ML20081M328
| ML20081M328 | |
| Person / Time | |
|---|---|
| Site: | Grand Gulf  |
| Issue date: | 01/26/1977 |
| From: | TRANSAMERICA DELAVAL, INC. |
| To: | |
| Shared Package | |
| ML20081M273 | List: |
| References | |
| NUDOCS 8311170212 | |
| Download: ML20081M328 (57) | |
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TEST REPORT 1
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I DELAVAL STANDBY GENERATOR SET GRAND GULF NUCLEAR STATION NO.1 & 2 MIDDLE SOUTH ENERGY INC.
ENGINE UNIT NO.1 v.ad;a u-..n
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DMSION 8311170212 831115 PDR ADOCK 05000416 P
Pcga 2 of 57
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l QUALIFICATION TEST l
FOR DE LAVAL ENGINE GENERATOR SET l
j GRAND GULF NUCLEAR STATIONS #1 & #2 94*
MIDDLE SOUTH ENERGY, INC.
l C3 UNIT NO. 1 t
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LC lC PO BY C\\'
DE LAVAL ENGINE & COMPRESSOR DIVISION l
UNDER: MIDDLE SDUTH ENERGY, INC.
l SPEC NO. 9645-M-018.0 1
i REVISION 2 - NOVEMBER 30, 1976 Respectfully Submitted,
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. John J.' Ba rich, J r.'
i Manager, Research & Development l
January 26, 1977 t
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Pcg2 3 of 57
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INDEX SECTION 1 Applicable Documents Factory Test Summary I-Qualification Test Sumary Qualification Test Results & Discussion 2.6 Test Procedure 2.6.1 Functional Tests 2.6.2 Electrical Tests 2.6.3 Operational Tests 2.6.4 Starting Air System Tests T
2.6.5 300 Start Test C
2.6.6 Sequential Loading Tests 2.6.7 Load Rejection Tests 2.6.8 Margin Tests BC 2.6.9 Endurance Tests C
2.6.10 Load capability Qualificati on Tests 2.7 Acoustical Tests" N
2.8 Miscellaneous C.
2.8.1 Torsiograph Test SECTION 2 Factory Test Results (M ATTACRED)
Qc.3gldte EAdwrs.m E. Te.Sk (WEL REQUEU)
P ga 4 cf 57 1
SECTION I e
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Pega 5 cf 57
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APPLICABLE DOCUMEhES P.O. NO. 9645-M-018.0 SPECIFICATION 9645-M-018.0 - REV. 8 W5 MIDDLE SOUTH ENERGY, I NC.
O C36 QUALIFICATION TESTING PROCEDURE FOR DE LAVAL ENGINE GENERATOR SET Lf UNIT NO. 1 C
GRAND GULF NUCLEAR STATIONS #1 & 2 PO MIDDLE SOUTH ENERGY, INC.
pg C
REVISION 2 - NOVEMBER 30, 1976
Pcgn 6 of 57
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FACTORY TEST
SUMMARY
The results of this test Indicate that:
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- i. A satisfactory break-in was achieved.
2.
The unit's performance meets the requirements of the Engine & Compressor Division quality standards.
3.
The unit is now ready for Insta ation at the job site.
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C C.'
O M
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Pcgs 7 of 57
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QUALIFICATION TEST
SUMMARY
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l The engine generator was mounted on its test sub-base along with the
. aux!!Iary module in accordance with De Laval drawings R-3893 and LE-2060 l
j The air starting system, engine control panel and generator panel were connected in compliance with De Laval drawings 100485, 09-500-74033, and Delta Switchboard drawing D53430 A complete verification of all electric wiring was done prior to actually starting the engine.
The deliverable engine control panel was connected to both the engine and the non-deliverable i
special control console.
b At this time a series of checkout runs was made to verify the operation T
of all equipment including the non-deliverable control console.
C Af ter the complete system was operating satisfactorily, the qualification test was made in accordance with the test procedures, Rev. 2, submitted by De Laval and approved by Middle South Energy, Inc. dated November 30, 1976.
St:
The unit successfully completed its qualification test by meeting or C
exceeding the contract requirements. During the various tests, the recovery times of voltage and frequency were in compliance with the specifications.
The N
unit reached rated frequency in no more than seven seconds af ter the initiation C.
of the start signal on all starts. All of the required auxiliary equipment installed in the system perfonned their respective functions and successfully verified the total operating performance of the deliverable system.
All of the qualification testing was done with the engine generator set running at the synchronous speed of 450 RPM and 60 Hertz.
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Pcgs 8 of 57
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QUALIFICATION TEST
SUMMARY
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(Cont.)
2.6.1 Functional Tests The functional tests demonstrated the capability of the following systems:
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1.
Control System demonstrated that:
The engine would start when an emergency start signal was supplied.
a.
b.
The engine could be manually started.
c.
The engine could be manually stopped.
d.
The frequency and voltage could be manually regulated.
CC The voltage regulation could be automatically or manually regulated.
e.
f.
The generator exciter field could be manually removed and reset.
C3 CD g.
The governor and voltage regulator manually activated the I
droop and reset.
I h.
The local remote manual control selection was possible.
' Ln I.
The engine standby local maintenance selector switch worked properly.
- C3 2.
Surveillance System - These tests verified that the following alarms
- PC worked properly
C; a.
Diesel engine or exciter shutdown b.
Diesel generator fault trip c.
Control circui t fuse failure d.
Common alarm for any local annunciation with reflash feature e.
Diesel generator underfrequency condition f.
Diesel generator undervoltage condition E
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Pass 9 of 57 QUALIFICATION TEST
SUMMARY
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(Cont.)
g.
Failure to start h.
Diesel generator overvoltage condition I.
Diesel generator overcurrent condition (by simulation)
J.
Diesel engine was in local maintenance 3.
Protection System These tests demonstrated (by simulation) the protection a.
system for a reverse power and loss of field protection 0
(permitted to trip only upon diesel generator synchronization 9F with the preferred power supply).
CD b.
The fo! lowing tests demonstrated that the protection devices functioned to shut down the diesel and would also be retained durirg a LOCA or loss of power to an engineered safety features bus.
LC I)
Engine overspeed CD 2)
Crankcase pressure - high (by simulation)
F*
3)
Lube oil pressure
- Iow (by simulation)
CY 4)
Generator differential overcurrent (by simulation)
C 5)
Generator ground overcurrent (by simulation) 2.6.2 Not Applicable 4
g Pags 10 cf 57 QUALIFICATION TEST
SUMMARY
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(Cont.)
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2.6.3 Operational Tests Electrical Tests - Field Currents The generator field currents were measured at 7000 KW and 7750 KW at various power factors between.883 and unity.
l 2.6.4.1 Starting Bottle Capacity Test With the coppressor locked out and the air tanks isolated, five consecutive starts were made without any failures. This test was for gg CD record only.
C 2.6.4.2 Starting Air Compressor Capacity Test Following five engine starts, the starting air compressor successfully it.
demonstrated its ability to recharge the system enough in one-half hour so O
that 13 more consecutive starts could be made. This test was for record only.
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lC 2.6.5 300 Start Test The first engine was selected to conduct the 300 start test. More than 300 starts were made without a failure to start upon initiation of the start signal.
This included the actual 300 start test and all subsequent starts.
The strip chart reco s ings show that from the time of the initiation of the start signal, the engine was up to synchronous speed and picked up
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C-Page 11 of 57 14 QUALIFICATION TEST
SUMMARY
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(Cont.)
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'the 3500 KW load in no more than seven seconds. The first 270 starts were conducted from standby keep-warm temperatures.
For each start the l.
P/
engine was run until the normal operating temperatures of the tube oil and
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l Jacket water were reached. This took approximately ten minutes. Af ter these temperatures were reached, the engine was stopped and the water and oil were L
force cooled back to their standby conditions. This took approximately 15 minutes.
Starts #270 through 300 were conducted from the normal half-load temperatures of tube oil and jacket water. These starts were conducted on O
- approximately an eleven-minute cycle.
j C The engine operated in a normal manner throughout the test.
There were
'4 no abnormal Indications and the operating parameters were well within the design limitations of the engine.
At various intervals throughout the test, if, the Bechtel inspectors, representing Middle South Energy, Inc., signed the
. C various strip charts, temperature charts and log sheets.
With only one voided start, which was due to an operator error, more g
c than 300 official starts were made without any failures.
2.6.6 Sequential Loading Tests Af ter making minor adjustments, the sequential loading tests simulating i
the motor loa's for unit #1 was conducted in conformance with the approved d
De Laval procedure.
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Pcg2 12 of 57 QUALIFICATION TEST
SUMMARY
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(Cont.)
The tests successfully demonstrated the unith ability to handle the requirements in both Div. I and Div. II of Appendix "U",
Rev. #3, dated June 19. 1976, showing the step loading for unit #1.
The recovery time of voltage and frequency were in compliance with the specifications.
The test results confirmed the ability of the engine generator to handle the loads and remain within the Regulatory Guide 1.9 criteria, gg.
2.6.7
?.oad Rejection Ln The unit successfully demonstrated its ability to drop a 70X)KW (100%)
CD load, with only a momentary frequency increase, and then return to the C:
nominal frequency with all operating parameters remaining within the specified criteria.
LF.
2.6.8 Margin Tests C:
pq The unit successfully demonstrated its ability to simultaneously start CV two 1000 HP and one 300 HP motors (2300 HP total) and pick up a 2728 KW C:-
resistive load within ten seconds upon initiation of a start signal.
2.6.9 Endurance Test The unit successfully demonstrated its ability to pick up 7000 KW within a time spread of ten seccnds af ter having been operated at no load, rated speed for six (6) hours.
The 7000 KW load was successfully carried for two (2) additional hours.
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Paga 13 of 57 QUALIFICATION TEST
SUMMARY
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(cont.)
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2.6.10 Load capability Tes t l
The engine generator set was run at 110% load (7700 KW) at.905 power factor for two hours. The load was then dropped to 100% (7000 KW) l at.883 power factor for one additional hour.
The unit operated flawlessly during the enti re test.
I 2.7 Acoustical Tests PO The acoustical test was conducted in accordance with DEMA Standards and r
CD was for record only.
C I
2.8.1 Miscellaneous - Torslograph Test This test was conducted for record purposes and to verify results from l
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the analytical study.
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Psg2 14 of 57 2.6.1 FUNCTIONAL TESTS k.
PURPOSE To demonstrate the proper functions of the control, surveillance, and protection systems as outlined in the Qual;fication Test Procedure, Rev. 2, dated November 30, 1976 for the above engine.
INSTRUMENTATION Frequency Meter, Weston Model 339, S/N 1572 Watt Meter, Weston Model 329, S/N 2851 9T Voltmeter, Weston Model 34), S/N 25619 00 Ammeter, Weston Model 370, S/N 8932 O
DESCRIPTION OF TESTS C
1.
Control System I
a.
Verified that the engine would start fran an emergency start signal.
Ln This was done by supplying a start signal f rom the De Laval non-C:
deliverable control panel.
EU b.
Verified that the engine co.uld be manually str rted. This was done CV by pressing the start button on the deliverable engine control panel.
C c.
Verified that the engine could be manually shut down. This was done by pressing the stop button on the deliverable engine control panel.
d & e.
Verified manual f reqJ ency and voltage regulation, along with automatic or manual regulation selection. All of the following tests
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were conducted on the deliverable generator control panel. This was done by selecting automatic regulation and manually regulating
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Paga 15 of 57 2.6.1 FUNCTIONAL TESTS (Cont.)
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the frequency and voltage. Then, manual regulation was selected and again the frequency and voltage were manually regula ted, f.
Verified manual exciter field re.moval and reset.
The field removal was accornplished by pressing the " emergency shutdown" button.
l Resetting was done by pressing"the " emergency shutdown reset" button.
These switches tripped and reset the exciter field relay.
g.
Verified the governor and voltage regulator manually actuated droop and reset.
The governor droop relay was manually activated by E
flipping the "Isochronous-droop" switch, thereby energizing the LA relay.
The paralleling of the voltage regulator was verified by
^O simulation since there was no other unit to parallel with.
lc h.
Verified local remote manual control selection.
This was done by demonstrating that the unit could be controlled in either the local i
Lt.
or the remote mode.
jC
- i. Verifled engine standby local maintenance selector switch. This was f
done by turning the selector switch to local maintenance and showing
'N that the engine was " locked out".
C.
2.
Surveillance System a.
Verified diesel engine or exciter shutdown.
Throughout all of the testing, the " unit tripped" annunciator was energized any time that the engine was shut down.
By pressing the " emergency shutdown" button on the deliverable generator control panel, the exciter was shut down, as evidenced by loss of field current and voltage..
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Pegt 16 cf 57 2.6.1 FUNCTIONAL TESTS (Cont.)
b.
Verified diesel generator fault trip.
To demonstrate the " trip gen. fault" annunciator, the generator trip lockout relay was tripped.
c.
Verified control ci rcuit fuse fallare. The " control ci rcui t fuse fail" annunciator was energized by manually tripping the voltage balance relay.
d.
Verified the common alarm for any local annunciation with reflash feature.
Throughout the testing, the common alarm, which was the WD control panel horn, sounded whenever there was a local annunciation.
Ln e.
Verified diesel generator underf requency. The 'bnderfrequency" annunci ator was energized by manually lowering the engine speed.
g) f.
Verified diesel generator undervoltage. The " low voltage" annunciator was energized by manually lowering the voltage regulator LO setting.
g.
Verified start failure. The " unit failure to start" annunciator PC was energized by manually h61 ding the engine fuel injection racks 04 closed and attempting to start the unit.
h.
Verified diesel generator overvoltage.
The " generator overvol tage" annunciator was energized by manually raising the voltage negulator setting.
1.
Verified diesel generator overcurrent (by simulation). The
" generator overcurrent" annunciator was energized by manually tripping the generator overcurrent relay.
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Pcg2 17 of 57 2.6.1 FUNCT10hEL TESTS (Cont.)
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Verified diesel in local maintenance.
The 'Sn!t tripped" annunciator was energized by swit ching to the maintenance mode. Further verification involved checking continuity across pressure switch
- 40, which will be connected to a customer-supplied annunciator at the job site.
3.
Protection System a.
Demonstrated reverse power and loss of field protection (by simulation).
P4 This was done by manually tripping the reverse power and the field LO protection relays.
b.
Demonstrated protection devices which function to shut down the C3 diesel and which will also be retained during a LOCA or loss of power to an engineered safety features bus.
- 1) Veri fied engine overspeed shutdown. This was done by manually gp, C:
raising the engine speed and demonstrating that the overspeed PC governor shut the unit down.
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- 2) Demonstrated high crankcase pressure shutdown. This was done by C
simulating a high crankcase pressure condition and verifying that the unit was shut down.
3)
Demonstrated low lube oli pressure shutdown.
This was done by simulating a low lube oli pressure condition and verifying that unit was shut down.
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Prgs 18 of 57 2.6.1 FUNCTIONAL TESTS
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(Cont.)
4)
Generator differential overcurrent (by simulation). This was done by manually tripping the differential overcurrent relay and verifying that the generator was kicked off line.
5)
Generator ground overcurrent (by simulation). This was done by manually tripping the ground overcurrent relay and verifying that the generator was kicked off line.
All of the safety devices involved in the functional tests worked flawlessly throughout the testing.
gg Cy The tests were observed, logged and signed by:
CD H. Henricks, De Laval Senior Research Engineer D. Garton, De Laval Quality Control Engineer
- R. Reinsch, Representing Bechtel Corp.
LC ENCLOSURES CD A.
Test Data Sheets E-236 for 2.6.1 pg gq 8.
Foxboro Temperature Recording Chart C.
Page 19 of 57
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2.6.3 OPERATIONAL TESTS PURPOSE To perform tests as outlined in Qualification Test Procedure, Rev. 2, dated November 30, 1976 for the above engine, under Test Method number 2.6.3.1.
INSTRUMENTATION Frequency Meter, W'ston Model 339, S/N 1572 e
Watt Meter, Weston Model 329, S/N 2851 C5 Power Factor Meter, W ston Model 338, S/N 999 e
UN Voltmeter, W'ston Model 341, S/N 25619 e
CD Ammeter, Weston Model 370, S/N 8932 CD Temperature Recorder, Foxboro, S/N 1652300 Millivolt Meter, Westinghouse Model PX5, S/N 1425211 g,q DESCRIPTION OF TEST C5 The generator field current was to be measured at minimum and at unity PG power factor with a load of 7700 KW, The load and desired power factor were achieved using water rheostats, reactors and three 1000 horsepower motors C
(3000 HP total).
The test panel gauge readings for load, frequency, and power factor were verified against the calibrated laboratory instruments, Weston Model 329 Wattmeter, Weston Model 339 Frequency Meter, and W ston Model 338 Power e
Factor Meter.
t Ptg2 20 cf 57 2.6.3 OPERATIONAL TESTS (cont.)
This test was conducted during the 2.6.10 load capability qualification test.
Pertinent data was recorded on data sheets E-236.
SUMMARY
No abnormalities were noted in respect to engine operating parameters, noise or vibration during this test. The test was observed, logged, and signed by:
D. Reid, De Laval Research Engineer
' ED D. Garton, De Laval Quality Control Engineer
' WD R. Reinsch, Representing Bechtel Corp.
C3 A. G. Watson, Representing Bechtel Corp.
. CD l
ENCLOSURES A.
Test Data Sheet E-236 for 2.6.3 tr.
B.
Foxboro Temperature Recorder Chart l ca PO
'N C
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Pags 21 of 57 2.6.4.1 STARTING BOTTLE CAPACITY TEST
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l PURPOSE
. To perform tests as outlined in Qualification Test Procedure, Rev. 2, d'ated November 30, 1976 for the above engine under Test Method 2.6.4.1.
INSTRUMENTATION Temperature Recorder, Foxboro S/N 1652300 DESCRIP TION OF TEST One starting air system was chosen for this test. The systems were isolated and the receiver was filled to its rated capacity of 246 PSIG, and then the compressor was electrically " locked out" to prevent it from charging the system.
From the standby condition, the engine was then o
started without a failure for five consecutive starts. The pressures at the C
beginning and end of each run were recorded on log sheet E-236.
SUMMARY
This test was not a contract requirement; the data obtained was for 14 record only. The engine successfully made a total of five starts without O
a failure using only one air system. During all five starts, the unit p,,
reached rated frequency and voltage in less than ten seconds.
t, The test was observed, logged and signed by:
D. Reid, De Laval Research Engineer D. Garton, De Laval Quality Control Engineer R. Reinsch, Representing Bechtel Corp.
l ENCLOSURES A.
Log Sheets E-236 for Test 2.6.4.1
Psgs 22 of 57 2.6.4.2 STARTING AIR COMPRESSOR CAPACITY TEST PURPOSE To perform tests as outlined in Qualification Test Procedure, Rev. 2, dated November 30, 1976 for the above engine under lest Method 2.6.4.2.
INSTRUME NTATION Temperature Recorder, Foxboro, S/N 1652300 Stop Watch, Meylan Model 210, S/N 10-29-74 gg DESCRIPTION OF TEST WD One starting air system was chosen for this test. The systems were CD isolated and the receiver was filled to a pressure of 126 PSIG, which was EU the pressure after five starts had been made.
At this point, the compressor was turned of f, then started again and run for exactly 30 minutes.
The compressor was " locked out" and the engine C:
was started from a standby condition 13 times using the air in the receiver.
pc The unit failed to start on initiat,lon of the 14th start signal.
The CV pressures at the beginning and end of each run were recorded on log sheet E-236 C-
SUMMARY
This test was not a contract requirement. The data obtained was for record only.
However, from the system conditions after five starts, the compressor had ample capacity to recharge the receiver enough so that 13 more starts could be made.
Page 23 of 57 2.6.4.2 STARTING AIR COMPRESSOR CAPACITY TEST (Cont.)
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The test was observed, logged and signed by:
D. Reid, De Laval Research Engineer D. Garton, De Laval Quality Control Engineer R. Reinsch, Representing Bechtel Corp.
ENCL 0S URES A.
Test Data Sheet E-236 for Test 2.6.4.2 PO WD C3 CD t
Pcgs 24 of 57 2.6.5 300 START TEST
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PURPOSE To perform tests as outilned in Qualification Test Procedure, Rev. 2, dated November 30, 1976 for the above engine under Test Method 2.6.1.1.
INSTRUMENTATION Temperature Recorder, Foxboro S/N 1652300 Frequency Meter, Weston Model 339, S/N 1572 Watt Meter, Weston Model 329, S/N 2851
'I Voltmeter, Weston Model 341, S/N 25619 WD Ammeter, Weston Model 370, S/N 8932 C3 Visicorder, Honeywell Model 1508A, S/N 0305J/J71 C:
Transducers IPAC Series 750, Frequency Transducer LP, Transdata Inc. Model 10P5101, voltage Transducer C3 Transdata Inc. Model 10C5101, current Transducer Transdata Inc. Modei 20W5161, Kilowatt Transducer f\\'
DESCRIPTION OF TEST C
Prior to the official start of testing, the engine was run to establish a load of 1750 KW on rheostat "A" and 1750 KW on rheostat "B".
Throughout the test these rheostas were kept equal to or greater than 1750 KW, Appropriate test panel timers were then adjusted to achieve the required time for I,oad pickup.
The engine was also run for a period of time to establish normal operating temperatures.
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P g2 25 cf 57 2.6.5 300 START TEST (cont.)
A " forced cooling" system was used in cooling the engine back to the standby temperatures after each run. The system circulated engine jacket water through its cooler and engine lube oli through an additional cooler and the engine.
The start number, standby and operating temperatures, the starting air pressure before and af ter the test, and the generator parameters were recorded on data sheet E-236.
LD The engine lube oil and jacket water out of the engine were recorded on 40 a temperature recorder to show the engine at standby temperature, its rise C3 to normal operating temperature, and its return to standby temperature for C
each official start.
The visicorder strip charts show that f rom the time of the start initiation signal until the engine was up to synchronous speed and the Le C3 3500 KW load was picked up was no more than seven seconds. The first 270 E"'
starts were conducted f rom the stan'dby keep-warm temperature and the engine C'
was run until the normal operating temperatures of the lube oil and Jacket C.
water were reached. This took approximately ten minutes.
The engine was then stopped and the lube oil ~and jacket water were cooled back to their i
standby keep-warm condi tions.
This took approximately 15 minutes.
starts No. 270 through 300 were conducted f rom the normal half-load temperatures of lube oil and jacket water. These starts were conducted on approximately an eleven-minute cycle.
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Pcgs 26 of 57 2.6.5 300 START TEST (Cont.)
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The 300 start test proceeded on a 24-hour-per-day schedule.
Although the engine successfully started, run #299 was voided because the engine did not reach frequency within the required time.
This was because the operator tried to start the uni t before the engine shutdown mechanism had had time to reset itself.
Minor maintenance work was done on the air compressor af ter start 55 and routine engine maintenance was performed af ter starts #130, 244 and 275.
A total of 305 official starts were made during the test without any failures af ter initiation of the start signal.
The test as outlined in the Qualification Test Procedure, Rev. 2, dated C
November 30, 1976 for Test Method 2.6.5 was completed without any failures.
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The test was observed, logged and signed by:
E' H. Henricks, De Laval Senior Research Engineer C
H. Schilling, De Laval Senior Research Engineer P2 D. Reid, De Laval Research Engineer D. Garton, De Laval quality Cont rol Engineer R. Reinsch, Representing Bechtel Corp.
A. G. Watson, Representing Bechtel Corp.
ENCLOSURES A.
Data sheets for 2.6.1.1 - Starts #1 to #305 dated 12/11/76 to 12/16/76 8.
Visicorder strip chart recordings - Starts #1 to #305 dated from i
12/11/76 to 12/16/76.
C.
Temperature recorder charts - Starts #1 to #305 dated from 12/11/76 to 12/16/76 l' i
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Pggs 27 of 57 2.6.6 SEQUENTIAL LOAD UNIT NO. 1 P'RPOSE U
To perform tests as outlined in Qualification Test Procedure, Revision 2, dated November 30, 1976 for engine unit No. I under Test Method 2.6.6.
INSTRUMENTATION Temperature Recorder, Foxboro S/N 1652300 Frequency Meter, Weston Model 339 S/N 1572 W ston Model 329 S/N 2851 Wat*. Meter, e
%6 Voltmeter, Weston Model 341 S/N 25619 C)
Anmeter Weston Model 370 S/N 8932 Visicorder, Honeywell Model 1508A S/N 0305J/J7
.3 Transducers IPAC Series 750, Frequency Transducer Transdata Inc. Model 10P5101 Voltage Transducer
. j.
3 Transdata Inc. Model 10C5101 Current Transducer F3 Transdata Inc. Model 20W510.1 Kilowatt Transducer IN DESCRIPTION OF TEST L
2.6.6.1 Division 1 Preliminary runs were made to establish 2480 KW on rheostat "A",
900 KW on rheostat "B",
1400 KW on rheostat "C", and 950 KW on rheosta t "D".
Pegs 28 of 57 2.6.6 SEQUENTI AL LOAD UNIT NO. I i
(cont.)
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2.6.6.1 Division i The official test was conducted in the following sequence:
O seconds initiate start signal.
0+
8 seconds Simultaneously start two 1000 HP motors (2000 HP total) and pick up 2480 KW on rheoscat "A".
0 + 13 seconds Simultaneously start a 1000 HP motor and pick i
up 900 KW on rheostat "B".
0 + 18 seconds Simultaneously start a 500 HP motor, a 300 HP E
motor (800 HP total) and pick up 1400 KW on rheostat "C".
.O O + 23 seconds Simultaneously start a 300 HP motor and pick up 950 KW on rheostat "D".
Tabulated Results - Division i Voltage Freq.
Frequency
' Lt:
Motor Start Voltage Recover to Dipped Recover to Cum.:l a t i s e Test Time HP & KW Load Dipped to 90'X Rated to 987 Rated Load Seconds Voits Seconds Hertz Seconds Ku g
.N G+
7.8 2000 HP 3325
.45 57.3
.89 2500 2480 KW C
1 0 + 12.8 1000 HP 3800 0
59.3 0
3600 900 KW 0 + 17.9 800 HP 4100 0
59.4 0
5000 1400 KW 0 + 22.9 300 HP 4050 0
59.3 0
6000 950 KW
Psgs 29 of 57 2.6.6 SEQUENTIAL LOAD UNIT NO. 1 (Cont.)
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1 1
2.6.6.2 Division il Preliminary runs were made to establish 1580 KW on rheostat "A",1400 KW on rheostat "B", 2220 KW on rheostat "C", and 900 KW on rheostat "D".
The official test was conducted in the following sequence:
1 O
seconds initiate start signal.
0+
8 seconds Simultaneously start a 1000 HP motor and pick up 1580 KW on rheostat "A".
0 + 13 seconds simultaneously start a 1000 HP motor and pick up 900 KW on rheostat "D".
y, 0 + 18 seconds Simultaneously start a 1000 HP motor and pick up
.)
1140 KW on rheostat "B".
,7 l7 0 + 23 seconds Simultaneously start two 300 HP motors (600 HP total) and pick up 2220 KW on rheostat "C".
t Tabulated Results - Division 11 l Ji Voltage Freq.
Frequency Motor Start Voltage Recover to Dipped Recover to Cumulative D
Test Time HP & KW Load Dipped to 90% Rated to 984 Rated Load l
Seconds Volts Seconds Hertz Seconds KV sel
o+
7.8 1000 HP 3650
.24 58.1 70 1750 l :-
1580 KW l
1 0 + 12.9 1000 HP 3700
.20 59 3 0
2800 900 KW D + 17.9 1000 HP 3750 0
59.2 0
4350 1400 KW 0 + 22.9 600 HP 4050 0
58.6 1.31 6500 2220 KW i
! l l
l
Page 30 of 57 2.6.6 SEQUENTIAL LOAD UNIT NO. I
(
(Cont.)
The tests verified the unit's ability to handle the sequential load requirements in both Division I and Division ll of Appendix "U",
Rev. #3, dated June 19, 1976 for uni t #1.
SUMMARY
The tests as outlined in the approved qualification test procedure were followed. The unit met all of the contract requirements.
g The test was observed, logged and signed by:
lN H. Henricks, De Laval Senior Research Engineer
- C D. Garton, De Laval Quality Control Engineer O
R. Reinsch, Representing 8echtel Corp.
ENCLOSURES l
A.
Data Sheets for 2.6.6.1 and 2.6.6.2 B.
Visicorder Strip Charts for Sequential Load Tests C
C.
Foxboro Temperature Recording Chart jpq l b C
l l
l
~.
d i.
- Page 31 of 57
- g 2.6.7 LOAD REJECTION TEST
(
PURPOSE To perform tests as outlined in Qualification Test Procedure, P,ev. 2, dated November 30, 1976 for the above engine, under Test Method Number 2.6.7.
INSTRUMENTATION l
i j
Frequency Heter, Weston Model 339 S/N 1572 Watt Meter, Weston Model 329 S/N 2851 Voltmeter, Weston Model 341 S/N 26519 l
Ammeter, Weston Model 370 S/N 8932 l
Visicorder, Honeywell Model 1508A S/N 0305J/J7
- N Temperature Recorder, Foxboro, S/N 1652300 lC lC Tra nsduce rs l
l PAC Series 750, Frequency Transducer Transdata Inc. Model 10P5101 voltage Transducer V
Transdata Inc. Model 10C5101 Current Transducer O
Transdata Inc. Model 20W5101 Kilowatt Transducer PC l
DESCRIPTION OF TESTS lN Af ter conducting preliminary testing and stabilization of operating temperatures, a load of 7000 kilowatts was established using rheostats "A",
1 "B" and "C" as requi red.
The test panel gauge readings for KW, frequency, amps, and voltage were verified against the calibrated laboratory instruments.
Upon a signal f rom the load control panel, rheostats "A", "B" and "C" were dropped sjmultaneously, which resulted in an immediate no-load condition f rom l
a full rated load condition.
i
,26-
Pega 32 cf_57 f
2.6.7 LOAD REJECTION TEST
(
(Cont.)
S'JMM AR )
Ths outline for test 2.6.7 in Qualification Test Procedure. Res. 2, 1
was follo.ed.
The engine gosci nor system successf ully held the eas.ine..i thir.
the a cqai n co speed range das in.. the t s ansient load char.ge.
1 The Leat.as observed, loggeo dad signed by:
- h. Henricks, De Lc.al Senio-Research Engineer l(T D. Garton, De Lasal Quality Control Engir.cer
! P4 R. Reinsch. Represcating Bechtel Corp.
' C3 ENCLOSURES l cs A.
Test Data Shces for Test 2.6.7 B.
Teriperature Recon des Chart j y; C.
Vinicorder St rip Chart - Lead Rejection Test
- C Y"
I ce
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h i
i e
1 4
i 1 i,,w,e,-- - - -
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e- -, -,.. - -.
,,,.<-w.,_.,,,,,e--.e
,.-me,_,-.
_m,w.mm,i.
ym,m,w.
7y--,,,cv--w,-
Paga 33 of 57
)
j
{
2.6.8 MARGIN TEST
(
PURPOSE t
To perform tests as outlined in Qualification Test Procedure, Rev. 2, l
dated November 30, 1976 for the above engine, under Test Method 2.6.8.
1 INSTRUMENTATION l
Frequency Meter, W ston Model 339, S/N 1572 e
Watt Meter, Weston Model 329, S/N 2851 Voltmeter, W ston Model 341, S/N 25619 e
Ammeter, Weston Model 370, S/N 8932 P3 Visicorder, Honeywell Model 1508A, S/N 0305J/J7 N"
Transducers D
IPAC Series 750, Frequency Transducer C
Transdata Inc. Model 10P5101 Voltage Transducer Transdata Inc. Model 10C5101 current Transducer j;
Transdata Inc. Model 20W5101 Kilowatt Transducer DESCRIPTION OF TEST Preliminary tests were conducted to establi sh a load of 2728 KW on
- N' wa t e r rheo s t a t s "A" and "B".
The test panel gauge readings were verified
~
against the calibrated laboratory instruments of KW, frequency, amps, and voltage.
- t..
Pagt 34 of 57
~
2.6.8 MARGIN TEST (Cont.)
(
' The official test was conducted in the following sequence:
O seconds initiate start signal O + 7 seconds Simultaneously start two 1000 HP motors, one 300 HP motor (2300 HP total) and pick up 2728 KW on rheostats "A" and "B".
Two official tests were conducted on the unit.
Tabulated Results T
Voltage Freq.
Frequency
%g Motor Start Voltage Recover to Dipped Recover to Cumalatise Test Time HP & KW Load Dipped to 90% Rated to 98% Rated Load D
Seconds Volts Seconds Hertz Seconds KW l
o + 7.0 2300 HP 3250
.45 57.8
.82 3050 2728 KW 2
0 + 7. 0 2300 HP 3275
.41 57.8
.83 3100 JI 2728 KW The test verified the unit's ability to handle the load requirements.
?C
SUMMARY
j The tests as outlined in the approved Qualification Test Procedure were followed.
The unit met all of the contract requirements.
The test was observed, logged and signed by:
H. Henricks, De Laval Senior Research Engineer D.- Garton De Laval quality Control Engineer R. Reinsch, Representing Bechtel Corp.
t.
=
Pcge 35 of 57 2.6.8 MARGIN TEST (Cont.)
A ENCLOSURES A.
Data Sheets for 2.6.8 B.
Visicorder Strip Charts for Margin Tests C.
Foxboro Temperature Recording Chart it s
.)
3 9
f a
O G
I Pega 36 of 57 2.6.S ENDURANCE TESTS 4
$URPOSE To perform tests as outlined in Qualification Test Procedure, Rev. 2, dated November 30, 1976 for the above engine, under Test Method 2.6.9.
I NSTRUMENTATI ON i
Frequency Meter, Weston Model 339, S/N 1572 Wattmeter, Weston Model 329, S/N 2851 l
Power Factor Meter, Weston Model 338, S/N 999 WD Voltmeter, W ston Model 341, S/N 25619 e
jE" Ammeter, Weston Model 370, S/N 8932 i CD Temperature Recorder, Foxboro, S/N 1652300
! C3 l
DESCRIPTION OF TEST I
Preliminary tests were conducted to establish a load of 7000 KW divided gg between rheos tat s "A", "B" and "C".
The test panel gauge readings were I C3 verified against the calibrated laboratory instruments of KW, frequency, PC emps and voltage. The timers were then set to pick up rheostat "A" at zero seconds, rheostat "B" at five seconds, and rheostat "C" at ten seconds.
ICL l
When the engine had reached normal operating temperatures, the 7000 KW load was removed.
The engine was then idled at no load-rated speed for l
six (6) hours. At the end of this time period, the 7000 KW load was picked up within ten seconds and the engine was run with this load for two (2) l additional hours.
i Pertinent data was recorded on data sheets E-236 i
l
Paga 37 of 57 2.6.9 ENDURANCE TESTS
(
(Cont.)
SUMMARY
No abnormalities were noted in respect to engine operating parameters, noise, or vibration during this test.
Twice during the two (2) hour full load portion of the test, the circuit breakers tripped on one of the De Laval factory load cells. The load was immediately brought back to 7000 KW by utilizing a different load cell. Although there were minor problems with the De Laval factory test equipment, the deliverable engine p
pg 9enerator set operated flawlessly.
C3 The test was observed, logged and signed by:
C3 H. Henricks, De Laval Senior Research Engineer H. Garton, De Laval Quali ty Control Engineer A. G. Watson, Representing Bechtel Corp.
17.
R. Reinsch, Representing Bechtel Corp.
pq ENCLOSURES re A.
Test Data Sheet E-236 for 2.6.9 CL B.
Foxboro Temperature Recorder Chart
Pegs 38 of 57 2.6.10 LOAD CAPABILITY QUALIFICATION TEST
(
PURPOSE To perform test as outlined in Qualification Test Procedure Rev. 2 dated November 30, 1976 for the above engine, under Test Method 2.6.10 lNSTRUMENTATION Frequency Meter, Weston Model 339, S/N 1572 Voltmeter, Weston Model 341, S/N 25619 Watt Meter, Weston Model 329, S/N 2851 Temperature Recorder, Foxboro, S/N 1652300 4C Anuneter, Weston Model 370, S/N 8932 Power Factor Meter Weston Model 338, S/N 999 O
C DESCRIPTION OF TEST With engine at operating temperature, a load of 7700 kilowatts at.905 I
power factor was established using water rheostats "A",
"B", "C" and "D",
E' six shunt reactors, and three 1000 HP motors.
C The test panel gauge readings for load and frequency were verified against F'
the calibrated laboratory instruments, Weston Model 339 Frequency Meter, Weston Model 329 Watt Meter, and Weston Model 338 Power Factor Meter.
C The engine was run for a period of two hours with a 7700 kilowatt load while maintaining a 60 Hertz frequency. At the end of this period, the load was dropped to 7000 KW at.883 power factor and run for one (1) hour.
The power factors were the lowest obtainable with the De Laval factory test equipment.
Pertinent data was recorded on data sheets D-4173A/D-41738.
SUMMARY
No abnormalities were noted in respect to engine operating parameters, noise or vibration during operation in both the overload and full loao conditions.
The test was observed, logged and signed by:.
Psgs 39 of 57 j
i I
)
2.6.10 LOAD CAPABILITY QUALIFICATION TEST (Cont.)
l j
D. Reid, De Laval Research Engineer D. Garton, De Laval Quality Control Engineer
)
A. G. Watson, Representing Bechtel Corp.
I R. Reinsch, Representing Bechtel Corp.
ENCLOSURES A.
Test Data Sheets D-4173A/D-4173B for Test 2.6.10 m
B.
Temperature Recorder Chart Ps
. E)
' C3 I
. U**
- 3 N
N i C.
l
. ~.
Pcg2 40 of 57 y \\ te 2.7 ACOUSTICAL TEST I
i" ;
PURPOSE
.To perform tests as outlined in Qualification Test Procedure Rev. 2 dated November 30, 1976, under Test Method Number 2.7.
!NS1RUMENTATION I
Precision Sound-Level Meter and Analyzer, General Radio Type 1933, S/N 3590 Sound-l.evel Calibrator, General Radio Type 1562-A, S/N 19861 DESCRIPT)0N OF TESTS
' c 2. 7. t.
With only this unit operating in the shop at full load (7000 KW)
O<
- 3[
and rated speed, a complete set of sound level readings were 3 ~
taken for the following:
2.7.1.1 All octave band frequencies from 31.5 Hz to 16K Hz i
were taken at 11 locations.
' r.
2.7.1.2 "A" weighted scale readings (dBA) were taken at 37 locations.
.3 2.7.2 With no shop engines running, a complete background sound level
~
readings were taken for the following:
g.
2.7.2.1 All octave band frequencies from 31.5 Hz to 16K Hz were
?
taken at 11 locations.
o 2.7.2.2 "A" weighted scale readings (dBA) were taken at 37 locations.
/
SUMMARY
The sound level tests were conducted during the endurance test #2.6.9 between the hours of 140) and 1451 on December 27, 1976.
The background l
1 1
Peg 2 41 of 57 2.7 ACOUSTICAL TEST (Cont.)
(
' sound level tests were conducted the followirg day at about the same time with no engines running. The hours were between 1526 and 1601 on December 28, 1976. According to backgre:nd correction sheet 2.7.8, no correction in the sound ievels were required.
The test was conducted by Harold V. Schilling, De Laval Senior Research Engineer, and Dennis Reid. De Laval Research Engineer.
The rated load sound level test logs were witnessed by H. Duane Carton, De Laval quality Control Engineer, and by Mr. Richard M. Reinsch and e
Mr. A. G. Watson of Bechtel Corp.
D The background sound level test logs were verified by Larry Osness, De Laval quality Control Engineer, and by Mr. Richard M. Reinsch and i
Mr. A. G. Watson of Bechtel Corp.
EHCLOSURES f.
A.
2.7.3 Acoustical Layout, Octave Band Sound Level 3
w 8.
2.7.4 Acoustical Layout, "A", Weighted All-pass Sound Level N
C.
2.7.5 Sound Level Pickup Locations
~*
D.
2.7.6 Acoustical Test - Engine, Generator Running at Full Load and Speed, Form E-236.
E.
2.7.6.1 Full Load and Rated Speed Octave Band Sound Level Data F.
2.7.6.2 Full Load and Rated Speed "A" Weighted Sound Level Data Locations I thru 16 Pcga 42 cf 57 2.7 ACOUSTICAL TEST
(
(Cont.)
G.
2.7.6.3 Full Load and Rated Speed "A" Weighted Sound Level Data Locations 17 thru 37.
H.
2.7.7 Acoustical Test - Background Sound Level with No Engines Running 1.
2.7.7.1 Background Sound Level Data for Octave Band Frequencies J.
2.7.7.2 Background Sound Level Data for "A" Weighted Scale Locations I thru 16.
CQ K.
2.7.7.3 Background Sound Level Data for "A" W ighted Scale e
SS Locations 17 thru 37.
E L.
2.7.8 Background Sound Level Data Correction Curve C:
I bf.
'C?
PG CM C.
Pags 43 of 57 2.7J ACOU S T ICA L S URVEY LAYOUT RV-16 ENGlHE DEMA GRID 5
OCTIVE. BAND SOUND LEVEL
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CONDITIONS 5 *!i< t chin # 1e ie fil%!
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Pcgs 44 of 57 h' OUST IC A LS URVEY LAYOUT RV-/ 6 ENGINE DEMA GRID
'A ' WElGH TED ALL-Pass sound LEVEL
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2.7.5 SOUND LEVEL PICKUP LOCATIONS i
2.7.5.1 DEMA Grid Octave Band Sound Level pickup locations are ten feet apart and five feet from engine surface.
Two locations are in f ront of the engine and two behind the generator.
Three locations are on each side of the turbochargers.
We added the exhaust silencer 00 outlet location.
80 C3 2.7.5.2 DEMA Grid "A" Weighted Sound Level pickup locations are CD ten feet apart and five feet f rom engine surface all
(
around the engine and generator. We added the exhaust gn silencer outlet location.
C PG CN' C
. _= -.
r-Pcg2 46 of 57-g TOR $10GrdPH OF MIDDLE SCtrlH ENERGY ENGINE NO. 74033 GENERATOR SET DSiw-16-4, 9750 BHP, 7000 KW 60 450 RPM, 225 BHEP I N 031.A!!9 PLANT Ptif' POSE To. verify calculated f requency and stress level of the torsional mass clastic syste.n.
I HSTRlifiEill!.I I ON Lockheed Store la instrumentatiori Recorder Huulett-Packard Sr.,: etruin..iialyzer 3530- A Hewlett-Packas d Elect renic Digt tal Counter 5381-A Bell r. H raell C.C.C. Torslograrh 9-102 Bell & H.auell C.1.C. Viteration ficter 117 Al rpa>. Itognetic Pickup 1-0054 Generc; P.adio V riac Automatic Voltage Regulator 1591 A itASS EL ASTIC e.Y':TF!!
N ll.a cr: gin. I, tr.upled to the cont r6ct flAwhect and t;coniator os vrould Le ein'cr actual 3,1i e condi t ion.
W
.T_i.f.T I TircrD'Jr:[.-
Th.. tor. sic,rca;!. and t;:ced in:'l::iting devices v :re uoanted 0:i the foirt.:t i cnd C
o ' the c...nh '. :i t, ince : ort c.cnts recre take n,t:
375, ?Un,
~.>35, 3ilr., ?%, 405
'ilS. 415. 4ff, 435, 440,145, 450 %5 l.
cnd 400 it 81 at no lo: d, and at '.50 rfit wi th 27, boi, ?f,7,,100Z :.d 1107. rated loed.
M Yi r e.ESUL1s O
The test re s :l t s of thc.
v... leble speed nr. lo:c r:cis arc listcJ in E.ir.lo:,i rc ";"
..nd piot t us i n !.:.cle: ure/ t."..n t: "C ".
I t c.:n b:: rcetiiIy n en thst I he I !: and g
I h 1/2 cri t 1(alt rooked out. c.t h3ts c::6 382.2 PFM respc.ctively, givinc. s'w it.cesur.2d f i rt,t me.t c oc* isci.1 I rega ncy at 1720 VFit.
Wiwn compared to the i
gv 1730 Vht calculcted fi rr.
n.nl.: n1turet f r:.qu:.ncy. tha error is only.62.
C h far N ti.e em:6.11 ti:.!c r. cire c oncerne l. 1-4 1/2 hcs a ret.onence er.plits.Je of
.32 and 1 is I.:ve..?"# ithir.h c.orrespr.ndr. to /70!* PSI and 1943 FSI respectively 0
an: check til th th : <,..lcuir. :d v.alues sii 2743 atad ?ll45 PSI vt ry well.
1he test re ol ts of t! e t.vnchronnas si ecd varioW load runs are li sted in I.rcits.it.
"0",
and r.,l o ;t d i n Enclose..s "E".:nd "F".
Tie cifects on the
- 6..pl i ted. s th... i v load.u L';0 7 are very evides.t.
Enclosuru
'C" shie.u e t. L: !:. tion of rc.e..r.. red ampli te:'e and ihn cori csponding r.rt.ok pi a 's t : ne s ni il'c vario.i., ho:
nit.s due to dil't crent load settings.
Ike.e of tire s e rest. Ic.eis..oc to ti.- In..enic.:, at e injuriou:. and the everall level of ?bO/ :il at !OJ' !s A rv sat.:.fectory.
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rm>I@ C/ERAIL Pl!010 RDCORD W 27~ DEFICIENCIES CORREC'IE PA*E!!PAI!?OD d EXTERICII P!KnD # 6EE #7746//7) M/#' ter.s, sew. Tass, ~ E3IEN G*w3S,EIC. Noagr' INItttt0R Pil0!O # N / ggy N / L."1T Pld!1 MISCFIL. CI!RCKS N _/ O N l T.'ItT!!'J & WTnitsa. 2.D. P!A1E #518::S N/ 99 !C.A7 & SECU!S DATA CotTLEIE / N. 6
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(/)' ~* Pcgs 56 of 57 4 J:nucry 18, 1977 R & D TEST
SUMMARY
RV-027-3 ( ' TEST IDENTIFICATION Idle Endurance Test OBJECT To determine the performance characteristics of a DSRV-16-4 engine when a substantial step load was applied af ter the engine had been idied in a no-load condition for an extended period of time. AUTH3 R IZ ATl0N Warren Rhoades and John J. Barich O' PROCEDURE P* A 7000 KW nuclear standby engine was run in a no-load, rated speed condition for 168 hours. "At the end of this time period, a 1000 KW resistive load C3 was applied and one-half second later a 3000 KW resistive load was applied CD (4000 KW total). A visicorder chart recording of the voltage, frequency, emperage and power (load) was made. in addition, photographs were taken of the engine exhaust stack before, during and af ter the load was applied. The The Jacket water and L.O. temperatures were recorded during the test. engine-generator set was to be run wi thout any adj ustments or m aintenance work Cp unless a potentially-damaging problem arose. C3 RESULTS The results are tabulated on the following pages. The test instrumentation used is listed below: Cy C3, Temperature Recorder, Foxboro S/N 1652300 Frequency Meter, Weston Model 339 S/N 1572 Watt Meter, W'ston Model 329, S/N 2851 e Voltmeter, Weston Model 341 S/N 26519 Anmeter, Weston Model 370 S/N 8932 l Visicorder. Honeywell Model 1508A S/N 0305J/J7 Transducers IPAC Seri es 750, Frequency Transducer ~ Transdata Inc. Model 10P5101 Voltage Transducer l Transdata Inc. Model 10C5101 Current Transducer Transdata Inc. Model 20W5101 Kilowatt Transducer The log sheets are included in the appendix. i , t l i
I Pcgs 57 of 57 o / R & D TEST
SUMMARY
RV-027-3 g (Cont.) Load Application Voltage Frequency Recover Frequency Recover Load Voltage to 90% Dipped to 98% Cumulative Time KW Dipped to Rated to Rated Load 0 0 4160 0 60.0 0 0 0 +.3 1000 4080 0 59.5 0 1000 0 +.9 3000 4050 0 57.7 4.6 sec. 4000 CD SD DISCUS $10N C3 The engine-generator set performed flawlessly and requiredno maintenance C3 whatsoever during the entire test. The exhaust was clear at the start of the test and remained so until the load was applied. Af ter the load application, the exhaust smoke was heavy for about 20 seconds. As can be seen from the photographs, the exhaust was normal within 35 seconds of the load application. C3 CONCLUSIONS CD 1. The unit performed excellently throughout the rests with no evidence EU of combustion problems or engine malfunctions. f4 2. The engine was able to accept a 57% step load (4000'KW). C3 3. 1he exhaust stayed clear thoughout the test and smoked only slightly longer than normal following the load application. 4. The objectives of the test were successfully met. OUDMe b Dennis Reid DR/pn . -}}