Materials System Specification

30-SAMSS-001 15 June 2016

Diesel Engines
Document Responsibility: Gas Turbines and Diesel Engines Standards Committee

Contents
1 Scope.............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 General Requirements................................... 3
5 Design............................................................. 4
6 Inspection and Testing................................... 9
7 Guarantee and Warranty.............................. 10
8 Maintenance................................................. 10

Previous Issue: 10 July 2011 Next Planned Update: 15 June 2019

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Contact: Sabban, Mahmoud Abdulrahim (sabbanma) on +966-13-8760124

©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

1 Scope

1.1 This specification, together with the data sheet and purchase order, defines the
minimum mandatory requirements for reciprocating compression-ignition diesel
engines of the industrial type utilizing liquid fuel. In addition, diesel engines
driving firewater pumps shall be in compliance with UL 1247 or FM 1333 and
as superseded by the requirements in this specification.

1.2 Excluded from this specification are diesel engines having site continuous rating
below 50 kW (67 HP) and diesel engines for automotive use, marine propulsion
and electric generator drive.

1.3 Diesel engines shall be supplied by vendors qualified through experience in

manufacturing the proposed units. To qualify, the vendor must have
manufactured, at the proposed point of manufacture, at least two engines of
equal or greater rating, brake mean effective pressure and speed. These engines
must have been in service for at least one year and must be performing
satisfactorily. Verification of this experience shall form a part of the vendor's
proposal.

2 Conflicts and Deviations

2.1 Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Engineering Procedures (SAEPs), Standard Drawings (SASDs), or industry
standards, codes and forms shall be resolved in writing by the Company or
Buyer Representative through the Manager, Consulting Services Department,
Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative to be forwarded to the Manager, Consulting Services
Department, Saudi Aramco, Dhahran.

3 References

Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

Saudi Aramco Materials System Specification

34-SAMSS-625 Vibration, Axial Position and Bearing Temperature
Monitoring Systems

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

Saudi Aramco Forms & Data Sheets

SA-6237 & Diesel Engine Data Sheet
SA-6237-M
NMR-7908 Non-Material Requirements for Diesel Engines

Saudi Aramco Inspection Requirements

Form 175-300100 Diesel Engines

Saudi Aramco Product Specification

SAPS-A-869 Diesel (500 ppm Sulphur)

3.2 Industry Codes and Standards

Factory Mutual
FM 1333 Diesel Engine Firewater Pump Drivers

National Fire Protection Association

NFPA 70 National Electric Code

Oil Companies Material Association

EN 1834 (Safety Requirements for Design and Construction
of Engines for Use in Potentially Explosive
Atmospheres)

Society of Automotive Engineers

SAE J 1349 Engine Power Test Code - Spark Ignition and Diesel

Underwriters Laboratories Inc.

UL 1247 Diesel Engines for Driving Centrifugal Fire Pumps

4 General Requirements

4.1 The equipment covered by this Specification shall be suitable for the specified
operating conditions and shall be designed and constructed for a minimum
service life of 20 years. Diesel engines specified by the buyer for continuous
service shall be designed and constructed for at least 3 years of uninterrupted
continuous service.

4.2 Equipment sound pressure levels shall be less than 85 dB(A) at a distance of one
meter from the unit at 1.5 meter height above ground. Control of the sound
pressure to meet these requirements shall be the sole responsibility of the
vendor.

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

4.3 Unless otherwise specified, the engine will be installed outdoors in a desert area
with relative humidity ranging from zero to 100%. Site specific meteorological
and seismic data, as identified in the datasheets, shall be used for equipment
design.
Commentary Note:

Metal temperatures can reach 70°C when exposed to direct solar radiation.

Additionally, equipment which is not enclosed or hermetically sealed but is

situated offshore or nearshore (within ½ km of the shoreline) shall be protected
against failure due to windborne seawater spray and the accumulation of wetted
salt (NaCl).

5 Design

5.1 Definition of Terms

5.1.1 Service

Continuous Service: Service where operation exceeds 8000 hours per

year with uninterrupted periods of 1000 hours minimum. Shutdowns for
maintenance shall not exceed 24 hours.

Intermittent Service: Service where operation exceeds 4000 hours but

does not exceed 8000 hours per year with uninterrupted periods of
1000 hours minimum.

Standby Service: Service where operation does not exceed 4000 hours
per year with uninterrupted periods of 1000 hours maximum.

5.1.2 Rating

All effective ratings as defined below are outputs available at the

crankshaft under SAE J 1349 standard conditions.

Continuous Rating: Maximum effective output which the engine,

according to its application, is capable of delivering continuously, with
the limit of output being such as to permit an overload rating.

Overload Rating: Maximum effective output which the engine is

capable of delivering continuously for 1 hour or intermittently for a total
of 1 hour within a period of 13 hours. The overload rating shall be
considered 110% of the continuous rating unless otherwise specified by
the Vendor.

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

Maximum Rating: Maximum effective output which the engine is

capable of delivering for 15 minutes without mechanical and/or thermal
overload.

Minimum Rating: Minimum continuous output under worst site

conditions of temperature, altitude, and humidity which does not require
any design changes.

Site Rating: Available output at either continuous or overload

maximum rating when the engine is running under actual site conditions
of maximum temperature, altitude and humidity. The rating shall
consider inlet temperature for enclosed diesel engine.

Derating for site conditions shall be calculated in accordance with

SAE J 1349.
Commentary Note:

The terminology "Service" and "Rating" should be clearly distinguished.

Service definitions differentiate engines on the basis of accumulated
running hours.

5.1.3 Required Site Rating

The continuous rating at site conditions for all diesel engines with the
exception of those used to drive firewater pumps shall be equal to the
maximum required power of the driven equipment, including the losses
in any intermediate transmission. Diesel engines for firewater pump
drive shall be rated in accordance with UL 1247 or FM 1333.

5.2 Fuel and Fuel Systems

5.2.1 Engines shall be capable of starting at the site minimum temp on straight
diesel fuel.

5.2.2 Engines shall be capable of running on fuel of Saudi Aramco Product

Specification SAPS-A-869, unless otherwise specified.

5.2.3 For engines in continuous service, fuel filters shall be of the duplex, full
flow, cartridge type having a filter mesh not exceeding 10 micrometers.
The duplex filters shall have a cross over valve.

5.2.4 A guard, pipe protection shall be provided for all fuel lines exposed to
traffic or possible external damage.

5.2.5 Rubber hoses and tubing shall be manufactured to SAE standards,

Society of Automotive Engineers.

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

5.2.6 Fuel supply a return piping connection shall be of reinforced flexible

stainless steel hoses.

5.2.7 Fuel filter housing material shall be of stainless steel.

5.3 Barring Device

When specified, the engine shall be equipped with a safe barring device to
facilitate easy inspection and maintenance of the diesel engine. When dictated
by torque requirements, the barring device shall be pneumatically or electrically
powered. An interlock with indication shall be provided to prevent starting the
engine when the barring device is engaged. This is only applicable to above
1000 HP engines.

5.4 Air Filtration

5.4.1 Diesel engines in standby service or driving a firewater pump shall be

equipped with an air intake filter having a filter media that is replaceable
or a filter of the type that is intended to be cleaned and reused.

5.4.2 Diesel engines in continuous and intermittent services shall be equipped

with a combined inertial separator and dry filter arrangement with a
differential pressure indicator and shall be suitable for desert conditions.

5.5 Inlet and Exhaust Systems

5.5.1 For engines in services requiring prolonged operation below 65% load,
turbocharging is not acceptable.

5.5.2 Each diesel engine shall be equipped with a stainless steel exhaust
silencer.

5.5.3 The exhaust manifold shall be insulated to reduce the risk of burn injury
to operating personnel. When insulation is provided, the exposed surface
shall be nonporous.

5.5.4 For indoor locations, the vendor shall supply the complete exhaust
system. The exhaust piping layout and proposed location shall be
submitted through the company or buyer representative for review and
approval by the Chairman, Gas Turbines and Diesel Engines Standards
Committee, Consulting Services Department, Saudi Aramco, Dhahran.

5.6 Speed Governing

5.6.1 Governors for all mechanical drive applications with the exception of
firewater pump drive shall be in accordance with NEMA SM 23, Class C

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

or an equivalent international standard. Speed governors shall accept the

Buyer's control signal when remote control is specified.

5.6.2 An overspeed device shall be provided which overrides the governor

action. On engines driving firewater pumps, this shall be provided with
a manual reset.

5.6.3 The overspeed trip setting shall be 10% above the maximum continuous
operating speed of the driver/driven equipment train. Firewater pump
drivers setting shall be in accordance with UL 1247 or FM 1333.

5.7 Starting System

The starting system, except for those in firewater pump drivers, shall be capable
of handling a minimum of 3 consecutive starts without re-pressurizing the air
receiver or recharging batteries.

5.8 Cooling System

5.8.1 Engine cooling systems, either water-cooled or air-cooled, shall have

sufficient capacity to maintain stable operating temperatures at the
maximum engine output and under the worst site conditions of
temperature, altitude, and humidity.

5.8.2 Water cooled system using heat exchanger should be supplied with a
threaded rigid pipe bypass line. External water inlet valve should be car
sealed to avoid accidental isolation.

5.9 Lube Oil System

5.9.1 The main engine driven lube oil pump shall be easily accessible for
maintenance.

5.9.2 Preheating facilities shall be provided when required to obtain the

minimum required lube oil temperature before startup at site minimum
temperature.

5.10 Vibration

5.10.1 Diesel engines in continuous duty service having a site rating exceeding
560 kW (750 HP) shall be provided with one vibration velocity sensor,
located horizontally on the crank case, perpendicular to the crank axis.
Installation shall be in accordance with 34-SAMSS-625.

5.10.2 The maximum unfiltered vibration level shall not exceed 12.5 mm/s
RMS, measured adjacent to any crankshaft main bearing in a plane

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

perpendicular to the crankshaft axis.

5.11 Torsional Critical Speeds

5.11.1 The vendor shall submit a torsional critical speed analysis of the entire
equipment train when specified on the diesel engine data sheet.

5.11.2 The Vendor shall supply a torsional vibration damper and/or supply an
elastic coupling to limit the total vibratory stresses in the driver/driven
equipment train due to torsional vibrations.

5.12 Controls and Instrumentation

5.12.1 The Vendor shall provide all necessary controls and instrumentation
for proper operation, adequate monitoring, and safeguarding of the
engine.

5.12.2 All electrical equipment and wiring shall be suitable for and installed
according to the requirements of NFPA 70, National Electrical Code
for the specified area classification. For non-classified areas, except
firewater pump drivers, manufacturer's standard installations are
acceptable provided that the installation is of adequate mechanical
strength.

5.12.3 The engine Controller Enclosure shall be Type NEMA 4X rated.

5.13 Flame proofing

5.13.1 Diesel engines located in a Zone 2 area shall be flame proofed as noted
as per EN-1834.

5.13.2 Air-cooled engines are not permitted when flame proofing is required.

5.13.3 External metallic parts (e.g., fan blades) which may cause sparking by
contact with other parts shall be manufactured from non-sparking
materials.

5.13.4 Drive belts shall be anti-static and fire resistant.

5.13.5 The starter shall be either an AC mains operated electrical type or a

non-electrical type. Gasoline engines are not permitted.

5.13.6 The exhaust manifold shall be water-cooled. An exhaust gas heat

exchanger, a flame trap and a spark arrestor shall be installed
downstream of the exhaust manifold. The flame trap and spark
arrestor may be combined.

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

5.13.7 The inlet manifold shall be equipped with a flame trap downstream of
the air filter.

5.13.8 The surface temperature of any part of the entire system, including the
exhaust gas temperature shall not exceed 250°C when the engine is
running at the site overload rating.

5.13.9 The inlet manifold shall be equipped with an automatic shutoff valve to
stop the engine at overspeed.

5.13.10 The length of the flame path through or across any joint shall not be
less than 13 mm.

5.13.11 Suitable metal clad jointing or other acceptable material shall be

interposed between all joint faces to ensure that no leakage occurs.

5.13.12 Where valve spindles pass through the walls of any component of the
intake system, the diametrical clearance shall not exceed 0.13 mm for
an axial length of not less than 25 mm, unless end caps are fitted.

5.13.13 No screw, stud or bolt hole shall pass through the wall of any
component of the exhaust and inlet system.

5.13.14 Crank casings having a larger volume than 0.5 m³ shall be provided
with relief devices and shall be equipped with flame traps. The crank
case relief valves may discharge alternatively into the intake system
downstream of the intake flame trap as specified in paragraph 5.13.7
and upstream of the intake shut off valves specified in paragraph
5.13.9, if installed. Dip sticks and oil filler caps shall be screwed or
effectively secured by other means.

5.13.15 The engine nameplate shall be marked to show the Class, Division and
Group for which it is qualified.

6 Inspection and Testing

6.1 Inspection

The items manufactured to this Specification are subject to verification by the

Buyer's Inspection representative in accordance with the referenced Saudi
Aramco Inspection Requirements Form 175-300100.

6.2 Tests

Diesel engines shall be tested in accordance with the following testing

requirement with the exception of firewater pumps drivers which shall be tested

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

in accordance with UL 1247 or FM 1333.

6.2.1 Standard Shop Running Test

The Vendor's standard shop running test procedures shall be submitted

with the bid. If acceptable, certificates are required.

6.2.2 Test of engine overspeed trip system.

6.2.3 Test of engine starting system to prove that at least 3 consecutive starts
of 15 seconds duration each can be made.

7 Guarantee and Warranty

7.1 If any performance deficiencies or defects occur during the guarantee and
warranty period, the Vendor shall make all necessary alterations, repairs and
replacements free of charge. Field labor charges, if any, shall be subject to
negotiations between the Vendor and the Buyer.

7.2 Engines shall be warranted to be operable at a minimum of 110% of the required

site rating for 1 hour at the site ambient conditions.

7.3 Engines manufactured under a license agreement shall carry the licensor's
written guarantee.

8 Maintenance

8.1 All Equipment shall be designed to permit rapid and economical maintenance.
Major parts such as casing components, cylinder heads, etc., shall be designed
(shouldered or doweled) and manufactured to ensure accurate alignment on
re-assembly.

8.2 Engines shall be arranged such that sufficient space is available to permit
removal of the oil pan without the need to remove the engine from its baseplate.

8.3 An operating and maintenance instruction manual shall be included as part of

the package. This manual shall provide sufficient written instructions, including
a cross referenced list of all drawings, to enable the buyer to correctly install,
operate and maintain the unit. As a minimum, the manual shall contain the
following information:
1. Instructions covering start up, normal shutdown, emergency shutdown,
operating limits and routine operational procedures.
2. A description of the constructional features and the functioning of the
component parts and systems (such as controls, the lube oil, turbocharger,

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Document Responsibility: Gas Turbines and Diesel Engines Standards Committee 30-SAMSS-001
Issue Date: 15 June 2016
Next Planned Update: 15 June 2019 Diesel Engines

fuel injection, cooling systems, etc.).

3. Outline and sectional arrangement drawings, schematics and illustrative
sketches to identify all parts and clearly show the operation of all
equipment and components and the methods of inspection and repair.
Standardized sectional arrangement drawings are acceptable only if they
represent the actual construction of the engine being supplied.
4. As built data sheets containing all required information.
5. The following maintenance data:
- Maximum and minimum bearing and seal clearances.
- Instructions for measuring and adjusting cold clearances.
- Crankshaft float allowance.
- Crankshaft dimensions and re-grind allowance, if applicable.
- Interference fits on parts required to be removed or replaced.
- Runout and concentricity tolerances.
- Cylinder bore dimensions.
- Piston ring clearance and wear data.
6. The following re-assembly data:

The bolting sequence and torque values for cylinder head bolts, crank and
main bearing bolts, piston and connecting rod bolts, exhaust manifold bolts
and all other bolts that the vendor considers to be critical.
7. A parts list shall be furnished for all equipment supplied and shall include
pattern, stock or production drawing numbers and the material of
construction. The list shall clearly identify each part in order that the buyer
may identify interchangeability of parts with other equipment furnished by
the vendor. Standard purchased items shall be identified by the original
manufacturer's numbers.

Revision Summary
15 June 2016 Revised the Next Planned Update, reaffirmed the contents of the document, and reissued to
update firewater requirement as per vendor/project feedbacks and NFPA, UL & FM new
updates. Update the inspection requirement (175 forms) vendor/project feedbacks specifically
in firewater application.

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