Text

Production Test
	ML20094F575
Person / Time
Site:	Clinton
Issue date:	08/06/1984
From:	; STEWART & STEVENSON SERVICES
To:	;
Shared Package
ML20094F543	List: ML20094F540; ML20094F564; ML20094F575;
References
	FTR-75744-1, NUDOCS 8408100106
	Download: ML20094F575 (175)
	v • d • e

_

PRODUCTION TEST 1

TAELE OF CONTENTS ITEM PACE METER CERTIFICATION I

TABLE OF CONTENTS 2

INSTRUMENTATION DATA-3 COMMERCIAL DATA 4

MEGCER AND HI-POTENTIAL TEST OUTLINE 3

PROCEDUPE Sa DATA Sb*

VIBRATION TEST OUTLINE 6

PROCEDURE 6a DATA 6b LOAD TEST OUTLINI:

7 PROCEDU11 7a DATA 7b, 7c VOLTAGE NiD SPET.D STABILITY /JiD TRANSIENT IMSPTi3E OUTLINE 8

PROCE0"RE Sa DATA 8b CP. ART Sc SAFETY SJITRYNNS /St> A!JD:G 10ST

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OUTLINI:

9 PROCErrPI 9a DATA 9b*

TEMPERATUYJ. LISE Tif!

OUTLINg 10 PROCEDU n 10a DATA 10b v

FACTORY OE.ClJ.lf/d;10:e 2 E7s SECTION B TEST PER17.:NL'. CW.7.7* 1 *.'. f1 iU !!ILL FOLIM EACH TEST 84 '" " e t

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y;;gr /c;D I.0M ACCEPTANCE QUALIFICATION TEST PROCEDURE:

1.

A vclid. tact sad load test is defined as a stsrt 'from a keep warm temperat':re cenjition with acceleration to rated speed and voltage withir.. ten (10) secends. generator acceptance of 1935 KW (50% of rated load),

and stabilzat.ca of rated voltage and freauency.

s 2.

Maintain a' chart recording of the starting time, generator voltage, frequency, and load current verus time throughout the test.

3.

Following a s'.ent, and load run for 10 minutes, the unit will be stepped.2nd tr..

coling bypass valves changed permitting circulation for accciccated cooling, down to keep warm temperatures.

4.

The sutscquent t. tart ;ycle will be inisted when the outlet water f alls v e stendby keep-warm temperature (1250F) and lube oil treaperaterer f all to within +100F of stanby keeo-warm temoeratures.

This explies to al.' (270) starts from standby keep-warm temperature.

t.11 " hot" starts will be initiated af ter a five (5) minute shutdown O~

intervd freer the preceding start, to assure temperatures do not f all belov i 100F from nor=al operating temperatures.

5.

Af ter each twenty-fif th (25th) start the normal load run as determined in ptragraph 3 vill be replaced by a one (1) hour load run at 100%

load (3369 KW).

6.

After each 25th ctart, the moisture will be drained from the air volume tank (s), the strainers and starters will be removed, disasseebic, cicaned, inspected and maintained. Any repairs, adjusteents, or other observations will be recorded in the remarks section of the test record. STEWART & STEVENSON RETAINS TH6 PEROCATIVE OF BEINC ASLE TO SUBSTITUTE EICHT (8) AIR START MOTORS IN ORDER TO CONTIrlE TESTING IF REFURBISHMENT OF THE START MOTORS USED FOR THE PRECESDII;G 25 STARTS CANNOT BE ACCOMPLISHED OVERNICHT.

7.

Record all data required by the test record for each start, and record any calfunction, repair, observation, etc., which j

occurs in the cerarks section of the test record.

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i FTR-75744-1 Page 8 Change B 10-16 c l

~"N START AND LOAD ACCEPTANCE 41El %.'nf103 TES?

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. TEST TITLE: Factory Starting Reliability T1.s' OBJECTIVE: To determine that the set mesta r.hc start reliability and confidence level outlined in th.e Vroc9ruag.t Specification.

CENERAL SET-UP: The SSDG set will be con.nred on a test stand with all external support equic=cnt c.tnectr:0 by ficx couplings. The load will be applied by the nas of vt.rer rheostat load banks.

DESCRIPTION OF TEST: At least 300 v>11d stirc cuJ load tests will be made at the factory facility. Ivi.undred and severity (270) starts will be m,de with the sec vichin t 10 F of the standby keep-warm engine temperature of 125 F.

The ndditional thirty (30) starts will be made at normal temperatures ar,11owing a cold start sequence allowing a five (5) minute inte.tval icr sha cellection and recording of data. The " hot" secres will be int;iat:d t.s the tenth (10th) start, and every tenth start thoraafter. After each start signal the unit will fire, continue to ran, and reach rated speed and voltage within ten (10) cecen.'s cttar the trr ciaticn of the start signal. A load of 193'. 3/'(50% of rc.ted load) will be applied to the nait ai er the uni.:.as reached the rated speed of 60 HZ., and rited valtage of 4160 volte and will continue to

. operate for (10) ten minutes.

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ACCEPT / REJECT CRITERIA: During each succacSI'ul start, the engine shall reach rated speed and voltage within ten (10) seconds of the initiation of the start signal. At no tir.c during the loading shall vcitage decrease to less than 75% of ac2ina) 4160 Volts, or shall frequency decrease to less than 95% of ac:inal (60 HZ ).

Voltage should be restored in less than 2 second: to within 10% of nominal and frequency should be restored to within 2% of nominal in less than 40% of loading time interval. The unit shall accept 50% of the continous rated KW load as per IEEE 387.

A total of three hundred (300) starts will be made with no more than three (3) valid f ailures allowed. A failure rate in excess of one (1) per hundred (100) starts will require further testing as well as review of the system design adequacy.

A valid failure is the failure to start and load as defined in Paragrap!

I of the Tactory Starting Reliability Test Procedure.

A non-valid failure is definad as a malfunction in test equipment, external circuitry loads, or any conpcnent not attributable to the reliability of the engine-fencrator.

Alvu. any malfunction of any component during the atactin.? r.ycle uhich dces not hinder a successful start as defined in paragraph 1 is not emitidered to be a failure.

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Page 7 FIR-75744-1 Change A 10-16-8 j

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300 Start & t.oad Qualification Test The 300 Start Qualification testing began on 12-29-81 at 10:04 a.m.

The assigned test technicians were Tom Williams and Oscar Tatuaka un' der the direct supervision of Gary Heathcott, Test Department Manager. The test was witnessed by Tom Bixby of Stewart & Stevenson's Quality Control Department and Tom Flannery of Baldwin Associates.

The following information is a critique of each 300 start test parformed. The critique shall be utilized as an explanation and cir.rafication in the event any question arises to validity of any particular start test.

The test results shown on sheets 1 thru 6 we'e performed on 12-29-81 r

thru l-14-82.

The start tests shown were voided, due to the temperatt:re readings being recorded at the conclusion of the run, in lieu of the re:ording of the standby tempera ture at the time of signal to start.

fl-10 ITEll A: Starts 1 thru 10 shows temperatures recorded at ccmpletion of test.

420 ITEM B:

Start #20 has a start time of 11.3 and temperatures recorded at completion of test.

Slow start due to low air pressure.

rmy Pressure raised to 210 PSI.

x./t.1 ITEM C:

Start #21 temperatures recorded at completion of test.

22 ITEM D: Start #22 had a slow start of 10.5 seconds and temperatures taken at completion of test. Slow start caused by load being applied during start cycle.

23 ITEM E: Start #23. The start time wa's within Specification at 9.6.

The unit shut down af ter load was applied the unit shut down due to high crankcase pressure. High crankcase pressure resulted from auxilary lube oil cooler ruptured sendin3 cooling tower water into the crankcase. The main bearings were inspected by Oscar Tatuaka and it was decided that all main bearing shells should be replaced. The cause of the heat exchanger failure was a vibration crack in to inner tubes.

23 ITEM F: Start #23A. Test Personnel were instructed on when temperature data should be taken and from which instrument. This test was not recorded cn test report but is recorded in daily log.

The second attempt at Start #23 was conducted on 1-13-82.

The unit shut down due to low oil pressure due to a 380F temperature at lube oil temperature switch, s23 ITEM G: Start 233 & 24. The third attempt at Start #23 was performed on 1-14-82 at 10:28 a.m.

The start time was within Spec (9.4) but the KW Channel on strip chart was not operating. The test technician terminated the test after applying 1935 KW with

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not chart recording.

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300 Start & Load Qualification Test Page 2 m,

T ITEM H: Start #23C. Start 23C shows start tir.c cf 9.4 sec and

'9 temperature recorded properly.

24 ITEM I: Start #24. Time 9.5 sec, temperaturcs rcecrded properly and correctly.

25 IT,EM J: Start s'5.

Time 9.6 sec, temperatur? recorded properly and correctly. Water and lube oil temperatures high due to cooling tower low water caused by frozen switch.

26 ITEM X: Start #26. Terminated due to operator,. error in not starting the chart.

26 ITEM L: Start #26'A.

Terminated due to oper3 tor error in turning on the fuel pumps.

26 ITEM M: Start #26B. Start terminated due to o;.erator failure to open air valve.

26 ITEM N: Start time was 9.8 sec. with temperatures recorded prcperly and correctly.

27 ITEM 0: Start #27. Start time was 9.75 sec v ith Spec., tweratures recorded properly and correctly.

28 ITEM P: Start #28. Start time was 9.45 sec, wi thin Spec, temperatures recorded properly and correctly.

29 ITEM Q: Start #29. Start time was 9.4 sec, within Spec, temperatures

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were recorded properly and correctly.

\\ -i30 ITEM R:

Start #20.

Start #30 was a slow start, start titre was' 11.0 seconds, out of Spec. The Slow Surt was due to the failure of one motor to cr. gage.

Tc 9 nir un connected large & smaller receiver tanks together by means of a m?.nifold upon recor.mendation from Engineering.

30 ITEM S: Start #30A. Start time was 9.5 sec, within Spac, temperatures were recorded properly and correctly.

Start f 394 was a hot s ta rt.

The start was voided by note date 01-20-82 in order to minimize any confusion in starting over.

The previous starts and starting attempts were voided on 01-20-82 by Rich Stevens (see Sheet #7) due to the complete breakdown in cor.munication, tests not being performed in accordance with test procedures, IEEE 387-77, temperatures taken from wrong instruments and at incorrect time, not rerunning invalid starts, and not recording all starting attempts in the of ficial test report.

On 01-20282', after Test Review Review, it was decided to start testing over again.

The official vclid tests would begin with #31.

The start #31 wou!d ba off!:f ally noted as the #1 start. The !30 start was void ir. orcer to simplify the test starting, since the procedura stir 910tG every n

10th start shall be a hot start ana st.i. ts di-#39 were t

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valid starts meeting all tes't requir c- ?a.

5 tart #40, e

l-17-82, was hot s tart which was slo :

s.m -ting, 10.95 sec.

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300 Start f. LW i.. ":r9 tica.'Ist Page 3 i

The s!c,....u t w n th< result of an insufficient volume of 2

a va t ; ai, a-si. umony. ihe Test Department installed a second 't.r. a:r receiwr tank and leased an air compressor, in order '.0 c.iictain a.n independent air supply.

Or 01. /G 52 of ficial testing resumed with a hot start, start MJ. in the 0.'ficial Test Report, which showed no adve-ru pr.mtenis in rrcetin,g specifications or documentation.

The f00 y~.:,g.nforEr. tion is supplied to address and clarify any s:ces int whcre either the start time (10 sec) was not nH or e.hes.. leads weca terminated, starts were terminated as fai!cru r.ccured.

Start eni 8. cad Qualification Tests th, rough.#49 were performed in accurar.ce w' th a w4h.ir.i.rac (10 sec)pproved test procedgres, start times were temperatures,(125-100) standby keep warm, were caintsired P.nd t r: corded properly.

50 Start S.'uf en aut m tic shut down during load portion of test d.

. ; cve" hin t.ing.

The over temperature was the result ;f :.he eu.ti'.ory equipment (cooling tower water line) was c!:q.acd uc witt r!abris. The cause initially was thought to bc :.alve 12ini,r only half open, an oversight by the test wchnicion, s

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S tart +50 n cend attempt. The attempt, on 1-24-82, was initie ud 2t. 9:27 u.m.

The unit started in 9.8 sec. and shut dou.! If ter 7 minutes into the 1 hour1.157407e-5 days 2.777778e-4 hours 1.653439e-6 weeks 3.805e-7 months load run. The inve' He!.in af ter this shutdown showed the cooling tower wateriire :cs. clogged with debris.

The waterline was cleaned along wi E" De br.,ttom of the. cooling tower tank in order to assure the prcver. tion of re-occurance of this particular problem.

50 Start -50 third attempt-The third attempt of Start #50 shows a star tire of 9.1 sec and a high tenperature of 2200, 12 cylinder lobe cil, the same as was reached during the previous I hour load "un in Start #25.

The Starts #50 throur;ht #125 were performed in accordance with approval procedures. The start times varied from 8.9 see to 9.75 sec, within Spec. The temperatures were recorded properly and standby temperatures established prior to signal to start.

There were no failures, non valid starts, terminations or opera tor errors.

126 The first sta-t attempt on Start #126, as shown in the test reccrd never cce red. The test technicians read air manifold pressure :com '.' nit,1 gage panel and walked around unit and discovered uw m., t ! cry lube oil pump motor had smoke coming (ter tline equip) f rom cM ' tur.ing.

was determined the auxilary motor was 1

under

..: ri fe: the pump size.

The motor was replaced on n

2-1-87 'nd t.n.. n ; resumed.

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30] Start & Load Qualification Test Page 4 Starts #12'6 through #167 were performed in accordance with approved procedures.

The start times were within Spec,

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temperatures were establised prior to signal to start.

There were no failures, non valid starts, terminations or operator errors.

168 Start #168. The unit shut down af ter load was applied af ter approximately 50 secondsinto the load run. The ambient temperature recordgd in the test record shows 41 F, when actually it was 38 F at the location of the unit. The thermometer was located on the far side window of the test booth where heat from inside of the test booth caused a false reading on the thermometer. The temperature at the location cf the thermometer was compared to the temperature at the Unit #1 gage panel.

Thegemperature at the gage panel was 38 F,a difference of 3 F.

The 38 F, actual temperature.plus start #168 was the first start of the day, 2-4-82, at 7:51 g.m., resulted in a low oil pressure shut down.

The 38 F at which the unit shut down is below the minimum temperatures starting '.apabilities. The operator should have known the minimum temperature starting requirements.

The unit was not prelubed prior to test start, not allowing warmed oil to reach throughout the system resulting in a low lube oil pressure indication.

(

The test technician was instructed to relocate the U

thermemeter for ambient temperatures reading from the window of the test booth to the Unit #1 gage panel.

The first start #163 was not a valid failure, it is attributed to operator error and ambient temperature outside the parameter of specifications.

168-213 Starts #168-#213 were performed in accordance with the approved test procedures. The start times were within Spec. The temperatures were recorded correctly and readings taken prior to signal to start.

There were no failures, terminations or operator errors.

214 Start #214 failed to start in the specified time of 10 sec.

The start time was 10.8 seconds and is shown in the test record dated 2-8-82.

The start time was slow due to the test technicians failure to purge the air start system

,of mois ture.

The rea was completely covered with water due to the high humidity and low ambient temperature. The slow start caused the tech tician to realize his failure to purge. After completion of the air system purge (20 minutes later) the unit was started and reached a rated speed in 9.4 sec.

The start #214 is classified as an operator error under

[Ch IEEE 387-77 para. 6.3.2(5)( A)(B).

The first attempt t-at Start #214 was non-valid failure.

300 Start & Load Qualification Test Page 5 Starts #214-229 were perforce in cccordance with ipproved procedures. The start times were 'tithin Spec. and the temepratures were recorded properly.

femperatures were taken prior to signal to start. TWc urere no failures, invalid starts, terminations, operr.or errors.

230 Start #230 took approximately 15 seconds to reach rated speed. The unit was shut down at a yrodmately S:05 a.m.

The cycles on Start #229 fluctusud esproximately.5 cycles during the load test. The fluct:.:tinn was noticed by the test, technician. Start #230. e hot start, was attempted at approximately 8:05 a.m. at wnich tir.'e a failure occurred.

The unit was secured in order to r:rfor.r an investigation into the probable cause.

Woodward Governor was contacted i,y Mr. Heathcott to assist in the investigation. Woodacrd Govert e arrivsd on 2-11-82 to confirm Stewart & Stevensen the0.y that the pvernor on the 12 cylinder would not cpea t"c fu:1 r.:r.i ccm.iletely.

The 12 cylinder governor, S/ril55369, was sent to Woodward far failure analysis and repair. 'Adiard supr. lied Stewart & Stevenson with a repla< r.ent governar, S/fl 1911403. The replacement gov.arner was installed, but would not open fuel racks cos pletely in or der to start the unit in Spec. Wcodward wa:.: lied again to replace governor (S1911403) with originA rcbuilt governor (S/?il593769 ). Stewart & Stevens sn made 42 trcubla shooting starts on 2-23-82, 2-24-82 and 2-25-82.

The Start #230 is a failure in accor*.!ance with IEEE 387-77 Section 6.3.2 (1)(4).

The failure to reach reted voltage and frequency was not within Spec, caused by a failure of a major component.

230-279 Starts #230 thru #279 were pt.rfor.med in accord:nce with the approved test procedures. The start times were within Spec.

The temperatures were recorded correctly and readings taken prior to signal to start.

There were no failures, terminations or operator errors.

280-A Start #280A, dated 2-28-82 at 10:09 a.m.,

failed to start and reach rated voltage and frequency within 10 seconds.

The start time was 11.2 sec. and the load was applied for a period of 3 ninutes. The load was terminated due to the long start time, f!r. Heathcott contccted Woodward governor concerning the course of the failure. Woodward suggested replacement of the boost cylinder on the 12 cylinder engine.

The boost cylinder was replaced on 2-28-02 anc two trouble shooting starts for detection of any ot.her problems.

280-8 Start #280 Bon 2-28-82 at approx!.vtaly 12:J9 f ailed to start.

The signal to start was initirted and 'he engine made no response.

The lack of re.pnnse m.s :tue to the

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operator not letting the unit coci dn..n uf ficient amount

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300 S ta r t & '_<.u" Jo. '.' '":. c :iim i es t Page G Tne tr.rt sipal is 0,c.wn on the strip chart as a start signal.

The f.libere ta start ori.82808 was the direct result of an operator error as per IEEE-387-1977 Par 6.3.2 (5)( A). The operato. waited S..i.1utes prior to next attemp to ensure

280-300 lube oil pressure returning to zero.

Starts 1290-300 were performed in accordance with approved precedures.

The st. art tirnes were within specification.

The tentperaturcs were recorded and readings were taken prior to signal to start. There were no failures, terminctions or operator errors.

The final review of the 300 Start and Load Acceptance Qualitication Test shows that there were three non valid starts due to operator errors as per IEEE-387-77 Par. 6.3.2 (5)( A); 4 non valid starts attributed to temporary services as per IEEE387-77 Para. 6.3.2(5)(E);

and 2 failures, #230 and #280 as per IEEE387-88 Para 6.3.2(1).

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Record "# - /A-5

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Work Order No.

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--TEST TITLE:. Start and_ Load Acceptance Qualif f eretten Test - Air Start }!otor Refurbish:::ent PROCEDURE:
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FIR-75744-1 Page 13
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FUEL OIL PUliP TURNED ON................ TECi!. I N IT.
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TURN ON COOLING TOWEit FANS...............TECll. INIT.
. TECll. INIT.
4.
TURN ON JACKET WATER CIRCULATING PUMP
.TECll. INIT.
5.
TURN ON AIR COMPRESSORS *...............
W 6.
PLUG IN AND TURN ON BATTERY CllARCER,.. '....... TECl!. INIT.
7.
ASSURE CilART RECORDER IS ON AND WARM..........TECil. INIT.
8.
TURN ON RAW WATER CIRCULATION PUMPS... *...
. TECil. INIT.
~~NO STARTS PERFORMED UNTIL STARTING AIR PRESSURE REACllES 250 PSI.~~
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3869 KW. 4160 VOLT OFFICIAL TEST RECORD c O v r. in S r.f il l
R ATING SERVICE l
START AND LOAD ACCEPTANCE QUALIFICATION TEST DAILY CitECK S!!EET 7
PRIOR TO Tl!E INITIATION OF EACil DAYS START TEST. SEQUENCE, Tile FOLLOWillG ITEMS WILL BE l
VERIFIED AS OPERATIONAL AND Tile APPROPRIATE SPACE INITIALED BY Tile TEST TECllNICIANS.
1.
FUEL OIL PUMP TURNED ON.......... :...... TECl!. INIT.
...TECil. INIT.
2.
TURN ON D.C. POWER............
3.
TURN ON COOLING TOWER FANS...............TECil. INIT.
4.
TURN ON JACKET WATER CIRCULATING PUMP......... TECll. INIT.
J TURN ON AIR COMPRESSORS *................TECil. INIT.
5.
PLUG IN AND TURN ON BATTERY CitARCER,......... TECll. INIT.
6.
ASSURE CHART RECORDER IS ON AND WARM..........TECl!. INIT.
7.
.... TECII. INIT.
W 8.
TURN ON RAW WATER CIRCULATION PUMPS......
~~NO STARTS PERFORMED UNTIL STARTING AIR PRESSURE REACllES 250 PSI.~~
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CHECKEDbW SLO O NN N SERI AL NO.
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A 3869 KW. 4160 VOLT RATING v
A SERVICE START AND LOAD ACCEPTANCE QUALIFICATION TEST DAILY CllECK SHEET PRIOR TO THE INITIATION OF EACII DAYS START TEST SEQUENCE. Tile FOLLOWING ITEMS WILL BE VERIFIED AS OPERATIONAL AND Tile APPROPRIATE SPACE INITIALED BY Tile TEST TECliNICIANS.
FUEL OIL PUMP TURNED ON................ TECll. INIT.
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.TECil. INIT.
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5.
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ASSURE CHART RECORDER IS ON.tl:D 51 ARM..........TECil. INIT.
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TURN ON RAW WATER CIRCULA150N PUHPS........
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4tZu AL th5PECTION Governce dity outside and inside, small shios and crit cn co"ernor.
Terminal shaf ts rustv, C3MPLE*
O ATE CQMPLETED terminal shaf t paint on R side damaged.ED SV P. Jackson 82-2-17 A3 nEC21vt3 TEST Governor oressure cood until oilot valve omits oil to ocwer cylinder. nressure then droos to 20-60 PSI and nil finws from tno of onwar nieton.
C:MPLsTeo av
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Screw connectina ocwer oiston and seat not in olace (threads _ striroed). Governor was very dirty inside. Reolaced all check valves and drive shaft bearino. Converted covernor to a 3240-4820S ner order by installino two new solenoid valves (onercize to shistr'own GSI and GS2)
CO M P LJ.T E D 3 Y l Q ATE COMPLETE D B. Hewi tson l
82-2-18
~~INA L TEST ITIST 3PCC NUMSE8I COMPLETED SY~~
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~~IlSCELt ANEOUS t~~
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-~i -GTACH ACCITIONAL FC 1CCCA E
TOTAL PARTS IF;OM REVERSE SiOE) o FORMS IF MORE SPACE IS NEECEC o
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TOTAL ESTIMATE 11
WARRANTY CLAIM ENGINEERING OPINION
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sat.ES, CE P.VICE:
4 noms.r JJewart A Stevenson, Services Inc.
Customer No
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g *P 3 k hop Oroer a __ DMOOQSF Quantity 1
Failure Review Number 0:s:r; nation ??an m Governor Type FAR11P S/N i C O 't7 A 0 Cornpfaint s.
ENGINEERING DE3IGNATE:
,Re Arwed By Richard R. Lar.o Date 82-2-17__
As Re:eived:
Extertial Appearance R ef.
Other Conditions R ef.
Functions R e f.
O Excellcat (like new)
Cust. Adj. Made O Tests w/in spec
~~G Goo <f (scrviceable)~~
O Maintenance Acc.
O Does not test w/in saeet.
O Pocr (requires rwk)
O Maintenance other O Completely fur.:ticoal Q Seal Broken G Other O Partially function.s' In, hierence Remarks:
- Gnunenne -vorv di rty' i nt4da ' --Ail-lpal s-thru -onwor niston-whan gay,grooP~
i; nnten11ing (crow linkir g nnene nietnn en tnilend and enring en.1t innen. had faUpn catJnd_3as found in bottom of cower cylinder bore.
R" commend Warranty Approvat:
Yes No e
v QUALITY ASSURANCE:
9 Date Rejected DPC Cust. P.O. Date R2-2-9 S.O. Date R2-2 0 Probable Cause:
Nnt oe.tahlished Correctivt: Action:
None Sales _
_ Engineering Repair Assembly Test Customer
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. TECl!. INIT.
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. TECl!. INIT.
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PLUG IN AND TURN ON BATTERY CilARCER.. '.
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m_ _
f JOB NO._
zu.cu mes.m._.__ _ _
gu,9,,,,, }II.LINOIS POWER CO.
l U ETH00 NO._M 4 '
ME['9 t.O SOU1!! 211H STREET N-
~
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OATE_ N"g
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l LIMATU R, ILI.lNOIS. 62523 511 E
TESTED
/-
CONT. NO.
//
e CALC.BY
-Illd / /IMIM /I#f I
MODEL NO.
CHECKED bY I
SERI AL NO.
7
//
3869 KW. 4160 VOLT OFFICIAL TEST RECORD gov T. INS RATING V
i l/
'e GERVICE START AND LOAD ACCEPTANCE QUALIFICATION TEST DAILY CllECK SilEET PRIOR TO Ti!E INITIATION OF EACil DAYS START TEST SEQUENCE Tile FOLLOWING ITEMS WILL BE VERIFIED AS OPERATIONAL AND Tite APPROPRIATE S{ ACE INITIALED BY Tile TEST TECIIN M
~~1.. RIEL OIL PUMP TURNED ON................ TECH. INIT.~~
vo 2.
TURN ON D.C. POWER.......
.'.......TECil. INIT.
.TECil. INIT.
3.
TURN ON COOLING TOWER FANS......
.l.
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4.
TURN ON JACKET WATER CIRCULATING PUMP, J....... TECil. INIT.
JM
.TECll. INIT.
5.
TURN ON AIR COMPRESSORS *...............
.. TECll. INIT.
)
6.
PLUG IN AND TURN ON BATTERY CllARGER.. &
7.
ASSURE CllART RECORDER IS ON AND WARM..........TECll. INIT.
8.
TURN ON RAW WATER CIRCULATION PUMPS.
i....... TECll. INIT.
~~NO STARTS PERFORMED UNTIL STARTING AIR PRESSURE REACllES 250 PSI.~~
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CONT.NO.
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PRESSdRE AVG WITNESSED Fi7.F1 STA.tY FROM RATED Al AT INESN' PSI AMD SY UO.
TO 'MTr.D VOT.T
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D W OQSF Quantity-1 Failure Review Number P
Ocs r; nation.??an.4 A7 Go<ernor Type FAR1'P S/N 1 E f1 '47 An Corno!aint ENGINEERING DESIGNATE:
,Revimed ay Richard R. Lamo Date 82-2-17 _
A5 Re:cived:
Ext, rnal Appearance Ref.
Other Conditions Ref.
Functions Re f.
O Excelle.it (like new)
O Cust. Adj. Made O Tests w/in specs.
D. Gor <f (scrviceable)
O Maintenance Acc.
O Does not test w/in s,)ect.
O Pou (re ;uires rwk)
O Maintenance other O Completely fur.:tionai 0 Seal Broken O Other O Partially functional V~,x (1:terence Remarks:
Govarnnr very dirty incido Oil lenkt thro onwar nis tnn whan gcy.er,tw_
i.; a p 1 ling Errow linH rn nnwnr nie tnn
+n tailrnd and enrinn (nat innen_ had f 4 ; l n.
A eut_.cnd scs found in bottom of nower cylinder bore.
R" commend Warranty Approval-Yes No c
v QUALITY ASSURANCE:
F Date Rejected DPC Cust. P.O. Date R2-2-9 S.O. Date R2-7-4 Frobable Cause:
Not ottah'inhed.
Carrectim Action:
None Sales Engineering Repair Assembly Test Customer
,4 r M.9:aint Paett v,
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~~E.E c m NNuusEm 1 Co174;o 02_9.17 sTOME4 N AME g 00uNTav g: sT :: s j e:;sTouE. supCnasE O ROEa NuM8E9 Stowart A Stavan<nn Servicot I l_K A i 75Mng 1~~
p7:;7ad d?d7 t
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if.G. Sertice oersonnel said covernor would not contrni nuifion_ of fire _Qacks
~~lSU A L INSP E CTlo N~~
^
Governor dity outside and inside, small shios and crit on novernor. Terminal shafts rustv.
O AT" COMPLETEQ terminal shaf t paint on R side damag'LE*ED SY CO Mi ed.
P. Jackson 82-?-17 AS AECElvE3 TEST Governor oressur7 cood until pilot valve omits oil to com cylinder. nressure then droos to 30-60 PSI and oil ficws from eno of nnwar nic:tnn.
C=uPi.ETEs av l cats couPuzTEo P. Jackson
? ?.,. 7 1_7 Tr,moowN sP SPECTION AND AEPAIR W
)
U Screw connectino ocwer oiston and seat not in olace (thre.wis s rieced). Governor was very dirty inside. Reolaced all check valves and drive shaft bearino. _ Converted covernor to a 3240-482VS cer order by installino two new solenoid valyes_ (enarcije to shutdown GSI and GS2)
COMPLITED SY C ATE COMPLETED B. Hewi tson 82-2-18 AINA L TEST ITEST SPEC NUMBEM COMPLETED Sy l C ATE COMPLgTgg i D
.l s 4 c e n I
C9.9.10 USE FOR ESTI.'.1 ATES ONLY A E? As p AUTMc As;.g'l \\_
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VISUAt. INSFECTICN
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W. O. NO.
7 5 7 '. ?
Start, and I.c.id Acceptance Qualification Test - Air Start Motor Refurbishraent TEST TIT 1.E:
PROC" DURE:
s M-hY4 -
DATE:
k
~~1 STARTER S/N: dO h STARTS MADE ON THIS UNIT:~~
d PARTS REPLACED: _(_
Oh STARTS MADE ON THIS UNIT: [Y
~~2 STAh!ER S/N:,~~
PARTS REPLACED:_d. _..k_
START P.ADE ON THIS UNIT: (Y I
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START MADE ON THIS UNIT:
~~4 STARTER S/N:~~
P.GTS REPLACED:
ADDITIONAL CO!CfENTS:
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ETR-75744-1 Page 13
t'.. O. NO.
75744 TEST TITLE: Start and Load Acceptance Qualification Test - Air Start Motor Ref nbiduen
~
O P7.00EDURE: /
~
DATE:
~~1 STARTER S/N: 087 STARTS MADE ON THIS UNIT:~~
~~PART3 REPLACED: /dC7/~~
~~2 STAT.TER S/N: /60 STARTS MADE ON THIS UNIT: [~~
FAPTS RIPLACED: / d d h d 9h 7 START MADE ON THIS UNIT: N (n,v [ 43 STARTER S/N:
PARTS REPLACED: O h9 START MADE ON THIS UNIT:
ft. STARTER S/N:
PARTS REPLACED:
l ADDITIONAL COMMENTS:
.N'W~
[M DATE:
f TECHNICIANS SIGNATURE:/
l
. N d
FTR-75744-1 Page 13
f5 j
's J k j' 75744 JOO NO.
ILLINOIS POWER CO.
g')_,,'g' SOLD TO d
METHOD NO. I'N 500 SOUTil 27Fil STREET
, dU500 ADDRESS
_ gt DATE O->
DECATUR, LLLINOIS, 62525 g
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CALC.BY
-I/M/ N Mf// /Y Y i
SERIAL NO.
CHECKE[ 7' 3869 KW. 4160 VOLT cov r.inSe.<
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//
R ATING OFFICIAL TEST RECORD E
I II SERVIC,E START AND LOAi) ACCEPTANCE QUALIFICATION TEST DAILY CilECK SIIEET PRIOR TO Tile INITIATION OF EACil DAYS START TEST SEQUENCE, Tile FOLLOWING ITEMS WILL BE VERIFIED AS OPERATIONAL AND Tile APPROPRIATE SPACE INITIALED IlY TIIE TEST TECIIN CIANS. '
~~n E~~
1.
FUEL OIL PUMP TURNED ON................ TECil. INIT.
2.
TURN ON D.C. POWER
........TECll. INIT.
3.
TURN ON COOLING TOWER FANS.
.TECil. INIT.
A 4.
TURN ON JACRET WATER CIRCULATING PUMP.
. TECil. INIT.
5.
TURN ON AIR COMPRESSORS *.
. TECH. INIT.
[
6.
PLUG IN AND TURN ON BATTERY CilAPCER.
. TECil. INIT.
_e 7.
ASSURE CilART RECORDER IS ON AND WARM...
.TECll. INIT.
/
8.
TURN ON RAW WATEP CIRCULATIGE PUMPS.
. TEC!l. INIT.
II
~~NO STARTS PERFORMED UNTIL STARTING AIR PRESSURE REACllES 250 PSI.~~
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JOB NO.
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ADORESS.
DECATUR, ILLINOIS 62525 gf,51I DATE TESTED SY M 1 L // M A N A
//
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CALC.BY
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y ~ \\) (j, 7b700 JOB NO._ II.LIMOIS POWER CO. SOLD TO A ADORESS METH NO. 500 SOUW 27M STREET I DECATUR, ILLINOIS, 62525 l ptVkil50;) ' N.~f DATE ,,ogig", f, bS$., Y / CALC.8Y SERI AL NO. CHECKEt OY_ lM/ // TAM Ab-3869 KW, 4160 VOLT I / M RATING OFFICIAL TEST RECORD oOv T. ins U / SERVIC,E START MID LOAD ACCEPTANCE QUALIFICATION TEST ~# DAILY CllECK SilEET 1 PRIOR TO Tile INITIATION OF EACil DAYS START TEST SEQUENCE, TIIE FOLLOWING ITCMS WILL BE VERIFIED AS OPERATIONAL AND Tile APPROPRIATE SPACE INITIALED BY Tile TEST TECIINICIANS. 1. FUEL OIL PUMP TURNED ON. ........ TECil. INIT. 2. TURN ON D.C. POWER. ...............TECil. INIT. 3. TURN ON COOLING TOWER FANS. ........TECil. INIT. l 4. TURN ON JACKET WATER CIRCULATING PIIMP. . TECl!. INII. ] '1 / j / //,,_/ ll 5. TURN ON AIR COMPRESSORS *. .TECil. INIT. 6. PLUG IN AND TURN ON BATTERY CilARCER. . iEC3. INIT. f. l 7. ASSURE CilART RECORDER IS ON ANT. WAR!!. .TECli. INIT. !Ax_/ 8. TURN ON RAW WATER CIRCULATION PUMPS. . TECl!. INIT. i 'i I
~~NO STARTS PERFORMED UNTIL STARTING AIR PRESSURE REACllES 250 PSI.~~
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W. O. NO. 75744 Start and Load Acceptance Qualificatic,a Test - Air Start }!otor Refurbishmen-TEST TITLE: PROCEDURE: e N 'Od"k 1 DATE:
~~1 STARTER Ss'N: 8 STARTS MADE ON THIS UNIT:~~
~~PARTS REPLACED: 6 kh~~
~~2 STARTER S/N. 8 @[Y STARTh MADF. ON Tills UNII.~~
~~PARTS REPLACED: 8 kY'N 8 kk[ START M*.DE CN TilIE USIT: U -#3 STARTER S/N: PARTS REPLACED: OP@~~
~~4 STARTER S/N:~~
START ECE ON TilIS UNIT: PARTS REPLACED: ADDITIONAL COMMENTS: 4 Yd k m-DATE: TECHNICIANS SIGNATURE: p S b FIR-75744-1 Page 13
? we J W. O. NO. 757.*;4 Start sad Lead Acceptance Qualification Test - Air Start Motor Refurbishmen: TEST TITLE: C<#( PROCEDURE: y-N
~~M d~N DATE:~~
~~1 STARTER S/N:Id_d /~~
~~STARTS MADE ON THIS UNIT:_ PARTS REPLACED: d Mk~~
~~2 STARTER S/N:~~
~~_d h STARTS MADE ON THIS UNIT: PARTS REPLACED: /[dh START MADE 05 THIS UNIT: f~~
~~3 STARTERS /S:['f PARTS REPLACED: _~~
44 STARTER S/N: 8 _h M 7 START MADE ON THIS UNIT: e PARTS REPLACED: I ADDITIONAL COMMENTS: b 0 f y FTR-75744-1 Page 13 si
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( ~ ~ ' '. / 3 'N/S 75744 JOB NO. ILLINOIS POWER CO. p. SOLD TO ADDRESS _ 500 SOUTil 2 7Til STREET ,,, f'S vf[5ggi METHOD 40. U"~7 b 7 /- OATE DECATUR, ILLII;0ls, 62525 56 TESTED BY[db 04Nko ^ CONT NO. i / MODEL NO. CALO.BY l CHECKED b l#/*AMM MMI SERI AL NO. OFFICIAL TEST RECORD cov r.,NSe. w / /l ~ li 3869 KW, 4160 VOLT R ATING V f V b. SERVIC E. START AND LOAD ACCEPTA1;CE Qi!ALIFICATION TEST !i l' e DA11,Y CIIECK S!!CET ,- - - -, m. - -, m..,.t i' PRIOR TO Tite INITIATION OF EACil DAYS START TEST SEQ'JENCE Tl!E TOLLCUIrlG ITEMS WILL EE ] VERIFIED AS OPERATIONAL AND Tile APPROPRIATE SPACE INITIALED BY TliE TEST TECIINICIANS. 1. RIEL OIL PUMP TURNED ON................ TECi!. I N IT. ii 2. TURN ON D.C. POWER...................TECll. INIT. rvv' ....TECll. INIT. 3. TURN ON COOLING TOWER FANS. 4. TURN ON JACKET WATER CIRCULATING PUMP. ...... TECil. INIT. 5. TURN ON AIR COMPRESSORS *. ......TECl!. INIT. 6. PLUG IN AND TURN ON BATTERY CllARCER.......... TECl!. INIT. 7. ASSURE CllART RECORDER IS ON AND WARM. ......TECil. INIT. 8. TURN ON RAW WATER CIRCULATION PUMPS. ..... TECll. INIT.
~~NO STARTS PERFORMED UNTIL STARTING AIR PRESSURE REACllES 250 PSI.~~
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W. O. NO. 75744 TEST TITLE: Start and Load Acceptance qualifica.1on Test - Air Start Motor Refurbishmen d<*(/ PROCEDUKE: DATE: M -8 ['8
~~1 STARTER S/N: Ck STARTS MGi ON TF.IS UNIT:~~
~~PARTS REPIACED: /dd[~~
~~7 STARTER S/N' / O START 3 M?N ON TEIS UNIT:~~
~~PARTS REPLACED: /dd START. E ON THT.S UNIT: M[ W~~
~~3_. STARTER S/N: -~~
~~PARTS REPLACED: dk7I~~
~~4 STARTER S/N:~~
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I
~~y. O. NO.~~
~~757*.i and Lc.2d Acceptar;ce Qualification Test - Air Start Motor Refurbishmen TEST TITLE: Start PROCEDURE: C6 DATE: bh $b~~
~~1 STARTER S/N: C 9~~
~~STARTS MADE ON THIS UNIT: 90 PARTS REPLACED: _ h~~
~~2 STARTER S/S: C k 9 N' STARTS MADE ON THIS UNIT:~~
~~PARTS REPLACED:_d9 fi~~
3 STARTER S/N: d START WE Oh' THIS WW_M PARTS REPLACED: 0 k'C START MADE ON THIS UNIT:

4 STARTER S/N: __
~~PARTS REPLACED: _ ADDITIONAL CdMMENTS: 2 A ( 'w_ / FTR-75744-1 Page 13 l 1 )~~
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~~TESTED BY~~
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1. HJEL OIL PUMP TURNED ON................ TECil. INIT. 2. TURN ON D.C. POWER. .........TECil. INIT. .TECl;. INIT. W 3. TURN ON COOLING TOWER FANS. 4. TURN ON JACKET WATER CIRCULATING PUMP......... TECll. INIT. 5. 'nlRN ON AIR COMPRESSORS *. .........TECil. INIT. 6. PLUG IN AND TURN ON BATTERY CilARCER.. . TECll. INIT. M .TEC!!. INIT. 7. ASSURE CHART RECORDER IS ON AND WARM. 8. TURN ON RAW WATER CIRCULATION PUMPS. ...... TECH. INIT. )
~~NO STARTS PERFORMED UNTIL STARTING AIR PRESSURE REACHES 250 PSI.~~
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/'- 7 j CALC.BY CHECKE M / d > /I/64 N #I I { MODEL NO. / /l SCRIAL NO 869 KW, 4160 VOLT OFFICIAL TEST RECORD cov T. ins / () R ATING SERVICE START AND LOAD ACCEPTANCE QUALIFICATION TEST DAILY CllECK S!!EET PRIOR TO Tile INITIATION OF EACil DAYS START TEST SEQUENCE, Tile FOLLOWING ITEMS WILL BE VERIFIED AS OPERATIONAL AND Tile APPROPRIATE SPACE INITIALED BY Tile TEST TEC ............... TECII. INIT. 1. FUEL OIL PUMP TURNED ON. TURN ON D.C. POWER,..........I........TECil. INIT. 2. .........TECil. INIT. 3. TURN ON COOLING TOUER FANS. j . TECll. INIT. A/' 4. TURN ON JACKET WATER CIRCULATING PUMP. .TECil. INIT. 5. TURN ON AIR C05fPRESSORS*......... . TECll. INIT. W l I PLUG IN AND TURN ON BATTERY CIMRGER.. l Q 6. l ..TECll. INIT. I ASSURE CilART RECORDER IS ON AND WARM.... I 7. . TECil. INIT. 8. TURN ON RAW WATER CIRCULATION PUMPS.
~~NO STARTS PERFORIED 1R:TIL STARTING AIR PRESSURE REACllES 250 PSI.~~
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i STAM ANC LCAM ACCE?T,0!CE OUALIFICATION TEST s. T.T:0CCDL'RE : 1 Af t er cact' 251h, s t ar t, the air line strainer, .:i v line lubricator and all starters will be re-coved, disassembled, cleaned and maintained rtr Stewart 5 Stevenson Commercial and Parts Mertal. Ary adjustments or pertinent obser-vill be recorded in the remarkt sec-vattene tien of the Test Record. At the end of the resting cr<;uence the air starters will be re-moved and refurbished to new or like-new con- <1i t ion. -( m_.. i (Nh, ,C/ 1 Page.12 FIR-75744-1
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t Inspection o T.h:.. i...:a t.'on Tes t ir.g O, Page 2 \\ v4 N D. Check a i< bc.:: for excessive oil coming from the turbo charger. . Findings: F e eun pOOkL-0OTEL'CkS I O* g 00 60 g') r o S L t-o S c e L u:= AE.S, j u)M OOEUh" D V 6'T~' b-C-' O 'AU L'A TiO U ' ~ s. II. Crank Case Cundition: A. Remove cne c.ain bear ing cap and visually inspect the bearing shell for normalcy. Ccmpare with EMD Inspection and Q.alificaticn of Engine Main Bearing (Bulletin No. EMD-1 4.74). e O OM C ,p. ( (g 7, cy.) [4ndings: g 0 $ a.s e,tt!G .Is.16 {CcT G _ggmE A.uo: 9 c w e3 00Em **** ' [)* gg At-5 e c.ra.'.a.i.-1 G OU OE DUN og.O[s%.-)> 0 b.'O D G0c 5H Q%O# S t U B. Visually ins;ect the above Main Bearing Journal for any evidencr: of.fanage. Findings: So .O. c M E. C, e - III. Turbo Charger Cor.dition: (in place) A. Visually inspect turbo wheel for any nicks,' dents or other visual damage. Findings: UJ avM h. L. {g dug (gg M l { hi-t Tv0So I n e
Truection of Qualification Testing Fnp 3 B. Measure the clearance between ccmpressor wheel and the air y a Er-s6tHe C)ci?-l% C G nozzle. tiote the actual measurement taken. Measurement: - 0 \\ E U S.E C tT, Q., Ch t h Y W O.DIO O,016" C. Measur.e the end play of the thrust bear' ng. tiote actual measurement taken. _-jb-2 E H GI N S Measurement:,,;?t t 6. u G t 0 6-lt u 9,009 o.o n l X IV. Soak Back Pump A. Engage soak back pump and circulating pump and record v. discharge pressures. i ~ Pressure: h t Nd " f'., p S,.2 E n./G 'JJ C' T 5 & 'l-;. 7 WANA '= ~ D 7 h./. //2"F p g f5 /, /2 'f'
~~~~10. / //~~~~
V. Governor: / \\ i V A. Governor operation chec.k to be performed by the start up at equipment functional start after test equipment jumpers have been removed. Findings: o QQC(Z CDe To T C C, B. Perfonn a complete tune-up in engine, checking valves, injectors for proper setting, tiote any deficiency, other than normal adjustments. Findings: l g L) d U s C%. j
O t.:spection of Qualification Testir.g Page 4 w 3 0995 s VI. Starters: l2C I Check starters which are to be shipped with the tinit. l 09.9 2. A. /A. Have been rebuilt and inspected. ' Vg B. Rebuilt sheet available. l [C. Note Serial Number of starters to be snipped.
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~~~~NOTE: Any other conditions or adverse findings. }OCh bhi' On / G:. / -2 n e M e 7 ~ ( . %.,Q 1.- f) Qaality Centr.1 Insytcur - ,-~ 7 (my 7. .~.v. ;c,u. ~- a T.r.t. :. - ..}}~~~~

ML20094F575

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ML20094F575

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