ML20043F649

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Training Material for E-111 Emergency Diesel Generator Course, Table of Contents (3-16)
ML20043F649
Person / Time
Issue date: 02/12/2020
From:
Office of the Chief Human Capital Officer, Woodard Corp
To:
Gary Callaway
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Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 1.0 DIESEL GENERATORS AS EMERGENCY POWER SOURCES ........................ 1-1 1.1 Regulatory Basis for Redundant, Independent Power Systems ............... 1-1 1.2 RG 1.9 and the 3 Fundamental Performance Requirements for EDGs .... 1-2 1.3 Why DIESEL Generators? ....................................................................... 1-3 1.4 An Overview of EDG Regulations, Guides, Codes, and Standards ......... 1-4 1.4.1 Early Plants Licensed under AEC General Design Criteria ...................... 1-4 1.4.2 Plants Licensed by NRC Using the GDC of 10CFR50 Appendix A .......... 1-5 1.4.3 Top Level NRC Regulations that Pertain to NPP ................................... 1-5 1.5 Implementation of These Criteria into Site-Specific System Design ......... 1-7 1.5.1 Overview of Primary Regulatory .............................................................. 1-7 1.5.2 Licensees Implementation of EDG System Design Criteria..................... 1-9 1.5.3 EDG Component Selection ......................................................................1-11

2.0 INTRODUCTION

TO DIESEL ENGINES ............................................................. 2-1 2.1 Introduction to Emergency Diesel Generators.......................................... 2-1 2.2 Energy Conversion ................................................................................... 2-1 2.2.1 Combustion .............................................................................................. 2-1 2.2.2 Cylinder Activity ........................................................................................ 2-2 2.2.3 Four-Stroke Cycle Operation.................................................................... 2-3 2.2.4 Two-Stroke Cycle Operation - Conventional ............................................ 2-5 2.2.5 Two-Stroke Cycle Operation - Opposed Piston........................................ 2-6 2.2.6 Two-Stroke vs Four-Stroke Cycles ........................................................... 2-7 2.2.7 Typical Times for All Events ..................................................................... 2-8 2.3 Diesel Engine Terminology ...................................................................... 2-8 2.3.1 Dimensional Specifications ...................................................................... 2-8 2.3.2 Engine Performance.................................................................................2-10 2.3.3 Engine Efficiency. .....................................................................................2-11 2.3.4 Additional Terminology .............................................................................2-12 2.4 Typical Engine Design Criteria .................................................................2-13 2.5 Chapter Summary ....................................................................................2-13 Rev 3/16 1 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 3.0 DIESEL ENGINE CONSTRUCTION .................................................................... 3-1 3.1 Structural Components............................................................................. 3-1 3.1.1 Structural Loading .................................................................................... 3-1 3.1.2 Engine Block. ........................................................................................... 3-2 3.1.3 Engine Cylinders ...................................................................................... 3-2 3.2 Engine Bearings ....................................................................................... 3-3 3.2.1 Journal Bearings ...................................................................................... 3-3 3.2.2 Rolling Element Bearings ......................................................................... 3-3 3.3 Rotating and Reciprocating Components ................................................. 3-3 3.3.1 Pistons. .................................................................................................... 3-3 3.3.2 Piston Rings ............................................................................................. 3-4 3.3.3 Piston Pins ............................................................................................... 3-6 3.3.4 Connecting Rods. ..................................................................................... 3-6 3.3.5 Crankshaft ................................................................................................ 3-7 3.3.6 Flywheel and Vibration Damper ............................................................... 3-7 3.4 Cylinder Heads......................................................................................... 3-8 3.4.1 Cylinder Head Construction ..................................................................... 3-9 3.4.2 Valves and Valve Seats ........................................................................... 3-9 3.4.3 Valve Guides ............................................................................................ 3-9 3.4.4 Valve Springs and Retainers .................................................................... 3-9 3.5 Camshafts and Valve Mechanisms .......................................................... 3-9 3.5.1 Cams ........................................................................................................3-10 3.5.2 Cam Followers. ........................................................................................3-10 3.5.3 Camshaft Drive Mechanism .....................................................................3-10 3.5.4 Rocker Arms and Pushrods .....................................................................3-10 4.0 COMBUSTION AIR, FUEL, AND EXHAUST SYSTEMS...................................... 4-1 4.1 Introduction to the Air and Fuel Systems.................................................. 4-1 4.1.1 Air and Fuel for Combustion..................................................................... 4-1 4.1.2 Combustion Chemistry ............................................................................. 4-2 4.1.3 The Combustion Process ......................................................................... 4-2 4.2 The Intake Air System .............................................................................. 4-3 4.2.1 Intake Air System Requirements .............................................................. 4-3 4.2.2 The Typical Intake Air System.................................................................. 4-4 4.2.3 Blowers and Turbochargers ..................................................................... 4-5 Rev 3/16 2 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 4.3 The Diesel Engine Fuel System ............................................................... 4-6 4.3.1 Fuel Oil Storage and Transfer System ..................................................... 4-6 4.3.2 Fuel Oil Supply System ............................................................................ 4-7 4.4 Fuel Injection System ............................................................................... 4-8 4.4.1 Fuel Injection Pump and Nozzle System .................................................. 4-9 4.4.2 Fuel Injection Nozzles ..............................................................................4-10 4.4.3 Injection Nozzle Operation .......................................................................4-11 4.4.4 Unit Type Fuel Injectors ...........................................................................4-11 4.4.5 Injector Operation .....................................................................................4-11 4.5 The Exhaust System ................................................................................4-13 4.5.1 Exhaust System Requirements ................................................................4-13 4.5.2 Exhaust System Components ..................................................................4-13 5.0 ENGINE LUBRICATION SYSTEM ....................................................................... 5-1 5.1 Lubrication Fundamentals ........................................................................ 5-1 5.1.1 Friction ..................................................................................................... 5-1 5.1.2 Lubrication................................................................................................ 5-2 5.1.3 Lubricants................................................................................................. 5-2 5.2 Lubrication Systems ................................................................................. 5-4 5.2.1 Lube Oil Sump ......................................................................................... 5-4 5.2.2 Lube Oil Pump ......................................................................................... 5-4 5.2.3 Lube Oil Strainers .................................................................................... 5-4 5.2.4 Lube Oil Filters ......................................................................................... 5-4 5.2.5 Lube Oil Cooler ........................................................................................ 5-5 5.2.6 Lube Oil Header ....................................................................................... 5-5 5.2.7 Pressure Relief Valve ............................................................................... 5-5 5.2.8 Pressure Regulating Valve ....................................................................... 5-5 5.2.9 Engine Prelube/Keep Warm System ........................................................ 5-6 5.3 Crankcase Vacuum ................................................................................ 5-7 5.4 Bearing Temperature Monitoring 6.0 ENGINE COOLING SYSTEMS ............................................................................ 6-1 6.1 Engine Cooling ......................................................................................... 6-1 6.1.1 Cooling System Basics............................................................................. 6-1 Rev 3/16 3 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 6.1.2 Engine Cooling Systems .......................................................................... 6-2 6.1.3 Jacket Water Keep Warm Systems .......................................................... 6-4 6.2 Intercooler Water System ......................................................................... 6-5 6.3 Other Cooling Requirements .................................................................... 6-5 7.0 DIESEL ENGINE STARTING SYSTEMS ............................................................. 7-1 7.1 Technical Specification Starting Requirements ........................................ 7-1 7.2 Starting Characteristics ............................................................................ 7-1 7.2.1 Admission of Air ....................................................................................... 7-1 7.2.2 Compression of Air Charge ...................................................................... 7-2 7.2.3 Injection of Fuel ........................................................................................ 7-2 7.2.4 Compression Characteristics ................................................................... 7-2 7.3 Starting System Capability ....................................................................... 7-2 7.3.1 System Capability .................................................................................... 7-2 7.3.2 System Redundancy ................................................................................ 7-3 7.3.3 Energy Storage System ........................................................................... 7-3 7.4 Starting Air Systems ................................................................................. 7-3 7.4.1 Direct Air Injection Systems ..................................................................... 7-3 7.4.2 Starting Air Motor System ........................................................................ 7-6 7.4.3 Supplemental Components ...................................................................... 7-8 7.4.4 Starting Air Supply Systems ..................................................................... 7-9 7.4.5 Control Air ................................................................................................7-11 7.5 Electric Starting Systems .........................................................................7-11 7.5.1 Electric Starting Motor ..............................................................................7-11 7.5.2 Batteries ...................................................................................................7-12 8.0 DIESEL ENGINE CONTROLS AND GOVERNING .............................................. 8-1 8.1 Control Fundamentals .............................................................................. 8-1 8.1.1 Diesel Engine to Generator Relationship ................................................. 8-1 8.1.2 Governor Principles .................................................................................. 8-2 8.1.3 Governor Classification ............................................................................ 8-4 8.1.4 Principles of Operation ............................................................................. 8-4 8.1.5 Nuclear Application Governors ................................................................. 8-7 Rev 3/16 4 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 8.2 Engine Governor Operation ..................................................................... 8-8 8.2.1 Woodward EG Governor / Actuator ........................................................... 8-8 8.2.2 EGA Control Box ......................................................................................8-13 8.3 The 2301A Governing System .................................................................8-16 8.3.1 2301A Actuator ........................................................................................8-14 8.3.2 2301A Control Box ...................................................................................8-14 8.3.3 Speed Reference Input ............................................................................8-15 8.4 Governor System Change-Out .................................................................8-16 8.4.1 Advantages and Disadvantages...............................................................8-16 8.4.2 Fast Start Problem ...................................................................................8-16 8.5 Other Possible Governor Systems ...........................................................8-17 8.6 Governor-Linkage Relationship ................................................................8-18 8.7 Engine Overspeed Governor/Trip ............................................................8-18 9.0 GENERATOR, EXCITER, AND VOLTAGE REGULATION.................................. 9-1 9.1 Generator Principles ................................................................................ 9-1 9.1.1 Electromagnetic Induction ........................................................................ 9-1 9.1.2 Induced Voltage ....................................................................................... 9-1 9.1.3 How the Generator Works ........................................................................ 9-2 9.2 Generator Construction ............................................................................ 9-3 9.3 Generator Terminology ............................................................................ 9-4 9.3.1 Generator Frequency ............................................................................... 9-4 9.3.2 Mechanical Loading ................................................................................. 9-4 9.4 Generator Control .................................................................................... 9-4 9.4.1 Frequency Control .................................................................................... 9-5 9.4.2 Voltage Control ........................................................................................ 9-5 9.4.3 Generator Rating...................................................................................... 9-5 9.5 Excitation and Voltage Regulation ........................................................... 9-7 9.5.1 Types of Excitation Systems .................................................................... 9-7 9.5.2 Explanation of Elements of the Excitation System ................................... 9-8 9.5.3 Brushless Excitation Systems ..................................................................9-10 9.5.4 Digital Voltage Regulation ........................................................................9-11 Rev 3/16 5 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 9.6 Generator Output Breaker ........................................................................9-11 9.7 Generator Differential Protection ..............................................................9-11 9.7.1 Generator Monitoring and Protection .......................................................9-12 9.7.2 Generator Stresses ..................................................................................9-13 9.8 Generator Connection and Alignment to the Engine ................................9-13 10.0 EMERGENCY DIESEL GENERATOR CONTROL AND MONITORING ..............10-1 10.1 EDG Control Systems ..............................................................................10-1 10.2 Engine Protection Systems ......................................................................10-2 10.3 Engine Parameter Monitoring...................................................................10-3 10.3.1 Temperature Monitoring ...........................................................................10-3 10.3.2 Pressure Monitoring. ................................................................................10-4 10.3.3 Engine Overspeed ...................................................................................10-4 10.3.4 Vibration Trips ..........................................................................................10-5 10.4 Summary of Trips and Alarms ..................................................................10-5 10.4.1 Shutdown-Trips with Alarms.....................................................................10-5 10.4.2 Alarms-Any Mode-Any Time ....................................................................10-5 10.4.3 Monitored Items .......................................................................................10-6 10.5 Typical Engine Control Circuitry ...............................................................10-7 10.5.1 Starting Circuit ..........................................................................................10-7 10.5.2 Speed Monitoring and Stop Circuits .........................................................10-8 10.5.3 Fault Monitoring Circuits...........................................................................10-8 10.5.4 Summary ..................................................................................................10-9 10.5.5 Digital Instrumentation and Control ..........................................................10-9 10.6 Engine-Generator Responses ................................................................ 10-11 11.0 QUALIFICATION, SITE ACCEPTANCE AND SURVEILLANCE TESTING .........11-1 11.1 EDG Type Qualification Tests for Nuclear Service ...................................11-1 11.1.1 Three Basic Type Qualification Tests for Nuclear Service EDGs .............11-2 11.1.2 Additional EDG Evacuation by Test or Analyses......................................11-4 11.1.3 Analysis / Test of Design Change to EDG Previously Qualified ................11-4 11.2 Factory Production Testing ....................................................................11-4 Rev 3/16 6 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 11.3 Initial On-Site Set-up of EDG ................................................................... 11-5 11.4 Site Acceptance Testing........................................................................... 11-6 11.5 Pre-Operational EDG Testing ................................................................ 11-7 11.6 Periodic Testing (Surveillance)............................................................... 11-10 11.6.1 Availability Test ...................................................................................... 11-10 11.6.2 System Operation Tests ........................................................................ 11-10 11.7 Records for Each EDG Unit ................................................................... 11-10 11.8 Concerns about the Adequacy of Licensee Periodic Testing ............... 11-11 11.9 NRC Position on the Use of EDGs for Peaking ...................................... 11-11 11.10 Observation on EDG Control When in Parallel with Grid........................ 11-12 11.10.1 Frequency-Load Control Issues When Connected to the Grid .............. 11-12 11.10.2 Voltage-KVAR Control Issues When Connected to the Grid ................. 11-12 11.11 Typical EDG Surveillance Run ............................................................... 11-14 11.12 Observations Pertaining to EDG Selection and Operation ..................... 11-15 12.0 EDG PERFORMANCE MONITORING AND MAINTENANCE ............................. 12-1 12.1 EDG Maintenance & the Critical Need for Condition Monitoring ..............12-2 12.2 Overview of Regulatory Criteria Pertaining to System Requirements ......12-3 12.3 EDG Parameter Monitoring and Trending Fundamentals ........................12-3 12.4 Monitoring Prerequisites...........................................................................12-4 12.5 Fuel Oil Quality Monitoring .......................................................................12-5 12.6 Lube Oil Analysis and Trending ...............................................................12-7 12.7 EDG/Support Systems Monitoring ...........................................................12-9 12.8 Jacket and Cooling Water Analysis ........................................................ 12-11 Rev 3/16 7 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 12.9 Exhaust Emissions Analysis ................................................................... 12-11 12.10. The Use of Engine Analyzers to Monitor EDG Performance ............... 12-12 12.10.1 Phased Cylinder Pressure Type ............................................................ 12-12 12.10.2 Phased Engine Vibration (VT) and Ultrasonic (UT) Type ...................... 12-13 12.11 Practical Cylinder Balancing by Approximation Method ......................... 12-14 12.12 Crankcase Oil Mist Detection of Engine Mechanical Distress ................ 12-14 12.13 Infra-Red (IR) Scanning An Effective, Under-Utilized Tool.................. 12-14 12.14 Visual (and Other) Human Senses......................................................... 12-15 12.14.1 The Walkaround Inspection................................................................. 12-15 12.14.2 Assembled Inspections.......................................................................... 12-16 12.14.3 Dissembled Inspections ......................................................................... 12-16 12.15 Selective Maintenance Concerns and Observations for EDGs .............. 12-17 13.0 CASE STUDIES - LESSONS LEARNED, AND CONCERNS .............................13-1 13.1 Starting Failures .......................................................................................13-1 13.2 Controls-Related Failures.........................................................................13-2 13.3 Engine-Mechanical Failures .....................................................................13-5 13.4 Fire Protection System Issues and EDG Building Fires ...........................13-6 13.5 Engine Cooling Failures ..........................................................................13-8 13.6 Fuel Oil/Lube Oil Related Failures ...........................................................13-9 13.7 Special Concerns for Ultra-Low Sulfur Diesel Fuel ................................ 13-12 13.8 Combustion/Ventilation Air ..................................................................... 13-13 13.9 Special Concerns for Biodiesel Fuel (B5) ............................................... 13-14 13.10 Site Switchyard and Distribution............................................................. 13-15 13.11 Grid Reliability Concerns ........................................................................ 13-17 Rev 3/16 8 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 13.12 The Ticking Clock: Aging Issues Relevant to EDG Systems .................. 13-18 13.13 Industry EDG Activities........................................................................... 13-20 14.0 SOME OTHER ENGINES ....................................................................................14-1 14.1 EMD EDG Engines ..................................................................................14-1 14.2 Cooper EDG Engines ...............................................................................14-2 14.3 Nordberg EDG Engines............................................................................14-2 14.4 Worthington EDG Engines .......................................................................14-2 14.5 SACM EDG Engines ................................................................................14-3 14.6 DeLaval EDG Engines .............................................................................14-3 EDG UNITS AND ASSOCIATED EQUIPMENT AT PLANT SITES ................. 14-22 APPENDIX A REFERENCES APPENDIX B USNRC REGULATORY GUIDE 1.9, Rev. 4, March 2007 APPENDIX C IEEE 387-1995 APPENDIX D - TECHNICAL SPECIFICATION (EXAMPLE)

APPENDIX E -GLOSSARY Rev 3/16 9 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS WALKAROUND SESSIONS SESSION NUMBER

0.0 INTRODUCTION

TO THE TRAINING SCHOOL 2.0 THE 2-STROKE CYCLE OP AND 4-STROKE CYCLE ALCO ENGINES ............2-48 2.1 OP Engine Rotatable Cutaway Explanation ....................................... ..2-48 2.1.1 Pistons and Piston Rings .........................................................................2-49 2.1.2 Lube Oil Supply to the Piston ...................................................................2-50 2.1.3 Injection of Fuel into the Cylinder .............................................................2-50 2.1.4 Engine Cooling .........................................................................................2-51 2.2 ALCO Engine Cut-away Model Demonstration ........................................2-52 4.0 COMBUSTION AIR, FUEL, AND EXHAUST SYSTEMS 4.1 COMBUSTION AIR SYSTEM ..................................................................4-44 4.2 FUEL OIL SYSTEM .................................................................................4-44 4.3 EXHAUST SYSTEM.................................................................................4-45 5.0 ENGINE LUBRICATION SYSTEM .......................................................................5-26 5.1 Lube Oil Flow Path ...................................................................................5-26 5.2 Components .............................................................................................5-27 6.0 ENGINE COOLING SYSTEMS ............................................................................ 6-11 6.1 Jacket Water Cooling System .................................................................. 6-11 6.2 Components ............................................................................................. 6-11 7.0 DIRECT AIR INJECTION SYSTEM......................................................................7-27 7.1 Air Start System and its Components ......................................................7-27 7.1.1 Air Start Distributor ...................................................................................7-27 Rev 3/16 10 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS WALKAROUND SESSIONS (CONTINUED)

SESSION NUMBER 8.0 DIESEL ENGINE CONTROLS AND GOVERNING ..............................................8-39 8.1 The Mechanical / Hydraulic Governor .......................................................8-39 8.2 The Electric / Hydraulic Governor..............................................................8-39 8.3 Governor Output Power Linkage ..............................................................8-39 9.0 GENERATOR, EXCITER, &VOLTAGE REGULATION .......................................9-33 9.1 The Generator ..........................................................................................9-33 Rev 3/16 11 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS HANDS-ON TRAINING SESSIONS SESSION NUMBER 3A.0 ENGINE CRANKSHAFT(S) ................................................................................. 3-70 3A.1 Vibration Damper ..................................................................................... 3-70 3A.2 Engine Bearings, Crankshaft End Float and Web Deflection ................... 3-71 3A.3 Checking Crankshaft End Float................................................................ 3-73 3A.4 Checking the Crank Web Deflection - Crankshaft Alignment .................. 3-73 3B.0 PIELSTICK ENGINE ............................................................................................ 3-75 3B.1 Cylinder Heads, Valves & Valve Operating Mechanism ........................... 3-75 3B.2 Cylinder Liner-Jacket Assembly ............................................................... 3-76 3B.3 Main Bearing Assembly............................................................................ 3-77 3B.4 Piston and Connecting Rod Assembly ..................................................... 3-78 3B.5 Power Output Shaft Gear-Drive Support Systems ................................... 3-78 3C.0 ENGINE CRANK-LEAD & FUEL INJECTION TIMING (OP ENGINE) ................. 3-80 3C.1 Checking/Setting the Crank-lead.............................................................. 3-80 3C.2 Checking High Point of CAM .................................................................... 3-82 3C.3 Setting the Injection Pump Timing............................................................ 3-83 4A.0 COMBUSTION AIR TURBOCHARGERS & SCAVENGING BLOWERS ............. 4-46 4A.1 Turbochargers .......................................................................................... 4-46 4A.2 Scavenging Air Blowers ........................................................................... 4-47 4B.0 FUEL INJECTION PUMPS & FUEL INJECTION NOZZLES ................................ 4-48 4B.1 Injection Pumps and Injection Nozzles ..................................................... 4-48 4B.2 Injection Nozzle Assemblies..................................................................... 4-48 Rev 3/16 12 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS LIST OF ILLUSTRATIONS 1-1 Diesel Generator Systems ................................................................................... 1-12 2-1 Fixed Volume....................................................................................................... 2-16 2-2 Fixed Volume Plus Heat ...................................................................................... 2-16 2-3 Addition of Piston................................................................................................. 2-17 2-4 Addition of Piston Plus Heat ................................................................................ 2-17 2-5 Addition of Crankshaft ......................................................................................... 2-18 2-6 Addition of Crankshaft Plus Heat ......................................................................... 2-18 2-7 Cylinder Configuration Stroke Cycle .............................................................. 2-19 2-8 Intake of Air Charge ............................................................................................. 2-19 2-9 Compression of Air Charge ................................................................................. 2-20 2-10 Injection of Fuel ................................................................................................... 2-20 2-11 Development of Power ........................................................................................ 2-21 2-12 Exhaust of Spent Gases ...................................................................................... 2-21 2-13 Air Standard Diesel Cycle .................................................................................... 2-22 2-14 Diesel Cycle - Pressure vs Stroke Diagram ......................................................... 2-23 2-15 Cylinder Configuration Stroke Cycle EMD Engine ......................................... 2-24 2-16 Intake Event......................................................................................................... 2-25 2-17 Compression Event ............................................................................................. 2-26 2-18 Combustion and Power. ...................................................................................... 2-27 2-19 Cylinder Configuration Stroke Cycle, OP Engine ........................................... 2-28 2-20 Intake Event......................................................................................................... 2-29 2-21 Compression Event ............................................................................................. 2-29 2-22 Combustion and Power Event ............................................................................. 2-29 2-23 Cylinder Bore and Stroke .................................................................................... 2-30 2-24 Clearance Volume ............................................................................................... 2-31 2-25 Compression Ratio .............................................................................................. 2-32 2-26 Typical Times for Events 900 rpm Diesel Engines .............................................. 2-33 2-27A Typical Timing Diagram Stroke Cycle ............................................................ 2-34 2-27B Typical Timing Diagram Stroke Cycle ............................................................ 2-35 2-28 Cross Section of Fairbanks Morse OP Engine .................................................... 2-36 2-29 Cross Section of ALCO 4-Stroke Cycle Engine ................................................... 2-37 2-30 OP Engine Crankshaft ......................................................................................... 2-38 2-31 OP Engine Vertical Drive. . . . . . . ....................................................................... 2-39 2-32 Cylinder Liner and Associated Parts.................................................................... 2-40 2-33 Piston and Connecting Rod Disassembled.......................................................... 2-41 2-34 Operation in Single Cylinder ................................................................................ 2-42 2-35 Injection Nozzle Mounting-OP Engine ................................................................. 2-43 2-36 Injection Pump Adjustments ................................................................................ 2-44 2-37 Chain Type Camshaft Drive Mechanism ............................................................. 2-45 2-38 Camshaft Control End . . ..................................................................................... 2-46 2-39 Fuel Injection Assembly ....................................................................................... 2-47 2-40 Injection Pump Plunger Positions ........................................................................ 2-48 Rev 3/16 13 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 3-1 Cylinder Forces ................................................................................................... 3-11 3-1A Cylinder X-Y Forces during Power Stroke ........................................................... 3-12 3-2 Multi-Piece Construction ...................................................................................... 3-13 3-3 12-Cylinder OP Engine Cylinder Block ................................................................ 3-14 3-4 16-Cylinder PC Engine Cylinder Block ................................................................ 3-15 3-5 Dry Type Cylinder Liner ....................................................................................... 3-16 3-6 Wet Type Cylinder Liner ...................................................................................... 3-17 3-7 Integral Type Cylinder Liner................................................................................. 3-18 3-8 OP Engine Main Bearings ................................................................................... 3-19 3-9 OP Piston and Con-Rod Assembly...................................................................... 3-20 3-10 Trunk Type Piston ............................................................................................... 3-21 3-11 Floating Skirt Piston ............................................................................................. 3-22 3-12 Piston Ring Nomenclature ................................................................................... 3-23 3-13 Piston Ring Sealing ............................................................................................. 3-24 3-14 Compression Ring Designs ................................................................................. 3-25 3-15 Piston Ring Joint Design...................................................................................... 3-26 3-16 Oil Control Ring ................................................................................................... 3-27 3-17 Oil Control Ring Designs ..................................................................................... 3-28 3-18 Piston Ring Placement ........................................................................................ 3-29 3-19 Two-piece Crown Piston with Connecting Rod & Wrist Pin ................................. 3-30 3-20 Conventional Connection Rod ............................................................................ .3-31 3-21 Angle Cut Connection Rod ................................................................................. .3-31 3-22 Articulating Connecting Rod Assembly ................................................................ 3-32 3-23 Fork and Blade Connecting Rod Design (EMD) .................................................. 3-33 3-24 OP Engine Crankshafts ....................................................................................... 3-34 3-25 Engine Crankshaft Oil Passages ......................................................................... 3-35 3-26 Engine Flywheel .................................................................................................. 3-36 3-27 Spring Type Vibration Damper ............................................................................ 3-37 3-28 Gear Type Viscous Damper ............................................................................... .3-38 3-29 Bifiler Type Vibration Damper .............................................................................. 3-39 3-30 Cylinder Head Assembly ..................................................................................... 3-40 3-31 Valve Seat Angles ............................................................................................... 3-41 3-32 Valve Seat Assembly .......................................................................................... .3-41 3-33 Camshaft Lobes .................................................................................................. 3-42 3-34 Cam Follower Designs ........................................................................................ 3-43 3-35 Gear Type Camshaft Drive Mechanism ............................................................... 3-44 3-36 Chain Type Camshaft Drive Mechanism-OP ...................................................... .3-45 3-37 Rocker Arms and Pushrods ................................................................................. 3-46 3-38 Pendulum Torsional Damper ............................................................................... 3-47 3-39 Monofilar Type Torsional Damper ....................................................................... 3-48 3-40 Crankshaft Strain Gauge Readings ..................................................................... 3-49 3-41 Crankshaft Strain Readings ................................................................................. 3-50 3-42 Pielstick Engine Cross Section ............................................................................ 3-51 3-43 Cylinder Head with Rocker Arm Assembly .......................................................... 3-52 3-44 Rocker Arm Assembly. . ..................................................................................... 3-53 3-45 Sequence and Timing Events . . . ........................................................................ 3-54 Rev 3/16 14 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 3-46 Standard Main Bearing . . .................................................................................... 3-55 3-47 Lube Oil Distribution . . . ...................................................................................... 3-56 3-48 Timing Gear and Auxiliary Drives ........................................................................ 3-57 3-49 Camshaft Bearing Lubrication ............................................................................. 3-58 3-50 Fuel Injection Pump . . . ...................................................................................... 3-59 3-51 Flexible Drive Gear . . . . ...................................................................................... 3-60 3-52 Overspeed Governor and Trip Mechanism .......................................................... 3-61 3-53 Manual Barring Device . ...................................................................................... 3-62 3-54 Crank-lead Timing Drive End............................................................................... 3-63 3-55 Crank-lead Timing . . . . ....................................................................................... 3-64 3-56 OP Engine Drive Gear and Timing Chain. . . . . . . . . . ......................................... 3-65 3-57 Flywheel Coupling Readings ............................................................................... 3-66 3-58 OP Engine Fuel Injection Pump........................................................................... 3-67 3-59 Depth Micrometer ................................................................................................ 3-68 3-60 Fuel Control Linkage Adjustment . . . . . . ............................................................. 3-69 4-1 Combustion Activity ............................................................................................. 4-17 4-2 Diesel Cycle - Pressure vs Stroke ....................................................................... 4-18 4-3 Basic Intake and Exhaust System ....................................................................... 4-19 4-4 Dry Type Air Filter................................................................................................ 4-20 4-5 Oil Bath Air Filter ................................................................................................. 4-21 4-6 Blower/Supercharger .......................................................................................... .4-22 4-7 Exhaust Driven Turbocharger .............................................................................. 4-23 4-8 Intake Air and Exhaust Flow ................................................................................ 4-24 4-9 Typical Basis for Diesel Generator Ratings/DEMA Ratings ................................. 4-25 4-10 Exhaust Gas Silencer .......................................................................................... 4-26 4-11 Fuel Oil Storage and Transfer System ............................................................... .4-27 4-12 Fuel Oil Supply System ....................................................................................... 4-28 4-13 Fuel Oil Strainer................................................................................................... 4-29 4-14 Fuel Oil Supply Pump ......................................................................................... .4-30 4-15 Fuel Oil Filter ....................................................................................................... 4-30 4-16 Pump and Nozzle System ................................................................................... 4-31 4-17 OP Injection Pump Construction......................................................................... .4-32 4-18 Zero Fuel Delivery ............................................................................................... 4-33 4-19 Low Power ........................................................................................................... 4-34 4-20 Full Power............................................................................................................ 4-34 4-21 Injection Nozzle ................................................................................................... 4-35 4-22 Injection Nozzle Spray Pattern ............................................................................ 4-36 4-23 Pintle Nozzle........................................................................................................ 4-37 4-24 Unit Type Fuel Injector ........................................................................................ 4-38 4-25 Injector Operation. ............................................................................................... 4-39 4-26 Zero Fuel Delivery ............................................................................................... 4-40 4-27 Low Power ........................................................................................................... 4-41 4-28 Full Power............................................................................................................ 4-42 4-29 Turbocharger Cutaway Section ........................................................................... 4-43 4-30 Casing Assemblies ......................................................................................... 4-44 4-31 Brown and Boveri Turbocharger .......................................................................... 4-45 Rev 3/16 15 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 5-1 Frictional Surfaces ............................................................................................... 5-10 5-2 Types of Friction .................................................................................................. 5-11 5-3 Rolling Friction ..................................................................................................... 5-12 5-4 Laminar Flow ....................................................................................................... 5-13 5-5 Wedge Formation ................................................................................................ 5-14 5-6 Shaft and Bearing ................................................................................................ 5-15 5-7 Lube Oil Circulating and Cooling System ............................................................ 5-16 5-8 Lubricating Oil Pump ........................................................................................... 5-17 5-9 Lubricating Oil Filters ........................................................................................... 5-17 5-10 Lubricating Oil Cooler .......................................................................................... 5-18 5-11 Pressure Relief Valve .......................................................................................... 5-19 5-12 Pressure Regulating Valve .................................................................................. 5-20 5-13 Lube Oil System with Keepwarm Added ............................................................. 5-21 5-14 Pielstick Lube Oil Flow ........................................................................................ 5-22 5-15 Pielstick Valve Rocker Flow................................................................................. 5-23 5-16 Crankcase Diaphragm Type Pressure Monitoring Switch ................................... 5-24 5-17 Bearing Temperature Probe ................................................................................ 5-25 6-1 Jacket Water Cooling System with Keepwarm .................................................... 6-7 6-2 Jacket Water Pump ............................................................................................. 6-8 6-3 Thermostatic Control Valve ................................................................................. 6-9 6-4 Intercooler Water Cooling System ....................................................................... 6-10 7-1 Cranking Speed versus Compression Pressure .................................................. 7-13 7-2 Starting Air System .............................................................................................. 7-14 7-3 Starting Air Admission Valve ............................................................................... 7-15 7-4 Starting Air Distributor (OP Engine) ..................................................................... 7-16 7-5 Spool Valve - Off Cam ......................................................................................... 7-17 7-6 Spool Valve - High Cam ...................................................................................... 7-17 7-7 Spool Valve - Low Cam ....................................................................................... 7-17 7-8 Starting Air Check Valve-Open ............................................................................ 7-18 7-9 Starting Air Check Valve-Closed ......................................................................... 7-18 7-10 Vane Type Starting Air Motor .............................................................................. 7-19 7-11 Bendix Drive Assembly ........................................................................................ 7-20 7-12 Governor Boost Cylinder (Woodward Governor) ................................................. 7-21 7-13 Starting Air Supply System .................................................................................. 7-22 7-14 Typical Components Direct Air-Over-Piston Starting System .............................. 7-23 7-15 Typical Direct Air-Over-Piston Starting System ................................................... 7-24 7-16 Electric Starting Motor System ............................................................................ 7-25 7-17 Air Start Check Valve. . . . . . ............................................................................... 7-26 Rev 3/16 16 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 8-1 Droop-Isochronous Relationship ......................................................................... 8-22 8-2 Basic Mechanical Governor ................................................................................. 8-23 8-3 Basic Governor with Hydraulic Power Piston....................................................... 8-24 8-4 Electronic Governor Hydraulic Actuator............................................................... 8-25 8-5 EGB 10C Actuator Schematic ............................................................................. 8-26 8-6 EGA Governor Control Box ................................................................................ 8-27 8-7 2310A Control Box .............................................................................................. 8-28 8-8 EGA Governor Control Block Diagram ................................................................ 8-29 8-9 2301A Control View ............................................................................................. 8-30 8-10 2301A Control Block Diagram ............................................................................. 8-31 8-11 Typical Magnetic Pickup ...................................................................................... 8-32 8-12 MOP for 125 VDG Motor ..................................................................................... 8-33 8-13 Schematic of MOP Unit ....................................................................................... 8-34 8-14 Digit Reference Unit (DRU) ................................................................................. 8-35 8-15 DRU Connections ................................................................................................ 8-36 8-16 Relationship Between Governor Output and Control (Rack) ............................... 8-37 8-17 Over-Speed Trip (Governor) Mechanism ............................................................ 8-38 9-1 Conductor in Magnetic Field ................................................................................ 9-16 9-2 Simple Generator (Alternating Current) ............................................................... 9-17 9-3 Single Phase Sine Wave ..................................................................................... 9-18 9-4 Three Phase Generation ..................................................................................... 9-19 9-5 Cutaway of Generator - Identification of Parts ..................................................... 9-20 9-6 OP Engine Generator Assembly (under test) ...................................................... 9-21 9-7 Cut-away of Generator - Identification of Parts .................................................... 9-22 9-8 Complete Rotor Assembly ................................................................................... 9-22 9-9 Generator Shaft - Coupling End View.................................................................. 9-23 9-10 Rotor Spider ........................................................................................................ 9-23 3-11 Field Pole Wedges .............................................................................................. 9-24 9-12 Field Pole Blocking .............................................................................................. 9-24 9-13 Field Pole with Amortiser Bars............................................................................. 9-25 9-14 Field Wiring to Slip Rings .................................................................................... 9-25 9-15 Slip Ring Assembly .............................................................................................. 9-26 9-16 Winding Coil Form ............................................................................................... 9-26 9-17 Windings Installed in Stator Slots ........................................................................ 9-27 9-18 Coil Tying and Bracing ........................................................................................ 9-27 9-19 Lead Cable Terminations .................................................................................... 9-28 9-20 Complete Stator Assembly .................................................................................. 9-28 9-21 Rotor Installed within Stator ................................................................................. 9-29 9-22 Bearing and Housing Assembled to Rotor Shaft ................................................. 9-29 9-23 Exciter System Block Diagram (SEVR/SB Types) ............................................... 9-30 9-24 Brushless Exciter System Diagram ..................................................................... 9-31 9-25 Generator Differential Fault ................................................................................. 9-32 9-26 Engine-Generator Alignment ............................................................................... 9-33 Rev 3/16 17 USNRC HRTD

Emergency Diesel Generator Table of Contents TABLE OF CONTENTS 10-1 Starting Circuitry ................................................................................................. 10-14 10-2 Speed Monitoring and Stop Circuitry .................................................................. 10-15 10-3 Fault Shutdown and Monitoring Circuits ............................................................. 10-16 10-4 Motor Start Loading ............................................................................................ 10-17 10-5 Typical Loading Situation.................................................................................... 10-18 11-1 IEEE 387-1995 Table 3, Site Testing of EDGs ................................................... 11-21 11-2 IEEE 387-1995 Table 4, Test Parameters (Required Data) .............................. 11-22 12-1 Piston with Advanced Tin Smear ........................................................................ 12-20 12-2 Failed Piston - Tin Wiped Off .............................................................................. 12-21 12-3 EDG Diagnostic Report - PFP vs Crank Angle (Right Bank) .............................. 12-22 12-4 EDG Diagnostic Report - PFP vs Crank Angle (16cyl.) ...................................... 12-23 12-5 EDG Diagnostic Report - PFP vs Crank Angle & Swept Volume (4L) ................ 12-24 12-6 EDG Diagnostic Report - PFP vs Crank Angle & Swept Volume (2R)................ 12-25 12-7 Crankcase Oil Mist Monitoring System ............................................................... 12-26 12-8 EDG Failure by Responsible System ................................................................. 12-27 12-9 IR Thermographs of Impending Failures ............................................................ 12-28 13-1 Correct and Incorrect Air Start Motor Sub-Assembly 13-21 13-2 Location of Defective DeLaval Governor Drive Coupling .................................... 13-22 13-3 Location of Missing Cooper KSV Engine Valve Keeper Seals ........................... 13-23 13-4 Depiction of Water Tree in Electrical Cable Insulation (Fault Paths) ............... 13-24 14-1 EMD Engine Cross Section ................................................................................. 14-4 14-2 EMD Engine Service Data Sheet......................................................................... 14-5 14-3 Cooper Engine Connecting Rods & Bearings ...................................................... 14-6 14-4 Cooper Engine Service Data Sheet ..................................................................... 14-7 14-5 Cooper Engine Cross Section ............................................................................. 14-8 14-6 Cooper Engine Cross Section (left side) .............................................................. 14-9 14-7 Cooper Engine Timing Bar Graph ...................................................................... 14-10 14-8 Nordberg Engine Linkshaft ................................................................................. 14-11 14-9 Nordberg Engine Service Data Sheet................................................................. 14-12 14-10 Nordberg Engine Operating Pressures & Temperatures .................................... 14-13 14-11 Nordberg Engine Cross Section ......................................................................... 14-14 14-12 Worthington Engine Service Data Sheet ............................................................ 14-15 14-13 Worthington Engine Cross Section ..................................................................... 14-16 14-14 Worthing Engine Timing Diagram ....................................................................... 14-17 14-15 SACM Engine Service Data Sheet ..................................................................... 14-18 14-16 SACM Generator Service Data Sheet ................................................................ 14-19 14-17 DeLaval Engine Service Data Sheet .................................................................. 14-20 14-18 DeLaval Engine Articulating Connecting Rod Assembly .................................... 14-21 EDG UNITS AND ASSOCIATED EQUIPMENT AT PLANT SITES .................... 14-22 Rev 3/16 18 USNRC HRTD

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