121205

© 2014 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.

PETRONAS TECHNICAL STANDARDS

Petroleum And Natural Gas Industries-High-Speed Special-Purpose Gear Units

PTS 12.12.05

May 2014

PETROLEUM AND NATURAL GAS INDUSTRIES - HIGH-SPEED SPECIAL-PURPOSE GEAR UNITS

PTS 12.12.05

May 2014

Page 2 of 25

FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,

experience and best practices of the PETRONAS group supplementing National and International

standards where appropriate. The key objective of PTS is to ensure standard technical practice across

the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where

PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes

all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of

work, goods and services meet the required design and engineering standards. In the case where

specific requirements are not covered in the PTS, it is the responsibility of the

Contractors/manufacturers/suppliers to propose other proven or internationally established

standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or

completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall

ensure accuracy and completeness of the PTS used for the intended design and engineering

requirement and shall inform the Owner for any conflicting requirement with other international

codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored

in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording

or otherwise) or be disclosed by users to any company or person whomsoever, without the prior

written consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be

kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information

to PETRONAS that this requirement is met.

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ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from 2013 - 2015 which includes revision to numbering system, format and content. As part of this change, the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required make reference to other PTS in its revised numbering to ensure consistency. Users are requested to refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For further inquiries, contact PTS administrator at [email protected]

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mailto:[email protected]


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Table of Contents

1.0 INTRODUCTION ............................................................................................... 5

1.1 SCOPE .......................................................................................................................... 5

1.2 GLOSSARY OF TERMS .................................................................................................. 5

1.3 SUMMARY OF CHANGES ............................................................................................. 5

2.0 AMENDMENTS/SUPPLEMENTS TO ISO 13691:2011 FOR HIGH-SPEED SPECIAL-PURPOSES GEAR UNITS .................................................................................... 6

3.0 BIBLIOGRAPHY ............................................................................................... 23

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1.0 INTRODUCTION

This PTS provides requirements and recommendations for design of high-speed special-purpose gear units for onshore and offshore services. This PTS fully adopts and supplements the ISO 13691 and based on PETRONAS lessons learnt and best practices.

1.1 SCOPE

The detailed scope of high-speed special-purpose gear units shall be as per the engineering data requisition sheets for supply of the equipment in compliance with this PTS including relevant codes & standards. Vendor shall include all special features necessary for reliable and safe operation as well as safeguarding and control of the equipment considering required operating conditions e.g. start up, shutdown, any fluctuations of operating parameters as indicated in the data sheet.

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS 00.01.03 for General Definition of Terms & Abbreviations.

1.2.2 Specific Definition of Terms

No Term Definition

1 Wheels Lower speed gear element in mesh (also reffered to as “gear”)

Table 1 Specific Definition of Terms

1.2.3 Specific Abbreviations

None.

1.3 SUMMARY OF CHANGES

This PTS 12.12.05 replaces PTS 31.29.00.32 (January, 2011).

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2.0 AMENDMENTS/SUPPLEMENTS TO ISO 13691:2011 FOR HIGH-SPEED SPECIAL-PURPOSES GEAR UNITS

In this section, the reference clauses of ISO 13691:2011 are amended or supplemented, existing clause is deleted or new sections are added as mentioned. The clauses of ISO 13691:2011 that are not mentioned in this PTS shall apply and remain valid.

1 SCOPE

Addition of new clauses;

For gear ratio of up to 1:9, one-stage speed increasers or reducers shall be utilized. Higher gear ratios shall be subject to Owner approval and shall use two-stage speed or epycyclic gear increasers.

For critical services, application of either a single-helical gear or double-helical gear shall be agreed by the Owner. Double-helical gears shall be applied where large cyclic torque variations are expected (e.g. reciprocating compressors), and shall be the first preference due to its advantages of having a balanced thrust, smaller “footprint” and ligher weight.

Configurations where extended periods of load reversals may take place such as a power recovery train; gear selection shall be subjected to Owner’s approval. Gearboxes experiencing extended periods of load reversals require special design considerations with regards to tooth accuracy and tooth profile modification on the normally unloaded face which may differ from the normally loaded face, lubrication points, and bearing load direction changes.

Manufacturer shall supply the gear unit inclusive of all relevant information (e.g. dynamic analysis, performance, dimensions, noise emission, etc.) to the Contractor for mounting on the equipment common base plate, unless otherwise specified.

Special-purpose gear units shall be supplied by qualified Manufacturer with referenced experience in manufacturing at least two gear units of similar duties and build specifications with comparable power rating, selection factor, pinion speed, and pitch line velocity to the proposed gear unit. Each of the gear units being referenced shall have acquired a minimum of 16,000 hours of trouble free operation.

The qualified Manufacturer and its sub-Suppliers shall have an implemented and effective quality system in accordance with ISO 9001, or an equivalent internationally recognised quality system acceptable to the Owner.

Primary quotation by the Manufacturer shall conform to the requirements of this PTS. Alternative quotations offering significant price, delivery, or technical advantage may be be submitted with the alternative proposals clearly defined.

5 BASIC DESIGN REQUIREMENTS

5.1 GENERAL

5.1.3 Delete the clause and replace with;

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Noise control shall be in accordance with PTS 12.01.02. Contractor shall communicate the noise limitations specification to the Manufacturer using Standard Drawing D12.90.009 and PTS 12.90.011 as part of the requisition. The Manufacturer has the responsibility to assure that the equipment noise limitations have been specified.

The Manufacturer shall submit the guaranted sound power levels, sound pressure levels and the relevant information in accordance to Standard Drawing D12.90.009. Any silencing measures required in order to meet the specified sound levels shall be indicated by the Manufacturer.

5.1.4 Addition the the clause;

The equipment shall be designed to handle maximum torque transmissions during any anticipated transient conditions demanded by the driver or driven equipment, during start-up or overload torques. Consideration should also be given to maximum power generated by diesel and gas turbine drivers when operating at the specified minimum ambient temperature, whereby it is the responsibility of the Contractor to ensure Manufacturer is made aware of such loads.


The arrangement of the equipment, including piping and auxiliaries, shall provide adequate clearance areas and safe access for operation and maintenance.


Electrical components and installations shall be suitable for the area classification, gas grouping, and temperature classes specified by the Owner on the engineering data requisition sheets.


Oil reservoirs and housings that enclose moving lubricated parts (such as gears, bearings, shaft seals), highly polished parts, instruments and control elements, shall be designed to avoid contamination by moisture, dust and other foreign matter during periods of operation and idleness.

5.1.8 Delete the second sentence and replace with;

The Contractor shall be responsible for the performance of the combined units after installation on-site.

5.1.9 Delete the second and thid sentences of the clause and replace with;

Design of the base-plate and the machinery train overall alignment scheme shall be the responsibility of the Contractor. Levelling features on the base-plate shall be provided to ensure the gear unit is not twisted on the base-plate. The Manufacturer shall submit the static and dynamic foundation loads and the expected shaft displacements to the Contractor for alignment purposes. The Contractor’s proposed base-plate design and the Contractor’s foundation details shall be reviewed by the Manufacturer. Prior to unit handover, tooth

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contact pattern and cold and hot alignment checks shall be verified by the Manufacturer’s representative at the Owner’s site.


Owner shall specify the weather and environmental conditions in which the equipment must operate (including maximum and minimum temperatures, humidity and dusty or corrosive conditions).


Gear units shall not require a running period at reduced speed and load in the field. In case of the oil to be used in the field is not compatible with FZG gear testing requirement for initial operation, Manufacturer shall include running-in of the gear as part of the supply scope. The running-in oil shall be thoroughly removed and cleaned from the gear unit.

5.1.14 Addition to the clause;

The procurement of spare parts shall be available from the Manufacturer. The Manufacturer shall retain all manufacturing drawings for a minimum of 20 years or the equipment service life specified.


Vertically offset, parallel gear sets are allowed.


5.1.17 Any change made to which is not proven in similar machines manufactured for the last five years, or which have not acquired a minimum of 16,000 hours of trouble-free operation shall have the changes listed in the Manufacturer’s proposal and shall be subject to approval by the Owner.

5.1.18 Component having design or manufacturing error, faulty material or damage shall be replaced. In the event the component is proposed to recover instead of being replaced, the repair method shall be submitted to the Owner for approval. Additional tests or calculations may be necessary to establish the repair effectiveness and to ensure no detrimental effect on the serviceability of the component.

5.1.19 Primary quotation by the Manufacturer shall conform to the requirements of the requisition documents and this PTS. Alternative quotations offering significant price, delivery, or technical advantage may be submitted with the alternative proposals clearly defined.

5.2 GEAR RATING

5.2.3 Rating criteria

Addition to the clause;

Scuffing resistance shall be considered in the gear design, where calculations of the probability of scuffing (scoring), including flash temperature index shall be performed and

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reviewed with the Contractor and Owner. The probability of scoring shall be demonstrated to be no higher than Vendor’s prior satisfactory experience.

5.2.6.1 General

Delete the last sentence of the third paragraph and replace with;

When modified helices are to be furnished, minimum acceptable tooth contact patterns obtained in the checking stand, housing or test stand shall be specified by the Manufacturer.

5.2.7 Scuffing

The last sentence of the clause is deleted and replace with;

Manufacturer may use an alternative method to the flash temperature method and the integral temperature method in order to evaluate scuffing resistance but shall provide evidence to support the method used.

5.2.8.3 Selection factor, KSL

The selection factor (KSL) shall have a value of no less than the value as indicated in ISO 13691 Table 5 (Selection Factors KSL). Gas turbine driven generator sets, regardless of base-load or peaking application shall have a minimum selection factor of 1.3.

5.3 GEAR ELEMENTS

5.3.1.1 Addition to the clause;

Gear teeth shall be finished by grinding, unless otherwise approved by the Owner. Finishing by lapping to achieve the required surface finish is not allowed.


Plating of gear teeth shall be subject to Owner’s approval.


The agreed solution shall be consulted with the Owner and subjected to the Owner’s approval.


The inspection of mating gears (each pair) shall be in accordance with this clause. The results of the tooth contact check shall be well-kept with a copy of the results included in the maintenance manual.

Addition of new clause;

5.3.2.4 Shaft position and centre distance tolerances shall be in accordance with DIN 3964.

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Gear backlash and teeth thickness deviations and tolerances shall be in accordance with DIN 3967 class 25 or superior standards. Actual standard of accuracy applied in manufacturing shall be stated by the Manufacturer.

5.3.3.2 Delete the first paragraph and replace with;

Gears shall be integrally forged with their shafts regardless of pitch line velocities.

Delete the NOTE and replace with;

It shall be noted that non-homogeneities (e.g. non-metallic inclusion, shrinkage, segregations or cavities) may affecting an integrally forged gear for a unit with a ratio of about 1:3 or higher from forgings with high volume concentrations of material. Heat treatment process can further exaggerate these discontinuities from residual stresses in creating possible crack initiation locations. A strict quality control such as full radiographic inspection required to be put in place for non-metallic elements on the material if allowed by the material specification. The application of hollow shaft designs or separate forging (in special cases) for gear and shaft may lessen the problem.

Addition of new clause; intensify

Design of gear units with pitch line velocities above 150 m/s at maximum continuous speed shall be subjected for review by Contractor and Owner and shall be approved by Owner prior to acceptance.


5.3.3.3 Use of shrunk-on, forged rims shall be subjected to the Owner’s approval. Finishing of gear mesh shall only be carried out after the gears are shunk unto the shaft.

5.3.4 Shaft


Stress-relieve shall be applied to all shafts prior to machining.

5.3.4.2 Delete the word “purchaser’s” in the last sentence of the NOTE and replace with “Owner’s”

5.3.4.4 Addition of new clause;

Integrally forged, flanged shaft-ends to which couplings shall be bolted shall be supplied when possible. When shafts with integrally forged flanges are not possible, hydraulically fitted couplings should be supplied, subject to Owner’s approval. Shrink-fitting of couplings using heat shall not be used.

5.4 CASINGS

5.4.1.1 Delete the clause and replace with;

Gear casings shall be casted and stress relief annealed to ensure dimentional stability.

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5.4.1.6 Delete the last ssentence of the clause and replace with;

Threaded connections shall not be used.

5.4.1.7 Delete the text paragraph only and replace with;

All piping and nozzles shall be AISI 316 stainless steel. When flanges are not possible due to space limitations within the gear, stainless steel tubing and forged AISI 316 stainless steel compression fittings shall be used. The stainless steel tubing size and thickness shall meet the requirements of ISO 13691 (Minimum Tubing Wall Thickness). The make and model of fittings shall be subject to the Owner’s approval. All nuts and fastening devices inside the gear shall be positively locked against becoming loose and preventing disengagement. Sealing tape is not allowed.


The filter-breather outlet shall be flanged to allow connection to a fully closed vent system or piped to a safe location, if specified by Owner.

5.4.1.13. Delete the clause and replace with;

Application of permanent coating or painting inside the casing is not permitted.

5.4.4.2 Delele the fourth sentence of the clause and replace with;

Lifting lugs or similar fixed lifting point(s) shall be provided for any maintenance item with a mass greater than 20 kg. For internal components, screw-type eyebolts may be utilized when other lifting arrangements are not practical. Permanent and clear identification of the lifting points shall be applied where the lifting points are intended for lifting the cover only and not for lifting the complete gearbox.


5.4.4.3 Bearing clamped in position by bearing caps independent of the casing cover is the preferred design and should be used if available. Otherwise, bearings clamped by the upper casing part with long stay bolts may also be used. The upper and lower halves of the bearings shall be positively fixed together and the complete bearings shall be precisely fitted to the lower casing part and locked against any rotational and axial movement. The bearings along with its clearances or the alignment shall not be disturbed when upper part of the casing is removed.

5.4.4.4 The upper casing shall not have any auxiliaries or junction boxes mounted to it.

5.4.4.5 Two (2) standard earthing bosses shall be diagonally installed on the casing, in accordance with standard drawing S 68.004.

5.5 CASING CONNECTIONS


Lubricating oil supply connection shall be a single connection.

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5.5.5.1 All connections including instrument connections shall have its connection at the outside of the enclosure when noise hood is supplied.

5.5.6 Delete the second sentence of the clause and replace with;

On weldable casings when not practical for flanged, machined and studded openings, DN25 or greater openings shall be full penetration butt welded connections and socket weld connection is not allowed. For openings smaller than DN25, reinforced boss connections of the “weldolet” type may be applied using full penetration butt welds only. Threaded connection is not permitted.

5.5.6.3 The words “or slip-on” in the clause is deleted.


All flanges for casing connections shall be raised face, welding neck and rating class 300 in compliance with ASME B16.5 or alternatively, rating PN 50 in accordance with ISO 7005-1.

5.5.7.1 The clause is deleted.




Threaded connection is not permitted.

5.6 DYNAMICS

5.6.1 Critical speeds

5.6.1.4.3 Delete the clause and replace with;

The Manufacturer shall submit both undamped analysis and the damped unbalanced response analysis. Consideration of unloaded operation shall be made for proper performance.


The gear lateral analysis is the responsibility of the gear Manufacturer and the lateral critical speed analyses report shall be submitted to the Owner.

5.6.1.6 Delete the last sentence of the clause and replace with;

The Manufacturer shall submit the damped unbalanced rotor response plot for all the conditions which are applicable to map the undamped critical speeds and operating speeds. The rotor response plots to unbalance weight, damped and undamped, at no load, 50% load and full load torque shall also be included in the report.

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The undamped, torsional natural frequencies of the complete train shall be at least 10% above or 10% below any possible excitation frequency between minimum continuous speed and trip speed.

Torsional and lateral analysis of the complete train shall be performed by the Contractor unless otherwise specified in the engineering data requisition sheet. The Manufacturer shall furnish all necessary data to the Contractor for performing the rotor-dynamic analyses and submitted to the Owner for review. Necessary modifications may be specified by the Contractor.

If specified, Manufacturer shall perform a torsional analysis of the entire train (independent of the above) with the basic dimentions, stiffness data and torsional excitation sources that is provided by the driver and driven equipment Manufacturers. The minimum requirements of the torsional analysis shall include the following:

i. Analyses method to be describe in detail. ii. Graphical view of the mass elastic system.

iii. Table of mass moment of inertia and torsional stiffness for each identified component in the mass elastic system.

iv. Graphical view of exciting frequencies or sources versus natural frequencies. v. Table of torsional critical speeds and with its associated deflections.


The acceptable amplitude of any discrete, non-synchronuous vibration shall be less than or equal to 20 % of the allowable unfiltered vibration level, or 3 microns peak-to-peak, whichever is less. This applies to both cold and hot operating conditions with the limits including the combination of mechanical and electrical run-out.


5.6.3.5 Delete the second sentence and replace with;

The overall unfiltered vibration maximum limit on the bearing housing in any plane, measured in the specified speed range shall be 3 mm/s RMS.

In Table 9, the Note a is deleted.

5.7 BEARINGS AND BEARING HOUSINGS

5.7.1 General


Bearing shells locations and orientation shall be marked on the shell at assembly.


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If specified otherwise by Owner, bearing metal temperature detection shall be by platinum RTDs (100-Ohm, 3-wire) with arrangement as follows:

i. Two (2) simplex RTDs shall be supplied and located within the expected load zone of radial bearings.

ii. Six (6) simplex RTDs (three (3) on the active side and three (3) on the inactive side, one RTD per pad) with each RTD located in the highest loaded area of the pad of thrust bearings.

iii. The maximum bearing metal temperature shall be 110 °C, under any load condition with the maximum specified oil inlet temperature.

5.7.2 Radial bearings


Means of adjusting the gear mesh shall be provided by the Manufacturer should the tooth contact is not optimum.

5.7.3 Thrust bearings


Bearings design shall be able to deliver stable performance for the full operating speed range with 0% to 100% of the rated power and allow for load angle changes during transient torque conditions. When specified by the Owner, a graphic display of speed versus bearing maximum load capacity shall be submitted by the Manufacturer for approval. The display shall show the boundaries of minimum oil thickness and the transmitted power which produces the maximum bearing lining metal temperature with consideration of any intrinsic misalignment.


For all single-helical gear sets, each shaft shall have thrust bearings.

The last sentence is deleted.


Hydrodynamic thrust bearings shall be multiple-segment type and self-equalizing. The design of a fixed, taper-land thrust bearings are not permitted. Integral thrust collars with the shaft shall be used when possible.

5.7.3.3 In the third sentence, delete the word “Table 9” and replace with “Table 10”.

5.7.4 Bearings housing


Probes and proximeters shall be supplied by the Manufacturer as per the type specified while read-out instrumentation may be provided by others. The probes shall be capable of being adjusted within the probe holders while the gear unit is in operation and shall be in housing

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suitable for the specified area classification. All probes shall have the same cable length and wiring shall be in conduits.

5.8 LUBRICATION

5.8.5 Delate the clause and replace with;

Pressurised oil systems shall conform to the requirements of PTS 12.12.01.


It is the responsibility of the Manufacturer to coordinate with the Contractor to guarantee the oil used in any testing (such as in a string test at the Contractor’s works) has an adequate FZG (gear testing) factor for the gear unit.


5.8.7 The lubricating oil specifications, supply temperature, pressure ranges and the required amount shall be stated by the Manufacturer in the operating manual.

5.9 MATERIALS

5.9.1 General


Deviations in the Manufacturer’s material specification (i.e. physical properties, chemical composition, and test requirements) from the specified material shall be included in the proposal and subject to the Owner’s approval.


Materials used for wheel and pinion teeth shall be carburized and case-hardened. Through-hardened gearing may be offered as an alternative should it offer technical and/or commercial advantages.


5.9.1.7 All repairs inspection requirements and acceptance standards shall be in accordance with the original material specification. Major weld repairs shall be approved by the Owner prior to the repair. Major weld repair is defined as repair through either removal of at least 50 % of the wall thickness, or a length exceeding 150 mm in one or more directions, or a total repair surface area of more than 10 % of the original surface area.

5.9.2 Welding of rotating elements

5.9.2 The clauses 5.9.2.1, 5.9.2.2, 5.9.2.3 and 5.9.2.4 are deleted and replace with;

Welding of rotating elements is not permitted.

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6 ACCESSORIES

6.2 COUPLINGS AND GUARDS


Couplings shall conform to PTS 12.12.06. Unless otherwise agreed by the Owner, gear and pinion shall be furnished with integrally forged coupling flanges.


The coupling mounting shall conform to PTS 12.12.06. The coupling mounting shall transmit torque only through friction and shall not have any proportion of the torque transmitted by shear on the coupling bolts. When used in an electric power generator, the gear unit and coupling connections shall be able to withstand the torques produced from the conditions as follows:

i. line to line short circuit. ii. mis-synchronisation to the grid

Both the Manufacturers for the driver and generator shall compute the resulting torques and the results presented to the Owner for approval. It is the responsibility of the Contractor to coordinate the information flow between all parties involved.


6.2.7 The Contractor shall furnish the Manufacturer with the selected couplings’ certified prints indicating all necessary data (i.e. type, rating, torque, weight, location of centre of gravity, mass moment of inertia, torsional stiffness, axial stiffness, balance, end play tolerance)

6.2.8 Coupling guards shall be supplied and shall be made of aluminium or of other suitable non-sparking, metallic material. Fully enclosed coupling guards shall be oil tight and equipped with vent and drain connections, each at least of size DN 50. The coupling guard shall have stainless steel bellows at one end to accommodate axial and lateral movements of the adjacent machines. Coupling guards size shall be sufficiently adequate to ensure the guard temperature is kept below 85°C, or lower if necessary e.g. due to iinstrumentation.

Non-sparking, metallic material open type coupling guards shall be preferred for cases where dry type couplings are specified. Guards design shall accommodate for axial and lateral movements of the adjacent machines.

6.3 MOUNTING PLATES

6.3.1 General


Levelling screws shall be supplied for mounting plates intended for installation on concrete.

6.3.2 Baseplate

6.3.2.7 Delete the first sentence of the clause and replace with;

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Mounting pads on the bottom of the base plate shall be machined flat in one plane with the maximum tolerance of 0.05 mm over the base plate total length in order to allow for a single-level foundation.


Gear mounting surface shall be machined to achieve a parallel surface of within 0.1mm/m for each surface.

6.3.3 Soleplates and sub-soleplates


The finish of the sub-soleplate mating surfaces shall match that of the soleplates.

6.4 CONTROLS AND INSTRUMENTATION

6.4.1 General


PTS 14.10.02 and PTS 14.10.03 shall be applied for instrument connections and instrumentation.


The Owner specifications in the engineering data requisition sheets shall be complied for all electrical equipments and instrumentation such as applicable temperature classes, gas grouping and area classification.

6.5 PIPING AND APPURTENANCES


Lubricating-oil piping and appurtunences shall comply with PTS 14.10.02, unless otherwise specified.


6.7 SPARES

The recommended spare parts by the Manufacturer shall be listed. Spares to be supplied with the gear unit shall be proposed by the Contractor for Owner’s approval

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7 INSPECTION TESTING AND PREPARATION FOR SHIPMENT

7.1 GENERAL

7.1.1 Delete the first sentence of the clause and replace with;

The participation from the Owner and the Contractor in the inspection and testing shall be as follows:

Delete clause item a) and replace with;

a) The extent of the Owner’s and the Contractor’s participation shall be specified prior to manufacturing.

In clause item b), the word “the purchaser” is replaced with “the Owner and/or the Contractor”. “ In clause item 1), the words “the purchaser or” is replaced with “the Owner and/or”. In clause item 2), the word “purchaser” is replaced with “Owner”. In clause item 3), the word “purchaser” is replaced with “Owner”. In clause item c), the word “purchaser” is replaced with “Owner”.


The Manufacturer shall provide adequate advance notice to the Owner before conducting any inspection or test that the Owner desires to be witnessed or observed.

7.2 INSPECTION

7.2.1 General


A record of all “as built” dimensions and running clearances of the final assembly shall be supplied by the Vendor to the Owner.

Agreement with Owner shall be obtained on the acceptance criteria of any tests not already specified in this PTS or ISO 13691 prior to the testing.


The extent of liquid penetrant, magnetic particle, radiographic and ultrasonic examincation to be carried out by the Manufacturer shall be specified by the the Contractor and subject to Owner’s approval.


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ASME VIII, Division 1, Appendix 6 shall be complied with for magnetic particle examinations.

7.2.2.4.2 Delete the first paragraph of the clause and replace with;

Welded fabrications acceptance standard shall be in accordance with ASME VIII, Division 1, Appendix 6.

Castings acceptance standard shall be in accordance with ASME VIII, Division 1, Appendix 7.

Table 11 is deleted.


ASME VIII, Division 1, Appendix 8 shall be complied with for liquid penetrant examinations.

7.2.2.5.2 Delate the clause and replace with;

Welded fabrications acceptance standard shall be in accordance with ASME VIII, Division 1, Appendix 8.

7.2.2.6.3 Addition to the clause;

100% ultrasonic inspection shall be performed after rough machining on main forgings and hot-rolled shaft steels, with the acceptance criteria subject to the Owner’s approval.

7.3 TESTING

7.3.1 General


Prior to testing, the Manufacturer shall submit final test procedures and test agendas for any of the specified test to the Owner for Owner’s agreement.

7.3.2 Mechanical running tests


Mechanical test shall be run with loads i.e. representative of the loads that are expected to be experienced in the field. Testing with no load condition shall also be considered since this condition may be the worst condition for vibration behaviour, particularly for generator drive applications.

Sufficient load shall be applied on the gear to ensure similar sitting of the shaft journals in the bearings as per during service, hence ensuring meaningful vibration measurements during the mechanical test.

Delete the clause c) and replace with;

c) Prior to any test, oil system components cleanliness downstream of the test-stand oil filters shall meet the requirements of PTS 12.12.01.

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7.3.2.2 j) Delete the clause and replace with;

The mechanical running tests shall verify that no resonant condition exists within the operating speed range. Lateral critical speeds shall comply with the critical speeds requirements of this PTS clause (5.6.1).

7.3.2.2 k) Delete the last sentence and replace with;

The speed range covered by these plots shall be 400r/min to the specified trip speed of the driver.

7.3.2.2 l) Addition to the clause;

During mechanical running test, the vibration levels and frequency spectrums shall be recorded with the lubricating temperature varied. The lubricating temperature shall be held at the temperature corresponding to the maximum allowable viscosity of the specified oil, and at the temperature corresponding to the minimum allowable viscosity of the specified oil, for 30 minutes at each condition. During the test, the levels of vibration and the temperatures of bearing shall be recorded and well inside the limits specified.

7.3.2.3 b) Addition to the clause;

After the completion of the mechanical running test, dismantling of unit may be needed for inspection when malfunction, excessive repair, improper fabrication or other possible defects are evident. The extent of disassembly shall be as required in order to verify the unit integrity.


All testing requirements are also applicable to the spare gear set if a spare gear set is supplied.


During the mechanical running test of the equipment, any oil leakage is not acceptable and shall be the reason or basis for rejection.

7.4 PREPARATION FOR SHIPMENT

7.4.1 Delete the second sentence and replace with;

The preparation shall make the equipment suitable for outdoor storage from the time of shipment, with no disassembly required before operation as specified by the Owner.

7.4.3 b) Delete the clause and replace with;

Exterior machined surfaces shall be coated with a proper rust preventive suitable for outdoor storage for the duration as specified by the Owner.

7.4.3 d) Addition to the clause;

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Prior to any storage preparation, equipment shall be completely water free. All internals of the equipment shall be protected to prevent ingress of water or dirt. Large cavities such as bearing housings, and flange covers shall have vapour phase inhibiting crystals installed and attached to it. Corrosion preventative and drying agents shall be listed with its details of quantity and location to ensure its removal during preparation for start up.

7.4.3 i) Delete the first sentence in clause and replace with;

When spare gear elements are purchased, the rotors shall be suitably prepared for unheated indoor storage for a period of at least five years.

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8 VENDORS DATA

8.2 PROPOSALS

8.2.3 Technical data

Delete the clause b. and replace with;

b. Noise levels with and without attenuation features conforming to PTS 12.01.02 requirements.


n. Radial and thrust bearings data with full details.

o. Manufacturer’s quality plan in accordance with this PTS and ISO 13691 Annex F.

p. Full load or partial load testing capability with the cost and timing of the test.

8.3 CONTRACT DATA

8.3.1 General


8.3.1.5 All data sheets and documentation shall apply the International System of Units (SI).

8.3.6.3 Manual for operation, maintenance and technical data


Manufacturing reports inclusive of material certificates for casings, shafts and gears shall be included as part of the manuals. Certificates for heat treatment records, non-destructive test records and hardness results shall be included. In addition, the Manufacturer shall also furnish records of “as-built” clearances, rotating equipment balancing, shaft run-out checks, tooth contact and surface checks, and complete results from running tests.

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3.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publication. Unless specifically designated by date, the latest edition of each publication shall be used, together with any supplements/revisions thereto:

PTS STANDARDS

Index to PTS PTS 00.01.01

Requirements, General Definition of Terms Abbreviations & Reading Guide

PTS 00.01.03

Noise control PTS 12.01.02

Equipment noise limitation (data/requisition sheets)

D12.90.009

Rotating equipment acoustic enclosures (data/requisition sheets)

D12.90.011

Flexible couplings for mechanical power transmission - special purpose applications

PTS 12.12.06

Lubrication, shaft sealing and control oil systems for special-purpose application

PTS 12.12.01

Instruments for measurement and control PTS 14.10.02

Instrumentation for equipment packages PTS 14.10.03

STANDARD DRAWINGS

NOTE: The latest revisions of Standard Drawings are identified in PTS 00.11.01

Earth bosses D68.004

AMERICAN STANDARDS

Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

AGMA 2001-C95

Specification for High Speed Helical Gear Units AGMA 6011-H98

American Gear Manufacturer's Association 500 Montgomery Street Suite 350 Alexandria, VA 22314-1560

Special Purpose Gear Units for Petroleum, Chemical, and Gas Industry Services.

API 613

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Lubrication, shaft sealing, and control oil systems and auxiliaries for petroleum, chemical and gas industry services

API 614

Issued by: American Petroleum Institute Publications and Distribution Section 1220 L Street Northwest Washington DC. 20005 USA.

Pipe flanges and flanged fittings, NPS ½ through NPS 24

ASME B16.5

ASME Boiler and Pressure Vessel Code: Rules for construction of pressure vessels

ASME VIII, Div. 1

Issued by: American Society of Mechanical Engineers ASME International Three Park Avenue M/S 10E New York NY 10016 USA.

GERMAN STANDARDS

Deviations of shaft centre distances and shaft position; Tolerances of casings for cylindrical gears

DIN 3964

System of gear fits; Backlash; Tooth thickness allowances; Tooth thickness tolerances; Principles

DIN 3967

Issued by: Beuth Verlag GmbH Burggrafenstrasse 6 D-10787 Berlin, Germany

INTERNATIONAL STANDARDS

Metallic Flanges - Part 1: Steel Flanges ISO 7005-1

Quality Systems - Model for quality assurance in design, development, production, installation and service

ISO 9001

Calculation of Load Capacity of Spur and Helical Gears - Application to High Speed Gears and Gears of Similar Requirements.

ISO 9084

Petroleum and Natural Gas Industries - Flexible Couplings for Mechanical Power Transmission - Special Purpose Applications

ISO 10441

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Petroleum and Natural Gas Industries – High-Speed Special Purpose Gear Units

ISO 13691

Issued by: International Organisation for Standardisation 1, Rue de Varembé CH-1211 Geneva 20 Switzerland. Copies can also be obtained through the national standards organizations.

Steel Pipeline Flanges MSS SP44

Issued by: Mfrs Stdztn Society of the Valve & Fittings Ind. 127 Park Street NE Vienna, VA 22180-4602

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