ML20136B612
| ML20136B612 | |
| Person / Time | |
|---|---|
| Site: | Summer  |
| Issue date: | 09/04/1979 |
| From: | Kelley D GILBERT/COMMONWEALTH, INC. (FORMERLY GILBERT ASSOCIAT |
| To: | |
| Shared Package | |
| ML19249C121 | List: |
| References | |
| NUDOCS 7909070464 | |
| Download: ML20136B612 (300) | |
Text
{{#Wiki_filter:' e PRSfJ.H. W2oda, SCE& GCo. Jenintville SC. 30 ** ' Attn: Nztenna Hall , i s e. : 0 (cd b J GILBERT ASSOCIATES, INC. sucineras Awo consut;.a;is P.o.soxiase Ip\ RE ADING. PA 19603 _] ' DATE 09-21-78 LETTER NO. CGG5_16617 MR. O.W. DlXON, JR., GROUP MANAGER PRODUCTION ENGINEERING / 5OUTH CAROLINA ELECTRIC & GA5 CO. P.O. BOX 764 COLUMBIA, SOUTH CAROLINA 29218 R.. VIRGIL C. SUMMER NUCLE AR ST ATION UNIT NO. I CAI NO. 4461-00 FILE 18.10125 Diesel Generator Units Qualification Information DEAR MR. DIXON: Response Code:* NRR ATTACHED PLE ASE FIND THE' ITEMS LISTED bet.0w FOR THE PURPOSE 5 INDICATED: [N
> XX FOR INFORMATION MARKED BY gal
/ FOR COMMENT 5 APPROVED BY gal FOR APPROVAL APPROVED A5 CORRECTED 8Y CAI FOR DISTRIBUTION PR E LIMIN A RY 11CM DESCRIPTION (TITLE, NUMBER OR SUBJECT) Control No. C7989
-Qualification Test Documents for Diesel Generators as transmitted by Colt Industries letter 289/53 dated February 14, 1978.
CTRIC 4 c RECElVED k' cd C7 o'
, SEP 2 81978 lis. A $
REMARK 5:
.O RETURN COPie5 0r THE A8ovE wiTN iPPROvAt OR COMMEHT5 BY The attached documents, when combined with the seismic analysis reports and the Q/A document package constitute the documentation of qualification to IEEE 323-1971 per SP-546-044461-000, item 2:08.2.
..: v.C. 5-., VERY TRULY YOUR5,
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D. A. H D. Kelly T.c. Hies ' '
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( l., J,, v.A. willi . SY Electrical Engineer 0.w. Desen, Jr. (2) FOR E. wlE LKOPOL5Kl/H.E. YOCOM
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N PC F/ Die.a PROJECT MANAGER A.w. c .. PRSfj.M. Woods w/ Attach 79090704 @9'. f E. Wielkopolski/EIDF w/ Attach R.P. Cronk/ File 30 E.H. Hahn
i ~, .. Coltindustries riirb1nka u:r=2 . Engins Divislin
, 701 Lawton Avenue Beloit. Wisconsin 53511
~608/364 4411 (d \
(206152)289/53-( 'f C[{f - February 14, 1978 i Gilbert Commonwealth' . P. O. Box 1498 l' Reading, PA 19603
- Attention: E. Weilkopolski/H. Yocum i
Subject:
South Caroliria Electric & Gas Company Virgil C. Summer Nuclear Station - Unit 1 P.O. .#SN-10125-SR ; Colt Sales Order 206152
Reference:
(a) Specification SP546-044461-000, Paragraph 2:08.2.2
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Enclosure:
(1) Qualification Test Documents .from 1971 Test Series (2) Qualification Test' Documents from Testing of the Third Unit for Alabama Power Company Gentlemen: Two (2) cooies of enclosures (1) and (2) are attached per reference (a). Very truly yours, hc ' '" '* COLT INDUSTRIES OPERATING CORP FAIRBANKS MORSE ENGINE DIVISION
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l' i 1 I \~ I I Final Report i i Starting and Load Acceptance 4 , Reliability Test I 4 ; August 6 through August 10, 1971 I t l Colt Industries u Fairbanks Morse I l Power Systems Division i r 3500, INC. I*E " 19 21'78 we
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(V y Coltindustries Fairbanks Morseinc PowerSystems Division 701 Lawton Avenue Beloit, Wisconsin 53511 Tel: 608/3644411 All P.ecipients of Starting & Lo5d Cable Address:COLTIND Acceptance Reliability Test Report Gen tl emen : Fairbanks Morse Inc. has completed a starting and load acceptance reliability test on a 12 cylinder Colt-Pielstick PC-2 engine generator set installed in their Beloit, Wisconsin plant. The purpose of the test was to: (/) ss-
- 1) Demonstrate the rapid and positive starting achieved with the air over piston system. .
- 2) Demonstrate the engine's ability to withstand the extreme thermal stresses induced by repetitive rapid loading to rated capacity and unloading of the engine.
We are familiar with the requirements for emergency diesel generator sets for Nuclear ?lant Protection Service. We realize rapid start and acceleratioq to rated speed and full voltage is extremely important. We also appreciate only units with the ability to accept rated load instantaneously without thermal distress can be considered for this service. We further feel the only way of insuring this ability is to demonstrate, through a repetitive test program, that a unit has a proven fast load pick up reliability. This is the reason we conducted the test. Brief Outline of Test The diesel generator set was direct connected (i.e. without circuit breaker) to a water rheostat. The set was brought to rated speed and the water rheostat was adjusted to 4730 KW load prior to initi-ation of the test. The set was shutdown and the controls were set to sequence as follows:
- 1) Start unit and accelerate it to rated speed and load.
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- 2) Maintain 4730 KW load for five minutes.
- 3) ' Shut .the unit down without an idling or cooling off period and allow it to stand until temperatures !
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drop to the keep warm system level. (This was de-termined to be a one hour complete cycle).
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- 4) Repeat 1, 2 & 3 above through (100 ponsecutive cycles.
The test was completed with 100% success without any adjustments to the unit. Af ter completion of the test the engine was torn down for inspection and was found to be in excellent condition. There was no evidence of abnormal wear or any parts failure. The unit was made available for inspection by Utility Engineers from August 11 through August 13, 1971. An. appendix containing photographs and diagrams documenting the test is attached to this report. We certainly feel that the results of our tests establish our engine as having the utmost reliability for Nuclear Plant Protection Service. For reliability -- proven by public demonstration -- there are only two fully tested units. Fi rs t , Fairbanks Morse 38TD8-1/8 with ratings to 3250 KW, and now for even higher output, our Colt-Pielstick with ratings up to 7000 KW. No other engine manufacturer has undertaken such an ambitious program, with the full advance knowledge of the market place and emerged successful . For applications demanding the highest attainable reliability to start and instantly accept load, Nuclear Plant Protection units from Colt Industries are the only proven choice. Yours very truly J. M. Moriart Manager, Util Sales JMM/s1
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l l l TABLE OF CONTENTS - ILLUSTRATIONS 1 Fig. 1 Block Diagram of Equipment Arrangement - for Reliability Test i ! Fig. 2 Colt Pielstick Nuclear Plant Protection j Unit - 4730 KW Fig. 3 Engine Dismantled for Inspection l Fig. 4 Connecting Rod and Piston Pin ' Fig. 5 Cylinder Head Showing Inlet and Exhaust Valves I - l Fig. 6- Piston Crown l Fig. 7 KW Loading Record (fold-out chart) i i l I_ - . , _ _
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RESISTANCE l 473OKW ENG.- G E N. !O - RE"EATE J S-~A RT AN J _OA J ACCEPTA\CE TEST I S-~ ART ENGINE a LOAD TO 4730
<W FO R 5 MINUTES. ,
2 SFUTJOWN FOR I HOUR UN-~lL WAT3R TEMPERATURE tJROPS TO 130 3] 3 REPEAT 100 TIMES WITHOUT ADJUSTING ENGINE. 4 INSPECT ENGINE IN PRESEhCE OF WITNESS. O l Fig. 1 Block Diagram of Equipment Arrangement for Reliability Test __m. --eu--w- w .me-mwe* w w-- -w - m-- rew--w--www-w--m---'wum-W WI- rvtW"""F -'-YN7W'*9"*C ""
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- < m l ALABAMA POWER COMPANY FitP2-34 a s ,
f i FARLEY NUCLEAR PLANT UNIT #2 U s. 3 }
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l' + April 22, 1975
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i I. . ; , i be i i - (+ . ( Prepared By: Approved Byy M .
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f,Qz o ' x 't w S b - ~' R. Humke J. Balderston , I h l i l , Distribution: - I
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.sr.aolca ENGINEERING HEPORT 5"tCT 1 r5 N O- 1 rewer system cMsten
(($nnt Order 35-20591 ALABAM P0'.lER C0!!PA'IY FilP2-34 oArc April 22, M75 mircr f FARLEY llVCLEAR PLA*lT U: LIT #2 FREPARrD W R. Ilumke EtS*' 200 CYCLES START TEST ^"'y" J. Balders tor OBJECT To perform a 200-cycle start and load acceptance reliability test. Engine to start and accelerate to rated speed and voltage within 10 seconds and 100% load to be applied within 25 seconds or less from initiation of the start signal. A minimum of 170 starts to be made at standby (keep warm) conditions and 30 starts to be made at hot equilibrium temperature conditions. C0llCLUSIO:ls The performance of the diesel engine was very satisfactory. The engine did
- not fail to start once for a total of 230 start cycles. The engine
(' ; accelerated to rated speed and voltage within 10 seconds for all 230 start
) cycles and 100% load or greater was attained within 25 seconds or less for 225 cycles.
( PROCEDURE - DISCUSS 10:1 The test procedure specified 200 start cycles:
- 1. 170 starts to be made at engine " keep warr>" temperatures of Jacket water 110*F and lube oil 125'F. Start and accelerate to rated speed and voltage within 10 seconds and apply full load within 25 seconds from initiation of the start signal. Operate at full load of 4107 KW 01.0 P.F. (5660 Bhp) for not less than 5 minutes. If necessary, time to be extended until jacket water temperature reaches 140*F. Remove load and shut down. Auxiliary jacket water cooling system used to cool jacket water from 140* to 120*F. Complete cycle--I hour
- 2. 30 starts to be made at hot equilibrium temperature conditions which are lobe oil in--120" to 140*F, and jacket water out--140*F to 160*F.
Engine to be loaded the same as (1.) above. Engine to operate at full load (4107 Kil) for 10 minutes maintaining the jacket water out at 140" to 160*F and the lube oil in at 120* to 140*F. Remove load and shut desn. Engine to be shut down for approximately 10 minutes. The complete cycle--approximately 20 minutes. The " keep warm" start test was as described in (1.) above except that a total of 194 cycles were performed instead of the 170 cycles. Hot equilibrium tests were as described in (2.) above, except a total of 36 ([, cycles were performed instead of 30 cycles.
tre sranien ENGINEERING HEPORT sacu 2 cr 5 na 2 nte ran spw:s cMska numen Order 35-20591! f~f sunter ALABAMA POWER C0P.PANY FHP2-34 FARLEY HUCLEAR PLANT UNIT #2 April 22._1975 rar.rxnco n R. Ilumhe ( ) EEPORT Appnoyrg "E 200 CYCLES START TEST n J. Baldersto. Loading was done manually using two 5000 VJi water rhoostats connected in parallel. Setting and maintaining a precise load is . difficult because load is a function of the temperature and quantity of water and the depth of the electrodes. The first seventeen (17) " keep warm" starts were performed by applying load in one step. Because of the difficulty in controlling load due to temperature changes of the water in the rheostats, there were instantaneous loads as high as 123; (b061 Ku O 1.0 v F.) of rated KW (4107 KW 0 1.0 P.F.J. The procedure was then changed to apply load in tuo steps. Fifty per cent load was applied immediately upon reaching rated speed and voltage, followed by bo% load witntn S seconds of the engine's acceptance of the first 50% load and witnin 25 seconds trom initiation of the start signal. The change to this procedure did not completely clininate the loading problem; however, it did help to reduce the frequency of the excessive instantaneous overloads encountered when applying the load in i(]j v' one step. Due to the difficulty in controlling the load, there were 14 cycles.for which it was necessary to drop load to regain speed and then reapply load back to 100%. The instantaneous overloads for these 14 cycles ranged from 110% to 123% of rated load. There was a total of 5 cycles for which the load did not reach 1003 because of the cold water in the rheostats. ( These loads ranged from 82% to 90% of rated load. The first 187 cycles were performed with " keep warm" conditions followed by 35 cycles at hot equilibrium conditions and the last 7 cycles were performed at " keep warm" conditions for a total of 230 cycles. This test is to be used in conjunction with the 100 cycle start and load test previously perforced (August,1971) on a similar 12 cylinder PC2 engine. The combined total of 330 start and load tests exceeds the requirement of AEC Bulletin BTB-ElCSB-2 which requires a total of 300 valid start and load tests. Bulletin BTB-ElCSS-2 also requires that at least 90% of these start tests shall be made from hot standby (Leop warm) conditions and 10% from design hot equilibrium temperature conditions. A valid start and load test defined as a start from the specified temperature conditions with loading to at least 50% of continuous rating within the required time intervals and continued operation until temparature equilibrium is attained. Except for the 5 cycles that were between 82 to 90% load, all cycles were performed with loading to 100% load or greater in less than 25 seconds, which exceeds the 50% load application requirement. A fuel leak occurred at both the left and right hand brass fuel check valves during the 89th and 90th cycles respectively. Both valves had cracked in the thread root due to strain caused by installation procedure error and unsupported pipe. Replacement valves with stainless steel bodies were installed using correct procedure and pipe support. The change out of these valves did not interrupt the one (1) hour starting cycle sequence. ((~ 3l ' There were no further problems with these valves. L/ 4
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racc ar.seson 4 ENGINEERING REPORT curn 3 or 5 na 3 row sntems CWics [Nera Order 35-20591 ALABAIM P0' DER COMPA:1Y F!lP2-34 DATE April 22, 1975
" FARLEY llVCLEAR PLAilT UillT P2 EY R. Humke
^ " ' ' "
i 200 CYCLES START TEST ny During the ll8th cycle there was a significa-t change in the flo.1 cylinder exhaust temperature. Instrumentation was checked and found to be correct. The 110. 1 injection nozzle was removed for test. The nozzle opening pressure was within limits. The flo.1 cylinder liner was visually inspected and found to be in good condition. The injection pump drive assembly was inspected and it was found .that the lock nut on the tappet capscrew was not tight and port closure of ilo. 1 injection pump had changed. The injection pump port closure was reset to the proper setting and the pump tappet capscrew lock nut was tigh tened. During the following start cycle (119) the flo.1 cylinder exhaust temperature was normal and remained normal throughout the remainder of the start cycles. During the post trial inspection following the 230 cycles, the ilo.1 fuel injection pump and drive assembly were disassembled and found to be in good condition. t :
\, l '- EQUIPliEllT DESCRIpTIO!(: -
- 1. Colt-Pielstick PC-2 Engine (S/fl P04-205919)
(' flo. Cylinders 12 Bore, Inches 15.75 Stroke, Inches 18.11 Speed, RPM S14 Rating 0 0.8P.F. Continuous - 4075 KW (5660 Blip) 2000 llour - 4353 KW b 300 Hour - 4474 KW 30 Minute - 4881 KW
- 2. BPS Alternator (S/il 503920-Rl)
TypeTGZDd KVA - 5950 KW - 4760 RPM - 514 Frequency (Hz) - 60 Phase - 3 Voltage - 2400/4160 70*C Rise, Class F insulated
- 3. Static Exciter and Voltage Regulator Bassler Type SBilV Static Exciter Regulator j
PACE surrr 4 or 5 no. 4
- r.sous O ENGINEERING REPORT rem sntms nisica pyrraOrder 35-205919
. ALABA!'A POWER COMPNiY FitP2-34 DATE April 22, 1975 E"'IEC' '
FARLEY tiUCLEAR PLANT UNIT #2 rarranto av R. Hurke
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Erc"' 200 CYCLES START TEST s
- 4. Water Rheostats Two (2) 5000 KW Water Rheostats connected in parallel
- 5. Air Start Tanks Two (2) 30" x 108" Tanks charged to 425 psig INSTRUttENTATION:
The basic recorder tised in subject tests was a Bell & 110well, Model 5-134 light beam oscillograph. The transducers used to display the various functions that were recorded are listed below: _,n\ (' ) 1. AC voltage, current and frequency transducers that were used are manufactured by Voltron Products, Inc. which, with appropriate potential and current transformers, convert AC signals to Analog DC signals. These signals, through resistive attenuators, were used to ( drive Bell & Howell Model 7-325 galvanometers.
- 2. Engine & Turbo Speeds Pulse signals obtained by magnetic pick-ups and toothed gears were used with frequency to DC type speed indicators. The Analog DC signals from tachometers were used to drive Bell & ilowell 7-349 galvanometers, t.
- 3. Rack Position A linear potentiometer was attached to the engine rack. This transducer with appropriate power supply and galvonometer amplifier gave AC signal and trace proportional to rack motion, llote: The slider on the linear pot was becoming worn and introduced considerable noise in the signal, s 4. KW Load The KW load was recorded on Esterline-Angus Recorder.
- 5. Jacket Water Out and Lube Oil In Honeywell Recorder was used to record the jacket water out and lube oil in temperatures.
['S L/ ' E
PACE rain y -ENGINEERING REPORT SHEET 5 cr 5 no. 3
~
re:er systems DMilon pty:n Order 35-20591l ALABNM POWER COMPAflY FNP2-34 DATE - (A susicer FARLEY tiUCLEAR PLMIT U! LIT #2
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NES" 200 CYCLES START TEST 3y TEST RECORDS:
- 1. Test Log Sheets tios. I and 2
- 2. ' Oscillographs 1 through 230 cycles -
- a. Engine RPM
- b. lurbo RPM
- c. AC Volts
- d. AC Amps
- e. I-requency
- f. Fuel Rack O 3. Honeywell Chart Jacket Water Out and Lube Oil In
- 4. Esterline-Angus Chart
{ 101 Load
- 5. Post Trial Inspection after 200 Start Test t,
' (/7 O
,( I y/" N i ALABAMA POWER POST TRIAL INSPECTION AFTER 200 START TEST ! . j 1 i-
- April 24, 1975 t .
4 4 + I i / I i j Prepared By: . Ap r/} oved By:,7
.h, , hi gu, C0 06
- R. Humke J. Balderston l l
Distribution: ' i l Y 6 l 9 L i 6 4 r e
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,. PAGE srision ENGINEERING REPORT entrT or no. 1;i
[' ren sptem DMsion [Etern Order 35-20591 D^ April 24,1975 I sunsc7 ALABAIM PO'.!ER - 205919 - 7, ^'q , rarge H. e
' " POST TRIAL IflSPECT10;! AFTER 200 START TEST *
"I/ic ^ PP,"y l
The engine components were inspected in accordance with F.M. inspection P12606682 and results are as folicws:
- 1. All infection nozzles except l10. 7 were rusty upon removal. See F.M.
Engineering Report dated 4-22-75 for full details on cause and resolution.
- 2. Removed all cylinder heads. Visual inspection and dye checking indicated no abnormalities of the cylinder heads, tio. 2 head gasket showed indica-tions of combustion leakage near the bolt where the liftina device is installed. fio. 3 cylinder had nut frozen to the cylinder head hold n down stud. Replaced the stud and nut. Also replaced all 12 head (LJ j gaskets as normal procedure for post trial inspection.
, 3. All startinc air valves were in good condition with the exception of flo.1, which had a combustion leak at the body to cylinder head seat. / All internal parts were in good condition. flo.1 valve body was re-( fitted to the cylinder head. flo. 5 valve was replaced due to "over lapping" of the valve seat to the body during reassembly.
- 4. Visual inspection of the intake and exhaust valves and the seats of cylinder heads on fio. 's 1, 3 & 9 was completed. All were found in good condition.
t.
- 5. The rocker assemblies of cylinders flo.'s 1, 3, 7 & 9 were disassembled and inspected. All rocker bushings appeared to be in good condition.
- 6. Pistons flo.'s 1, 3, 7 & 9 were removed from the engine. The pistons have very light carbon deposits on the skirt and can be considered normal. Due to an inexperienced man, an oil ring and piston pin cover were damaged and had to be replaced. The piston rings and the piston pins and bushings are in good condition. The connecting rod bearings and the crank journals had light scratches. The bearings were cleaned 1
up and journals lightly polished per standard practice. Charted tio. I ring width and gap, and the width of the ring groove on fio.'s 3 & 7 pis tons . See Chart tio. lA (attached).
- 7. All cylinder liners were visually inspected and found in good condition.
Charted cylinder liner bores. See attached Charts tio.'s 1 thru 12.
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- ALABAMA POWER SKIDDED UNIT 20591g I
r g' Post Trial Inspections after 200 5 tart Test * ,
. h,
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(1) NOTE: Obtain Product Engir.eering approval before proceeding with Post Trial D Inspection.
- 1. Remove all injection nozzles for visual inspection and checking and (d) Typical air start valve intake and exhaust valves. r.
recording nozzle opening pressures. , l * (e) Injection nozzle as removed. .-
- 2. Remove all cylinder heads for visual inspection and dye checking of . ,
* *'" #'* (f) Injection pump plunger and barrel.
- 3. ve d disasseit>1e all cylinder head starting air valves for visual. (g) Cylinder liner in place.
' (h) Piston pin and bushing. .
- 4. Remove intake and exhaust valves from three cylinder heads for visual Inspection of valve seats. f (1) Air start distributor. *
'5. Otsassemble four rock'r e arm assem11es for visual inspection of rocker ,
0 spindle bushings, i Note: In the event a significant defect is formd in a component selected for typical inspection, all sistlar components must be
- 6. . Remove tuo piston / connecting rod assembites from each bank for visual checked. ,
- inspection of piston, piston rings and connecting rod bearings. Make - .
visual inspection of piston pins and b'uthings. Chart top piston ring 1 . gap, width and top pisten ring groove width of two pistons. . 14 AFTER POST TRIAL INSPECTION and reassembly of engine, operate the engine , in accordance with the established Engir.eering Re-Run procedura .
- 7. Hake visual inspection of all cylinder liner bores. Chart liner bores.' .
established for this type of disassembiy, *
- 8. Remove three main bearing caps for visual inspection of crank journals ,
- . ; _ . . . , . - 3 and bearing shells.
. I
.L
- 9. Remove one fuel injection pump complete with its drive asse21y. 01sas- * .'
', serbie pump for visual inspection of plunger and barrel. Make visual f' - ,
tespection of fuel can follower asse21y. two camshaf t bearings and fuel g cam. , B ,
. 10. Make visual inspection of camshaft drive gear
- train and water /o11 pump . , ,
drive assect>11es. , , {l- 't i-tu
- 11. Remove air start control valve and both starting air distributors for ,
s
* .j, .I .
. disassemly and cceplete visual inspection. .
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- 12. Retignten all main bearing caps hydraulically and check tightness cf all
> counterweight fasteners. ,
- 13. Make inspection report complete with the following photographs: M/,
4 ,
. (a) Cylinder head before and af;er dye checking cort >ustion face.
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4 (b)' Typical piston. 5 l (.
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(c) Hain bearing shell.. ) !! aa
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,7. r 1 4788l/8/7 i (1) Added
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- b. U. Y R . Hur+ e 3/25/75 POST TRIAL AFTER 200 START 5 s
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stc. l l src. Alabana Power Skf dded Unit 205919 733 Cycles Start Te_st 'd D 2. 33 Cycles at Equilibriun Terperatures , t 1.0 Of the 200 start cycles. 30 are to be inade at bot equ11thriue te ocrat re conditions. namely: Lube 011 Int' 120* to 140*f; Jacket Watcr out: ( 8) 110* to it0*T. The hot equilibrin start cycle program shall beeiin a'ter 170 viltd Keep Warm icrperature start cycles. 1.1 start Test orncedu,re 1.11 . *f ter 173 valid start cycles fron keep Warn Terreratures. 'rcstart the cuine and operate at full resistive load until the tube oil inlet tremerature reaches 130*r and the jacLet water outlet (8) to .asrature has stabilized in the ranne of 1*0* to 10"T. It will require from 2 to 4 hours rurning at full loaJ for tiac til C to reach 130*T. Renove IcaJ and shut dmn. (g) 1.12 St art up frei both startino sf r tanks and accelerate to ratcJ s;ccj anJ voltage within 10 seccnds. Apply loaJ in accordance with Paragraph 1.12. Sheet 1. Orcrste at full resistive locJ (Will kw) fer ten ntnutes wit's the 1* cIl outlet tenpciature ruinteincJ within the ranae T2ei to 140*/ and tae jacket witt r (8) uitbin the rance l'O' to 160 r. Perove load and shut J w.n. " - 1.13 "f th the eneine at rest for 13 eiinutes and the starting air 'd ccccressors continuing to rechargo the air bottles. check t1at toc McLet water teeperature renains within the ItY to If 0*F rar.M. Use the aamillary Jacktt water pg if nect.ssary to u,ntrol any tenperature rise a!.ove 100*r during the shi.tds:n periuJ.
, 1.11 r.cpast Steps 1.12 and 1.13 for 33 consecutive cycles.
1.2 : totes (In addition to nctes 1.21 through 1.27. Sheet 1.) 1.23 The hot equilfbrium start cycle test results shall 1:e r:cordeel is a continuation of the results already rentstered by the recording instrurents for the 170 va11J start tests from Keen Warm tenrerature cenJitions. f / A . . . . .
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sm l sEc. Alabama Power skidded Unit 20591) M1
~~ Cycles Start Test ~ ~ -
i... a f t he u u .r- for ta11urr' ta St.rt or sacg t Ic ;d te. actorjsoce alth A. '73 cveles frem teep Warm Tenperatures (1) ' ic precedina w4u' n. c t.Ils .nJe att of the f oll e He cat.w ric s , Q t it r*r tic .l .r te'.t raf bc 'is rerwrJed and t ic test sei.ucruc resu' c l D 1.0 his test requires a temporary ausiliary Jacket Water coeling systen cormer tel 1~llwhq td. ntiti.atiu. af tin c iu.c of t!.c unucce.sf ul at tecot sna te the stid at tt'e calstini 6* connections with check valve aircidy furniW J t. Linq v 'ute,t r r ;w. are n s e" itr to rrevrnt tnat se r i ause f rrn for ca;tertr's iuulliary cump. ied. rrup t in a '. m .xces s f ul pe r toi r lore if tite rettale.n'in tr .t'. in the u ries: The te Torary systen will Corprise one 603 gpa'. retnr.drlven purp anJ an ' te IF neat eschanger coeled bf ton.er Water. The systen v ill be uscJ to c .o1 the 1.22.1 1,r eJ V t ent of can'rs.1 nlNhes, relavs or ecN12teri tut jaar.t wJ'er frcn 140*F to 110*F when the engine is shut _ down af ter each st tr*.191 my na.e Leen ( 1:in7d llah'.r ter:tly ;'rtcr to tut ret t e.21 tr test. ' ta r t '.cs t. a I..J.2 tallurc of anf of tbc tegor try service syste-s ".ach as $ncp i.] 5 tart T+st Prcredare Pawar, eutput ctro.it t,rcalcr, load, teterrcnnecttnet rtrine, nau :es, twratreters, tharricouples, tarbercters, 5tV' equip-1.1% f a:h start of the engine.nenerator unit is *o be<:In at eniine fcer ' lit . t rnt, ann anciator, t irin1 am! anf othrr sur.rcrt sys tem that typ;eatures (Lcep Warm te**ccratures are 'later: 11)*F, 011: 12'.' f ) . is not an intersi rart of Ltc iicsel (niine. Start o from both starting air tant s and accelerate to rited speed C and vcitaic within 13 seconds, i.22.3 f t is als) allmeJ to rate repairs to the en11ne, suc% as Icelino 14.tets, v41.cs, pu Ss. f hnics, etc. that were nc ted t>y the
!.12 Aeply to.11ad truvdtately upon reaching rated s;'ecei and voltale (d operatcrs during a Treviou- start.
followed by the remaining 50; load wit 1tn 5 seconds of the enntre's ac.estance of tne first 5% load and within 25 seconis frnn int *.intion 1.22.J If the ' fill to start" cause requircs a re;tlicerrnt cf an en1ine of tne start siqnal. Operate at fall resistive Icad (5000 bhp, <1115 h) corp nt before the test can continae, that cc: rocer.t s'i.ill be for nei less toan five tiluutes. If necesserf, estend this ti ie ur.tli rtplactd .snJ the test continued untti a ritntrun of 033 su ccuful the .tidet water terrerature reaches IQ*f. Pcciove leaJ end shut da..n. st )rts 'las becn CYolet *J. Arf ad:!ltionJI starts will t,e at the _ Jiu retion of the tngincaring Department. I 1.13
- tart up aufliary jacket water pwrp and c031 jacket water ter'pt ratt,rc d to lir F in 50 to 60 ninates. Shut dmn aant tiary pumr. 1.23 All pro;.lems anj li.tcrrupticos oust lic recudcJ in the lec.
1.84 Hepeat steps 1.11,1.12 and 1.13 fer 1M cycles. ( 3) 1.?4 bechtel Corp. Instector will be orc'.ent during tt.cse tests, Lut ns
, LLst shoulj be delafed ponJiv. his arrival.
4.15 lesting suf be interrupted for hottoays, weetenJs and scneduled i shutjwr.s. 1.25 Contract air cogressor anJ startina air tanks nast t,e uscJ. (6) 8 1.16 ProcccJ to Sheet 2, 30 cycles at Equilibriun Temt cratures. (1) 1.26 Contract Control Panel (Cri) rust be used. 1.2 l votes , 1.27 Ubtain Product Engineerinc approval before proceeding with Post Trial Inspecticn. (5) ' 1.li lor the duration of caca start cycle an oscillograph record must te takcn of: , See bheet 2 for llot Equilibrium Terocrature Start Tests (7) Alternator f requency AC volts AC Arps Jacket Water tenperature out of the engine d tube Ull temperature into the enq1re. ,i [ A . . . . . . .
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,,- [d$sta Order 35-205919 April 24,1975
,r su m er ALABAfM POWER - 205919
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- 8. flo.'s 2, 4 & 6 main bearings were removed for inspection. All bearing halves are in good condition. fio. 6 lower half of bearing had very minor dirt scratches which were cleaned up before replacing the bearing.
- 9. Remove fio.1 fuel injection pump and drive assently. The drive assembly was found to be in good condition. The fuel pump was disassembled and also found to be in good condition.
- 10. All cams were inspected and found satisfactory. ilo.'s 3 & 10 cam bearings were removed and inspected. fio. 3 bearing and shaft had scratches.
Cleaned up bearing and shaft per standard practice. flo. 10 bearing was in good condition. (j) ( 11. The cam shaft drive gear train was inspected and found in good condition. The water and oil pump drives were also found in good condition.
- 12. The air start control valves and both air start distributors were dis-assembled and found to be in good ccndition. The drives are in good
(- condition.
- 13. Checked tightness of main bearing caps and counterweight fasteners and retorqued in accordance with standard practices.
The photographs listed below are intended to provide a typical view of engine components that were removed during the post trial examination. (a) Cylinder head before and after dye checking combustion face - l 18754E and 18757E l (b) Typical piston - 18771E l (c) fiain bearing shell - 18788E l (d) Typical air start valve - 18796E (e) Injection nozzle as removed - 18777E (f) Injection pump plunger and barrel - 18785E and 18797E (g) Cylinder liner in place - 18780E (h) Piston pin and bushing - 18784E and 18783E (i) Air start distributor - 18781E (j) Typical intake and exhaust valve - 18756E (k) Injection pump drive assembly - 18795E a ,
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