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TMilllin IESSitt PINI EMERGENCY DIESEL GENERATOR - ENGINE CONTROL AND PROTECTION ggjgg[gg NL-LP-11204-00-C 1 I Il.E 2 g,gg((,],
OUTSIDE AREA OPERATOR 11EV I S 1011:
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FORMAT A.
Lecture with visual aids MATERIALS A.
Overhead projector D.
Transparencies C.
White board w;tt. markers EVALUATION A.
Written or oral exas ia w urction with other lesson plans IV.
REMARKS A.
A performance-based instructional unit (!U) is attached to the lesson plan as a student handout.
Af ter the lecture, instruction should be provided for the attached instructional unit.
The instructor should be available to answer any questions that may arise concerning the 10 saterial.
After instruction on the IU, the student will perform, simulate, observe or discuss (as idetitified on the cluster signof f criteria list) tha task covered in the instructional unit in the presence of an evaluator.
MASTER COPY 9202190546 920116 PDR ADOCK 05000424 S
o NL-LP-11204-00-C 1.
PURPOSE STATEMENT:
FOLLOWING COMPLET!ON OF Tylt LEBBON, THE iTUDENT WILL P088E88 THOSE KNOWLEDGES SYSTEMATICALLY IDENTIFIED FOR THE PERFORMANCE OF DIESEL ENGINE CONTROL AND PROTECTION SY6 TIM TASKS II.
LIST OF OBJECTIVES:
1.
State the uses of the pneumatic portion of the emergency diesel engine control and protection system.
2.
State the source of air supplied to the pneumatic engine control system.
1 List the basic uses of the A, B, and C control circuits, and state how they are monitored.
4 List the diesel engine and generator control panel permissives that are necescary for the following to occurs I
a.
Normal manual start, from control room b.
Normal manual start, from engine control Automatic start on loss of offsite power c.
d.
Automatic start on safety injection signal l
5.
List the protective trios available to the diesel generators af ter a normal start.
6.
List the protective trips available to the diesel generator
,aftar an emergency start has occurred.
7.
Describe the operation of the PULL-TO-RLN/ PUSH-TO-STOP button at the engine front.
i l
B.
For the following pushbuttons on the diesel engine control panel, state the response which will occur when each is pushed (or actuated).
a.
EMERGENCY START (when glass is broken) b.
START c.
OPERAT!ON NODE d.
MAINTENANCE 60DE e.
ENGINE ROLL f.
EMERGENCY STOP (break glass, pushbutton) g.
EMERG-STOP RESET h.
STOP 1.
RESET FROM LOCA 2
j
NL-LP-11204-00-C II.
LIST OF OBJECTIVES For the fqilowing indicators on the diesel engine control panel, 9.
state the,%ignificance of each being litt a.
UNIT AVAILABLE b.
EMERGENCY STOP c.
DIESEL AUTO START SIGNAL d.
SHUTDOWN SYSTEM ACTIVE e.
SAFETY INJECTION SIGNAL f.
IN TEST SEQUENCE g.
52-G CLOSED h.
READY TO LOAD 1.
RUNNING J.
STOPPING k.
BYPASS TEST FAILURE 1.
STARTING 10.
State the function of the Woodward Governor System.
11.
Give a brief description of the uses for the three control knobs I
on the EGS-35 governor actuator, and the approximate values to which they are normally sets a.
LOAD LIMIT b.
SPEED SETTING ADJUSTMENT c.
SPEED DROOP 12.
Describe how the Woodwatd type SG Overspeed Trip functions to
[
shutdown the diesel engine.
13.
Describe the eksponse of the fuel rack shutdown cylinder and combustion air valves to a dJesel trip signal.
14.
State the permis,sives which allow barring of the diesel engine, and state the difference between barring and rolling.
15.
Give a brief description of the cylinder moisture check.
16.
Discuss how trends in the parameters monitored by logging (using 11885-C) during operation can be used to determine operational problems.
17.
State a probable consequence of starting the EDG with an inadequate governor oil level, or without proper governor venting by maintenance personnel.
1 18.
State the method of detecting engine. imbalance and the possible
' consequences of sustained engine operation in an unbalanced condition.
19.- State the reason for the cylinder moisture check after the emergwncy diesel generator has been run, nd give the time scheduled for the check.
3
NL-LP-11204-00-C REFEREACES:
1.
PLANT V0GTLE PROCEDURES:
13145, DIESEL GENERATOR (REV 8) 13146, DIECEL GENERATOR FUEL O!L TRANSFER SYSTEL (REV 1) 14900, DIESEL GENERATOR OPERABILITY TEST'(REV 1; 13427, 4160 VAC 1E ELECTRICAL DISTRIBUTION SYSTEM 17035, ANNUNCIATOR RESPONSE PROCEDURES (REV 3) 17038, ANNUNCIATOR RESPONSE PROCEDURES (REV 3)-
2.
TECHNICAL SPECIFICATIONS:
3.0.1 ELECTRICAL POWER SYSTEMS, AC SOURCES 3.
STANDBY (EMERGENCY) DIESEL GENERATOR, V0GTLE TRAINING TEXT CHAPTER 16C, VEGP 4.
PLANT MANUAL CHAPTER 36, REV 0 5.
P&lDS, LOGICS AND OTHER DRAWINGS:
PIPING AND INSTRUMENT DIAGRAMS:
1X4DB170-1 (REV 21) 1X4DB170-2 (REV 21)
VENDOR DRAWINGS:
AX4AK01-27 (LUBE OIL) t AX4AK01-26 (JACKET WATER)
AX4AK01-29 (STARTING AIR)
TX4AK01-29 (FUEL O!L)
CONTROL LOGIC DIAGRAMS:
1X5DN107-1 (D6 FUEL O!L SYSTEM) 1X5DN107-2 (D6 UNIT ENGINE) 1X5DN107-3'(6ENERATOR)
ELEMENTARY DIAGRAMS:
1X3D-BH-603C (REV'2) 1X3D-BH-603D-(REV 1) 1X3D-BH-603E (REV 2) 1X3D-BH-603F (REV 2) 1X3D-BH-G036 (REV 1) 1X3D-BH-603H (REV 3) 1X3D-BH-603! (REV 2) 1X3D-BH-603J (REV 3)-
ONE-LINE DIAGRAMS 1X3D-AA-A01A (REV 12) 1X3D-AA-K01A (REV 7) 4
NL-LP-11204-00-C REFERESCES:
~
6.
VENDOR MANUALSt AX4AK01-509 (REV 0)
AX4AK01-510 (REV 2)
AX4AK01-563 (REV 6) 7.
F.S.R.R.: B.3, 9.5.4, 9.5.5, 9.5.6, 9.5.7, 9.5.B 0.
'JNAVAILABILITY OF EMERGENCY POWER CAUGED BY DIESEL AND E9EAKER UNAVAILABILITY SOER 83.001 DIESEL GENERATOR FAILURES SOER 84.042 SYSTEM INTERDEPENDENCY OVERSIGHTS RESULTS IN LOSS OF REDUNDANT SAFESUARDS FUNCTIONS IEN 85.028 PARTIAL LOSS OF AC POWER AND DIESEL GENERATOR DEGRADATION IEN 84.069 OPERATION OF EMERGENCY DIESEL GENERATORS OMR 297 SRID HIGH VOLTAGE AND UNDERVOLTAGE TRIP RELAYS CONTRIBUTE TO EDG OUTPUT BREAKER LOCKOUT NUREG 1216.000 SAFETY-EVALUATION REPORT-RELATED TO OPERABILITY, AND RELIABILITY OF EMERGENCY DIESEL GENERATORS -
MANUFACTURED BY TRANSAMERICA DELAVAL, INC" (NOT AN DAP ACTION ITEM, BUT A TRAINING COMMITHENT) 9.
INSTRt CTIONAL UNITS: NONE 10.
TRANSPsRENCIES:
NL-TP-11204-001 LESSON OBJECTIVES NL-TP-11204-002 BASIC DG GOV. CONTROL NL-TP-11204-003 EGB-35 GOV / ACTUATOR CUTAWAY NL-TP-11204-004 EGB-35 GOV / ACTUATOR 3eVIEW NL-TP-11204-005-OVERSPEED TRIP, FRONTf810E NL-TP-11304-006 OVERSPEED TRIP - CROSS-SECTION NL-TP-11204-007 ENGINE CONTROLS, PDG2/PD64 NL-TP-11204-008 DG CONTROLS, QEAB 11.
STUDENT-HANDOUTS:
l Nt-HO-11204-C-001-EMERSENCY DIESEL GENERATOR: EN67NE-CaidTROL l
AND PROTECTION 5
NL-LP-11204-00-C
__111. LESSON OUTLINE:
NOTES I.
INTRODUCTION i
A.
This lesson describes how the diesel engine controls function in the starting, running, and stopping of the engine, and include a review of engine protection devices B.
The operation of Woodward governing systems used for adjusting engins speed and load are presented C.
There is a separate lesson for the generator and its protection D.
Present Lesson Objectives NL-TP-11204-001 II.
PRESENTATION A.
Over vi ew, Engine Controls 1.
Provides a means of starting, loading, running, and stopping the diesel generator 2.
Locations a.
Normal control from control room (OEAB)
{
b.
Backup control from diesel engine control panel PDG-2 (Train A) j PDG-4 (Train B) 3.
Two basic modes of operation a.
Operational mode 1)
Control circuits armed
- 2) Must be in operational mode to be operable b.
Maintenance mode
- 1) Start circuits locked out
- 2) Used f or repair, maintenance, barring rolling
- 3) Pushbutton on local panel 4)
DG INOPERABLE in MAINT. MODE 4.
Selection of control station a.
LOCAL / REMOTE switch 6
J NL-LP-11204-00-C Ill.
LESSON OUTLINE:
NOTES 1)
Switch on Generator Control Panel PDG-1 Train A PDG-3 Train B 2)
Normally in REMOTE (control room operation)
- 3) MAINTENANCE mode selection possible only af ter local operation is selected 4)
DG "!NOPERABLE" in LOCAL No start on SIS (Auto)
No start on Loss of Offsite Power (Auto)
Can be manually started, PDG-2/PDG-4 Can be emergency started PDG-2/PDG-4 B.
Ge.',eral Functions 1.
Electrical control circuits Three circuits, A, B and C, 125VDC 4.
l b.
Function l
1)
Start and stop inputs
- 2) Alare functions 3)
Generator interface 4)
Control of auxiliaries l
2.
Pneumatic control circuits 60 psig control' air, supplied from Air Objective 2
~
a.
Start Systes (regulated from approx.
Drawing 250 psig to 60 psig) 09-500-76021-2 in AXLIAK01-509 b.
Ball check valves allow supply, even if one receiver depressurized c.
Functions and uses 1)
Monitor various engine parameters, Objective 1 1.e.,
pressures and temperatures l
7
A NL-LP-11204-00-C ill.
LESSON OUTLINE:
NOTES
- 2) Generate a shutdown signal in response to sensor tripping, to cause engine trip by closing combustion air dampers and move fuel racks to "no fuel" d.
Pneumatic logic is binary logic
!)
Example: three-way valves, one passage closes as another opens 2)
AND, OR, NOT, MEMORY, etc.
e.
Pneumatic delay circuits 1)
Timing chamber in accumulatorg air is metered through orifice 2)
It takes a specific time to bleed or charge the accumulator with control air 3.
Pneumatic / Electric Interfaces a.
Inputs from electrical system, generaths pneumatic signals b.
Pressure switr.hes 1)
Dutputs from pneumatic system, used as i
status and control inputs to electrical portion l
4.
Governing Systems - General NL-TP-11204-002 Functions control amount of fuel oil being a.
supplied to engine by injector pumps, in Objective 10 l
order to control DG, speed or load
(
l b.
Generator Output Sensed i
1 1)
Speed - (frequency of AC) - UNIT 2)
Load - (volts and amps) - Parallel c.
Load or speed signal compared to contr'1 o
input l
1)
Control input is speed setting of potentiometer 2)
Local or control room handswitch adjusts motor driven potentiometer B
NL-LP-la204-00-C Ill.
LESSON. OUTLINE:
NOTES d.
Governor-Actuator 1)
" Error signal" from electric control causes changes in governor-actuator output 2)
Output from governor-actuator controls flow of fuel to engine 3)
Governor-actuator has a centrifugal (mechanical) section. governor to back up the electric governor C.
Components 1.
Woodward EGB-35 Governor-actuator More detail in Vendor's Manual a.
Stalled work capacity 35 f t-lbs torque AXUAK01-564 b.
Electric governor section, mechanical NL-TP-11204-003 governor, and actuator to position terminal (output) shaft Self-contained hydraulic oil supply 011 supply critical c.
1) 011 heat exchanger cools governor oil, using Jacket water 2)
Self-contained oil pumps d.
Small DC speed - adjusting actor on top of ours is not connected for use e.
Mechanical governor 1)
Centrifugal speed sensing flyweight head, driven oy the engine, opposed by
" speeder" spring force f.
Electric governor
- 1) Receives output of EGA control box l
l 2)
Polarized coil produces force proportional to current in coil changing electric signal to hydraulic g.
Three external adjustments 1)
Lead limit knee Cbjective lia a)
Limits maximum engine load, NL-TP-11204-004 whether the unit is controlled by mechanical or by electric 9
NL-LP-11204-00-C Ill.
LESSON OUTLINE:
~
NOTES governor / actuator b) Range " MIN FUEL" to " MAX FUEL" c) Normal Setting MAX FUEL 2)
Speed setting adjustment knob Objective 11b a)
Sets the speed to which the mechanical governor will control engine speed b) 470 rpm (approx. 4 1/2% higher than nora.al speed) c) Vernier dial, turning knob changes tension on speeder spring d) Setting adjustmant varies from governor-to governor, but ranges of 11 - 14 expccted.
Actual setting must be obtained from standby mode status checks.
Checklists in Procedure 13145-1, l
or Operability Test i
e) Spned setpoint of mechanical l
governor (470 rpm) is high enough to not interf ere with normal operation of electric governor 3)
Speed droop control knob - sets speed Objective 11c drcop of secnanical governor 1
)
a) Normal setting is 2.5 (5% vpeed droop of mechanical governor) b) Speed droop can be calculated by noting dif f erence in no-load and full-Icad speed, divided by no-load speeds c) Example: Assume that all we had was a mechanical governor. If the engine is started, the spend would go to 470 rpm, if speed droop was 4 1/2%
(470-450)/470 Now we load the generator, and by full load, diesel generator speed should 10
e
-a NL-LP-11204-00-C Ill.
LESSON OUTLINE:
NOTES have " dropped" to 450 rpm, due to the added load h.
Booster Servomotor
- 1) Compressed air from the starting air system moves a spring-loaded piston, inside the servomotor
- 2) Governor oil on other side of piston 3) 011 under pressure supplied to governor, and governor moves fuel linkage to fuel-on
- 4) Engine fires at once, rather than waiting for buildup of governor oil pressure Woodward EG-A Control Box a.
Electronic unit, in generator control 1X3D-BH-G03G panel b.
Works along with speed-setting l
potentiometer (GOV" MOP" on print) c.
Function - to produce a signal to the electric portion of the EGB-35 governor-actuator, to control speed (and frequency) if in unit mode, or load, if in parallel (droop) mode d.
Speed detected by output frequency of generator 1)
Frequency signal converted to DC, and compared to DC signal of speed-setting potentiometer 2)
Speed (frequency) is the sensed and controlled parameter when in isochronous (unit) mode
- 3) When speed (frequency) agrees with l
speed demanded by speed-sensing l
potentiometer, a constant signal will be sent to electric governor section of EGB-35 governor-actuator Lead is detected by generator output s.
voltage and current 1)
DC signal produced, proportional 11
~.
NL-LP-11204-00-C lli.
LESSON OUTLINE:
NOTES to KW output of generator
. 2)
DC LOAD signal summed with opposing signal from speed-setting potentiometer
- 3) When the load signal and speed-setting potentiometer do not agree, a current is sent to a coil in the electric portion of the governor-actuator
- 4) Electric signal changed to a hydraulic signal 3.
Woodward Overspeed Trip. Type SG NL-TP-11204-005 a.
Driven from same engine that drives the fuel pump b.
Self-resetting after trip, when speed drops below tripping speed c.
517.5 rps tripping speed d.
Flyweight, spinning, proportional to engine speed, tends to lift a plunger value NL-TP-11204-006 l
Flyweight assembly opposed by speeder Objective 12 e.
spring f.
At trip speed, oil under pressure passes through pilot plunger, lif ting power piston l
l g.
Power piston causes terminal shaft to rotate h.
Arm out terminal shaf t moves, striking two air vent valuas 1.
Vent values - do not self-reset, must be manually reset J.
Vent values cause air to be supplied to close air damper and extend fuel shutdown cylinder D.
Controls and Instrumentation 1.
125VDC 2 Class 1E, and one non-1E, interfaced A & B one 1E with DG for control purposes C is non-1E a.
'A' Power (125V DC) 1X3D-BH-GO3C Objective 3 (part)
- 1) Starting (baste uses) 12
NL-LP-11204-00-C 111. LESSON OUTLINE:
NOTES a) Deactivate shutdowns (on emerg.
start) b)
1 sec. field flash delay c)
Two air start solenoids energize d) Activate shutdowns (normal start) e) Safety inj start from SSPS f) Breakglass emerg start (PS-45A) g) Loss of offsite power (sequencer) h)
Speed switches (200 and 440 rpm) 2)
Monitoring (basic use) a) Optical isolators b) Several generator related (and other) annunciators 3)
DIST pn1 1AD11, Bkr 72-11 (Train A).
4)
DIST pnl 1BD11, Bkr 72-11 (Train B) 5)
'A' Power monitored bys "A power available" white indicating -
i light on PDG2/PDG4 b.
'D' Power (125VDC)
I
!)
Starting (basic use)
Objective 3 (part) a)
Sta11ar functions as 'A' circuit 2)
Stopping. functions (basic use) a) EMERG stops b) MAINT/0PERATIONAL mode circuits c)
STOP circuits d)
"IN TEST SEQUENCE" indicator l
(sequencer in testing),
3)
DISTR. panel 1AD12, BKR 72-11 (Tr. A) 4)
DISTR. panel IBD12, BKR 72-11 13
NL-LP-11304-00-C-111. LESSON OUTLINE:
NOTES (Tr. B) i 5)
'B' power monitored by "B power available" white indicating light on PDG2/PDG4 c.
'C' Power (125VDC) 1X3D-BH-603E Objective 3-(part)
- 1) Alarms (basic use)
PS-9N 1, 2 from fuel rack cyl.
a) Failed to start alarm <200 rpe in extended 5 see Roset P.B. part of annunciator reset sw 2)
Power for PDG2/PDG4 panel indicating lights (basic lights)
- 3) Annunciator power (basic use) (logic, horn) 4)
Crankcase fan and generator heater control power 5)
DISTR panel IND31, BKR 72-07 (A train)
(Non 1-E) 6)
DISTR panel IND32, BKR 72-11 (B train)
(Non 1-E) i j
7)
'C' power monitored by:
l "C power.available" white indicating light on PDG2/PDG4 d.
120VAC i
1)
Power to thermocouple digital indicator panel " Doric Trendicator" 2)
Hour-meter
- 3) Panel heater and interior light 2.
Engine Starts 1
a.
Normal engine starts 1)
Control Room - manual pushbuttons l
- 2) Diesel generator control panel (local) pushbuttota l
14
NL-LP-11304-00-C Ill.
LESSON OUTLINE:
~
NOTES
- 3) Automatic - loss of offsite power b.
Emergency engine starts 1)
Automatics safety injection signal
- 2) Manuali local emergency breakglass 3.
Permissives for engine starts - normal IX5DW170-2 a.
Normal start - pushbutton, control room Objective 4a (OFAB)
- 1) Local / remote switch (LRS) in REMOTE 2)
DG is in OPERATIONAL mode 4
b.
Normal start - pushbutton, local engine Objective 4b panel (PDG2/PDG4)
- 1) LRS in LOCAL 2)
DG is in OPERATIONAL mode c.
Normal start - loss of offsite power -
Objective 4e automatic start
- 1) LRS in REMOTE
- 2) From sequencer, loss of voltage, 2/4 UV for.8 seconds at 70% nominal voltage
- 3) From sequencer, degraded voltage i
2/4 UV f or 20 sec, at 88.5% normal voltage l
NOTE: Alarm is 2/4 UV 93.1% for 10 sec.
4)
D6 for the bus with the UV starts d.
What occurs on man, normal starts l
1)
Start air solenoids energize a)
Start air to engine until 700 rps or 5 seconds 2)
Safe shutdown trips inservice (some initially bypassed for 90 sec.)
3)
Accessories affected 15
NL-LP-11204-00-C f
Ill.
LESSON OUTLINE:
NOTES a)
Gen space heater off b) JW keepwarm pump off c) LO keepwarm pump off d) Hour-meter actuated 4)
Generator's field flashed a) After 1 second, OR b) When 200 rpm reached
- 5) At 440 rpm (and 90% generator voltage) a) Permissive to close breaker b) Breaker closure requires other permissives, covered in another lesson plan c)
Breaker stays open 6)
Auto normal start same, excepti a)
On loss of of f site power, governor speed-setting potentiometer (and voltage regulator's adjusting potentiometer) pre position to 60 HZ and 4160V position b) Speed and voltage can not be adjusted for 15 seconds from initiation c)
DG output breaker closes:
90% voltage, 440 rpm 4.
Permissives for engine starts, emergency 1X5DN 170-2 a.
Automatic seergency start - SIAS l
1)
LRS in Remote Gbjective 4d 2)
DG "DPERATIONAL" mode 3)
Start air pressure > 150 psig 4)
Safety injection signal occurs b.
Manual emergency start 16
NL-LP-11204-00-C
~
lll.
LESSON OUTLINE:
NOTES 1)
DG in " OPERATIONAL" mode 2)
Break the lens on the breakylass for emergency start (button is released) 3)
LRS in either position c.
What happens on emergency start 1)
Shutdown system deactivated, leaving only four trips available 2)
Normal trip signals bypassed 3)
Governor and voltage regulator Also, if in motor operated potentiometers PARALLEL, gov. is pre-position (60HZ, 4160 VAC) is changed to UNIT N3D-BH-G03G, H "UPR" rel ay 4)
Air start solenoid valves closet 200 rps, or air receiver pressure drops to 150 psig (If start did not occur, local checks made before wasting nora air. Restarts can be made using normal starts) 5)
Engine starts, comes to speed, gen.
voltage established 5.
Modes a.
Operational Mode PS-40A 1)
Hust be in Operational mcde for any start 2)
To enter a)
Barring device locked out b)
No shutdown signals present c) Press " Return to Operational Mode" b.
Maintenance Mode
- 1) No DG start available in Maint. Mode 2)
To enter a)
Go to LOCAL first 17
NL-LP-11204-00-C Ill.
LESSON OUTLINE:
NOTES b)
Shutdown system active (no S!S) i c)
Engine not running d)
Maintenance pushbutton pressed
- 3) Can Air Roll DG - if barring device is locked out c.
LOCAL / REMOTE switch 1)
Switch on gen. control panel 2)
In Remote, engine can start one a)
Normal manual start, control room b)
Saf ety injection signal 3)
In Local, engine can start one a)
Start pushbutton on PDG2/PDG4 (normal start)
NOTE: Local emergency star't Breakglass starts can occur if local or remote 6.
Trips, automatic 1X5DW170-2 a.
Af ter normal start Objs.tive 5
- 1) Lube oil temp high, 200"F 2)
Engine bearing temp high, 228 F
" resetting" involves replacing fusible rod temp. detectors NOTE: The following are inhibited from causing an engine trip for the first 90 seconds after start 3)
Crankcase pressure high, 3 psi 4)
Turbocharger oil-pressure low, 15 psig 5)
Jacket water pressure low, 6 psig
- 6) Vibration (two engine sensors, and one for each turbocharger)
NOTE: The above six trip signals l
l 18
NL-LP-11204-00-C 111. LESSON OUTLINE:
NOTES lock-out a normal restart for 90 seconds, but will not lock-out an emergency start 7)
Generator fault, 1869 a)
Normal restart after resetting of lockout b)
No 90-seconds post-trip timer NOTE: The following four trips will also stop the DG if emergency started 8)
Generator dif f ersntial,187, via 186A lockout a)
Lock-out, and Emerg Trip Reset P.B. to restore 9) 2/3 lube oil pressure low, 30 psig a)
Emerg trip reset P.B.
10) 2/3 high Jacket water temp 200 F a)
Emerg trip reset P.B.
11)
Overspeed, 517.5 rpe a)
Must manually recet two air valves b)
Emerg trip reset 7.
Trips after Emergency start Objective 6 a.
1864 Generator Differential Trip 1)
Lockout relay reset, and Emerg Trip Guidance from reset pushbutton to restore, plus SS needed to reset administrative guidance b.
2/3 Low Lube Oil Pressure, 30 psig 1)
Emerg trip reset P.B. to restore and allow restart c.
2/3 Hi Jacket Water Temp, 200 F 1)
Emerg trip reset P.B. to restore and allow restart d.
Overspeed, 517.5 rpm 19
NL-LP-11204-00-C 111. LESSON OUTLINE:
~
NOTES 1)
Roset two air valves and Emerg trip reset to restart 8.
Manual Stops 1X5DW 170.-2 a.
Normal Stops 1)
Control Room stop P.B.
a)
LRS in Remote
- 2) PDG2/PDG4 stop P.B.
a)
LRS in Local b.
Emergency Stops 1)
Control Room Emerg Stop P.B.s a) 2/2 P.B.
(pressed at same time) b)
LRS in Remote 2)
PDG2/PDG4 Emerg Stop a) -Breaks glass, push button b) LRS either position
- 3) Must press Emerg Trip Reset to allow recovery a)
DG inoperable after an Emergency Stop, until restored c.
Stopping af ter Emergency Start 1)
" Reset LOCA" pushbutton, then normal stop
- 2) The Emerg Stop method WILL stop DG, but it is inoperable until reset and placed back in service, and is not the procedural method f or normal recovery 9.
Response to Trip Signal a.
DG output breaker trips l
b.
Generator excitation circuits tripped (A h B)
Objective 13 c.
Fuel Rock Shutdown Cylinder Extends
" extensible link" 20
NL-L P-11204-00-C Ill.
LESSON OUTLINE:
NOTES i
1)
Control air to actuator
- 2) Fuel racks on injector fuel pumps go 1X4AK01-443-4 to "no fuel" d.
Combustion air valves - both close 1)
Control air to actuators e.
Governor and regulator potentiometers:
STRESS AIR pre-position in preparation for next start required to shut-down DG 10.
PULL-TO-RUN/ PUSH-TO-STOP switch Objective 7 a.
Located at front of auxiliary skid b.
Wi!! trip DG when pushed c.
DG restart sends air signal to reset the switch, so does not keep DG shut down, if needed 11.
Controls on Engine Control Panel NL-TP-11204-007 l
a.
EMERGENCY START - breakglass Objs-tive Sa Breaking glass -(or removing lens cover) 1X3D-BH-G03C, allows spring loaded button to " pop" out.
1X3D-BH-G03D, DG starts, with normal shutdown deactivated 1X5DN107-2 b.
START - Pressing START pushbutton starts Objective 8b DG (if LRS is in LOCAL) with normal shutdown in service c.
OPERATIONAL mode - returns DG from MAINT Objective Oc asde to OPERATIONS mode.
Must be in OPERATIO R mode to start DG d.
NAINTENANCE mode - with LRS in LOCAL, Objective Bd pressing pushbutton takes DG out of OPERATIONAL mode, inhibiting all starts -
l DG will not start.
Must be in MAINTENANCE mode for barring and rolling operations.
DG inoperable e.
ENGINE ROLL - in MAINT: mode, allows Objective Be spinning of DG while P.B. is pressed.
Engine does not start.
The DG will~stop spinning when the button is released f.-
EMERGENCY STOP - breakglass in either Objective Bf local or remote with LRS, breaking glass and pushing button stops DG locally. It can Glass is broken, not be restarted untti emerg, stop has been buttons pushed.
21
NL-LP-11304-00-C
~
Ill.
LESSON OUTLINE:
UOTES reset, so DG is INOPERABLE until EMERG STOP Diffe's from EMERG r
is reset START breakglass g.
EMERGENCY STOP-RESET - Pressing pushbutton Objectiva 89 resets manual or automatic EMERGENCV STOPS, once trip conditions have b'ven cleared.
Permissive to restart DG, if no other trip signals present h.
RESET FROM LOCA - Resets Emergency Start Objective 81 signal to DG start circuits, and places normal shutdown trips in service, allowing a normal stop (control room or local)
Normal recovery method after emergency start 1.
STOP - will stop the DG from PDG2/PDG4 Objective Bh if LRS is in LOCAL, and engine has been started under normal start J.
TEST BYPASS - tests blocking of' normal DG trips when DG is running under an Emergency Start k.
Annunciator Pushbutton
- 1) TEST t
2)
SILENCE (born) i 3)
ACKNOWLEDGE
- 4) RESET Annunciator pushbuttons must be depressed Keeps 1cgic correct in correct sequence when an alarm occurs SILENCE / ACKNOWLEDGE / RESET Horn does not sound if engine is not running and alarm occurs prevents burning up horn in unattended building i
i RESET also resets latching relays for FAILED TO START alarm 1.
PUSH-TO-READ pushbuttons for day tank and lube oil sump level indicators 1)
Control air supplied to " bubblers" 12.-
Indicating lights on PDG2/PDG4 Objective 9b a.
EMERGENCY STOP - RED 1X3D-BH-G03D 22
NL-LP-11304-00-C Ill.
LESSON OUTLINE:
NOTES
- 1) Lit until renet, can not restart until R-23B-3 contact reset 2)
From Manual Emerg Stop, or one of the four Auto Emerg Stops b.
52G CLOSED - RED Objective 99 1)
Gen output breaker closed c.
SHUTDOWN SYSTEM ACTIVE - RED 1X3D-BH-G03E Objective 9d 1)
Engine normal shutdowns active
- 2) Lit on normal start 3)
Extinguished on EMERGENCY STARTS d.
BYPASS TEST FAILURE - RED 1X3D-BH-603E If lit red during Emerg Start, with TEST PS-36N BYPASS pressed, indicates a nermal trip can Objective 9k trip the DG e.
UNIT AVAILABLE - BLUE Objective 9a 1X3D-BH-G03E, and No overspeed, and DC start ekt. power 1X5DN107-2 available, STARTING AIR PRESSURE
> 150 psig, barring device locked out i
f.
DG AUTO START Signal RED Objective 9c l
l DG Auto Start signal exists from Loss of 1
Offsite Power, or Safety Injection g.
SAFETY INJECTION SIGNAL - GREEN Objective 9e l
Lit on EMERGENCY START - from shutdown synt
(
deactivate signal h.
IN TEST BEQUENCE - RED 1X3D-BH-G03D, Relay DG 1A-AX
- SEQUENCER (SFSS) IN TESTING Objective 9f
- K 357 1.
READY TO LDAD - BLUE Objective 9h 1)
Engine at 440 rpm 2)
DG voltage 1 907 normal SQL202-3A, B
- j. RUNNING - RED Speed switches 23
I NL-LP-11304-00-C Ill.
LESSON OUTLINE:
NOTES 1)
Engine speed above 200 rpm Objedtive 91 k.,
STOPPING - RED Objective 9J f
1)
Lit on unit trip PS9-NI 2)
Engine will not normal start when lit 3)
Pressing START will only waste air i
Objective 91 1.
STARTING - RED 1X30-BH-G03E, 1)
Lit when starting is initiated 1X4AK01-44-9 2)
Normal or emergency starts PS32-N2 m.
'A' POWER AVAILABLE 1) 125VDC control power to 'A' circuit 1X3D-BH-603C
- 2) CB 1-2 on engine panel, 1E sources n.
'B' POWER AVAILABLE 1X3D-BH-603D 1) 125 VDC control power to 'B' circuit 2)
CB 3-4 on engine panel,1E sources o.
'C' POWER AVAILABLE - 125 VDC Control Power 1X3D-BH-G03F to 'C' Circuit.
CB 5-6 on engine panel, Non-1E source E.
Operations NORMAL DPERATIONS 1.
Local control panels - normal standby a.
All annunciator lights extinguished b.
" UNIT AVAILABLE" light lit c.
'A' POWER AVAILABLE light lit d.
'B' POWER AVAILABLE light lit e.
'C' POWER AVAILABLE light lit f.
REMOTE / LOCAL switch on generator panels in REMOTE g.
JW Keep-warm pressure gauge 15 - 25 psig h.
L.O. keep-warm pressure gauge 30 - 50 psig 24
NL-LP-11204-00-C lil.
LESSON OUTLINE:
NOTES 1.
Control air pressure gauge 50 - 62 psig J., L.O. IN, OUT (Digital Thermo-142 - 170 F couple k.
JW IN, OUT (Digital Thermo) 142 - 170 F 2.
Cylinder Moisture Checks a.
DG inoperable while in LOCAL b.
Reason f or running - to check f or evidwnce Objective 19 of wat.er which may have leaked into a cyl inder.
This can cause hydraulic lock of a colinder, causing cylinder and head cracks or damage, if an engine start is attempted with full air pressure c.
Shif t Supervisor notified of ANY moisture discovered, or if resistance is encountered when barring d.
When perf ormed 1)
Prior to a scheduled run, if not done t
within previous f our hours 2)
Four to eight hours af ter shutdown 3) 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> after shutdown Rolling is use of starting air to spin the Objective 14 (part) e.
engine, without its starting f.
Barring is slowly turning the engine a small amount at a time.
Barring is'done with a barring device, using air pressure to extend a rod, wir-the rod pushing the engine's flywheel at holes in-the flywheel g.
Permissives/ interlocks to. allow barring Objective 14 (part) 1)
LR8 in LOCAL 2)
Engine not running
- 3) No LOCA signal present
- 4) MAINTENANCE mode selected-5)
Removal of lockout pin h.
Cylinder moisture check - brief description Objective 15 25
NL-LP-11804-00-C Ill.
LESSON OUTLINE:
NOTES NOTE: Permission must be obtained -
DG inoperable during check -
Licensed Operator must consult Tech Spec 1)
LRS to LOCAL - PDG1/3
- 2) MAINTENANCE pushbutton pressed -
PDG2/4
- 3) Verify fuel and air shutdown cylinder fully extend 4)
Open all cylinder cocks Note presence of any moisture BEFORE barring AND after
- 5) Open air supply valve to barring device
- 6) Unlock pneumatic barring device by removing lockout pin 7)
Engage device in flywheel, bar over i
at least two revolutions of the flywheel This takes each piston thr'ough all l
four combustion cycles 1
8)
Check f or evidence of moisture 9)
Disengage and lockout barring device 10)
Verify "BARRING DEVICE ENGAGED" alare resets l
- 11) Close isolation valve from receiver to barring device 3.
Engine Imbalance Objective 18
(
a.
Cylinders not carrying an equal load b.
Detected by observing cylinder exhaust temperature on Digital Thermocouple Readout (Doric Trendicator).
One (or more) cylinder's temperature excessively higher or lower than the average indicates possible imbalance c.
Cylinder exhaust temperature which is Raft greater than 1 50 F of average should be AXUAK01-509, l
2b
NL-LP-11204-00-C Ill.
LESSON OUTLINE:
NOTES investigated Page'8-3, and G-H-1, 2 d.
Causes:
Misadjustment of fuel injection pump,s (possibly following maintenance activities)
Injector problems According to Dirt, impurities in fuel oil factory rep, plugging of two spray nozzles on an injector will cause fuel line to injector to rupture e.
Results of cylinder imbalance - cylinder (s) carrying excessive load, possibles 1)
Scored pistons and liners 2)
Excessive vibration
- 3) Excessive piston, valve, bearing, and crankshaft wear 4)
Excessive fuel consumption 5)
Excessive lube oil usage 4.
Reviewing the DG Operating Log (1185-C)
- Commitment i
SOER 83-001 a.
Majority of engine problams preceded by begins some change in operating data.
Data changes can be so slight that tends may be hard to detect in short time intervals Trends easier to determine if readings are taken under the same conditions b.
Long-teres From Vendor's Manual
Bearing wearing b)
Lube oil wearing c)
Relief valve not functioning properly d) Possibly fuel dilution 27
NL-LP-11804-00-C 111. LESSON OUTLINE:
NOTES
Problem with heat exchanger.
possibly plugging up
- 3) Lube oil consumption increasing a)
Piston rings starting to foul b)
Valve guide wear.
c) Leaks in lube oil cooler (Lube oil pressure higher than JW pressure, so leaks will be into the water system)
- 4) Crankcase vacuum starts to decrease a)
Piston ring wear, causing blow-by 5)
Jacket water temp. starting to rise a)
JW cooler starting to foul b)
Would be hard to determine, since temperature control valve can causeouglettemperaturetovary up to 15 F
- 6) Jacket water outlet temperature drops (greater temp. dif f erential across engine) a)
Poor combustion b)
Leaky head gasket (s) c)
Scuffed pistons d)
JW system not vented e)
Faulty water pump Short term, possibly f ound by reviewing From 17035-1 c.
previous f ew logs Objgetive 21 begins 1)
Keepwarm filter plugging (engine not running)
- 2) Exhaust temperature in one cylinder different than ave age 28
NL-LP-il204-00-C lll.
LESSON OUTLINE:
NOTES a)
Bad fuel pump, or injector norrie 3)
Eubaust stack temperatures above lamits a) Engine overloaded
- 4) Lube oil temperature IN/0UT increasing a)
Inadequate coolant flow through lube oil HX b)
Inadequate NBCW flow through JW cooler
)
c) High NBCW temp d)
Biofouling of NSCW side of JW cooler e;
Engine overload 5)
Fuel oil pressure decreasing a) Fuel oil filter clogged b) Fuel oil strainer clogged c) Pressure regulator f alling open di Fuel pump malfunction 6)
Jacket water pressure decreasing al JW pump ealfunction b) Leak in system c) Standpipe level decreasing 7)
Lube oil pressure decreasing a) Lube oil filter clogging b) Lube ett strainer t; logged c) Pressure regulator (6) failing open-d) Pump malfunction e)
Low sump level 0)
Fuel filter diff, preas, increasing 29
NL-LP-11204-00-L 111. LESSON OUTLINE:
NOTES a)
In-service it1ter fouling l
b)
Can switch to standby filter with engine running (Procedure 13145-1)
- 9) Lube oil filter diff. pressure increasing a)
In-service filter clogging b)
Can switch tu standby filter with engine running (Procedure 13145-1) 3 i
10)
Turbocharger oil pressures decreasing a) Lube oil filter clogged b)
Lube oli strainer clogged c)
Lune oil pressure reg. failing open d)
Engine-driven tube ott pump malfunction e)
Low lube oil sump level Also, short-term, turbocharger prelube valve left open Objective 21 ands SOER 83.001 ends t
ABNORMAL OPERATIONS 1.
Loss of Control Air Pressure a.
Running D6 continues to run b.
Cannot be shut down by normal means, since fuel rack shutdown c'dinder will not entend and air dumpers will not close c.
Loos of engine protection 2.
Low Governor 011 Level IEN 86.07 Objective 17 a.
Probable engine overspeed and trip b.
Uncontrollable engine speed c.
This occurred at Grand Gulf nuclear station, causing internal engine damage.
Maintenance had been performed on the governor, and it was incorrectly vented when reinstalled.
In their case, the 30
NL-LP-l!804-00-C Ill.
LESSON OUTLINE:
NOTES overspeed trip device was incorrectly adjusted. On engine startup, the engine oversped several seconds IX4AK01-443-4 d.
Our DG was modified, with a second over-speed air vent valve, so combust:on air dampers respond quicker 3.
Transferring LRS a.
On PDGt/3 b.
If parallel with RAT and LRS transferred to LOCAL 1)
Governor and voltage regulator taken out of DROOP, to UNIT 2)
Governor will now sense for speed 3)
Any dif f erence in speed (detected) signal and setting of speed-set potentiometer will be detected
- 4) Governor will try to make up f or the error signal, taking on a large load, and tripping on overcurrent 4.
Prolonged Operations DG should not be operated for prolonged a.
periods at less than 30% power b.
DG should be loaded to at least 50% f or two hour's every 24 during low or no-load operation 5.
Failure of Class 1E Safety-Related Switchgear Begin IEN 83.050 Circuit Dreakers to close on demand (Ref er to IEN 03-50, August 1, 1983) a.
Failures attethuted to a problem within the circuit breakers closing control circuitry located inside the breaker cubicle b.
Typical causes f or f ailures triclude 1)
Blown control cireuit fuses-2)
Interoittent electrical connectioas 3)
Dirty or corroded contacts 4)
Malfunctions in the spring charging 31
NL-LP-11804-00-C
- Ill, LESSON OUTLINE:
NOTES motors or associated spring position switch contacts
- c.. Nearly 25% of tabulated events involve diesel generator output breakers i
1)
Due to more permissive interlocks associated with the closing circuit of these breakers - reason for relatively high percentage of occurrences d.
Important for breakers to be checked f requently f or proper status, i.e., control power, spring charge, etc.
End j
ILN 83.050
SUMMARY
A.
Review Lesson -Ian Objectives for Summary f
G i
32 l
- - - - -