ML19209B796
| ML19209B796 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 12/01/1977 |
| From: | Hartman C METROPOLITAN EDISON CO. |
| To: | |
| Shared Package | |
| ML19209B793 | List: |
| References | |
| 1301-8.02, NUDOCS 7910100492 | |
| Download: ML19209B796 (40) | |
Text
.
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1301-8.2, Revision o
'12/01/77 THREE MILE SLAND NUCLEAR STATION b,
UNIT
- 1 SUR'!EILLANCE PROCEDURE 1301-8.2 W i<
1 OIESEL GENERATOR ANNUAL INSPECTION.
' Table of Effective Pages CONTROLLED cvPy Pace Date Revision Pace Date Revision Pace Date Revision
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i Unit 1 Staff Recom encts pproval Unit 2 Staff Recommen Approval
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Date Approval i ;-
Date Approval Cognidnt D'apj. Head Cognizgnt fdp Hpd Unit 1 PORC Recommends Approval Unit 2 PORC Recomme s Approval Ven,a Date //bol77 l
Date y, Chairman of FORC Chairmand FOR PORC comments of -
included PORC comments of included ypeam
- ceate, BY
_ Date By Date Approva)_
lx))
Date ~ AccrovaC ?
's Date. 1 I. I, -
Galfe71sNb$$
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- Unit Superin:tadent p/0/0o 9Q
s' SP.'1301-8.2 kPR 171U5 evision 1 SURVEILLANCE PROCEDURE 1301-8.2 Diesel Generator Annual Inspection Required Interval - Annually 1.0 Purcose 1.1 To accomplish inspection of the emergency diesel generators in accordance with manufacturer's recommendations and Technical Spec-ification 4.6.1.c.
2.0 Plant Status 2.1 The reactor may be operating or shutdcwn except as specified in section 3.1 and 3.2.
3.0 Limits and Precautions 3.1 The reactor shall not be made critical unless both diesel generators are operable and at least 25,000 gallons of fuel oil are available in the storage tank.
3.2 From the date that one of the diesel generators is made inoperable, reactor operation is permissible for the succeeding seven days pro-vided that during such seven days the operable diesel generator is tested immediately and daily.
In the event two diesel generators are inoperable, the unit shall be placed in hot shutdown in 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br />.
If one diesel is not operable within an additional 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> period the plant shall be placed in cold shutdown within an additional 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> thereafter.
3.3 Prior to ccamencing inspection, ensure that air start manual shut-off valve (EG-VISA or EG-VISB) associated with unit to be inspected is closed. Open only as necessary to perform this procedure.
3.4 Exercise caution when fuel system has been opened.
Fuel oil is flammable and vapors are explosive.
1.0 1412
'08
, Sp '1301-3.2 e i for. 1 3.5 When inspection cavers are removed or when cleaning installed parts, exercise care to prevent foreign matter from entering engine.
4.0 Location of Assembly 4.1 Diesel generators 1A and 18 are located in the diesel generator building.
5.0 Eouicment Recuired See section 6.0 of Maintenance Procedure 1405-3.2.
6.0 Procedure 6.1 Start and load the engine in accordance with SP 1303-4.16. Allow the engine to reach operating temperature and stabili;:e (about 10 minutes). W'lile the engine is operating, check the following:
6.1.1 Turbocharger Performance Check turbocharger performance by recording the para-meters detailed on data sheet one, if any conditions are found to be unacceptable, repair as necessary in accord-ance with Maintenance Procedure 1405-3.2.
6.1.2 Check the fuel oil filter pressure drop and recorc on data sheet one.
If the pressure drap exceeds 10 psid, the filter cartridge must be replaced in accordance with MP 1405-3.2, section 7.5.1.
6.1.3 Check the lube oil strainer pressure drop and record on data sheet one.
If the pressure drop exceeds 18 psid, the strainer r.ust be clesned i.a.w. MP 1405-3.2 section 7.3.2.
6.1.4 Inspect the Fuel Control Governor linkage for roper op-erstion and record findings on data sheet one. Linkage should be mechanically sound and properly transmit motien from the Governor to the Fuel Control.
14 2
W.)
2.0
APR 171975 e
.' SP,1301-8.2 Revision 1 6.1.5 Examine the fuel oil injection racks for proper balance and operation. All mechanical joints should be tight and all rack settings should be the same (t 1).
Record find-ings on data sheet one.
6.1.6 Inspect all engine associated piping for leakage while the engine is operating.
Re-inspect after the engine has been shutdown.
Record findings on data sheet one.
6.1.7 Complete the operating log sheet from SP 1303-4.16 and attach a copy to data sheet one. The vendor's represent-ative and the cognizant engineer may use this log as the basis for recommending the inspection of areas not spec-ified below.
6.1.8 Secure the engine in accordance with SP 1303-4.16.
6.2 Mechanical Inspections s
With the engine shutdown and tagged out, perform the following in-spections:
~
NOTE:
In many of the below listed steps, inspection covers are to be removed.
In all cases, the inspection covers are to be ceplaced as soon as possible.
'4 hen replacing covers, new gaskets are to be used if the old gasket is torn, damaged or otherwise deteriorated.
6.2.1 Injection Noz:le Operation 6.2.1.1 Removal from Engine a.
Clean injection tube connections with fuel oil and wipe dry with clean cloth before disturbing connections.
b.
Remove injection and drain tubes.
c.
Remove collar stud nuts.
CAUTION: DURING N0ZZLE RE'40 VAL, 00 NOT STRIKE 1412 510 3.0
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Sh*1301-8.2 Yevisfo END OF N0ZZLE ASSEMBLY AGAIi4ST ANY HARD SURFACE. NICXING OR OTHER DAMAGE TO N0ZZLE MAY RESULT.
d.
Remove nozzle assembly using puller.
e.
Cover open end of injection ttbe and nozzle hole in cylindar liner to prevent entry of dirt, etc.
6.2.1.2 Nozzle Test a.
Connect nozzle to bench type nozzle test pump and pump handle rapidly for several short strokes prior to checking nozzle.
b.
Check nozzle opening pressure by slcwly 'op-erating pump while observing test pump pres-sure indicator. The highest pressure in-
' dicated is the opening pressure.
Stop pump-ing after pressure drops.
c.
Correct openino pressure is 2200 +100, -0 psig.
d.
If opening pressure is incorrect, adjust as follows while testing nozzle in (ccordance with steps a and b:
(1) Loosen locknut on nozzle assembly.
(2) Set desired pressure.
(3) Tighten locknut.
e.
Evaluate nozzle suitability for use as follcws:
WARNING: KEEP HANDS, ETC., AWA( FROM N0ZZLE SPRAY. OIL IS EJECTED WI'li SUFFI-CIENT '0RCE TO PUNCTLRE SKIN AND MAY CAUSE BLOCD POISONING.
(1) Observe nozzle spray cone pattern.
Pattern should be symmetrical with no heavy droplets, no side stringers or other irregular forms.
NOTE: Heavy streamers of fuel in the pattern, specially on slow lift acticn during testing, usually indicates dirt in the nozzle and can be corrected b/ cleaning parts.
4.0 1412 511
[.*'SP,'1301-3.2 Rdvidi$nk
~
NOTE: Chatter may or may not occur..
Chatter is not abnormal.
(2) Drops of fuel from the nozzle tip indicate valve seat leakage.
(3) If spray cone pattern is not correct or if seat leakage is indicated, nozzle should be replaced.
f.
Record results en data sheet two.
6.2.1.3 Replacement of Nozzle a.
Fit collar on studs as nozzle holder is in-serted into adapter.
b.
Ensure that spring sleeve and inlet plug are in a horizontal position when nozzle assem-bly is on engine and that assembly is position-ed so that nozzle will spray to right of cy-
' linder as viewed from each sice of engine (nozzle on each side of engine sprays to right of cylinder as viewed from its side.)
c.
Tighten collar stud nuts to 20 to 2:i ft. torque.
6.2.2 Exhaust Manifold
- 6. 2. 2.1 When this inspection is due in an even numbered year, the Opposite Control Side exhaust manifold is to be removed. For inspection due in odd num-bered years, the Centrol Side exhaust manifold is to be removed.
NOTE: Control Side is the side with the governor.
6.2.2.2 Exhnust manifolds - removal a.
Remove exhaust compartment covers.
b.
Remove exhaust manifold to extensien pipe bolts and capscrews using special wrenches at combined exhaust fitting to remove ext-ension pipes.
c.
Remove capscrews securing exhaust manifolds to exhaust bolts.
6.2.2.3 Inspect the exhaust ports for carbon deposits.
Clet.n as necessary.
Record findings on data sheet i412 512
- .'5p'1301-8.2 Nikio$h two.
6.2.3 Air Manifold 6.2.3.1. Remove the air part inspection covers (located on the control side of the engine).
Inspect the air manifold for cleanliness, cort csion, and pieces of broken piston rings.
Record findings on data two.
6.2.4 Ring Catcher 6.2.4.1 Remove the ring catcher inspection plate from the bottom of the turbocharger inlet of the exhaust manifold that was not removed above.
Check the ring catcher for pieces of broken piston rings.
Record findings on data sheet two.
- 6. 2. 4. 2 Replace ring catcher.
6.2.5 Inspection of piston Rings 6.2.5.1 Jack the engine as necessary so the piston rings are visible through the exhaust and air ports.
Visually inspect the rings for wear by examir'7g the groover in the compression rings.
I f t' rings have been worn smooth they must be rep, ced in accordance with applicable sections of MP.1405-3.2 part 7.3.
Record finc.ings on data sheet two.
- 6. 2. 5.2 Inspect the cylinder l'iiters for any abnomal wear,
~
patterns.
(Such as linear patterns or pitting)
Any such patterns must be evaluated by the vendors representative and the cogni:: ant engineer before proceeding.
Record findings en dita sheet two.
6.0 1412 5 \\ h
~
APR.17 137I>
SP.1301-8.2 Revision 1 i
6.2.5.3 When all pistens and liners have been inspect-ed, replace the air port in'pecticn covers.
6.2.5.4 Replace the exhaust manifold as follows:
a.
Assemble exhaust manifold and extension pipe to the exhaust belts and extension elbcws start-ing with the inner manifold (first section near-est turbocharger).
~
b.
Tighten bolts and capscrews to following tor-que values:
Thread Size Ft-Lb Toroue 3/8 in.
30-35 1/2 in. and 9/6fn. 50-55 c.
Install remaining exhaust manifolds and ex-
' tension pipes in sequence.
d.
Tighten flange bolts en long extension to 50 - 55 ft-lb.
NOTE: The heat shields may be left off un-til after the engine has been run in section 6.5 in order to check for ex-haust leaks.
6.2.6 Crankcase and Bearings 6.2.6.1 Remove inspection covers as necessary to inspect the upper and lower crankcase.
6.2.6.2 Inspect the main bearings for evidence of flash-ing.
(A flashed bearing will have bubbles on the edges).
Check all bearings with a 0.002 inch.
feeler guage.
If the feeler can slide between the crankshaft and the bearing, the bearing has failed and must be replaced in accordance with applicable sections of M? 1405-3.2 part 7.7.
Record findings on data sheet two.
7.0 j4j}
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5P*1301-8.2
,7 6.2.7 Crank Strain 6.2.7.1 Measure the icwer crank strain by installing a strain gauge on the #12 crank throw.
A d the engine forward and measure the strain on the crank throw.
Jack the engine in reverse and measure the throw. Acceptable strain is +0.002 in. to -0.002 inches.
Record results on data sheet two.
6.2.8 Crank Lead 6.2.8.1 Bar engine until No.1 icwer crankpin is N
the crank lead past inner dead center (refer
/
to figure 6.28-1). Use protractor or lead gauge on machined surface to check crank E'
N position.
N 6.2.8.2 Check position of upper crankshaft.
N 6.2.8.3 Machined surface on No. I upper crankweb nust be in vertical position so that crankpin
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is at inner dead center.
0 0
6.2.8.4 Bar engine in reverse rotation 25 to 30 :
s (a) Then bar engine in dire: tion of rota-tion and recheck cranks.1 aft lead timing.
(b)
If timing is not 180 +1/20, crankshaft must be raised and a different gear tooth engaged or the vertical drive coupling hub must be repositioned.
6.2.8.5 Record crank lead en data sheet tso.
6.2.8.6 Replace upper and lower crankshaft inspecticn Covers.
14\\2 5\\S 6.2.9 Vertical Drive 6.2.9.1 Remove inspection covers fr:m the vert: cal drive 8.0
AFR 17 IGE SP~1301-3.2 Revision 1
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1412 316 5.0
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,, SP~1301-8.2 Cover.
6.2.9.2 Visually inspect the vertical driv 9 for broken springs, loose nuts and any other mechanical abnomalities.
Record findings on data sheet two.
i b
\\ 9 6.2.9.3 Replace inspection cover.
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6.2.10 Timing Chain s
6.2.10.1 Remove the top inspection cover.
6.2.10.2 Visually inspect the timing chain for indications of being worn out of pitch or elongation.
6.2.10.3 Reach into the front cover and check the chain tension at the chain centerline between the tightener sprocket and the control side sprocket.
There should be 3/8" to 1/2" total slack in the chain.
Record findings on data sheet two.
NOTE:
Zue to the inaccessibility of the chain centerline, this measurement will be an approximation.
6.2.10.4 Replace the timing chain inspection cover.
6.2.11 Air Blower and Drives g. n y]
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Fig. 6.2.11-1 Location of Clearance Check Pcints ) 4 ) }h)f 10.0
son s.n GS SP 1301-S.2 RWis7dn 6.2.11.1 Remove outer end cover and check condition of thrust bearing rollers.
6.2.11.2 Using a feeler gauge, check for excessive clear-ance between roller and race.
Initial clear-ance was less than 0.0015 EG-Y-1 (A & B).
6.2.11.3 Check end clearances of thrust bearings by indi-cating lateral movement of impeller shafts.
In-itial end clearances were:
EG-Y-1A EG-Y-1B (1) Upper shaft
< 0.001
< 0.001 (2) Lower shaft
< 0.001
< 0.001 6.2.11.4 Remove inspection plugs on outer bearing plate and check condition of ends of impellers.
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o IP8Pection Flug Holes F gure 6.2.11-2 6.2.11.5 Check impeller clearances using feeler gauge through inspection plug holes. Any variation from values stamped on the end plate is an in-dication of need for more thorough blower inspect-ion.
11.0 1412 518 4.a 6
SP 1301-8.2 APR.1.1 1975 Revision 1 6.2.11.6 If inside of blewer appears to be extremely oily, check the following potential causes in the order listed:
(1) Dirty air intake filters.
(2) Unseated oil rings.
(3) Blewer oil seals.
6.2.11.7 If more thorough inspection is required, bicwer must be remove'd in accordance with Mp 1405-3.2.
6.2.11.8 Record all findings on data sheet two.
6.2.11.9 Replace inspection plugs and outer end cover.
6.2.12 B1cwer Drive 6.2.12.1 Remove blower drive inspection cover.
6.2.12.2 Visually inspect blower drive for wear and mechanical integrity. Record findings on data sheet two.
6.2.12.3 Replace blower drive inspection cover.
6.2.13 Torsional Dan:pers 6.2.13.1 Remove torsional damper inspection. covers.
6.2.13.2 Visually inspect the upper and lower torsional danpers for mechanical integrity. Record findings on data sheet two.
6.2.13.3 Replace torsional damper inspection covers.
6.2.14 Governor Drive i
6.2.14.1 Remove governor drive inspection cover.
6.2.14.2 Visually inspect governor drive for wear and mechanical integrity. Record findings on data sheet two.
6.2.14.3 Replace governor drive inspection cover.
12.0 j /[ j }
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SP 1301-8.2
$v} sis 3 6,2.15 Attached Pump Drives 6.2.15.1 Remove attached pump drive inspection covers.
6.2.15.2 Visually inspect attached pump drives for wear and mechanical integrity. Record findings on data sheet two.
6.2.16 Ai.- Start System 6.2.16.1 Remove. the air start distributor inspection cover.
6.2.16.2 Visually inspect the air start distributor for wear, mechanical integrity and evidence of moi-sture. Record findings on data sheet two.
6.2.16.3 Replace air start distributor inspection cover.
6.2.16.4 Choose one air start valve for inspection by consulting the diesel generator machinery history.
Choose the valve with the least recent inspect-ion or any valve that has never been inspected.
6.2.16.5 Remove the chosen air start valve, disassemble and inspect for wear, mechanical integrity and evidence of moisture. Record results on data sheet two.
6.2.16.6 Reassemble the air start valve and replace.
6.2.17 Air Filters 6.2.17.1 Check the air inlet filters and replace dirty elements as necessary. Record completion on data sheet two.
6.2.18 Water System 6.2.18.1 Remove the expansion tank inspection cover.
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k[vidfon"f SP 1301-8.2 6.2.18.2 Inspect the expansion tank for evidence of scale or corrosion products in the Jacket water system. Record findings on data sheet two.
6.2.19 Engine Timing NOTE: Special Precautions e
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a.
After determining a tining setting, the set-ting should be rechecked before proceeding to the next step.
b.
During operations performed in setting in-jection timing, always bar engine in direct-ion of rotation.
c.
If setting is overran, bar in reverse beyond desired point and again come up to desired setting.
This results in always taking up slack in timing chain in the same direction.
d.
Check tension and condition of timing chain prior to checking fuel injection timing.
This procedure is provided in paragraph 6.2.10.
6.2.19.1 Check crankshaft lead in accordance with paragraph 6.2.8.
6.2.19.2 Install stroke gauge on the No.1 (right side) injection pump.
(1) Remove injection tube and discharge valve cage yoke, cage and valve stop, if free from cage, and valve and spring.
Leave valve seat and gasket in place.
(2)
Insert stroke gauge plunger through hoke in the discharge valve seat.
Ensure that beveled end of gauge is positioned so that it may be easily seen.
(3) Tighten thumb nut.
6.2.19.3 Bar engine so that coupling pointer is between 150 and 200 6.2.19.4 Bar engine in direction of rotation until hairline on stroke gauge plunger lines up with hairline on stroke gauge body. Recoru reading indicated by coupling pointer.
6.2.19.5 Continue barring engine until plunger of stroke gauge moves to bottom of stroke and returns to positions where hairlines are again lined up.
Rect rd reading indicated by coupling pointer.
rs.
1412 522
,,SP,1301-8.2 Nvisin R
6.2.19.6 The t:o flywheel coupling readings locate points on the camshaft lobe equal distances on either side of the cam high point. This is shown graphically by figure 6.2.19-1.
6.2.19.7 Find the center between these points with ref-erence to inner dead center of the lower crank-shaft or "0" on the flywheel coupling as folicws:
(1) Add first and second coupling pointer read-ings.
(2) Divide by 2.
The resulting number is the desired center or cam high point.
NOTE:
In figure 6.2.19-1:
16 + 58 = 74; 74 t 2 = 37; 37 is the center or cam high point. Actual cam shaft high point should be approximately 37 after inner dead center of No.1 piston. Optimum injection timing 3'
should be determined by manufact-urer during fnitial testing and may
.s vary from 37.
Initial values are as follows: Oposite Control Side lA Diesel Generator:
380
- 18 Diesel Generator 37 3/40; Centrol Side 1A Diesel Generator
380; IS Diesel Generator: 37 1/20 6.2.19.8 If center (cam high point) determined in step v
6.2.19.5 above is not correct, governor side camshaft timing with respect to lower crankshaft must be changed.
6.2.19.9 If the determined can high point is less than 380 l
for lA Diesel Generator (380 for IB Diesel Gen-erator), timing is early; if greater timing is late. The difference is the number of degrees to advance or retard the ca:. shaft.
NOTE: Advance timing requires rotation of cam-shaft opposite the direction of icwer 16.0
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no.r.N RiviSich SP,'1301-3.2
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P00R ORGM 1 Pt.UNCER M A24 AB *VE 300Y t.iAR,;'
m STARTS TO MOVE COWti.
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FLYWHEEL COUPLING RCTAT: CPI A?40 MARKINGS VIEWED FROM ENCtt4E g
OtRECTION OF ROTATION SIDE CF FLYWHEEL CCUPLtNG.
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{ PCtN T CF C AM llIlll}llll[IllllllillIllljlllljill&llillllllllilll{11j!
60 EO 40 30 20 30 EXAMPLE CF FLYWNEEL CCUPLt?IG RE40iNCS
__194>933C Graphic Procedure to Det: mine High Point of Cam Figure: 6. 2. 19 -1 3
1412 424 17.0
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, SP,1301-8.2 crankshaft rotation. Retard timing requires camshaf t rotation in the dir-ection of lower crankshaft rotation.
6.2.19.10 Change timing as follows:
(1) Remove cover plate and loosen locknut.
(2) Rotate timing adjusting nut in direction indicated by the folicwing:
a.
To advance timing, rotate nut counter-clockwise.
b.
To retard timing, rotate nut clockwise.
(3) Tighten locknut and replace cover.
6.2. 19.11 Remove stroke gauge and reinstall discharge valve.
a.
Install discharge valve seat
- and cage gasket in pump body.
e b.
Place valve cage, valve stop (if free from cage), valve spring and discharge valve in s
the valve cage yoke.
c.
Raise the valve cage yoke on pump body studs.
- d.. Note the position of the ' discharge valve with
~
respect to the valve seat as the yoke is rais-ed.
J Tighten cage yoke stud nuts to 60-80 ft-lb e.
6.2. 19.12 Install stroke gauge on No.1 (left side) inject-fon pump in accordance with 6.2.19.2 above.
6.2.19.13 Check cam high point for left hand pump using procedure provided by steps 6.2.19.3 thrcugh 6.2.19.7.
6.2.19. 14 If the determine cam high point is not correct, camshaft sprocket must be shifted in relation to the camshaft.
6.2.19.15 If cam highpoint is less than '80 for lA Diesel ISO 1412 525
3 ;:.
APR.dion 17 19 5 nev1
, SP,1301-8. 2 0
Generator (38 1B Diesel Generator), timing is early; if greater, timing is late.
6.2.19.16 Change timing as follows:
NOTE. Slotted holes are provided in the camshaft sprocket to pennit adjustment.
(1) Loosen camshaft sprccket nuts.
(2) Bar engine in direction indicated by the following:
a.
If timing is late, rotate crankshaft in direction cpposite to normal engine rotation the required number of degrees.
b.
If timing is early, rotate crankshaft in direction of normal rotation the required number of degrees.
(3) Tighten nuts to 80 to 90 ft-lb torque.
Remove stroke gauge and reinstall discharge valve in accordance with step 6.2.19.11 above.
6.2. 19. 17 Record as found timing, any adjustments made and final timing on data sheet two.
6.3 Electrical Checks 6.3.1 Generator Cleanliness 6.3.1.1 Remo te generator inspection cover.
6.3.1.2 Inspict generator and exciter for cleanliness.
Clean as necessary with ZEP.
6.3.1.3 Record findings on data sheet three.
6.3.2 Collector Rings and Brushes 6.3.2.1 Inspect brushes as follcws:
(1) Brushes should move freely in the brush holders and the shunts or pigtails should not be loose.
(2) Brushas should not be chipped, broken or worn to 7/S" or less.
1412
- 26 IS-
1301-8.2 Revision 4 04/13/77 Brush pressure, as measured with a spring scale should be
'3)
Insure that the measurement is made in 2 to 3 pounds.
the directio'n of brush motion.
Record findings and brush pressure on data sheet three.
6.3.2.2 Record Inspect collector rings for burned spots or pitting.
6.3.2.3 results on data sheet three.
6.3.3 Check timer settings.
Using a stop watch or timer accurate to i1 second, check each 6.3.3.1 timer listed on Data Sheet 3A.
For each timer except TDL and TDR three operations of the 6.3.3.2 timer shall be checked to assure that the timer operation is consistant.
If the timer does not meet the required tolerance (on all 6.3.3.3 three tests) adjust, clean, or replace the timer as regt. ired.
Record as left data and initial the Data Sheet.
i 6.4 Instrumentation Check and calibrate as necessary, the setpoints on the following switches and relays. Record resul a on data sheet four.
6.4.1 TS-0TLA Low Lube Oil Temperature Alarm. Set normally closed set of contacts to close at 90 F (15 F) on decretsing temperature.
0 0
Set normally TS-0THA High Jacket Coolant Temperature Alarm.
I 6.4.2 open contacts to close at 195 F (+5 F, -2 F) on increasing 0
0 0
temperature.
0 6.4.3 TS-CHT Water Heater Thermostat. Set normally closed contacts 0
0 0
to open on increasing tem;:eratures at 135 F (+5 F, -0 F) and reclose at 130 F (+5 F, -0 F) on decreasing temperature.
20.0 1412 527
1301-8.2 Revision 5 12/1/77 6.4.4 TS-GBT Fan Gear Box Thermostat.
Set normally closed contacts to open at 80 F (15 F) on increasing temperature.
6.4.5 PS-OPLS Low Speed Low Oil Pressure Alarm and Shutdown Pressure Switch. Two sets on contacts. Set #1 to close at 5 psi (i 1) on decreasing pressure and open at 7 psi (1 1) on increasing pressure. Set #2 set to open as 5 psi (1 1) on decreasing pressure and close at 7 psi (i 1) on increasing pressure.
f After returning diesel to service have operations start diesel
'and operate 'At idle speed. Leosen fitting at OPLS and bleed air i
i from the line.
~
NOTE:
Do not disconnect fitting or OPLS.will trip the diesel.
Wipe up any oil spilled. Assure fittings are tight.
1 i:
~
1412 628 d
e e
e
=
e 20.1
12/01/77 1301-8.2 Revisinn 5 6.4.5 PS-OPL 1, 2, & 3 Low Pressure Alarm and Shutdown Switches OPS 1 has two sets of contacts. OFL 2 & 3 have one set of contacts each. OPL 1 Contact Set #1, OPL 2 & 3 set to close at 16 psi
(+3, 0) on decreasing pressure and open on increasing pressure at 18 psi or that pressure required for a differential of 2 psi (1 1/2). OPL 1 Contact Set #2 set to open at 16 psi
(+3, 0) on decreasing pressure and close en increasing pressure at 18 psi or that pressure required for a differential of 2 psi (11/2) After returning the diesel to service have operations start diesel and operate at idle speed. Loosen fitting at the oil pressure gauge and bleed the air frem the oil line. Catch the oil or wipe up after bleeding line. Assure fittings are
~
tight.
6.4.7 PS-CCP 1, 2, & 3 Crankcase Pressure Alarm and Shutdown Switches.
3 Set normally open contacts to close at 0.5 inches of H O 2
/
p pressure (+0.2, 0.0) on increasing pressure. Set differential at minimum.
d.4.8 PS-FPLA Fuel Oil Low Pressure Alarm. Set normally closed contacts to close on decreasing pressure at 10 psi (12) and 3
reopen on inceeasing pressure at 15 psi (11).
C.4.9 PS-ADLA (PS-534) Low Ai~r Pressure Alarm. Set normally closed set of contacts to clesa at 150 psi (110) on decreasing pressure and re-open on increasing pressure at 200 psi or that pressure required for a differential of 50 psi (15).
6.4.10 PS APS 1 (PS-533 A & C) and APS 2 (PS-533 3 & 0). Cranking Ai. Pressure Switch. Set normally open contacts of each switch to close at 150 psi (i10) on increasing pressure and reopen on decreasing pressure at 100 psi or that pressure required for a differential of 50 psi (15).
1412 429 6.4.11 PS-CPLA Low Jacket Cetlant Pressure Alarm. Two sets of cen-j 21.0
1301-8.2 Revision 3 07/01/76 tacts. Contact set #1, set to close at 12 psi (12) on decreasing pressure and to open at 18 psi '12) on increasing pressure.
Contact set #2, set to open on decreasing pressure at 12 psi and to close on increasing pressure at 18 psi.
6.4.12 PS-APC 1 (PS-531 A & B) and (PS 532 A & B). Air Compressor Motor Start-Stop Switch.
Set to stop motor at 250 psi (15) on increasing pressure and start motor at 225 psi (15) on decreasing pressure.
6.4.13 LS-CLLA Expansion Tank Low Level Alarm. Functional test of the nomally closed contacts by pushing the float down. The alarm should actuate at 3" level (+2", -0").
6.4.14 LS-OLLA Low Lube Oil Level Alarm. A functional test of this capacitance probe type switch may be made by removing the probe from its well. The alarm should energize when the probe is removed & clear when it is returned.
NOTE:
1)
The following instruments are to be :hecked and/or calibrated at intervals not ta exceed 24 months + 25%.
2)
The instruments in parenthesis are located on EG-Y-18.
Instrument Rance Tolerance 6.4.15 PI-529A(PI-530A) 0-600 psi i 6 psi 6.4.16 PI-529B(PI-5308) 0-600 psi 1 6 psi 6.4.17 PI-535A(B) 0-400 psi 1 2 psi 6.4.18 TI-J500A (B)30-240 F Adjust scale to read correctly 9 ambient 0
0 check 0 32 F & 212 F 6.4.19 TI-J501 A (B)
~
6.4.20 TI-502 A (B) 6.4.21 TI-J503 A (B) 22.
412 63C)
1301-8.2 Revision 4 04/13/77 Instrument Ranae Tolerance 6.4.22 TI-J504A(B)20-220 F Check 0 Ambient 0
6.4.23 TI-J505 A (B) 0-1200 F 0
6.4.24 TI-J506 A (B)30-240 F Check at 32 & 212 F Adjust scale as requirec Compare actual level with indication 6.4.25 LI-501 A (B)
Empty-Full i
6.4.26 PI-J501 A (B) 0-60 psi f_0.3 psi 6.4.27 PI-J502 A (B) 0-60 psi
+ 0.3 psi 6.4.28 PI-J503 A (B) 0-30 psi f_0.15 psi 6.4.29 PI-J504 A (B) 0-5" H 0 Vac.
Insure that mancmeter 2
Fluid level reads :ero 1
/,
6.4.30 PI-J505 A (B) 0-160 psi f_0.8 psi 6.4.31 PI-J505 A (B) 0-400 psi
' 2 psi
%.^
6.4.32 PI-J507 A (B) 0-30 psi f.0.15 psi i
1
- )
s i
23.0 1412 (31
SP 1301-S.2 Revision 2 6.5 Engine Operation 6.5.1 Start the engine in accordance with SP 1303-4.16.
6.5.2 Emergency Stop 6.5.2.1. Before engine has been brought to rated speed, test the local emergency stop butt.n (located on the engine, above the governor) by pushing it. The engine should coast to a stop.
6.5.2.2 Reset fuel racks by puliing leve: beneath the stop button towards front (control end) of the engine.
6.5.2.3 Decrease governor speed back to minimum, then restart engine.
~
6.5.2.4 Record results on data sheet five.
h 6.5.3 Operation i.
1412 532 23.1 m
v m ee e
o
SP 1301-8.2 R
19;'5 6.5.3.1 Put the engine on the line in accordance with SP 1303-4.16 and load to 1500 XW.
6.5.3.2 When exhaust temperatures have stabili:ed.
complete the operating log from SP 1303-4.16, and attach a copy to data sheet five.
Insure that the data sheet is clearly labeled for 50%
load.
6.5.3.3 Load the engine to 100% (2000 Kw).
6.5.3.4 When exhaust temperatures have stabilized.
complete the operating log frca SP 1303-4.16 and attach a copy to data sheet five.
Insure that the data, sheet is clearly labeled for 100" 4
- load, h
6.5.4 Make a complete visual check of the engine. Look especially
[
for lube oil leaks in the vicinity of the exhaust manifolds.
Make ri: pairs as necessary. Make note of any leakage (and whether or not it was repaired) or any other abnormal conditions on data sheet five.
6.5.5 Shutdown the engine in accordance with SP 1303-4.16, 7.0 Acceptance Criteria 7.1 All inspections and checks must have been performed and equipment found satisfactory (as shown on data shaets) or repaired / replaced.
24 1412 433
hehibfen k' 5p,1301-8.2 i
Surveillance Procedure 1301-8.2 DATA SHEET Ot:E Engine Operating EG-Y-1 6.1.1 Turbocharger Performance Cooling Water Pressure psi
(<40 psig)
Lube Oil Pressure psi (30-40 psi at full load) 0 Combined Exhaust Temp.
F
(<1200 F)
Vibration (Sat or Unsat)
~ - - ~ ~
initials 6.1.2 Fucl Oil Filter Pressure Drop psid (<10 psid) initials If a P is greater than 10 psif initial here when filter is replaced:
initials
'6.1.3 Lube Oil Strainer Pressure Drop psid (<18psid) 6 initials If a P is greater than 18 psid, initial here when strainer is cleaned:
initials 6.1. L Fsel Control Governor Linkage Findings initials (linkage tight, motion properly transmitted) 1412 534
Yevi1IonY R
',.SR 1301-8.2 DATA SHEET ONE CONTINUED 6.1.5 Fuel Oil Injecticn Racks Findings initials (Mechanically tight, all rack settings the same I l)
- 6. I. 6 Engine Associated Piping Lube Oil Fuel Oil Jacket Water initials i
6.1.7 Attach Operating Log from SP 1303-4.16 Data Sheet Completec oy Date Approved Date em m
e 1412
$35 26.0
,.5P 1301-2.2 gR,14(p Surveillance Procedure 1301-8.2 DATA SHEET Til0 Mechanical Insgection EG-Y-1 6.2.1 Injection Nozzles,
Cylinder Nozzle Oceration Ooerating Pressure Initials Number CS OCS CS OCS 1
2
~
3 4
5 6
7 8
9 10 r
11 12 (2200 + 100 - O psig)
Note: CS = Control Side OCS = Opposite Contml Side 6.2.2 Exhaust Manifold and Por:s Findings (no carben in ::diaust ports) 6.2.3 Air Ports initials (manifold clean, no corrosion, no pieces of becken rings) itl2 556 27.0 i
-- y...:-
A P R 1 7 t?.~5, Revision 1
,Sp 1301 8.2 DATA SHEET 2 (con't.)
SP 1301-8.2 EG-Y-1 6.2.4 Ring Catcher initials (No broken rings) 6.2.5 Cylinder Upper Lower Cylinder Number Piston Piston Liner Initials 1
2 3
4 5
6 C
-z '
7 en 8
s 9
10 4
11 g
~
s' s
l 28.0
}4}2 23[
APR t 7 t~.13I
', SP, 1301-8.2 Reviticn 1 DATA SHEET 2 (can't.)
SP 1301-8.2 EG-Y-1 6.2.6 Crankshaft and Bearings Bearing Upper Lower Nuraber Crank Crank Initials 1
2 3
4 S
6 7
8 9
10 11 12 13 14 (Sat or Unsat) 6.2.7 Crank Strain Strain Forward Reverse
(+.002 in!'to -002 in.)
Analysis
/-
initials J9.0
} 4 l 2.
30
APR t 7 1;73
.. S,P 1301-8. 2 Revision 1
~
,e OATA SHEET 2 (con't.)
SP 1301-8.2 EG-Y-1 6.2.8 Crank Lead As Found
' Adjustments b
Final (18" t gV) initials 6.2.9 Vertical Drive Findings __
'N initials j
(No Broken springs, no loose nuts, mechanically sound) gs 6.2.10 Timing Chain Ny Findings J
initials (No elongation) 6.2.11 Air Blower s
Clearance between roller and race in.
End clearance of thrust bearings Upper shaft
___i n.
Lower shaft in.
Impeller clearance in.
Condition of ends of imoellars:
Cor.dition of inside of blower:
initials (not extremely oily)
}k)5.
g3Q 30.0
~ - - -.
APR t71E70 S,P'1301-8.2 Revision 1 i
DATA SHEET 2 (con't.)
EG-Y-1 6.2. 12 Blower Drive Findings initials (no excessive or abnormal wear; mechanically sound) 6.2.13 Torsional Dampers Upper Lower initials (no excessive or abnormal wear; mechanically sound) 6.2.14 Governor Drive 1__
Findings
?C '
~
initials
~4 (no excessive or abnormal wear; mechanically sound) 6.2.15 Attached Pump Drives Fuel Oil Pump s-initials Water Pump initials (no excessive or abnormal wear; mechanically sound) 6.2.16 Air Start Distributor Findings inicials 31,0 1 A 17
' 4. q t4eu
~ ~
APR 17 ISE 57 1301-8.2 Revisica 1 I
DATA SHEET 2 (con' t. )
SP 1301-8.2 EG-Y-1 6.2.16 can't.
(no abnormal wear, no moisture, mechanically sound)
Air Start Valve Number Findings initials (no abnormal wear, no moisture, mechanically sound) 6.2.17 Air Filters Filters Checked:
initials Nurber of elements replaced:
6.2.18 Water System Fladings initials 5.2.19 Engine Timing As Found CS OCS Adjustments Final:
CS OCS (about 37U) initials e
All inspections complete:
All results satisfactory:
Mecnanical Maintenance Foreman Oate Approved:
Cognizant Engineer Date 1412 '4' 32.0
APR 17 EE
~~~
$P'1301-8.2 Revisica 1
,s, DATA SHEET THREE SP 1301-8.2 Ele,ctrical Inspection EG-Y-1 6.3.1 Cleanliness Findings initials (no accumulations of dirt) 6.3.2 Collector Rings and Brushes 1
Brush Numbering Engine 4
Brush Brush Brush Brush Nurrber Movement Wear Pressure Initials 1
2 3
4 (sat or unsat)
(wear less than 7/8")
(2-3lbs.)
Collector Rings (no burned spots, no pitting)
ALL INSPECTIONS COMPLETE:
ALL RESULTS SATISFACTORY:
Electrician Date APPROVAL:
COGi41ZAt4T ENGliiEER Date 33.0 1412 442
dwit 1 i mea
'5?.1's01-6.2 evisicn I
'f 9
9 DATA SHEET 4 e%%
SP 1301-8.2 EG*Y-1 Note:
- As recuired for proper differential TOLERAt1CE OR SECTICN INSTRU:iENT SETPOINT DIFFERENTIAL AS FOU:1D AS LEFT
!?!ITI ALS 6.4.1 TS-0TLA C00 9 90 F t50F 6.4.2 TS-CTHA COI O 195 F l+5, -2 'F 00t 3 135 c vs, -00F I
6.4.3 TS-CHT C00 9 130 F
+5,
-GoF 6.4.4 TS-GBT 00I O 80 r t50F ICOD o 50si i est 6.4.5 PS-0PLS SW1 DOT 0 7csi Ilosi 000 0 50si l:1 osi l
i PS-0PLS SW2 COI C 70si l:1 osi l
00f
- iciff;20s1 Ils t
6.4.6 PS-OPL 1 SWM00 9 16 nsil +3, -00si i
por*
iciff;20si 'si PS-OPL 1 SW2non 3 la ns4
+3,
-0 osi I 00f
- diff:20siDs i I
PS-OPL 2 rnn a te ne 4' +3,
-0 asi i i
nni
- diff:20si Isi I
PS-OPL 3 crn 1 14 nei +3. -0 osi l l
101 0 0.5"
+0 2 -O 0"u,0 6.4.7 PS-CCp 1 7v diff: min. 'I COI 0 0.5"
,+0.2,-0.0"HoO PS-CCP 2 H2O diff; min.
[0100.5"
+0.2.-0.0"H,0 1
PS-CCP 3 tio0 diff; min. 'l I
C00 J 10 osn i 2csi e
6.4.8 pS.pplA SW 1 001 "
diff;50si;l I PS-APLA E00 J 150 es1 : 10 nsi i l6.4.9 (PS-534) 001
- di f f;500si!51 PS APS 1 Noi 9 150csli ;10 os1 i
6.4.10 (PS 533 A+c)D00 "
diff:50csi 5 PS APS 2 E0I 9150 ori:10 csi i
(PS 533 8+01000 "
.diff;500si:5 PS-CPLA E00 9 12cs1 i:2 csi i
i 6.4.11 SW a.1 001 e laos 1 1:2 osi i
l PS-C lA
[J00 0 12cs1 1:2 si i
i SW32 LOI 3 180si I:2 osi i
i S-APC 1 00i uddoost i:5 ost i
i i
f(PS 531 A/g)C00 'J2250sr i:
6.4.12 5 asi i
i I
DOI J2500si 1:5 csi l
I i
pS 532 A/B CCD 92250si I:5 osi i
i I
(
5.4.13 3" level
+2", -0" LS-CLLA
)4}2 hkJ 34.0
1301-8.2 Revision 4 DATA SHEET 3A 04/13/77 SP 1301-8.2 Electrical Inspection Section 6.3 EG-Y-l _
Required i
Timer Setcoint Tolerance As Found As Left Initial I.
T3A 20 Sec.
+ 2 Sec.
(TDD0)
T3B 20 Sec.
+ 2 Sec.
(TDDC) l T3C 20 Sec.
+ 2 Sec.
(TDDO) 4
'I 5
60 Sec.
+ 10 Sec.
j (TDD0) 51
/-
N T2A 9 Sec.
+ 1 Sec.
I (TDOE)
TSettingof 9 Sec. or greater is
' desirable)
/
T2B 9 Sec.
+ 1 Sec.
(TD0E)
TSettingof9 c
Sec. or greater is desirable) tdt.
180 Sec.
+ 15 Sec.
(TD0_)
TDR 180 Sec.
+ 15 Sec.
(TDOE)
Performed By Date Reviewed By Date 34.1 1412 544
,' * ' SP.1301-
~
k " 7 ' ' '
Revision 2 02/13/76 DATA SHEET 4 SP 1301-8.2 EG*Y-1 Note: as required for proper differential TOLERA:lCE OR SECTION It!STRUMENT SETPOIllT DIFFERE!!TIA. AS FOUt!D AS LEFT IrlITIALS Low lube functional 6.4.14
,LS-OLLA oil level check only NOTE: THE FOLLOWIfiG It45 TRUME tTS ARE TO SE CHECKED WHEit THE ItiSPECTIO:1 15 DUE IN E'fEli flUMBERED YEARS.
PI 529A I 6 osi 6.4.15 (PI 530 A) 0-600 osi i
PI 529 8 6.4.16 (PI 530 B) 0-600 asi t 6 osi 6.4.17 PI 535A(B) 0-400 osi t 2 osi see body of 0
6.4.18 TI-J500A(B)30-240 F orocedure 0
6.4.13 TI-J501A(B)30-240 F 0
6.4.20 TI-J502A(B)30-240 F 6.4.21 TI-J503A(80 30-240 F 0
0 6.4.22 TI-J504A(B)20-220 F 0
g 6.4.23 TI-J505A(B) 0-1200 F 0
6.4.24 TI-J506A(B)30-240 F II 6.4.25 LI-501A(B) emoty-full 6.4.26 PI-J501A(B) 0-60 asi 0.3 psi 0.3 psi 6.4.27
- PI-J502A(B) 0-60 osi f
10.15 psi 6.4.28 PI-J503A(B) 0-30 asi az m-,
(I-J504A(B)0-5"H
- vac procedure 6.4.29 P
t.80si 6.4.30 I-J505A(B) 0-160 osi 0
t20si 6.4.31 I-J506A(B) 0-*00 osi t.15csi 6.4.32 I-J507A(B) 0-30 asi 0
1412 545
=
35.0
APR 17!sra
~
+
- b,, fP 1301-8 2 Revision 1
,. '.F, t
DATA SHEET FIVE SP 1301-8.2 Engine Operation 6.5.2 Err.ergency Stop
~~
Stop Button Works Properly initials 6.5.3 Attach Operating Log for 50% and 100% work load Evaluation of operation Cognizant Engineer 6.5.4 Leakage Check List any leaks found initials ENGINE ACCEPTABLE FOR OPERAT*0N:
Date APPROVED:
Gognizant Engineer Date 1412 446 36.0
.