ML17157A087

Rev 0 to Procedure TP-024-087, Data Collection for E Diesel Generator Combustion Intake Air Temp Test.

ML17157A087
Person / Time
Site:	Susquehanna
Issue date:	03/19/1990
From:	PENNSYLVANIA POWER & LIGHT CO.
To:
Shared Package
ML17157A088	List: ML17157A087 ML17157A089 ML18030A071
References
TP-024-087, TP-24-87, NUDOCS 9003280186
Download: ML17157A087 (18)

Text

T P-024-087 Revision 0 DATA COLL E CT 0 N F 0 R I E D I ES EL G E N E RATO R COMBUSTION INTAKE AIR TEMPERATURE TEST 9003280186 9003i9 PDR ADOCK 05000387 8 =-- = .. poc-

TP-024-087 Revision 0 Page 2 of 17 TABLE OF CONTENTS SECTION PAGE 1.0 PURPOSE

2. 0 DISCUSSION

3.0 REFERENCES

4.0 TEST EQUIPMENT 5.0 PRECAUTIONS 6.0 PREREQUISITES 7.0 PROCEDURE 8.0 RESTORATION 9.0 ACCEPTANCE CRITERIA

10. 0 REVIEW 11.0 RECORDS 12 ATTACHMENTS ATTACHMENT PAGE A Test Control Documentation Sheet 13 B Data Collection Table 14 C Diesel Generator Flows 15 D Calculation of Avg. ESW Spray Pond Temp 16 E Special Tools/Equipment 17

TP-024-087 Revision 0 Page 3 of 17 1.0 PURPOSE To provide a controlled method for coordinating the "E" diesel operation and ESW flow to the E diesel generator intercoolers to enable engine balancing and collection of combustion air intake temperatures.

2.0 DISCUSSION As a result of the ongoing investigation into the root-cause of the recent diesel generator crankcase explosions an area of concern is, what impact does combustion intake air temperature have on diesel operation.

Per the manufacturers specifications thi s test will increase combustion intake air temperature to within a range of 105-110'F. At this temperature an engine analyzer will be utilized to measure parameters such as cylinder peak firing pressure, firing angle and horsepower. A review of this data will determine if the E Diesel Generator is properly balanced, If necessary engine adjustments will be performed and another engine analyzer data collection will be performed. This process will be repeated until the diesel is considered to be balanced. Upon obtaining a balanced diesel the ESW flow thru the diesel intercoolers will be increased and measured until certain intake air temperatures are obtained. Finally the ESW flow through the intercoolers will be returned to its normal status (i.e., inlet valve full open) and an engine analyzer run will be performed. The data from this final analyzer run will be compared to the previous analyzer runs to determine the characteristics of engine operation with respect to intake air temperature.

Presently the ESW Inlet Valve to the E Diesel Generator Intercoolers is Full Open. Therefore, by throttling in the closed direction during this test, more flow will be directed to the other components supplied by ESW. As a resul't, if affected, the flows to other components supplied by ESW will be conservatively affected.

3.0 REFERENCES

3. 1 Unit 1 and 2 Technical Specification 3.8. 1. 1 Action b 3.2 Unit 1 and 2 Technical Specification 4.8. 1. 1.2.a.4 3.3 Unit 1 Technical Specification 3.8. 1. 1 Action d 3.4 AD-gA-422, Surveillance Testing Program 3.5 OI-024-002, Diesel Generator Start Log 3.6 OP-024-001, Diesel Generator s

TP-024-087 Revision 0 Page 4 of 17 3.7 TI-PE-009, Test Procedures 3.8 Cooper Bessemer Document gCG-6724, Power Cylinder Load Balance Procedure 3.9 MT-024-024, Diesel Engine Analysis and Load Balancing E.E TEST ETT TPMENT 4,1 Engine Analyzer (anyone of the following) (1)

a. EN SPEC 1000

b. EN SPEC 3000

c. BETA 250 4.2 Ultra Sonic Flow Detectors - Model DHT-P or equivalent (1) 4.3 C-clamps 2 3n (2 4.4 One ( 1) hP gage capable of reading up to 3000 gpm flow at FE-01112E 5.0 PRECAUTIONS

5. 1 Do not parallel the generator to the bus out of phase or equipment damage will occur.

5.2 Do not exceed a steady state voltage limit of 4400 volts.

5.3 Do not exceed a short term 2-hour rating of 5500 kw (nominal) or a continuous 5000 kw and 867 ampere rating.

5.4 At Local Panel OC519E observe that kvars remain between + 1500 kvars but as close to 0 as possible, when the generator is paralleled.

5.5 Do not attempt to restart an engine after an automatic shutdown occurs or if an overheating condition exists, until the problem is found and corrected.

TP"024"087 Revision 0 Page 5 of 17 R.R PREREITRI IIII

6. 1 No maintenance or other testing is being performed or planned on the E diesel generator and its associated 'auxiliary systems that would affect this test.

Confirmed By Date 6.2 .The remaining operable diesel generators are aligned in standby, are not under test and are not scheduled for testing during performance of this procedure.

Confirmed By Date 6.3 ENSURE E diesel generator is available for operation in the test mode and not required for substitution for the A-0 D/G's.

Confirmed By Date 6.4 INSTALL a hP gage at FE-01112E which is capable of reading a hP equivalent to 3000 gpm at FE-01112E. RECORD instrument calibration data on Attachment E.

Confirmed By Date 6.5 Reliable means of communication is available between Control Room and diesel generator E bay in test.

Confirmed By Date 6.6 Mechanical Maintenance Department has been notified that diesel testing is to be conducted.

I NOT FIED? YES/NO (Circle One) Confirmed By Date P

6.7 Personnel are available to take hourly diesel generator readings using

.the operating log provided in OI-024-004.

Confirmed By Date

TP-024-087 Revision 0 Page 6 of 17 6.8 Fuel oil, sampled and accepted by Chemistry, is available to replenish the diesel oil storage tanks.

WA ¹ /

Confirmed By Date 6.9 gualified personnel available to operate engine analyzer.

Confirmed By Date 6.10 ENSURE ESW is operating in accordance with OP-054-001 Section 3.2, to support the operation of the E diesel in the Test Mode.

Confirmed By Date

6. 11 Electr ical Maintenance is available to support this test.

Confirmed By Date

6. 12 INFORM Unit 1 and Unit 2 Supervisors that diesel testing will be performed.

Confirmed By Date

6. 13 Severe weather conditions which could affect offsite power stability are not predicted.

Confirmed By Date

6. 14 All test personnel have been properly briefed.

Confirmed By Date

6. 15 Surveillance Requirement 4.8. 1. 1.2.a.4 has been performed on the Standby Diesel Generators, if applicable.

Confirmed By Date

TP-024-087 Revision 0 Page 7 of 17 7.0 PROCEDURE NOTE (1): Attachment A is for Test Control Documentation and is used for the identification or amplification of any information that is considered appropriate by the Test Director for the evaluation of this test. It is also used for recording date and time of a test suspension and last step completed prior to a test suspension and test restart information.

NOTE (2): In Section 7 1 the loading times and power increments are to be

~

adhered to in the order delineated. But, the level of power to which the machine is ultimately increased to, will be at the discretion of the test director.

7. 1, Diesel Generator Start and Warmup

7. 1. 1 START Diesel Generator E in accordance with OP-024-004 "Operation of E Diesel Generator in Test Mode."

Confirmed By Date

7. 1.2 OPERATE Diesel Generator E unloaded for 15 minutes.

Confirmed By Date

7. 1.3 SYNCHRONIZE Diesel Generator E to transformer OX207 from OC619 in accordance with OP-024-004 section 3.3, Operation of Diesel Generator E in Test Mode.

Confirmed By Date

7. 1.4 INCREASE Diesel Generator E load to 1250 kw and,operate for 30 minutes.

Confirmed By Date

7. 1.5 INCREASE Diesel Generator E load to 2500 kw and operate for 30 minutes.

Confirmed By Date

TP-024-087 Revision 0 Page 8 of,l7 7.1.6 INCREASE Diesel Generator E load to 3750 kw and operate for 30 minutes.

Confirmed By Date 7.1.7 INCREASE Diesel Generator E load to 5000 kw and operate for 60 minutes.

Confirmed By Date 7.2 Engine Analyzer and Intake Air Temperature Data Collection NOTE: In Section 7 ' of this procedure the steps must be'performed in the order delineated but which power levels and what data to be taken at these levels can be determined per the discretion of the test director.

RECORD the requested data under Column ¹1 of Attachment B.

Confirmed By Date 7.2.2 PERFORM Engine Analyzer data collection per MT-024-024.

Confirmed By Date.

7.2.3 REDUCE Diesel Generator E Load to 4000 KW.

Confirmed By Date, NOTE: When throttling ESW Flow with valve 011501 C-clamps

~

may be required to maintain valve in desired position.

7.2.4 THROTTLE ESW Inlet to E D/G Intercoolers Valve 011501 in the closed direction until an intake air temperature of 105-110 F is obtained in both intake manifolds.

/

Confirmed By Date 7.2.5 RECORD the requested data under Column ¹2 of Attachment B.

Confirmed By Date

TP-024-087 Revision 0 Page 9 of 17 7.2.6 After at least 30 minutes of operation at 4000 KW, PERFORM Engine Analyzer data collection and adjust engine parameters

'onfirmed as necessary to balance the engine per MT-024-024.

By Date 7.2.7 Once the E Diesel Generator has been determined balanced, ENSURE both intake air temps are 105-110'F and RECORD the requested data under Column ¹3 of Attachment B.

Confirmed By Date 7.2.8 PERFORM Engine Analyzer data collection per MT-024-024.

Confirmed By Date 7.2.9 INCREASE Diesel Generator E load to 5000 KW.

Confirmed By Date 7.2.10 ENSURE both Intake Air Manifold Temperatures are 105-110'F and RECORD the requested data under Column ¹4 of Attachment B.

Confirmed By Date 7.2. 11 After at least 30 minutes of operation at 5000 KW, PERFORM Engine Analyzer data collection per MT-024-024.

Confirmed By Date 7.2. 12 ENSURE Diesel remains balanced per MT-024-024, balance diesel per MT-024-024.

if not, Confirmed By Date 7.2.13 THROTTLE valve 011501, ESW Inlet o E D/G Intercoolers, until the intake air in each manifold is between 65-75~F.

Confirmed By Date

TP-024-087 Revision 0 Page 10 of 17 7.2. 14 RECORD the requested data under Column ¹5 of Attachment B.

Confirmed By Date 7.2.15 RETURN valve 011501, ESW Inlet to E D/G Intercoolers, to the Full Open Position and RECORD data requested in Column ¹6 of Attachment B.

P Confirmed By Date 7.2. 16 PERFORM Analyzer data collection per MT-024-024.

Confirmed By Date 7.2.17 REDUCE Diesel Generator E load to 2500 KW.

Confirmed By Date 7.2.18 RECORD the requested data under Column ¹7 of Attachment B.

/

Confirmed By Date 7.2.19 After at least 30 minutes of operation at 2500 KW, PERFORM Engine Analyzer data collection per MT-024-024.

Confirmed By Date 7.2.20 If during the per formance of this procedure adjustments have been made to the diesel generator then perform SO-024-001E to declare the E Diesel Generator operable. If no adjustments made then N/A.

Confirmed By Date 7.2.21 . REMOVE and Shutdown Diesel Generator E from the test mode in accordance with OP-024-004 Section 3.3.

Confirmed By Date

TP-024-087 Revision 0 Page 11 of 17 7.2.22 INFORM Shift Supervision upon completion of this procedure and that the testing diesel generator can be returned to service.

Confirmed By Date 8.0 RESTORATION 8.1 REMOVE hP gage at FE-01112E, installed per step 6.4.

Confirmed By Date Verified By Date 8.2 ENSURE ESW Inlet to E D/G Intercoolers, valve 011501 is LOCKED in Full Open Position.

Confirmed By Date Ind. Verified By Date 8.3 ENSURE required Post Calibration Data Recorded on Attachment E.

Confirmed By Date 9.0 ACCEPTANCE CRITERIA This procedure is intended only to collect data. Therefore, the information collected in Attachment A and MT-024-024 shall be evaluated to determine the appropriate actions relative to Combustion Air Intake Temperature.

10.0 REVIEW

10. 1 This test has been reviewed in conjunction with MT-024-024 by the Technical Staff Electrical Group Supervisor.

Elect. Group Supv. Date

TP-024-087 Revision 0 Page 12 of 17 10.2 This test has been reviewed in conjunction with MT-024-024 by the Maintenance Diesel Engineer.

Maint. Diesel Eng. Date 11.0 RECORDS Completed TP transmitted to OCC via Transmittal Form 3179 to File R48-1 and cross referenced to file S024.

Confirmed By Date

Attachment A TP-024-087 Revision 0 Page 13 of 17 TEST CONTROL DOCUMENTATION SHEET Sheet of

.COMMENT NO. COMMENT INITIAL/DATE Page 1 of 1

Attachment B TP-024-087 Revision 0 Page 14 of 17 DATA COLLECTION TABLE Col 1 Col 2 Col 3 Col 4 Col 5 Col' Col 7

1) Temperature Manifold LT Pt. 5 TI-03418E (OC521E)

2) Temperature Manifold RT Pt. 6 TI-03418E (OC521E)

" 3) ESW Flow at FI-01112E

• 4) ESW Flow Upstream of Val ve 011501 (Intercl g)

" 5) ESW Flow Upstream of Valve 011507 (Jkt. Wtr)

• 6) ESW Flow Upstream of Valve 011506 (F. 0.)

" 7) ESW Flow Upstream of Valve 011508 (L. 0.)

"" 8) ESW Avg. Spray Pond Temp.

9) Oenote Position of Valve 011501 (¹ of Notches from full open)

10) Record Outside Air Temp from PMS Meterological Format NOTE: To obtain flows for Items 3, 4, 5, 6 and 7 use Attachment C.

NOTE: Calculate and Record Avg. ESW Spray Pond Temp as shown in Attachment 0.

Page 1 of 1

Attachment C TP-024-087 Revision 0 Page 15 of 17 DIESEL GE ERATOR FLO S

( F - 0/G)

E D/G UT VEI.OCITIES/FLOWS ACTUAL ( NOCE 2 8< 3) TOTAL WEIGHTED AVG ACTUAL FLOW ILOW JACKET FUEL UT (NOTE 5) (NOTE 6)

IOIAL P LUBE OIL INTER CLll WATER OIL FLOW LUBE INTER JACKET FUEL LUBE INTER JACI(ET FUEL TEST 01E I VEL FLOW EL FLO VEL FLO EL FLOW OTE OIL CLR WATER OIL OIL CLR WATER ~ OIL NOTES:

1) lo de<ermine transpose gpm E D/G Act<<al I low ( lola l) reference flow characteristics curve for FE-01112E, readings o<<to Attach<nent B, Step 4.

2) Ul Velocities aro exl>ressed in feet. per second (I'ps)

3) Ul f lows = UF Velocity Reading x 79.4 gpm/fps for l.ube Oi I & Intercooler 35.0 gl>m/I'ps for Jacket Wtr. Clr 5.5 gpm/I'ps for f<<el Oil Clr 4 ) lola I UI Flow . S<<mme<.ion of Ul Flows for Lube Oi I, Intercoolor, Jacket Wt.r and Fuel Oi I Coolers

5) W<!igl<<od Avg = Ul I low (for oach coolor) lotal UT F low for 0/G E (Note 4) f>) Actual Flow =' D/0 Actual (otal F low (Note I) x Weighted Avg for each cooler (Note 5)

I'ag<! I of I

Attachment D TP-024-087 Revision 0 Page 16 of 17 CALCULATION OF AVG ESM SPRAY POND TEMP A) Record following temperatures at Spray Pond Div. 2 (Panel OC529B) Spray Pond Temp (TI-01228B) .

I Col 1 Col 2 Col 3 Col 4 Col 5 Col 6 Col 7

a. Surface Temp. (Pos, 5)

b. Middle Temp (Pos. 4)

c. Bottom Temp (Pos. 6)

d. Compute Avg. Temp.

a+b+c/3 Page 1 of 1

Attachment E TP-024-087 Revision 0 Page 17 of 17 SPECIAL TOOLS/E UIPMENT CALIBRATION CALIBRATION LOCATION OF INSTALLED M8cTE NO TYPE RANGE DATE DUE DATE INSTALLATION IN STEP see step 4.4 FE" 01112E Page 1 of 1