standards at the time of the order should be used.
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3.2 Additions and Exceptions to API 677 (1st Edition)

The following paragraph numbers refer to API 677, First edition, March 1989 which shall be
considered as forming a part of this General Engineering Specification.

In API 677 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 677 unless otherwise
stated. Paragraph numbers in this specification which do not appear in API 677 are new paragraphs.

1.1 Scope

1.1.1 Add:

"General purpose gear units shall be supplied by Vendor/Contractors 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 furnish a reference first proving that their gear units have been
performing successfully in similar duty for a period of more than one year".

2.1 General

2.1.5* GES A.04 shall apply. The sound pressure level measured at 3.3 ft. (1m) from the
surface of the equipment shall not exceed 85 dB(A).

2.1.9* The Owner shall specify the electrical area classification.

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

2.1.16* The Owner shall specify on the Data Sheets the gear rated power.

2.3 Shaft Assembly Designation

2.3* The Owner shall specify the shaft assembly designation.

2.4 Shaft Rotation

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

2.5 Rating

2.5.1.1* See paragraph 2.1.16 above.

2.5.2* The minimum gear service factor (SF) shall be specified by the Owner on the Data Sheets
using Table 2.

2.7 Casing Connections

2.7.1.2* Casings shall be provided with inlet purge connections.

2.7.2.1* Lube-oil inlet and drain connections shall be flanged.

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2.8 Gear Elements

2.8.4.2* Provision for the installation of non-contacting vibration probes shall be provided either
at the time of manufacture or later.

2.9 Dynamics

2.9.1.3* The Vendor/Contractor shall provide a typical lateral critical speed analysis.

2.9.1.5* Operating conditions at less than 50% of maximum torque, or less than 70% of maximum
continuous speed, shall be specified by the Owner on the Data Sheets.

2.9.1.8* The Vendor/Contractor shall supply to the driven-equipment vendor all necessary
information for lateral and torsional vibration analyses.

2.9.1.9* Paragraph 2.9.1.9.1 shall apply.

2.10 Bearings

2.10.3.2.2* Thrust bearings shall be of the babitted multiple-segment type.

2.10.4.3* Bearing housings shall be designed to accommodate noncontacting vibration and axial
position probes.

2.10.4.4* Bearing housings shall be designed to mount velocity transducers.

2.12 Lubrication

2.12.3* If there is expected to be a wide variable speed range, the Owner shall specify these
speeds.

2.12.7* Wherever possible the gear lubricating oil shall be provided by the driver/driven
equipment lubrication oil system.

2.12.9* A pressurised lube oil system is preferred.

2.12.10* b) An automatically controlled full-size standby pump, separately driven, shall be

provided.

c) Steel pump casings are required for pumps not located above sump oil level or
enclosed in a reservoir.

d) The oil cooler shall be of the air-cooled type unless the Owner specifies
otherwise.

e) Full-flow filters shall be 10 microns nominal.

f) A thermostatically controlled electric immersion heater shall be provided.

g) The oil reservoir may be located in the gear casing.

j) An alarm switch signalling low oil pressure shall be provided.

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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.

3.4 Controls and Instrumentation

3.4.1.3* Resistance temperature detectors shall be provided.

3.4.4* Oil-filled gauges shall be provided in locations subject to vibration.

3.4.5.2* Thermal relief valves shall be provided for components that may be blocked in.

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

3.5 Piping and Appurtenances

3.5.10* A flexible metal hose shall be used between the coupling guard drain, and the oil return
header.

4.0 MATERIALS

4.1 API 677 Requirements

The Vendor/Contractor shall provide materials in accordance with paragraph 2.13 of API 677, as
amended below:

2.13 Materials

2.13.5 Materials and thicknesses not covered by the ASME code shall not be used.

5.0 INSPECTION

5.1 Procedures

5.1.1 The inspection requirements are covered by the document "General Conditions of Purchase" which
forms part of 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 its 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.

5.1.3 Inspection shall be in accordance with API 677, First Edition and this specification. Inspection
procedures shall comply with paragraphs 4.1 and 4.2 of API 677, as amended below.
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4.1 General

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

4.1.6 * The Owner will inspect for cleanliness.

4.2 Inspection

4.2.3.1* All welds in rotating elements shall receive 100% 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 4.1.8 of API 677. The Quality Control Plan shall be
coordinated 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-contractor's 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 677, paragraphs 4.2, as amended below.

4.2 Inspection

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

4.2.4.1* All gear and pinion teeth shall be 100% inspected by the magnetic particle method.

4.2.4.2.2* All forgings and bar stock for major rotating elements shall be 100%inspected by the
ultrasonic method.

5.3 Nameplates

Nameplates shall be provided complying with paragraph 2.14 of API 677, as amended below:

2.14 Nameplates and Rotation Arrows

2.14.2* The nameplate shall be in customary units.

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6.0 TESTING

6.1 Required Tests

Testing shall be carried out in compliance with paragraph 4.3 of API 677, as amended below:

API 4.3 Testing

4.3.3.3.5* The mechanical running tests shall be conducted with half-couplings and idling adapters
in place.

4.3.4.1* A full-speed/full or part-load test shall be carried out.

4.3.4.2* A full-torque/slow-roll test is not required.

4.3.4.3* A full-torque/static test shall be carried out.

4.3.4.4* A back-to-back loaded-torque test is not required.

4.3.4.5* A sound-level test is required.

6.2 Test Procedures

Testing shall comply with paragraphs 4.1 and 4.3 of API 677, as amended below:

4.1 General

4.1.3* The following tests shall be witnessed by the Owner:

- full-speed/full or part-load test,

- full-torque/static test.

6.3 Test Certificates

Test certificates shall be provided as defined in paragraph 4.2.1 of API 677.

6.4 Fluids

6.4.1 When required by the Owner, the Vendor/Contractor shall supply for startup, 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 gear unit.
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7.2 Schedules and Reports

7.2.1 The Vendor/Contractor shall supply with his proposal, 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 5.2.4 of API 677 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 contract.

7.2.3 After the 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 (6) weeks of the placement of the purchase order, as
defined in paragraphs 5.2.2 of API 677, to review all engineering and manufacturing requirements of
the order.

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 677 with
the additions/amendments below:

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

5.1 Proposals

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

7.3.3.2 Contractual data shall be provided as defined in paragraph 5.2.1 of API 677, as amended below.

5.2 Contract Data

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

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7.4 Drawings

7.4.1 Review and Approval

Review and approval of drawings shall be according to the commercial section of the
proposal/contract.

7.4.2 Proposals

Drawings shall be submitted by the Vendor/Contractor, as defined in paragraph 5.1 of API 677.

7.4.3 Contractual

Contract drawings shall be provided by the Vendor/Contractor, as defined in paragraph 5.2.2 of API
677.

7.5 Manuals

7.5.1 Data Book

Two (2) copies of Data Books shall be provided containing the items specified in paragraphs 2.9.5 and
5.2.3.2 of API 677.

7.5.2 Installation, Operating and Maintenance Manual

Six (6) copies of Installation, Operating and Maintenance Manual shall be provided containing the
information defined in paragraph 5.2.3.4 of API 677.

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 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 677 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.
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The equipment shall be prepared for export shipment by sea. Shipment as non-
containerised deck cargo is not allowed.

4.4.4 Delete this paragraph.

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 usually be shipped as part of a packaged 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 and 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.