ML20100P176
| ML20100P176 | |
| Person / Time | |
|---|---|
| Site: | Shoreham File:Long Island Lighting Company icon.png |
| Issue date: | 09/17/1984 |
| From: | LONG ISLAND LIGHTING CO. |
| To: | |
| References | |
| OL-I-016, OL-I-16, NUDOCS 8412140048 | |
| Download: ML20100P176 (200) | |
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LILCO, Aug UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION
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Before the Atomic Safety and Licensing Board In the Matter of
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LONG ISLAND LIGHTING COMPANY
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Docket No. 50-322(OL)
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(Shoreham Nuclear Power
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Station, Unit 1)
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CRANKSHAFT EXHIBITS TESTIMONY OF ROGERT L. McCARTHY, PAUL R. JOHNSTON, EUGENE MONTGOMERY AND SIMON K. CHEN
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AND TESTIMONY OF EDWARD YOUNGLING AND FRANZ PISCHINGER
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TESTIMONY OF CLIFFORD WELLS, DUANE JOHNSON, HARRY WACHOB, CRAIG SEAMAN, DOMINIC CIMINO AND N. K. BURRELL
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VOLUME II Exhibit 16
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NUCLEAR REGULATORY C0f4 MISSION Docket No. 50-b1 (ou Orrreia: Exh. no I
16 24h(({$h tigj 6 la the mitter of Sf2ff ICENTIFIED
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Applicant RECElVED Intervenor
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REJECTED Cont *g Offr ceciracin cATE 9 ~ 17- $$
Wit'855 bh 8 l
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8412140048 840917 DMy DR ADOCK 05000 orhr Q
1 LILCO, August 14, 1984 y
UNITED STATES OF AMERICA NUCLEAR REGULATORY CCMtISSION D
~ and Licensing Board Before the Atomic Safety In the Matter of
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LCNG ISLAND LIGHTING COMPANY
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Docket No. 50-322(OL)
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(Shoreham Nuclear Power
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Station, Unit 1)
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CRANKSHAFT EXHIBITS B
C-1 Evaluation of E=ergency Diesel Generator Crankshafts at Shoreham and Grand Gulf Nuclear Power Stations prepared for TDI Diesel Generator Owners Group dated May 22, 1984 (hereinafter " Owners Group Crankshaft Report"), Figure 3-4 O
C-2 Specification for Diesel Generator Sets, Shoreham Nuclear Power Station - Unit 1, Spec. No. SH1-89, Revision 2, January 26, 1983, page 1-20.
C-3 U.S. Nuclear Regulatory Commission Regulatory Guide 1.9, Revision 2, December 1979.
C-4 IEEE Standard Criteria for Diesel-Generator Units Applied as Standby Power Supplies for Nuclear Power Generating Stations, Std 387-1977.
C-5 Transcript of July 11, 1984 meeting of the TDI Diesel D
Generator Owners Group, pages 124-25.
C-6 Available Logged Hours of Gperation of DSR-48, Rated 3500 KW
@ 450 RPM.
C-7 TDI Diesel Generator Run Historv Shoreham Nuclear Power D
Sation - Unit 1 - August 6, 198'4 C-8 Results of non-destructive examinations of replacement crankshafts at Shoreham after 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of operation at full load or greater.
D C-9 American Bureau of Shipping, Rules for Building and Classing Steel Vessels (1983), 5 37.17.1.
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C-10 American Bureau of Shipping, Rules for Building and Classing Steel Vessels (1983), Table 34.3.
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C-11 TDI Crankshaft Drawing Number 03-310-05-AC.
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C-12 American Bureau of Shipping Reports on Castings or Forgings of Replacement Crankshafts.
C-13 American Bureau of Shipping letter to TDI dated May 3, 1984.
C-14 Diesel Engine Manufacturers Association Standard Practices 3
for Low and Medium Speed Stationary Diesel and Gas Engines l
(1972 ed.), pages 53-56.
C-15 TDI Proposed Torsional and Lateral Critical Speed Analysis, August 22, 1983.
C-16 Field Test of Emergency Diesel Generator 103 with 13 x 12
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Crankshaft, April, 1984.
C-17 Owners Group Crankshaft Report.
C-18 Crankshaft Torsional Stress Calculations for 8L 17.x 21 Engine-Generator Set, July 19, 1984.
C-19 Table 2.2 from Owners Group Crankshaft Report showing natural frequencies from TDI analysis.
C-20 Table 2.4 from Cwners Group Crankshaft Report showing single order nominal stresses from TDI analysis.
O C-21 Table 2.5 from Owners Group Crankshaft Report showing nominal stresses calculated from torsiograph.
C-22 Crankshaf t Torsional Stress Calculations for 8L 17 x 21 Engine-Generator Set, July 19, 1984, page 11.
D C-23 Figure 3-3 from Owners Group Report showing comparison of measured and calculated torque.
C-24 Tables 3.6 and 3.7 from Owners Group Crankshaft Report showing comparison between analytical and test results.
C-25 Figure 3-13 from Owners Group Crankshaft Report showing D
fatigue endurance limit of replacement crankshafts on Goodman diagram.
C-26 Oberg and Jones, Machinery's Handbook (18th Ed.) pages 352-53; Shigley, Mechanical Engineering Design (McGraw-Hill) pages 212-13: Rothbart (editor), Mechanical S
Design and Systems Handbook (McGraw-Hill) page 18-4 2
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C-27 Engineering and Design Coordination Report No. F-46109G.
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C-28 Military Specification No. 13165B, Amendment 2, June 25, 1979.
C-29 LILCO Operational Quality Assurance Reports (EDG 102 and 103 Crankshafts).
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C-30 Metal Improvement Ccmpany Certificate of Shot Peening (EDG 102 and 103 Crankshafts).
C-31 Certificate of Non-Destructive Testing Issued by Krupp Stahl AG (EDG 102 and 103 Crankshafts).
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C-32 LILCO Magnetic Particle Testing and Liquid Penetrant Testing Records (EDG 102 and 103 Crankshafts).
C-33 LILCO Ultra Sonic Testing Records (EDG 102 and 103 Crankshafts).
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C-34 H. Fuchs and R. Stevens, Metal Fatigue in Engineering (1980) at pages 226-227; H. Uhlig, Corrosion and Corrosion control at pages 132-133.
C-35 Metal Improvement Company Certificate of Shot Peening (EDG 101 Crankshaft).
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C-36 LIICO Operational Quality Assurance Reports (EDG 101 Crankshaft).
C-37 Certificates of Non-Destructive Testing Issued by Krupp Stahl AG (EDG 101 Crankshaft).
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C-38 LILCO Magnetic Particle Testing, Liquid Penetrant Testing and Ultra Sonic Testing Records (EDG 101 Crankshaft).
C-39 Kirk, Behavior of Peen-Formed Steel Strip on Isochronal Annealing, Proceedings of the Second International Conference on Shot Peening at page 231, (May, 1984).
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TN' FIEI.D TEST OF EMERGENCY DIESEL GENERATOR 103 l
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WITH 13's 12 CRANKSHAFT Prepared for
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SHOREHAM NUCIZAR POWER STATION LONG ISI.AND LIGHTING COMPANT by E. BERCEL
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J. R. HALL APRIL 1984
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Approved by:
-. orisible Engineer m
' Responsible Engineer R
E. Bercel R. Hall STONE & WEBSTER ENGINEERING CORPORATION
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B1-1160037-1
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TABLE OF CONTENTS Section Title Page t
EXECUTIVE
SUMMARY
1-1
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2 Os)ECTIvES......................
2-t 3
INSTRUMENTA? ION AND METHOD OF INSTALLATION......
3-1 3-1 3.1 TRANSDUCERS..
3-1 3.1.1 Strain..............
3-1
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3.1.2 Torque.
3-2 3.1.3 Torsional Vibration........
3-2 3.1.4 Cylinc-r and Intake Manifold Pressure.
3.1.5 Generator output, Voltage, Current and output Power.. 3-3 3.1.6 Crachahaf t Position, Rotational Speed......... 3-3 3-4 3.1.7 Temperature.
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3.2 SIGNAL CONDITIONING AND RECORDING EOUIPMENT...... 3-6 3.2.1 Strain and Torque; Radio Telemetry.......... 3-6 3-7 3.2.2 Torsional Vibration.......
3-7 3.2.3 Cylinder Pressure...........
3-7 3.2.4 Generator Output.
3-8 3.2.5 Temperature..........
3-8 3.2.6 Recording Equipment.
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3.2.7 Other Analysis and Calibration Instrumentation.
3-9 3.3 DOCUMENTATION OF THE INSTRUMENTATION USED IN TESTS..
3-9 ON DG103 3-9 3.3.1 Telemetry Equipment.
3.3.2 Signal Conditioning Equipment.
3-11 3.3.3 Transducers...................... 3-12 3-13
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3.3.4 Recording Equipment.
3-13 3.3.5 Data Analysis Equipment.
3-13 3.3.6 Calibration Equipment.
4 CALIBRATION PROCEDURES................
4-1 4.1 STRAIN........................
4-1 4.2 TORQUE........................
4-2
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4.3 TORSIONAL VIBRATION.......
4-2 4.4 CYLINDER PRESSURE...................
4-2 4.5 SIGNAL CONDITIONING EQUIPMENT.............
4-3 4.6 MAGNETIC TAPE RECORDERS..
4-3 5
TEST PROGRAM...........
5-1
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5.1 STATIC TORQUE TEST..................
5-1 5.2 TEST SERIES I, DYNAMIC TESTS......
5-1 5.3 TEST SERIES II, DYNAMIC TESTS...
5-1 6
DATA REDUCTION....................
6-1 6.1 STRAIN MEASUREMENTS........
6-1
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6.2 PRINCIPAL STRESS CALCULATIONS.
6-2 6.3 OUTPUT TORQUE.....................
6-2 6.4 TORSIONAL VIBRATION....
6-3 B1-1160d37-14 i
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Y TABI.E OF CONTENTS (Cont)
Section Title Pag 6-3 6.5 CTLINDER PRESSURE...................
6-4
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6.6 GENERATOR OUTPUT...................
6 6.7 OTHER MEASUREMENTS..................
7-1 7
DISCUSSION OF RESULTS..
7-1 7.1 GENERAL........................
7-2 7.2 TEST RESULTS..
7-3
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7.2.1 Strain Measurements..................
7-4 7.2.2 Computed Stresses...................
7-6 7.2.3 Output Torque.
7-7 7.2.4 Torsional Vibration............
7-7 7.2.5 Cylinder and Intake Manifold Pressure.....
7-8 7.2.6 Generator Output...................
7-10 7.2.7 Transient Phenomena........
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7.2.8 Torsional Natural Frequency and Sampling.
7-10 8
CONCLUSIONS......................
8-1 APPENDIX A
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Text Figures A-1 to A-28 APPENDIX B Tables B-1 to B-12
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Figures B-1 to B-96
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B1-1160037-14 11
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LIST OF TABLES Table Title Page 3-1 Summary of Transducer Characteristics 3-5
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3-2 Summary of System Frequency Response Characteristics 3-14 5-1 Test Series I, Data and Test Description 5-3 5-2 Test Series I, Data and Test Description 5-4
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5-3 Test Series II, Data and Test Description 5-5 I
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B1-1160037-14 tii
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D I
B ACXNOWLEDGMENTS The efforts of many organizations contributed to the successful completion I
of the testing of Diesel Generator 103.
The volume and quality of the collected data would not have been possible without their close cooperation.
The scope of the participation of the various groups in the planning, B
preparation, and testing was as follows:
SkIC, FaAA, LILCO, and TDI planned the test and identified the para-meters to be measured.
g FaAA installed the strain gages, the radio transmitters, and the pressure sensors for the test.
FaAA also assisted in the reduction of the cylinder pressure data in order to expedite the data reduction process.
D LILCO installed all the remote connections for the recording of the voltage and current and power output of the generator.
I SkIC planned, supplied, installed, and calibrated all other trans-ducers, instrumentation, and recording and analysis equipment used in the recording and reduction of the data presented in this report.
Also, SkIC performed all the data reduction and signal analysis associated with the evaluation"of the test results.
Thanks are expressed to the LILCO, SLIC, FaAA, and TDI field personnel for g
their assistance in working on the engine and installation of instrumenta-tion.
B1-1160037-1 y
SECTION 1 EXECUTIVE SLWfARY
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Extensive field tests were carried out on Diesel Generator (DG) 103 at the
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Shoreham Nuclear Power Station. The objective of the tests was to repeat the measurements performed on DG 101 to confirm that the new, stronger crank-shafts are adequate for their intended application.
Strain in the crank-shaft, torsional vibrations of the crankshaft, and output torque were the
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most critical measurements. The scope of the mandate of the Acoustics and Vibrations Group of Stone & Webster Engineering Corporation (SWEC) within the framework of a larger investigation was to provide and install the required instrumentation, to carry out the recording of the data during the tests, and finally, to reduce the data to a form readily usable for analysis.
h All intended measurements were successfully ac'complished.
This report contains the experimental results. The evaluation of the data is presented
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in an engineering report prepared by others.
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B1-1160037-1 1-1
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SECTION 2 OBJECTIVES
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The objectives of the tests and subsequent data reduction were:
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To measure and record the strain at critical points on the crank-shaft under various operating conditions.
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To measure and record the engine parameters that were considered potentially useful for an engineering analysis of the crankshaft.
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To reduce, organize, and present the field measurements in a form suitable for review and analysis.
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B1-1160037-1 2-1
SECTION 3 INSTRUMENTATION AND METHOD OF INSTAILATION 3.1 TRANSDUCERS
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D.1.1 Strain Hicro-Measurements Corp.
350-ohm, epoxy-backed, metal foil strain sages were installed on the crankpin at cylinder Nos. 5 and 7 as shown in Figure A-1.
The sage length was 0.062 inches.
The strain sages were cemented onto the crankpin with a two-part epoxy adhesive. Gage 30, four-conductor Teflon insulated flat cable was used for lead wires.
The three-wire connection technique was used on all strain gage elements to eliminate 9
unwanted lead-wire effects.
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The lead wires were led along the shortest route to the nearest web where they were connected to radio-telemetry transmitters. They were led inside a Teflon sleeve that was secured to the crankshaft with an adhesive.
The
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radio transmitters and the bridge completion resistors were housed in an oil-tight metal box, one box for the measurements at each cylinder. The box was secured to the adjacent web of the crankshaft with a specially designed steel harness as illustrated in Figure A-2.
The installation at cylinder
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No. 7 included a reference bridge and transmitter.
The radio telemetry equipment is described in Section 3.2.1.
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3.1.2 Torque Ninety-degree, two-element strain gages (rosettes) were installed on the
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exposed section of the crankskaft between the engine casing and the fly-wheel, as shown in Figure A-3.
The strain gages. (see description in B1-1160037-1 3-1
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4 D
I Section 3.1.1).were oriented at 45-degree angles to the axis of the shaft I
along the direction of the principal strain caused by pure torsion, and were connected to form a full bridge configuration that would minimize bridge
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sensitivity to strain resulting from other causes. To provide redundancy, two torque bridges were installed.
The radio transmitters, one for each torque bridge and one for a reference bridge, were housed in a sealed metal box secured to the engine side of the flywheel (see Figure A-3).
The radio
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telemetry equipment is described in Section 3.2.1.
3.1.3 Torsional Vibration A transducer based on the seismometer principle was mounted on the free end of the crankshaft concentrically with shaf t rotation.
The transducer is O
man :factured by Hottinger Baldwin Messtechnik.
The characteristics of the transducer are such that its response is proportional to angular displace-ment above 3 Hz and to angular acceleration below 3 Ez. The characteristics e
are presented in Table 3-1.
The transducer excitation and output signal were transmitted through a set of slip-rings integral with the transducer.
Figure A-4 is a schematic illustration of the transducer installation.
O 3.1.4 Cylinder and Intake Manifold Pressures e
Two piezoelectric pressure transducers (PCB Model 112A) were installed in the compression test cocks of cylinder Nos. 5 and 7 in an attempt to measure and record the time history of the firing pressure pulse and its relation-ship to the induced' shaft torque and strain. The pressure transducers were g
forced-air cooled throughout the tests. The installation of the pressure transducers is illustrated in Tigure A-6.
A third piezoelectric pressure B1-1160037-1 3-2 O
.n' J
D transducer (AVL 5007) was installed in the air-start valve of cylinder No. 7.
This location waa considered potentially more suitable than the test cock for accurate cy14ader pressure esasurenest. The installation was water D
cooled.
It is illustrated in Tigure A-7.
The intake manifold pressure was measured with a strain sage type pressure transducer (Seasotec TJE/708).
3 3.1.5 Generator Output, Voltage, Current and Output Power i
The output voltage from phases A and C and the output current free all three O
phases were measured using transformers and shunt resisters installed by Long Island Lighting Company (LILCO). The sensitivity of the circuitry was such as to provide 1.0 V for each 4200 V and 2.5 V for each 800 A of gene-rator output. The setup required the isolation of the signals, therefore, g
differential amplifiers were used as signal conditioners for the tape recorder.
A schematic of the circuitry is shown in Tigure A-5.
Two low level signals proportional to the active and reactive power output were also D.
obtained from the control room and recorded on tape.
The levels of these 0.1 V per 5,600 kW and 0.1 V per 2,800 k VAR, respectively.
signals were D
3.1.6 Crankshaft Position, Rotational Speed The flywheel was painted black over one-half of its circumference and white 3
over the other half to serve as a phasor target. The transition points were coincidental with the top-dead-center positions of cylinders Nos.1 and 8 and Nos. 2 and 7 respectively.
A photoelectric pickup isounted adjacent to 3
the painted surface provided a one-volt, zero-based square wave whose falling edge was coincidental with the top-dead-center position of the piston in cylinder No. 7.
The position of the sensor relative to the 81-1160037-1 3-3 g
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flywheel was established using the engraved marking on the latter and the accuracy of the marking was' verified with dial indicator seasurementa of the No. 7 piston position.
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3.1.7 Temperature Two Copper-Constantan thermocouples were used to monitor the bearing cap and crankcase oil temperatures near cylinder No. 5.
The characteristics of the transducers are summarized in Table 3-1.
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B1-1160037-1 3-4
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TABLE 3-1
SUMMARY
OF TRANSDUCER CHARACTERISTICS
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Tlat Trequency Natural Temperature Temperature Acceleration or Response Frequency Limitation Effect Vibration
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Transducer (Es)
(Mz)
(*F)
(%TS!*T)
Limitation I
1 Strain 20,000 N/A 260 0.1(static)
N/A l
Torque 20,000 N/A 260 N/A N/A
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Torsional acc.
160 0.001 1200 rad /s2 vibration 0 to 3 3.0 0 to 1200 disp.
rad /seca 3 to 1000 Pressure (PS)
I to 405,000 400 0.1 0.01 lb/in fg a
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O to 10,000 300,000 10,000 g z
lb/in t
Pressure (P7) 0.01 to 250,000 400 0.1 0.01 lb/in /g 0 to 10,000 300,000 10,000 g lb/inz 2
Pressure (P7-5) 0.01 to 250,000 400 0.1 0.01 lb/in /3 0 to 10,000 300,000 z
ib/in 2
Pressure (PM) 0 to 6000 7,000
'150 0.05 0.01 lb/in /3 0 to 30
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lb/inz Therno-N/A Copper-Constantan N/A N/A couples
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B1-1160037-1 3-5
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3.2 SIGNAL CONDITIONING AND RECORDING EQUIPMENT i
l 3.2.1 Strain and Torque; Radio Telemetry
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Strain and torque seasurements on the crankshaf t were made using FM radio telemetry.
Acurez Model 206A static strain transmitters and Acurex 5-
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channel receivers with 106 5 signal conditioning cards were used for this purpose.
Each of the three telemetry installations, strain at crankpin No. 5, strain at crankpin No. 7 and torque, was transmitted and received
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with a separate antenna. Three 5-channel receivers were used. Figures A-2, A-3, and A-8 show the relevant details.
The transmitters and the bridge completion resistors were premounted on a
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circuit board that was secured inside a metal box.
Bridge balance was achieved with fixed resistors. The batteries used to power the transmitters were Acurex high-temperature, 2000 milliamp-hour batteries.
The strain transmitters were used in the lowest sensitivity configuration providing a measurement range of 22600 micro-strain (10 s in/in).
The receivers were located near the recording instrumentation at the end of 140-foot coaxial
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antenna cables. However, the antenna signals were passed through an antenna booster located between the engine and the coaxial cable. The output from the receivers was connected to 4-channel tacore Model 502 de amplifiers for
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stepwise gain control (see Figure A-8).
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B1-1160037-1 3-6
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S E
3.2.2 Torsional Vibration The transducer described in Section 3.1.3 was connected to a remote carrier 9
amplifier HBM Model KWS 3073. The output of the carrier amplifier was fed directly to the recording equipment.
3.2.3 Cylinder Pressure g
The pressure transducer on cylinder No. 5 was connected to a charge-to-voltage converter (PCB Model 402) through a 5-foot length of low-noise O
cable. The converter was connected to a power supply / amplifier (PCB Model 480) also adjacent to the transducer.
The output from the amplifier was connected to a remote (140 feet away)
Trig-Tek Model 205A 7-channel de 9
amplifier for interfacing and gain control (see Figure A-8).
The two pressure transducers on cylinder No. 7 were connected to charge amplifiers (PCB 463A for P7 and Kistler 5007 for.P7-S in the air-start valve) whose E
output was fed into the Trig-Tek Model 205A de amplifier as shown in Figures A-8 and A-9.
In the first test series PS and P7 were recorded on two separate tape recorders. P7-S malfunctioned in those tests.
In the 9
second test series all three pressure measurements were recorded on the same tape recorder.
3.2.4 Generator Output p
The output signals from the circuitry described in Section 3.1.5 were connected in the differential mode to a 6-channel Trig-Tek Model 205A ampli-fier.
This arrangement provided the required isolation and convenient gain control.
The power measurements were recorded throughout the tests.
The B1-1160037-1 3-7 9
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D roltage and current measurements were only recorded at 2500 kW and 2700 kW when the generator was switched to the emergency bus and back in the first test series.
D 3.2.5 Temperature D
The temperature of the bearing cap and crank case oil in the vicinity of cylinder No. 5 was measured with Copper-Constantan thermocouples.
The output of the indicator (Trendicator) used for interfacing was fed to the Trig-Tek 205A differential amplifier.
g 3.2.6 Recording Equipment D
Two 14-channel TEAC SR-50 m tape recorders were used for recording the dynamic data. All of the data were recorded in the m mode at 9.5 cm/sec.
The flat frequency response of the record / reproduce system at that speed is D
specified to be 0-2500 Hz. The full-scale output voltage of the reproduce amplifiers is 21.0 V for full-scale input settings of 0.2 V to 10 V.
input gain settings on the tape recorder were also used during the tests for I
gain control. A summary of system frequency response characteristics from transducer to reproduce amplifier output is presented in Table 3-2.
A third tape recorder (4-channel) was also employed to record the temperature D
measurements.
These were essentially static measurements recorded st 4.25 cm/sec.
D I
B1-1160037-1 3-8
y 3.2.7 Other Analysis and Calibration Instrumentation For system setup, calibration and static tests, a digital multimeter,
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Beckman Model 3020, was used. For data reduction and analysis, both in the time and frequency domain, a Nicolet 6608 2-channel TTT analyzer was used in conjunction with an HP 7470 digital plotter.
In the analysis of the time
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history of the static component of the strain and torque signals, low pass filters (Rockland 432) were used.
In reading the values of the signals at desired points, the digital read-out facility of the Nicolet 6605 analyser l
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was employed.
3.3 DOCUMENTATION OF THE INSTRUMENTATION USED IN TESTS ON DG103
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3.3.1 Telemetry Equipment Measurement Make g
Serial No.
Strain Transmitters
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At Cylinder No. 5 55-1 Acures 206A 42943 S5-2 Acurex 206A 44978 S5-3 Acurex 206A 48521 S5-4 Acurex 206A 2-539 Receiver at cyl. No. 5 Acurex 155K 042698
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81-1160037-1 3-9
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I p.
f Measurement M
Samial_N3L Strain Transmitters At Cylinder No. 7
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57-1 Acurez 206A 48504 57-2 Acurex 206A 49547
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$7-3 Acures 206A 49117
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R7 (Reference)
Acurex 206A 49545 l
Receiver at Cyl. No. 7 Acurex 155K 044972
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Torque Transmitters On Output Shaft
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TQf Acurex 206A 48977 TQ9 Acurex 206A 48975 RT (Reference)
Acurex 206A 44964
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Receiver for Torque Acurex 155K 049302
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81-1160037-1 3-10
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9 Measurement Make Model Serial No.
g 3.3.2 Signal Conditioning Equipment Strain 55-1 to S5-4 Encore 502M 3
D S7-1 to S7-3, R7 Encore 502M 1
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TQ9, TQ9, RT Encore 502M 2
3 Pressure P5 PCB 402A/440D 3435/201 J
Trig-Tek 205A 103 P7 PCB 463A 254 Tris-Tek 205A 103 3
P7-5 Kistler 5007 173288 Trig-Tek 205A 103 PM Vishay 2310 042933 J
B1-1160037-1 3-11 g
D Measurement Make Model Serial No.
Torsional vibrations KBM KWS3073 28775 Electrical Measuresents D
Power KW, KVAR Trig-Tek 205A 103 Current, Voltage Tris-Tek 205A 103 3.3.3 Transducers D
Strain & Torque Micro-Measurement Metal Toil Gages 3
Three-Element Rosettes Type WK 06-061RB350 Cage Tactor 1.97-2.02 Single Gage (55-4)
Type WK 06-062AP350 Gage factor 2.00 D
Pressure PS PCB 112A 4033 D
P7 PCB 112A 4034 D
P7-S AVL 12QP505CL 1010 PM Sensotec TJE/708 75371 D
Torsional Vibrations RBM BD 720 D1 1160037-1 3-12 D
Measuremenc Make Model Serial No.
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3.3.4 Recording Equipment
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14-Channel Tape Recorder "A" Teac SR-50 143388 14-Channel Tape Recorder "B" Teac SR-50 143505A 4-Channel Tape Recorder "C" Teac R-61 162988 3.3.5 Data Analysis Equipment
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Spectrum Analyzer Nicolet 6608 1766-644
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Tracking Tilter Nicolet 24D 2698317 L.P. Tilter Rockland 432 1285820
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3.3.6 Calibration Equipment.
Strain & Torque
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Precision Resistors Micro-Measurement 175K and 350K
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Pressure _
2000 psi Transducer Schaevitz P703 00901
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81-1160037 1 3 13
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Measurement Make tfodel Serial No.
5000 psi Precision Ashcroft SNPS 192 Pressure Gage
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Signal Conditioner Vishay 2310 042834 Torsional Vibrations
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Proximity Probe Indikon 205XL-4 100
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Signal Conditioner SktC AV1
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81 1160037 1 3-14
D e
TABLE 3-2 SLWfARY OF SYSTE!! TREQUENCY RESPONSE CHARACTERISTICS D
Signal Overall System Conditioning
Response
g Measurement (Hz)
(Hz)
Limited By Strain 0-1000 0-1000 Transmitter Torque 0-1000 0-1000 Transmitter D
Torsional Vibration 0-1000 3-1000 Transducer / Signal f
Conditioning Pressure 100,000 0.5-2500 Signal Condi-tioning/ Tape Recorder S
Cenerator Output 100,000 0-2500 Tape Recorder D
D D
B1-1160037-1 3-15 D
D D
SECTION 4 CALIBRATION PROCEDURES D
4.1 STRAIN D
All strain gage channels were calibrated end-to-end statically using the shunt resistance calibration method.
A two-step calibration was employed using shunt resistances of 175 kilohn and 350 kilohn directly in the strain gage bridge. The simulated strain was computed according to Equation 4-1.
simulated strain in micro-strain
=R
( 9 '~ )
KR+g D
where:
Rg = bridge resistance in ohms Rc = shunt resistance in ohns K = gage factor D
The gage factors varied from gage to gage, within the range of 1.97 to 2.02.
The calibration system output (including radio telemetry) was recorded on magnetic tape. All strain gages were wired to obtain (+)ve output for (+)ve D
strain.
The calibration was performed at a system sensitivity of about 0.5 millivolt D
for each micro-strain. The sensitivity used in the tests was 2.5 and 1.25 times the calibration sensitivity.
D B1-1160037-1 4-1 D
ii -
Y
)
)
4.2 TORQUE s
The same method of calibration as the one described in Section 4.1 was used.
The calibration was performed at a system sensitivity of 0.5 millivolt for each full bridge micro-strain (0.25 micro-strain per azu).
The torque measurements were carried out at 2.5 and 1.5 times the calibration
)
sensitivity.
4.3 TORSIONAL VIBRATION
)
The HBN transducer was calibrated statically by displacing the internal seismic mass 13.0 degrees relative to the transducer casing using an exter-
)
nal permanent magnet. The resulting system output was recorded on magnetic The torsional vibration seasurements were carried out at 10.0 and 5.0 tape.
times the calibration sensitivity.
The transducer was dynamically calib-
[
rated after the test and its response characteristics were verified using
)
the method illustrated in Figure A-10.
The sensitivity 'and vibration amplitude range used in the calibration were those encountered during the tests.
4.4 CTLINDER PRESSURE
)
All four pressure transducers were calibrated before and after the tests. A 1500 psi (30 psi in case of the transducer on the intake manifold) static pressure from a compressed nitrogen supply was applied to the pressure
)
transducers.
A precision pressure gage and a calibrated pressure trans-ducer, capable of measuring static pressure, were also connected to the
)
B1-1160037-1 4-2
)
)
supply manifold. The step output of the transducers was recorded on tape.
The sensitivity of the transducer was determined using the transfer function measurement capability of the Nicolet 660 B analyzer.
The method is
)
illustrated in Figure A-11.
4.5 SIGNAL t.ONDITIONING EQUIP!fLVI
)
The accuracy of the step gain settings of all amplifier channels was veri-fied and found to be within 2 percent of the nominal values.
)
4.6 ffAGNETIC TAPE RECORDERS A calibration signal of '1.0 V peak-to-peak at 196 Hz was recorded on all
)
channels of the SR-50 recorder. This represented merely a functional check of the reproduce amplifiers since all calibrations as described above were performed en'd-to-end.
The accuracy of the step gain settings on the tape
)
recorder was verified and found to be within 1.5 percent of the nominal values.
)
b 3.
B1-1160037-1 4-3
)'
6
.O SECTION 5 TEST PROGRAM O
5.1 STATIC TORQUE TESTS
.O Prior to the dynamic tests, static torque tests were carried out.
Torque was applied by blocking the crank throw at cylinder No. 2 and applying a O
tansential force to the flywheel.
For this purpose, a 1\\-inch diameter radial pin was installed in one of the peripheral holes on the flywheel, and a tangential force was applied to the pin with a hydraulic ran actuated by a handpump.
Torque and strain readings were taken from the appropriate telemetry channels for both increasing and decreasing torque to verify that
[
the strain and torque instrumentation functioned correctly.
'O 5.2 TEST SERIES I, DYNAMIC TESTS These tests were performed on January 7,1984. All the steps prescribed in
,!O the test plan were carried out and all planned measurements except the P7-S pressure measurement were successfully performed.
Tables 5-1 and 5-2 summarize the activities in this test series.
O 5.3 TEST SERIES II, DYNAMIC TESTS g
Since the measurement of cylinder pressure at the air-start valve was considered potentially important, a second series of tests was carried out B1-1160037-1 5-1 g
on January 8,,after the malfunction of the pressure transducer had been
\\
corrected.
The measurements of the previous day were repeated at several i
power levels from speed-no-load to 3800 kW.
Table 5-3 summarizes the
)
activities and the measurements of this test series.
Figure A-12 provides a schematic illustration of the channel allocation and j
measurements during the two test series.
) -
J-J
)
)
i B1-1160037-1 5-2
)
i J
).
TABLE 5-1 TEST SERIES I JANUARY 7, 1984 DATA AND TEST DESCRIPTION
)
7.1.0 7.1.1 7.1.4 7.2.1 7.2.2 7.3.1 411-490 Isochr.
TEST 10-Minute Slow Roll 5-Minute rpm Load to DATA Air Spin SNL 720*
SNL No-Load 2700 kW MEASURED
)
VARIABLES CODE DATA TAKEN Strain 5-1 Yes A
Yes A
Strain 5-2 Yes A
Yes A
Strain 5-3 Yes A
Yes A
Strain 5-4 Yes A
Yes A
Strain 7-1 Yes A
Yes A
)
Strain 7-2 Yes A
Yes
'A Strain 7-3 Yes A
Yes A
Output Torque TQ9 Yes A,B Yes A
Torsional Vib.
TV Yes A
Yes A
Cyl. Pressure P5 Yes B
Yes B
Cyl. Pressure P7 Yes A,B Yes A
)
Cyl. Pressure P7-S No No Intake Pressure PM Yes B
Yes B
Active Power PWR Yes A,B,C Yes A,B,(
Reactive Power VAR Yes B
Yes B
Output Voltage EA No
> No Yes B
Output Voltage EC No
> No Yes B
Output Current IA No
> No Yes B
Output Current IB No
> No Yes B
Output Current IC No
> No Yes B
Crankshaft Pos.
TDC Yes A,B Yes A,B Bearing Temp.
TBS Yes C
Yes C
Crank Case Temp. TCS Yes C
Yes C
Yes B
> Yes B No Signal Reference Note:
"A",
"B", "C" Denote Tape Recorder Units 4
i r
4
+
- I 4
I 4
l B1-1160037-1 5-3
q
'%/
i TABI.E 5-2
,V TEST SERIES I JANUARY 7, 1984 DATA AND TEST DESCRIPTION O
7.4.2 7.4.1 7.4.3 7.4.4 7.4.5 7.4.6 7.6 On Grid 2800 kW Slow Roll TESTS on Grid on Grid P.F.
On Grid On Grid 720' DATA SNL 2S00 kW
.8,.8,1.0 3500 kW 3800 kW Air Sein n
HEASURED v
VARIABI.ES CODE DATA TAKEN Strain 5-1 Yes A
Yes A
Strain 5-2 Yes A
Yes A
Strain 5-3 Yes A
Yes A
Strain 5-4 Yes A
Yes A'
O' Strain 7-1 Yes A
Yes A
Strain 7-2 Yes A
Yes A
Strain 7-3 Yes A
Yes A
Output Torque TQ9 Yes A,B Yes A,3 Torsional Vib.
TV Yes A
Yes A
Cyl. Pressure P5 Yes B
Yes B
O Cyl. Pressure P7 Yes A,B Yes A
Cyl. Pressure P7-S No No Intake Pressure PM Yes B
Yes B
Active Power PWR Yes A,B,C Yes A,B,C Reactive Power VAR-Yes B
Yes B
Output Voltage EA No No 3
Output Voltage EC No No Output Current IA No No Output Current IB No No Output Current' IC No No Crankshaft Pos.
TDC Yes A,B Yes A,3 Bearing Temp.
TBS Yes C
Yes C
Crank Case Temp. TC5 Yes C
Yes C
g Yes B
Yes B
Signal Reference "A",
"B", "C" Denote Tape Recorder Units Note:
O 3
B1-1160037-1 5-4
,-)
)
TABII 5-3 TEST SERIES II JANUARY 8, 1984 DATA AND TEST DESCRIPTION
)
TISTS On Grid On Grid On Grid On Grid DATA SNL 1750 W 2800 W 3500 W 3800 W BEASURED.
VARIABLES CODE DATA TAEEN
)
Strain 5-1 Yes A
Yes A
Strain 5-2 Yes A
Yes A
Strain 5-3 Yes A
Yes A
Strain 5-4 Yes A
Yes A
Strain 7-1 Yes A
Yes A
Strain 7-2 Yes A
- - - - - - - - ~ ~ - - - - - - - - - >
Yes A
)
Strain 7-3 Yes A
Yes A
Output Torque TQ9 Yes A,3 Yes A,3 Torsional Vib.
TV Yes A
Yes A
Cyl. Pressure P5 Yes B
Yes A,B Cyl. Pressure P7 Yes A,B Yes A,B Cyl. Pressure P7-S Yes A
Yes A
Intake Pressure PM Yes B
Yes B
)
Act.ive Power PWR Yes A,B Yes A,B Reactive Power VAR Yes B
Yes B
Output Voltage EA No No i
Output Voltage EC No No No Output Current IA No Output Current IB No No Output Current IC No No Crankshaft Pos.
TDC Yes A,B Yes A,B Bearing Temp.
~35 No No j
Crank Case Temp. ICS No No Yes B
Yes B Signal Reference
' Note:
"A", "B". "C" Denote Tape Recorders Units t
l l
)
)
B1-1160037-1 5-5
Y I
SECTION 6 DATA REDUCTION
)
6.1 STRAIN IfEASUIUDfENTS
)
All seven strain telemetry systems functioned very well throughout the tests, and dynamic strain data of excellent quality were obtained.
The static component of the observed strain was subject to some small offsets, y
which were within the reported accuracy of the telemetry system.
Since significant static strain in the crankshaft is caused only by the trans-mitted load, several records on the tape corresponding to the output power
)
were plotted against the low-pass (I Hz) filtered signal of the strain measurements using the
'X-Y' plot capability of the Nicolet 660 B signal analyzer.
The results indicated a nearly linear relationship between the static strain in the crankshaft and the output power. The strain vs output power curves are presented in Appendix A (Figures A-13 to A-26).
The numerical value of the relationship was determined from those curves for
)
each strain gage installation in terms of micro-strain per kW.
The dynamic strain data were reduced in the time domain employing the
)
synchronous averaging feature of the Nicolet 660 B.
The strain signals were high-pass (1.0 Hz) filtered, and thirty-two 0.4-second samples of the signal, each sample precisely synchorized to the same point in the engine
)
cycle, were averaged.
Peak-to-peak readings were taken from those records.
B1-1160037-1 6-1
)
r
)
6.2 PRINCIPAL STRESS CALCULATIONS The synchronously averaged strain signals described in Section 6.1 were digitized into 1024 data points in the Nicolet 660 B.
The digitized strain data from the three elements of each strain gage rosette were read by an HP 9826 computer.
The applicable static strain component computed as
']
discussed in 6.1 was added to each data point and the time history of the principal stresses, and the maximum shear stress, as well as the bending and torsion related stresses, were computed for the 0.4-second (1.5 strain
]
cycle) time window of the strain samples.
6.3 OUTPUT TORQUE D
The torque measurements were made by measuring the strain in the output shaft as described in Section 3.1.2.
Of the two torque bridges installed, one was subject to some reduction in signal quality, but the other one (TQ9) provided excellent dynamic signals throughout the test.
Using the technique described in 6.1 the torque-power relationship was determined in terms of micro-strain /kW. The torque vs output power curves are presented
)
in Figure A-27 acd A-28 in Appendix A.
The obtained value was very close to the one calculated from the known material properties and geometry of the output shaft a; the section where the se. rain gage bridges were located. The
)
measured value for the torque-power relationship was 63.2 micro-strain per 1000 kW generated power (four-arm bridge, four times the actual strain in the shaft). Using the vendor specified figure of 96 percent for generator
]
efficiency, the calculated torque-power relationship is 63.2 ' micro-strain
^
~
B1-1160037-1 6-2
)
)
)
per 1000 kW of generated power.
Since the seasurement involved very low level signals the probable error is estimated at 5 to 8 percent.
1
)
The torque measurements at various selected load levels were analyzed in both the time domain and the frequency domain.
Synchronous averaging was used. in the time domain analysis.
In the frequency domain, synchronous averaging was employed in some of the analysis to obtain phase measurements
)
relative to the firing top-dead-center of cylinder No. 7.
These measure-ments were obtained in the 500 Hz range which provided a 0.8 second sample.
Ensemble averaging was used for general spectrum analysis to accurately display a region of resonance in the spectrum. Synchronous averaging tends to attenuate the data near a point of resonance in the spectrum as a result of the random nature of the spectrum there. The frequency range used was
)
50 Hz.
6.4 TORSIONAL VIBRATION
)
The torsional vibration data were analyzed in the time and frequency domains using the same techniques as described in 6.3.
Synchronous time averaging,
)
of the torque and torsional signals tagether, was also performed to display the two phenomena in relation to each other.
)
6.5 CYLINDER PRESSURES Synchronous time averaging of all three cylinder pressures was performed.
Frequency domain analysis was also done to measure the amplitude and phase of the 7.5 Hz and 15.0 Hz components of the cylinder pressure pulse, which i
B1-1160037-1 6-3
)-
)'
contribute most of the power in the power stroke.
These measuremencs were made in the 500 Hz range.
TaAA also performed data reduction on the cylinder pressure records. The results of their analysis are reported under
)
separate cover.
6.6 GENERATOR OUTPUT
)
All the electrical measurements were processed in the time domain.
The current and power seasurements were also analyzed in the frequency demain to examine any dynamic characteristics.
)
6.7 OTHER tfEASUREMENTS
)
The intake manifold pressure was constant for each output power level. Its variation with output power was measured in the time domain.
All other seasurements, including the bearing temperature and oil temperature mea-
)
surements, were done essentially for the purpose of monitoring the functioning of the instrumentation and to facilitate the diagnosis of instrumentation problems if they should occur.
As such they were not
)
analyzed and are not presented in this report.
)
B1-1160037-1 6-4 y
O O
SECTION 7 DISCUSSION OF RESUI.TS 7.1 GENERAI, g
The reduced data are presented in tables, graphs, and time and frequency domain plots produced on the Nicolet 660B analyzer.
All graphs and plots have been annotated in detail to assist the reader.
On the plots in Appendix B the following conventions have been used:
3 Each variable is plotted to a scale of +/- 5 divisions with zero in the center.
The full scale is denoted above the graticule. For example, O
1.5 + 0.3 means: full scale is 1500 engineering units.
up is always (+)ve VLN seans linear vertical scale VLG designates logarithmic vertical scale O
+
C under VLG or VLN means continuous data (Hanning weighting)
T under VLG or VLN means transient data (Flat weighting)
AR means channel A real component 3
AT means averaged time record SU 4 $eans averager set for four samples Tape A3:350 means record from tape 3 at counter 350 off tape O
recorder "A" RS means real spectrum FS means full scale l
AM means magnitude of variable A was plotted D
B1-1160037-2 7-1 g
1
l l
Results of the' tests are described briefly and comumented on to assist the reader.
The analysis of the data is presented in an engineering report prepared by others.
7.2 TEST RESULTS.
)
The results of the tests recorded at 2,700 kW on the emergency bus and at the 3,500 kW and 3,800 kW load levels on the external grid make up most of the detailed data presented in this report.
A summary of the measurements
)
of the mechanical variables frow 1,750 kW to 3,800 kW is provided in the form of peak and peak-to-peak values tabulated or plotted on graphs. The data reduced from the 2,700 kW, 3,500 kW, and 3,800 kW tests are presented
)
in time and frequency domain plots. Principal stresses for the 3,500 and 3,800 kW 1evels were also calculated and plotted for 1.5 engine cycles.
Phase measurements of the Tourier components of the observed torque and torsional oscillations and for the cylinder pressure pulses are also in-
)
cluded in the report.
The generator output voltage and current were measured at 2,500 kW on the grid and at 2,700 kW on the emergency bus. Those measurements are presented in time and frequency-domain plots. The output power and torque spectra are included for the variable power factor test at 2,800 kW and for the 3,500 kW
)
and 3,800 kW tests.
All the reduced data are found in Appendix B in Tables B-1 through B-12 and
)
Tigures B-1 through B-96.
The data presented in the form of graphs and plots are organized into four main groups.
The relationship between the
)
B1-1160037-2 7-2
[
mechanical variables and output power and the results of the variable speed test are illustrated in Tigures B-1 through B-11.
Tigures B-12 through B-78 contain the time domain data of the mechanical variables, including the
)
calculated principal stresses and transient phenomena.
The time-domain records of the electrical variables are in the third group in Tigures B-79 through B 86.
Finally, the frequency domain plots are presented in the
)
fourth group in Tigures B-87 through B-96 for both mechanical and electrical variables. In each group the figure numbers are arranged in ascending order with s'enerated power to assist the reader.
)
7.2.1 Strain Measurements In comparison to the dynamic strain, the static component of the measured
)
strain was small.
Since the dynamic range of the instrumentation had to accommodate the total strain, the static strain components were in the bottos 5 percent of the total measurement range. Nevertheless, the proce-dure described in Section 6.1 enabled the measurement of those components to satisfactory accuracy (about +/- 5 percent).
The values determined for a
the various load levels are given in Table B-1.
)
Measurements 5-3 and 7-1 represent the tensile components while 5-1 and 7-3 are the compressive strain components.
The dynamic strain records are 1
)
presented in the time domain only (Tigures B-12 through B-18, B-24 through B-30, and B-37 through B-43).
Each of those records represents 48 strain cycles averaged synchronously over a period of 12.8 seconds. To facilitate analysis, all records have been plotted to the same scale with a zero average and have been triggered at the same point in time. The time of the B1-1160037-2 7-3
)
Nm/
O trigger is 177 degrees after the firing TDC of No. 7 cylinder and each plot extends over three revolutions of the crankshaft. Table B-2 summarites all the mechanical measurements as a function of output power.
The largest O
peak-to-peak strain was measured at 5-3 and 7-1.
They both represent tensile strain.
Conversely 5-1 and 7-3 represent comyressive strain at location 5 and at location 7.
The largest values of peak-to-peak dynamic strain are about 1,400 micro-strain. The waveform of the strain for every 3
component is extremely uniform in time and varies only slightly in amplitude from one cycle to another.
The dynamic peak-to peak component varies linearly with output power (Figures B-1 and B-2).
3 7.2.2 Computed Stresses n
The principal stresses at location 5 and 7 are calculated from strain components 5-1, 5-2, 5-3, and 7-1, 7-2, 7-3 for various power levels. The three measurements that enter into the calculations were captured synchron-O ously.
Table 3 contains some synchronous readings of the dynamic strain data measured with the three-element strain gage cassettes.
The principal stresses were calculated from 1024 sets of such synchronous strain data.
4 The static strain values used in the computations were those in Table B-1.
The time history of the calculated stresses including the two principal stresses has been plotted in Figures B-50 through B-73 for the 3,500 kW and g
3,800 kW tests. The plots represent 1.5 stress (strain) cycles. Each plot begins in time at 177 degrees after the firing TDC of No. 7 cylinder and continues through three revolutions of the crankshaft.
The angle of
,J orientation of the Major Principal Stress with respect to the direction of B1-1160037-2 7-4 0
\\
l
)
5-3.and 7-1 has also been plotted. The zero for each.of.these plots (B-50 through B-73) is located in the middle of the vertical axis.
)
The planes of the principal stresses rotate relative to the crank pin as the shaft rotates.
It is possible to look at the state of stress in the Mohr's circle along a direction that remains fixed relative to the crank pin as the
)
latter rotates, for example, the axial direction of the pin. This was done in Figures B-54, B-60, B-66 and B-72.
Since the stress in the axial direc-tion may be caused mainly by bending action in the axial direction, it is
}
conveniently labeled as Bending Stress. - When the direction is fixed at 45 degrees from the axis of the crank pin, the observed stress is primarily caused by torsion. Figures B-55, B-61, B-67 and B-73 represent that stress and are correspondingly labeled as Torque Stress.
)
The results are consistent.
The Major Principal Stress at location 5 is larger than the Minor Principal Stress, and the converse is the case at I) location 7.
The Bending Stress at both locations has the waveform observed in the axial strain (5-2 and 7-2), while the Torque Stress wavefor especially in the case of crank pin 7, looks very much like the waveform of
)
the torque oscillation observed in the output shaft. The largest Principal a and Stress level was observed at location 5; it is 29,800 lb/in 2 for the 3,500 kW and 3,800 kW load conditions respectively.
31,300 lb/in
)
Table B-4 and Figures B-4 through B-6 list and illustrate the computed stress levels at the various load levels.
)
j B1-1160037-2 7-5
)
}
)
7.2.3 Output Torque As described in 6.3 the static component of the output torque signal, determined in terms of the sensured shaft strain, was 15.8 micro-strain per The 1,000 kW.
The torque-power relationship was found to be very linear.
vendor specifies the generator efficiency as 96 percent.
Therefore, the
)
required output torque for power generation is 16.3 lb-ft/kW. The conver-sion from shaft strain to output torque therefore is 1,032 lb ft/siero-strain.
The above conversion factor was used to interpret and label the
)
torque records in units of pound-feet.
The torque acasurements are presented in several forms. Time-domain records
)
have been plotted in Figures B-19, B-20, B-31, B-32, B-44 and B_-45.
These represent the synchronous average of 48 torque cycles and were triggered at the same point in the engine cycle as the strain records.
The waveform of the torque oscillations is very steady in time exhibiting only a small
)
fluctuation in amplitude.
The peak-to-peak amplitudes were tabulated in Table B-2 and plotted in Figure B-3 against output power.
The observed torque fluctuation was 357,100 and 369,460 lb-ft peak-to-peak at 3,500 kW and 3,800 kW loads, respectively.
It increased approximately linearly with output' power.
The frequency spectra of the torque are presented in Figures B-87 through B-89.
The range of analysis was 50 Hz and includes
)
13 half-orders.
A resonance around 38 Hz is evident.
The Fourier compo-are tabulated in nents of the torque oscillations (amplitude and phase)
Tables B-5 through B-8 for the 3,500 kW and 3,800 kW loads.
The fourth 1
)
order component was tabulated and plotted against output power in Table B-9 and Figure B-8, respectively.
The peak,-to-peak torque oscillations and
)
B1-1160037-2 7-6
t their fourth order Fourier component are presented for. the variable speed test in Tables B-11 and B-12 and in Figures B-10 and Bil.
M 7.2.4 Torsional Vibration The time-domain recorda of the torsional vibration are presented in
.O Figures B-21, B-33, and B-46 and also in Figures B-20, B-32, and B-45 where output torque and torsional vibration are presented together.
- Again, 48 cycles were synchronously averaged over a 12.8 second period.
The frequency-domain analysis of torsional vibrations was identical to that
-O described for the output torque in 7.2.3.
The results are presented together with those for the output tor ;o; in the same tables and figures.
O 7.2.5 Cylinder Pressures and Intake tfanifold Pressure The pressure in cylinder No. 7 was measured at two ports, P7 at the test LO cock and P7-S in the air-start valve.
In cylinder No. 5 only one measure-I ment port, the test cock, was used.
The time-domain pressure records obtained in the three measurements are very similar.
A closer examination O
reveals a slight amplitude difference of about 5 percent between the two cylinders and about 3 percent between the two measurements on the same cylinder.
These figures are within the expected accuracy of field measure-
!O ments of a complex phenomenon such as cylinder pressure. The time domain records, 48 cycles synchronously averaged, are presented in Figures B-22 and B-23, B-34 through B-36, and B-47 through B-49.
The peak-to-valley readings
" th ** P ots are tabulated in '!able B-2 and plotted against output power l
lO in Figure B-7.
The largest values were in the 1,650-1,700 psi range.
l lo B1-1160037-2 7-7
,-,--,,--,-_,_.,,,..--,--..n-
.----n... n.
na -
,)
)
The pressure records were analyzed in the frequency domain to determine the magnitude and phase of the 7.5, 15.0, and 30 Hz Fourier components which contribute most of the generated power. The measurements were based on the
)
Fourier transform of the synchronous average of 128 pressure cycles over a time period of.51.2 seconds. The results are presented in Table B-10.
The difference in the amplitudes of the 7'.5 Hz Fourier components is about the
)-
same magnitude as that observed in the time-domain overall amplitude.
The more significant difference is observed in the phase measurements (Table B-10). The measurements obtained from the air start valve location produced
^
)
a consistently larger phase value. This suggests that the location of the significant effect on the phase sensurements of the pressure sensor has a
Fourier components. From the information in Table B-10, the generated power in cylinder Nos. 5 and 7 can be calculated.
)
The intake manifold pressure was steady during each test without any sign of pulsation. It varied in the range of 11 to 32 psi with load in the 1,750 to 3,800 kW range (see Figure B-9).
As stated earlier, the pressure measurements were also analyzed by FaAA in
)
order to expedite the data reduction process.
The results of their analysis, presented under a separate cover, agree with the results presented here within the bounds of experimental error.
)
7.2.6 Generator output
)
Both the active and reactive power were recorded throughout the test. The time-domain synchronized average records of those variables are presented in B1-1160037-2 7-8
)
~:
y
)
The Figures B-85 and B-86 for output power levels of 3,500 kW and 3,800 kW.
frequency spectra of the output power, both active and reactive, are pre-seated in figures B-93 and B-94 for the 3,500 kW and 3,800 kW loads.
A relatively large component at 3.75 Hz is apparent in both spectra.
That fluctuation is also evident in the time domain.
)
The spectra of the output active power, one of the output currents (Ia) on the emergency bua and on the grid at 2,700 kW and 2,500 kW respectively, are plotted in Figures B-95 and B-96.
A very appreciable increase in the 3.75 Hz component of the output power is evident when the generator is tied to the external grid.
No similar increase in the current spectrum is visible, however the 3.75 Hz peak becomes broader. The peak corresponds to
)
the rigid body mode of oscillations of the crankshaf t generator system.
The frequency spectra of the output power and the output torque are present-ed in Figures B-90 through B-92 for the 0.8, 0.9 and 1.0 power factor condi-
)
tions at 2,800 kW.
No appreciable difference in the spectra is observed.
The time-domain records of two output voltages and three output currents have been plotted in Figures B-79 through B-84 for the on-the-grid and off-the-grid conditions at 2,500 kW and 2,700 kW, respectively.
A slight fluctuation in the output currents is evident when on the grid.
The
)~
frequency of the fluctuations is not steady, and therefore the fluctuations tend to average out to nothing in synchronous averaging. This is the reason for using a single capture. This smearing effect manifests itself as the broadening of the 3.75 Hz peak in the spectrum referred to earlier.
)
B1-1160037-2 7-9
).
7.2.7 Transient Phenomena During the various tests, many transient conditions, such as engine start,
)
sudden load changes, and switching from the grid to the emergency bus, were encountered.
No significant increase in torque oscillations, torsional vibrations, or strain was observed. Figures B-74 to B-78 contain records of such transients to demonstrate that fact.
7.2.8 Torsional Natural Frequency and Damping
)
As it was pointed out in Subsection 7.2.3, a torsional resonance was observed in the torque ' and torsional vibration spectra. The frequency of resonance is 38.6 Hz.
The damping associated with that resonance can be
)
estimated from the ratio of the magnitude at resonance to the magnitude of the spectrum at one half of the natural frequency.
The estimate of the
)
damping is 2.6 percent.
)
(
)
)!
).
SECTION 8 CONCLUSICNS The following conclusions are drawn based upon the test results presented in this report:
)
All the test and measurement objectives of the field test program have been achieved.
)
Reliable data were recorded at all test points.
A careful examination of the presented data has indicated that the
)
results are accurate and consistent.
J 3
)
B1-1160037-17 8-1
y
.e,-
g
,Sp4 g
6O '
APPENDIX A II.LUSTRATIONS AND SUPPORT DATA
)
)
)
)
)
)
B1-1160037-16
)
J
O i
O APPENDIX A TABIZ OF CONTENTS
^
Section TLtle Page i
A.1 CALIBRATION OF STATIC STRAIN AND TORQUE A-1 NEAsuRDfENTS 1-l 4
.O i
4
- O O
t a
,0 B
O i
i
.O i
l 1
B1-1160037-16 A-i O
,,--n,,-,-
,-c
-_,w,
-,-r,,-,
_-,,nr,,,--~.---
,---n
,.---,w,,--w,q-,
.,----nn,.~
--,----------g
,.-n
)
)
LIST OF TIGURES Tigure Title A-1 Location and Orientation of Strain Gages A-2 Antenna and Transmitter Installation for Strain Measurement A-3 Torque Measuring Instrumentation Schematic A-4 Torsional Vibration Transducer Installation A-5 Generator Output Voltage and Current Measurements A-6 Pressure Transducer Installation on Test Cock A-7 Pressure Transducer Installation in Air-Start Valve'
[)
A-8,9 Instrumentation System Block Diagrams A-10 Torsional Vibration Transducer Calibration A-11 Pressure Transducer Calibration
]
A-12 Tape Recorder Channel Assignment A-13 Static Strain vs Power SS-1 A-14 Static Strain vs Power S5-1 A-15 Static Strain vs Power S5-2
)
A-16 Static Strain vs Power SS-2 A-17 Static Strain vs Power 55-3 A-18 Static Strain vs Power S5-3 J
A-19 Static Strain vs Power S5-4 A-20 Static Strain vs Power $5-4 A-21 Static Strain vs Power 57-1 J
A-22 Static Strain vs Power S7-1 A-23 Static Strain vs Power 57-2 A-24 Static Strain vs Power S7-2
)
A-25 Static Strain vs Power 57-3 A-26 Static Strain vs Power S7-3 B1-1160037-16 A-il
)
C O
satsis losbne As doa*21D6 V-tL gsrsys losbne 4s 40a*3 ib6 y-ts O
O s
O O
'O i
O l
O O
C v-133
Mw,
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e 3'
APPENDIX A i
III,USTRATIONS AND SUPPORT DATA 3
TORQUE HEASUREMEY.f 3
CALIBRATION OF STATUS STRAIN AND A.1 nt
-g circuitry used for strain measureme the measurements Because of environmental effect onoutput shaft, the true zero of h
nt of the O
crank pins and on theThe shift had no effect on the measurem on the static obtain the shifted during the test.
In order to and torque.
assumed of strain
. dynamic component various load conditions it was value corresponding to the 3
strain that -
output power is at sero or torque in the crankshaft 1.
The strain 3
zero.
t power.
The strain increases linearly with outpu 3
2.
each strain determined for in 2 was linear relationship postulatedAt several t he output power The measurement as follows.
d or decreased.
3 the tests.
was relatively quickly increase throughout magnetic tape the recorded on 660 B analyzer, level was the Nicolet output power capability of plotted was Using the
'X-Y' plotting acasurement strain particular window O
representing output power for the time a
analog signal the analog signal representing of the resulting The slope against in output power.
rapid change containing the O
..i
J
)'
t
,)
In accordance with assumption 1, was then measured.
strain vs power curve icular strain measurement was computed for the static component of the part
)
each output power level.
largest power change took h
'X-Y' plots prepared for the case where t e numerical values have The The 3 to A-28.
place are prescribed in Figures A-1
)
B.
been tabulated in Table B-1 in Appendix N
I
)
)
)
l s
l A-2
- 11 Ann 17-16
)
.i
)'
ls
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[
1 {
SS-3(TENS;ON) 55 4
)
33 3 IN i
g PR.)
CRANKPlN AT
}
CY ER 7
CRANKPIM 1
V
( j 13 0*
)
I VIEW TOWARD GENERATOR
)
~
9R.)
l CRAM N AT
- 7 IO
)
GROUNO SURFACE) l l f,
/
/
1
- 5 ROSETTE:
0.50 in.
- 5 AXtAL:
0.5 41n.
- 7 ROSETTE:
1 E
AXIAL CROSS SECTION THROUGH GAG FIGURE A-1 LOCATION AND ORIENTA OF STRAIN GAGES OG 103 I
O
).
pSCX, MOUSING STRA6N g TRANSMITTERS & SATTERIES
/
)-
y
/
\\
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)
l L
l ENTENNA
's I
i
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j N,/
)
t x
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r J
L I
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TRANSMITTING D
4 l r
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/ItcE$fNG ANTENNA
-sv L. d T
)
o l
o
..N.
SE A.,NG pillow stocx g i
O O
i i
acueatroa y
)
F!GURE A-2 ANTENNA AND TRANSMITTdR INSTALLATION FOR
).
STRAIN MEASUREMENT DG 103
)
_r rTRAN$MITTING ANTENNA g
gag.
)
4 geox, HOUSING TRANSMITTERS
'(r n---
To$, TQS, RT & 8ATTERIES g..
I GENERATOR l
TQ4,TQS ENGINE r
l
}
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1 I
L TO(,TQS g
i l
i I
l RECZlVING ANTENNA ist.
p r
COAXIAL CA8LE 7
40 A iMPEDENCE FLANGE TQ$,TQ9
)
7 l
l TQ4,TQ9 COAXlAL
.i CA8LE TRANSMITTING ANTENNA b
y;,..,.
\\
1 2
41 f
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/*
BRIDGE 4\\\\
WIRING p2 3
4 ROSETTES DI AMETRICALLY OPPOSITE t2*
TWO TWO ELEMENT ROSETTES PER TCRQUE BRIDGE j
FIGURE A-3 TORQUE MEASURING
)
INSTRUMENTATION SCHEMATIC DG 103 V
l
)
)
SLIPRING TRANSOUCER H8M BD
)
_4 ENGINE g
E
)
T n77r I
EXCITATION AND -
SIGNAL CABLE
)
I AoAProR PLATE CRANKSHAFT N
i l
i k
e i
FIGURE A-4 TORSIONAL Vl8 RATION
)
TRANSDUCER INSTALLATION DG 103
?
l
O.
g.
GENERATOR OUTPUT PHASE A
g E O
B Q
1 l
o o
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1
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^^^^
h
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wp Y
}
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V, c
Y 1.OV/42OOV IC I B l A y
f 2.5 V/ 800 AMPS t
ik FIGURE A-5 3
GENER ATOR OUTPUT VOLTAGE i
AND CURRENT MEASUREMENTS DG 103 I
)-
1 OMPRES$10N TEST COCX 8
)-
)
)
v
)
(MOUNTING ADAPTER TEST COCKS gg pig PRESSURE TRANSOUCER 13
-=
,16 M
MOUSED INSIDE ADAPTER
~
~
v j
II
~
?
POLYETHYLENE TUBING FOR AIR COOLING l
l FIGURE A-6 PRESSURE TRANSDUCER INSTALLATION ON TEST COCK (P5 E. P7)
DG 103
ADAPTER w CYLINOER HEAD
)
i T
T pW N
~
4 c2 i
e d5)I I( 3
}
3 N
N.
N
/
dk
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/
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FIGURE A-7 I
PRESSURE TRANSDUCER
)
INSTALLATION IN AIR-START VALVE (P7-S)
. OG 103 a
}
STRAIN ANO TORQUE MEASUREMENTS
^
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k
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T ACuRa rM ENCORE RECEIVER SCE j
MITTER I
SRIDGE EXCITATION.
DEMODULATION 0.C.
SIGNAL CONDITIONING &
L AMPLIFICATION AMPLIFICATION RADIO TRANSMISSION
)
TORSIONAL VIBRATION 1
TRANSOUCER MGM 30 TO 3R 50,
)
Kws 3
CARA,ER AMPLIFIER CYLINDER PRESSURE P5 POWER SUP8LY/
TRANSDUCER CHARGE TD
(
g N
'gra
- To sRio i
- rgs
,.0-
,C.,,uO.
)
m,uFiCATioN
,C.
02
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AM CYLINDER PRESSURE P7 TRANSDUCER TR TEX
\\
TO 3R 50 g g
{
PC8112 AOS CHARGE 0, C, AMPLIFIER AMPLIFICATION PC8 63 A FIGURE A-8
)
INSTRUMENTATION SYSTEM BLOCK DIAGRAMS DG 103 i
)
CYLINDER PRESSURE P7-S CHARGE AMPLIFIER y
U Ex
- TOSRSO g
5
)
M.
AVL KISTLER O.C.
120PSOSCL 5007 AMPLIFICATION
)
MANIFOLD PRESSURE PM TRANSOUCER YI Y
E N
- TO SRSO f40' SENSOTEC CARRIER TJE 1708 gggpgggggg
)
GENERATOR OUTPUT (KW, KVAR, CURRENT, VOLTAGE)
)
CIRCulTRY M
TEK
$UPPLIED
- TO SR SO 4
$A l
BY LILCO ROTATIONAL SPEED AND POSITION REFERENCE l
l N
SWEC 1002
- TO SR SO OPTICAL 140' OETECTOR POWER SUPPLY C AMPLIFIER NICOLET TO SPECT9uM 240
ANALYZER 1
FIGURE A-9
)
INSTRUMENTATION SYSTEM BLOCK DIAGRAMS DG 103
7---_-_____
y i
y
(
TORSIONAL VISAATION TRANSOUCER MGM to
.\\o sll o
)
r.
R SMAKER A' 6 x
<s<<<<<<
sEE*ss" x
e euuuu/
}
SIGNAL SIGNAL CONDITIONER CONDITIONER
)
POWER AMPLIFIER
<iq,
<,o FFT AN ALYSIS TO COMPUTE SINE /MANOOM TRANSFER FUNCTION SIGNAL GENERATOR g
X/R FIGURE A-10
)
" TORSIONAL VIBRATION TRANSOUCER CALIBRATION DG 103
)
c---,---,_.--.,_,,,,-.,,--,,-,-------,,n-,--,_-,----,n-w w
ww--,--,
-,,--~,
e--,-
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n
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PRECISION PRESSURE y
i
[
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GAGE
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h
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[
4 PRESSURE MANIFOLD QUICK
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RELEASE e ALL VALVE
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9 4
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SIGNAL CONDITIONER
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P pn
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TAPE RECORDER 90 NITROGEN I
SUPPLY l
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N 1
7 i
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i FIGURE A-Il
)
PREdSURE TRANSDUCER Call 8 RATION DG 103 i
l
1 1
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i
-CHANNELS 1 4
= CHANNELS 1-5 J
SS-1 TO SS-4 REFERENCE SIGNALS OR ELECTRICAL MEASUREMENTS
-CHANNELS S-7
--CHANNEL 6,7 37-1 TO 37-3 PS PM
-CHANNEL 8,9
= CHANNEL 8,9 709 TV 704 TOS
= CHANNEL 10
- = CHANNEL 10,11 Pwn PwR VAR
)
= CHANNEL ll,1E
-CHANNELl3
= CHANNEL 13 VOICE VOICE
-CHANNEL 14
)
-CHANNELl PwR
-CHANNEL 2,3 TBS.Tsc FM FM TAPE DECK TAPE DECK
)
FM TAPE DECK "A"
" B" "C"
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14 CHANNELS I4 CHANNELS 4 CHANNELS i
FIGURE A-12 TAPE RECORDER CHANNEL ASSIGNMENT I
DG 103 e
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179.-06 V/EA 4.00+03 E
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C SHORlEH AM,
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179.-OS V/EA 4.00+03 E
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179.-OS V/EA 4.00+03 E
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Figure A-17
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Acoustics and Vibrations Lab.
179.-OS V/EA 4.00+03 E
VLN 1.26-03 V/EB 150.+00 E
C SHCREH,AM D G ;L O S,
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STONE WEBSTER ENGINEERING CORP.
Acoustics and Vibrations Lab.
i 179.-O6 V/EA 4.00+03 E
VLN 1.25-03 V/EB 200.+00 E
C
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ENGINEERING WEBSTER Vibrations Lab.
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STONE WEBSTER ENGINEERING CORP.
Acoustics and Vibrations Lab.
179.-OS V/EA 4.00+03 E
VLN 1.28-03 V/EB 100.+00 E
C S H O R {- I-I A M,
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. IIigure A-21
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Acoustics and Vibrations Lab.
179.-O6 V/EA 4.00+03 E
VLN 1.28-03 V/E8 100.+00 E
C Sj-lq R E H,A M
, D G ;L O S,
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40 Figure A -- 2 2
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STONE WEBSTER ENGINEERING CORP.
Acoustics and Vibrations Lab.
179.-06 V/EA 4.00+03 E
VLN i
1.24-03 V/EB 150.+00 E
C SHOR[EH AN,
O G 1,O S 1 /l21/ 8 4,
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ENGINEERINGLab.
WEBSTER Vibrations STONE and VLN Acoustics 4.00+03 E
C V/EA 179.-O6 150.+Od E
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ENGINEERING i
WEBSTER Vibrations Lab.
STONE and VLN l
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179.-06 250.+OO V/EB 1.26-03 1/S,/84 i, O G 1,0 3
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C STONE WEBSTER ENGINEERING CORP.
Acousties and Vibrations Lab.
179.-06 V/EA 4.00+0S E
VLN 1
26-03 V/E8 250.+00 E
C SHQREH,AM
,DG103, 1,/ 8 / p 4 I
5 5
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40 1r i gure A -- 2 6
v v
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v STONE WEBSTER ENGINEERING CORP.
Acoustics and Vibrations Lab.
179.-OS V/EA 4.00+03 E
VLN 5.00-03 V/EB 60.0+00 E
C SHOP {EH AM,
O G 1,O S 1/p/84, 5
5 5
5 5
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SU _ _ OUTPUT POWER BOO kW/DIV.
(A) 1 -
IT B -
TORQUE TOG 12 M-S/DIV.
(B)
R-x_-
UNLOAOING TAPE A3s 40 l
l l
l l
l l
- 1. OO O.50 A/16 SEC 40 (Zigure A-27
v v
v v
v v
v v
v v-c STONE WEBSTER ENGINEERING CORP.
Acousties and Vibrations Lab.
i 179.-OS V/EA 4.00+03 E
VLN i
5.00-03 V/EB 60.O+00 E
C
_S H C,R E H,A M
,_ D G ). O S,
1,/ 8 / p 4 l
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(8)
UNLOAOING TAPE A3s 40 1
l l
-l l
l l
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40 Figure A-28
..,.4
't O
O' 9
O O
APPENDII B TEST RESULTS O
O
.O t
1 l
1 O
l I
l O
i i
l l
i B1-1160037-15
I l
)
LIST OF TABIZS
)
i Table Title h
B-1 Relationship Between Static Component and B-1
)
Output Power for Strain and Torque B-2 Dynamic Components Measured on Time-Domain B-2 Plots B-3 Synchronous Strain Readings at 3500 kW B-4
)
B-4 Principal Stress vs output Power B-5 B-5 Torque, Phase and Amplitude Measurements at B-6 3500 kW B-6 Torsional Vibration, Phase and Amplitude B-7 Measurements at 3500 kW 4
3-7 Torque, Phase and Amplitude Measurements at B-8 3800 kW B-8 Torsional Vibration,. Phase and Amplitude B-9
)
Measurements at 3800 kW B-9 Fourth Order Component in Spectra of Torque B-10 and Torsional Vibration l
B-10 Cylinder Pressure Components, Phase B-11
)
and Amplitude B-11 Variable Speed Test, Dynamic Component B-12 Measured on Time-Domain Plots, Torque and Torsional Vibration B-12 Variable Speed Test, Fourth Order Component B-13
)
in Spectra of Torque a'nd Torsional Vibration
)
l
~
5 h
B1-1160037-15 B-i i
h I
LIST OF FIGU1tES l
Test Condition Finure Number l
1750 - 3800 W Hechanical Variables vs output Power B-1 to B-9 Variable Speed Test Torque and Torsional Vibration vs B-10 to 3-11 Output Power 2500 W on E. Grid Time-Domain, Gen. Voltage and Current B-79 to B-81 2500 W on E. Grid Frequency-Domain, Gen. Power and Current B-95 2700 W on E. Bus Time-Domain, Mechanical Variables B-12 to B-23 2700 W on E. Bus Time-Domain, Electrical Variables B-82 to B-84 h
2700 EW on E. Bus Frequency-Domain, Torque and Torsional B-87 Vibration 2
2700 kW on E. Bus Frequency-Domain, Output Power and Current B-96 2800 W on E. Grid Frequency-Domain, Output Power and Torque B-90 to B-92 0.8-1.0 P.F.
)
3500 kW on E. Grid Tine-Domain, Mechanical Variables B-24 to B-36 3500 kW on E. Grid Time-Domain, Principal Stresses B-50 to B-61 3500 kW on E. Grid Time-Domain, Output Power B-85
)
3500 kW on E. Grid Frequency-Domain, Torque, Torsion, Power B-88 and B-9:
3800 W on E. Grid Time-Domain, Mechanical Variables B-37 to B-49 3800 kW on E. Grid Time-Domain, Principal Stresses B-62 to B-73
)
3800 kW on E. Grid Time-Domain, Output Power B-86 3800 kW on E. Grid Frequency Domain, Torque, Torsion, Power B-89 and B-9 Transient Phenomena, Startup, SS-3 and B-74 and B-7}
Output Torque
)
Transient Phenomena, Load Changes, SS-3 B-76 to B-78 and Output Power
)
)
B1-1160037-15 B-Li
)-
)
TAILE 3-1 RIZATIONSRIP BEIVEEN STATIC COMPONENT AND CUTFUT POWIR FOR STRAIN AND TOROUE
)
Micro-strain 1750 W 2700 W 2800 W 3500 W 3800 kw Measured 100 W Static Strain, Micro-strain 55-1
-8.8
-15
-24
-25
-31
-33
}
55-2
+30.7 54 83 86 107 117 55-3
+35.6 62 96 100 125 135 55-4
-16.6
-29
-45
-46
-58
-63 37-1
+31.7 55 86 89 111 120 57-2
- 6.6
-12
-18
-19
-23
-25 37-3
-34.9
-61.
-94
-98
-122
-133 TQ 9
+15. 8 28 43 44 55 60 Note:
The values in this table vare derived from Tape A3:350, unloading from 3800 W to $NL i
Shoreham DC 103 i
Torsional Tests 1-8-84
)
\\
l 3
5-1
)
6 TABLE B-2 DYNAHic COHPONENTS HEASURED ON TlHE-D0HAIN PLDTS 11111TS: STRAIN = HICRO-STRAIN; TORQUE = 1000 lb-ft; PRE 8815E = PSI i
Var.
1750 kW 2700 kW 2800 kW 3500 kW 3800 kW Peak P-P Peak P-P Peak P-P Peak P-P Peak P-P
- 68
+260
+240
+313
+ 26 305 433 43g 514 540
-373
-153
-191
-20I
-214
- 334 92
+615
+724 5-2 663 908 93, t,024 I,151
-529
-339
-339
-413
-427 I
3I
- I'I 5-3 840 1,119 I,185 1,347 t,398
-453
-483
-444
-610
-630
+128
+512
+521
+628
- I 5-4 710 1,007 1,034 1,284 l.365
-582
-495
-513
-656
-104 l
+209
+ 03
+519 7,,
540 699 694 y,,
815
-331
-270
-251
-296
-296 l
+278
+284
- 3*3 l
~
7-2 397 504 558 693 728
-373
-267
-280
-409
-425
- I 25
- 8
+526 1,099 1,326
,,4,,
7-3 763 1,070
-609
-840
-874
-625
-645
- I23
+185
+167
- I'3
+20I THQ 214 295 305 357 369
-90.8
-137
-138
-164
-168
+0.696
+0.6M 40.727
+0.764 TV 0.87 3,gy g,g, 8.385 g,44
-0.410
-0.479
-0.490
-0.654
-0.674 Shoreham DC 103 l
Torsional Tests 111-1160037-4 8-2 1-4-84
~
TABLE B-2 (CONT)
DYNAHIC CONPOWENTS HEASINtED ON Tile-DOMAIN FIATS 1211TS: STRAIN = HICRO-STRAIN; TORQUE = 1000 lb-ft; PRESSINtB = PSI I
Var.
1750 kW 2700 kW 2800 kW 3500 kW 3400 kW Peak P-P esk P-P Peak P-P Peak P-P Peak P-P
'8I
- I'I
+1,210
- I'
'I' "
F5 92i 1,281 1,357 1,545 I,708
-105
-151
-147
-175
-204
+1,1 0
+1,1 0
+1,1 0 P7 895 1,217 l.283 1,505 1,630
-96
-87
-311
-385
-490
+ 04 I'l 0
'I'
+ 1,5M P7-S 909 1,310 l.550 1,640
-105 N/A N/A
-130
-150
-140 i
s i
1 l
1 i
Shoreham DG 103 Torsional Tests 111-1160017-4 R-3 l-8-84 l
O O'
TABT.E 3-3 SYNClut0 NOUS STRAIN READINGS AT 3500 kW STRAIN GAGE 10SETTES 5 AND 7 O
Strain 5-1 Strain 5-2 Strain 5-3 l Max.
Min. l
[
Max.'
Min. l l Max.
Min. l Time Q
(cee.)
0.02812 0.24961 0.08008 0.12266 0.08008 0.12305 Micro-strain S5-1 l 313
-201 l
-195 286
-195 -
288 O
$5-2 56 143 6 15
-4 13 695
-410 55-3
-226 263 736
-611 737 Strain 7-1 Strain 7-2 Strain 7-3 O
i nax.
r.=. l l naz.
.un. l
[ Max.
t xin. l Time (sec.)
0.07969 0.12461 0.22226 0.10742 0.02578 0.08047
)
Micro-strain g
57-1 503
-296
-34 301
-222 500 S7-2
-371 9
284
-409 222
-372 S7-3
-835 363 370
-652 486
-840 0
NOTE:
Synchronous readings of strain at ti=es shown.
Ti=a is arbitrary, =easured from capture trigger.
The three strain elements at one location were captured synchronously. The values framed represent the maxi =un and
-4"'-
values in the strain 3
cycle for the strain element involved.
The other values in the same colu=n represent the magnitude of the other strain ele =ents coincident in time vita the said==vd= = and minimum.
These readings were taken with the strain signals a.c. coupled.
The static ce=ponents in Table 3-1 have to be added to obczin absolute values.
G BD1-1160037-32 34
O D
TA3I.Z 3-4 PRINCTPAI. STRESS VS OUTPUT POWER O
Cylinder No. 5 Power 1,750 2,700 2,800 3.500 3,800 (kW)
Stress Peak Peak Peak
'Paak Peak O
(psi)
Major Principal 17,300 24,300 24,900 29,800 Minor g
Principal
-10,300
-12,800
-13,900
-15,000
-15,300 Nav41mam Shear 9.760 13,700 14,100 17,000 17,900 Bending Stress 13,200 18,600 19,100 22,900 24,000 Torque Shear 7,980 11.200 11,500 g
13,700 14,400 Cylintiar No. 7 Power (kW) 1,750 2,700 2,800 3,500 3,800 Stress (psi)
Peak Peak Peak Peak Peak 3
Major Principal 9,230 11,800 12,800 14,500 15,100 Minor Principal
-14,600
-20,100
-20,600
-24,900
-26,100 3
Maximum Shear 10,300 13,800 14,400 17,200 18.100 Bending Stress 6,450 7,630 8,030 9,890 10,500 3
Torque Shear 10,000 13,600-14,000 16,700 17,500 Nota: The values in this ca'cle represang SEOREHAM OG 103 the largest peak in each seress cycle.
TORSIONAL TESTS 01-08-8'
)
B-5
)
)
l TABIZ B-5 TORQW, PEASE AND AMPLITUDE HEASUREMENTS AT 3,500 kW
)
Phase, Degrees Amplitude Engine frequency Re. Sync.
Re. No. 1 lb-ft lb-ft Order Ez Trigger Firing TDC RMS Peak
)
0.5 3.75
-62.4
-151.15 908 1,280 1.0 7.50
-5.8
+176.70 2,477 3,498 1.5 11.25 140.6
-125.65 2,528 3,570
)
2.0 15.00
-86.7
-81.70 1,558 2,197 2.5 18.75 25.9
-57.85 4,706 6,656 3.0 22.50
-161.6
+25.90 15 4 218 3.5 26.25 135.5
-125.75 4.726 6,687 4.0 30.00
-128.1
-118.10 82,973 117,648 i
4.5 33.75
-22.9
-101.65 9,783 13,829 5.0 37.50 144.0
+48.50 7,977 11,249
)
5.5 41.25
-79.0
+24.75 33,127 46,853 I
6.0 45.00
-152.4
-137.40 2,776 3,922
\\
6.5 48.75 177.5
+103.75 6,171 8,731 j
)
7.0 52.50 86.0
-76.50 456 645 l
l l
Shoreham DG 103 j
Torsional Tests i
)
1-8-84
)
3-6
)
31-1160037-6
)
l l
TABI.E B-6 TORSIONAL VIERATION, PHASE AND AMPLITUDE IfEASUlu2fENTS AT 3,500 kW
)
Phase, Degrees Amplitude F.nsine Trequency Re. Sync,.
Re. No. 1 Degrees Degrees Order Ex Trigger Tiring TDC RMS Peak
)
0.5 3.75 174.3 85.55 0.0393 0.0556 1.0 7.50
-117.7 64.80 0.0037 0.0053 1.5 11.25 146.7
-119.55 0.1210 0.1710 2.0 15.00 45.0 50.00 0.0009 0.0013
)
2.5 18.75 32.4
-51.35 0.0920 0.1300 3.0 22.50 117.7
-54.80 0.0008 0.0011 3.5 26.25 137.0
-124.25 0.0407 0.0576 4.0 30.00
-124.7
-114.70 0.2300 0.3250 I
4.5 33.75
-17.3
-96.05 0.0454 0.0642 5.0 37.50
-144.2 48.30 0.0243 0.03 5.5 41.25
-73.9 29.85 0.0901 0.1270 6.0 45.00
-159.6
-144.60 0.0057 0.0081 6.5 48.75
-180.0 106.25 0.0112 0.0158 7.0 52.50 18.8
-143.70 0.0016 0.0022 l
[
Shoreham DG 103 Torsional Tests 1/8/84
)
3~7
)
B1-1160037-7 I
l l
)
).
TABLE B-7 TORQE, PEASE AND AlfPLITUDE EA5imDfENTS AT 3800 kW
)
Phase, Degree Amplitude Engine Frequency Re. Sync.
2a. No. I lb-ft lb-ft Order Hz Trigger-Firing TDC RMS Peak
)
0.5 3.75
- 61.0
-149.75 944 1,331 6.0 176.50 2,621 3,705 1.0 7.50 1.5 11.25 137.3
-128.95 2,3 12 3,271 2.0
- 15. 00
- 15.9
- 80.90 1,661 2,353 2.5 18.75 26.6
- 57.15 4,407 6,233 3.0 22.50
-142.1 45.40 174 247 3.5 26.25 137.0
-124.25 4,396 6,213
)
4.0 30.00
-125.6
-115.60 76,987 109,392 4.5 33.75
- 19.2
- 97.95 8,937 12,590 5.0 37.50
-137.8 54.70 8,431 11,971
)
5.5 41.25
- 74.7 29.05 31,063 43,963 6.0 45.00
-144.7
-131.70 2,714 3,839 6.5 48.75
-176.7 109.55 6,027 8,524
)
7.0 '
52.50 92.2
- 70.30 376 531 Shoreham DG 103 Torsional Tests 1/8/84
)
b l
B1-1160037-9 B-8 t..
)
TABLE 3-8 TORSIONAL VIERATION, PHASE AND AlfPLITUDE HEASUREMLVIS AT 38C0 KW l
h Phase, Degrees Amplitude Engine Frequency Re. Sync.
Re. No. I Degrees Degress Order Ez Trigger Tiring TDC RMS Peak 0.5 3.75 15 3.3 64.55 0.0435 0.0615
)
1.0 7.50
-145.3 37.20 0.0022 0.0030 1.5 11.25 144.7
=121.25 0.1320 0.1870 2.0 15.00 33.7 38.70 0.0008 0.0012
)
2.5 18.75 31.2
- 52.55 0.0989 0.1400 3.0 22.50 126.3
- 46.20 0.0009 0.0w13 3.5 26.25 136.0
-125.25 0.0432 4.0 30.00
-124.8
-114.80 0.2400 0.3390
)
4.5 33.75
- 16.8
- 95.55 0.0475 0. 0 6,' '
5.0 37.50
-138.6 53.90 0.0267 0.0378 5.5 41.25
- 70.9 32.85 0.0959 0.1360
)
6.0 45.00
-152.2
-137.20 0.0058 0.0083 6.5 48.75
-175.7 110.55 0.0122 0.0173 7.0 52.50 31.3
-131.20 0.0018 0.0026
)
)
)
SHORIIDJ! DC 103 TORSIONAL TESTS B1-1160037-8 3-9 1-8-84
)
3e TABLE 3-9 FOURTE ORDER COMPo!ENT IN SPECTRA 0F TORQUE AND TORSIONAL VIBRATION Amplitude 3
Power Level Rus Peak W
Torque Tots. Vib.
Torque Tors. Vib.
lb-ft Deg.
Ib-ft Deg.
3 1,750 44,500 0.138 65,100 0.195 2,700 67,100 0.192 94,200 0.271 2,800 70,200 0.200 99,000 0.283 3,500 81,500 0.229 116,000 0.324 3
3,800 84,600 0.239 120,000 0.338 9
3 a
O SHORIHAM DG 103 TORSIONAL TISTS 01-08-84 3-10 B1-1160037-10 0
..,,,-.__.,.--_-,-.m,-,__.._~..m--.-
D TABEE B-10 D
CY.INDER PRESSURE C02fPONENTS, A!fPLITCLE AND PHASE 2).
Output 1750 2800 3500 3800 Power f
Ampi Phase Ampi Phase Ampi Phase Aspi Phase Press.
Psi Psi Psi Psi O
Hz ras Deg.
ras Deg.
ras Deg.
ras Deg.
P5 7.5 97.4
-11.9 141.0
-12.9 169.0
-13.4 181.0
-14.0 15.0 62.8
-18.8 91.9
-19.2 108.0
-18.2 114.0
-17.8
- )
30.0 22.2
-38.9 34.0
-36.1 37.7
-29.9 40.1
-27.4 P7 7.5 94.3
-12.7 135.0
-13.4 162.0
-13.9 175.0
-14.0 15.0 60.6
-19.5 87.0
-19.4 102.0
-18.1 110.0
' -18.0 0
30.0 21.3
-39.2 31.7
-35.0 33.3
-28.3 38.0
-26.6 i
P7-S 7.5 99.3
-14.9 141.0
- 15. 3 171.0
- 15. 7 184.0
-16.3 15.0 62.1
-20.6 89.2
-20.2 106.0
-19.3 113.0 1-1S.9
- )
i I
30.0 21.4
-39.7 31.9
-35.7 36.3
-30.1 38.9
-27.5 D
D Nete:
Phase is referred :- fi.-ing 702 cf cylinder
[)
SHOREHAM DG 103 70P.510NAL TISTS 1-8-84 3~11 B1-1160037-11 9
)
)
TAB 2 B-11 J
VARIABM SPED TIST DYNAlfIC CoffPONENT IfEASSED ON TDfE-DOMAIN PI,0TS TORQ E AND TORSIONAI. VIBRATION
)
Tors. Vib. (des)
Speed P-P P-P
+
(rps)
+
411 74,300
-54,700 129,000 0.292
-0.172 0.464
)
429 68,100
-51,600 120,000 0.275
-0.146 0.421 442 58,800
-39,200 98,000 0.243
-0.120 0.363 450' 58,800
-39,200 98,000 0.231
-0.135 0.366 460 64,000
-43,300 107,000 0.241
-0.161 0.402 472 58,800
-44,300 103,000 0.265
-0.194 0.459 491 66,000
-54,700 121,000 0.264
-0.15 2 0.4*
2
)
Shorehu DG 103 Torsional Tests 1/8/84
)
)
)
)
B-12 B1-1160037-12
)
)
b TABI.E B-12 VARIABII SPEED TEST FOURTH ORDER COMPONENT IN SPECTRA 0F TGRQE AND TORSIONAL VTERATION
)
Amplitude RMS Feak Torg.ae Tors. Vib.
Torque Tors. Vib.
)
Speed (rya)
(1b-ft)
(des)
(1b-ft)
(des) 411 17,500 0.048 24,800 0.068 429 IP,600 0.052 25,800 0.074
)
442 19,600 0.056 27,900 0.079 450 20,600 0.059 29,000 0.083 I
460 21,700 0.064.
31,000 0.091 472 22,700 0.069 32,000 0.098 491 26,800 0.083 38,100 0.117
?
i I
D
)
su
u I8 n
J O
a u,
0 i
n8 a
o u
o O
. N a8 i
IAR T
S u
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I I
i M
N I
A O
R T
u S
K A
.8 i
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o T
K u
A o
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P
- 8 i
o Tt
~8 i
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j y8 38 g 88 mh ma.xW lcEm$
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?~
o
?-
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?*
042br.o m42$ 5. OCImC1oOEmlA ZOmE 29 u v
04r'.Ou
=g 00.
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v
1
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3
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)
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'#0 -
z E
a:
)
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8 z
A E
A
]
m E
.=
E A
6 A
7 3
Ew 4
1 400 D
200 i
3 i
0 0
1750 2700 2800 3500 3800 5000 POWER-KW
]
LEGENO C
7-1 f
6 72 a
7-3 FIGURE 8 2
)
DYNAMIC STRAIN vs. OUTPUT POWER 3
CYLINDER NO. 7 2700xw wEasumEo OG 103 CN EME8tGENCY SUS.
)
m U
U p
U 5
.E o8 o
S E
E RG E
s8 D E
a U
U N
Q O
R I
T O
A TN R
I B
A o
K R T
V I
AT5 F
U ES
,Eb8 -
L 8
A PO L
N
- R O
I OC S
I TM RO K
T A
K U
E A
E P
b y8.o8 P
'U U
88
,8
- 4. 8 o E8
- g No Mg o
U iOf E
- x(
~'m h o o
82" 75cmm Yw 4=E2F.3" n8 o<gyKb 4_OmOCT D20 dOh52 r I
I V
< E2k oz <m OC TC1 iOI9 D
$e OO O" t0,A>E,0 i
9 2mE$".5 U
)
o so,oco o
)-
)
o o
a N
O 6
R
)
E 1 mooo taJ Q
d 0
a A
A 0
5 m
O z
a
[
A O
o
)
- i>
0 0
E '0000 1,
)
O
)
)
O f
f' t
t o
1750 2700 2500 3500 3600 5000 POWER-KW LEGENO FIGURE S-4 CALCULATED STRESS vs.
e uuca paiNcipat a mixtuum SHEAR OUTPUT POWER
)
CYLINDER No. 5 c stNolNG $7RES$
DG103 O Tomous swan
h-30,000
)
)
E 6
3 o,ooo Ea U
A d
i o a
o D
e 0
o 0
z o
W
)
3 o
s 6
= ioom o
i 3
a O
j 1
II I
I o
1750 2700 2000 3500 3000 5000 POWER-KW I
LEGENO FIGURE 8-5 i
C MAJCR PRINCIPAL CALCULATED STRESS vs.
A Max! MUM sacAR OUTPUT POWER
)
a scuoino statss CYLINDER No. 7 o Tencut sacAR DG 103
k
-so.coe
)
a a
)
.I d
a
)
h-ao,ooo 0
5 w'
u
>=
)
E E
a a
E o
)
d>
O
- -10,000 -
se
)
5
)
I ef O
0 1750 2700 2000 3500 3000 5000
)
POWER -KW LEGENO FIGURE 8-6 CALCULATED STRESS vs.
o ww.on pamcipatis CUTPUT POWER
)
d WWOR PRWC! pat.:7 CYLINDERS No. 5 AND 7 DG103
)
~
I o
.O O
b o
O A
isoo
)
o ob i
A
)
7 8
S U
)
gioco
=
E
=
t
)
1 0
n.
)
soo
)
/
[
t
!I f
I O
1750 2700 2800 3500 3800 5000
)
POWER-KW LEGEN0 o es FIGURE 8-7 3
,7 CYLINDER PRESSURE VS.
)
a
,7,5 OUTPUT POWER OG 103
)
).
iso 0
.I20,000 g33o o A sto
)
{
-110,000 a.
oJoo [
w W
ico
)
A E
w
.im,mo W
,o 3*
5 m2 c
O g,o i
o.aso j M
e e
).
xa
..o,ooo "
5 4M J
w2
<2 1
9 m
to m
O
)
-80,000 c.200 a
t 1
70
-70,000 o.tSo i
ie i
o 1750 2Too 20eo 3500 300o Sooo
)
POWER KW i
I t.EGENO o Tomout d TOR $loNAL Vf 6R ATioN NOTE FIGURE 8-8 27coxw wtasuRED
~
oN EWCMGENCY SUS.
FOURTH ORDER PEAK vs.
)
OUTPUT POWER DG 103
Y
)
35
)
~
o 30 -
)
o
)
~
R E
)
y" a
w I
2
)
W 2
IS
)
o 10 -
)
I
/
s t
fI f
I o
1750 2700 2000 3500 3400 5000
)
POWER-KW LEGEN0 0 CN GRIO FIGURE B-9 0
"E"""""**"*
INTAKE MANIFOLD PRESSURE
)
vs. OUTPUT POWER DG 103
)
D
)
0.500 o
E e
D a
6 e
i20 0
o
-120,000 o
o E
4 ps a
5 M*
d 4%
-110,000 [
0.400 z wm i
o g
Ad 3
m a
OU 0
0 3
p 3100 -
1
-100,000 A
Q-LaJ b
E
-90,000 i
I f
f f
f f
0.300 g
400 4tl 429 442 450 440 472 491 500 SPEED-RPM D
LEGEND o TOROut 6 TORSIONAL VfSR ATION g
FIGURE B-lO DYNAMIC TORQUE AND TORSIONAL B
VIBRATION vs. ENGINE SPEED DG 103 D
k 45 0.i40 E
,M
=
b 0.120 $
~
E W
C
?
)
Em
?
-35,000 t 3
o
=
a 0.iOO g g
3 5
e o
- m e
a 8
g
-30,000 x 2
g C
0 0.0 0 m y-e g
x O
H
'a o
j y
-25,000 h w
0.060 I
f
?
I f
f f
g
)
400 412 429 442 450 46C 472 490 500 SPEED-RPM
)
LEGEN0 i
o TORout A TOR $10N AL VISR ATION l
FIGURE B-11 FOURTH ORDER PEAK VS, ENGINE SPEED (RPM)
DG 103
)
r v-v v
v v
v v
v v
v v.
l l
i l
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Acoustics and Vibrations Lab.
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Acoustios a n ci Vibratione Lab.
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Acoustics and Vibrations Lab.
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Acoustics and Vibrations Lab.
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Acoustics and Vibrations Lab.
2 AUXO 40.O+03 E
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Acoustics and Vibrations Lab.
2 AUXO 40.O+03 E
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Acousties and Vibratione Lab.
2 AUXO 40.0+03 E
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Acousties and Vibrations Lab.
2 AUXO 150.+00 E
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Acoustice and Vibrations Lab.
2 AUXO 40.O+03 E
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Acoustics and Vibrations Lab.
2 AUXO 40.O+03 E
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Acoustics and Vibrations Lab.
2 AUXO 40.0+03 E
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Acoustics and Vibrations Lab.
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Acoustics and Vibrations Lab.
2 AUXO 40.O+03 E
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Acoustics and Vibrations Lab.
2 AUXO 40.0+03 E
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Acoustics and Vibrations Lab.
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Acoustics and Vibrations Lab.
2 AUXO 40.O+03 E
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2 AUXO 40.0+03 E
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2 AUXO 40.O+03 E
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2.52-03 V/EA 1.00+03 E
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2.52-O3 V/EA 1.00+03 E
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