ML20211D152

200 Hour Rating Qualification Test Rept

ML20211D152
Person / Time
Site:	Crystal River
Issue date:	01/25/1994
From:	Miller T, Monahan G BALTIMORE GAS & ELECTRIC CO.
To:
Shared Package
ML20211D112	List: 3F0997-30, Forwards Suppl Info to TS Change Request Notice 210 Re Proposed Changes to TS & Other Aspects of Licensing & Design Basis,To Address Mods & Procedure Changes Required to Mitigate Consequences of Certain SBLOCA ML20211D152 ML20211D161
References
NUDOCS 9709290060
Download: ML20211D152 (10)

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BALTIMORE CAS & ELECTRIC CO. Daft January 25, 1994

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Tmz N 200 HOUR RAT 1RG QUALIFICATION TEST REFORT W.Y.h&o

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BALTIMORE CAS & ELECTRIC CO.

, s CUSTOMER ORDER NO. 85380GS F.M. CONTRACT 35-734133 200 HOUR RATING QUALIFICATION TEST REPORT 4

9709290060 970925 PDR ADOCK 050003 2-e .

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\W ENGINEERING REPORT meer 2 or 5 mo. 2 Feltbenks Merse mz Engine Olvleton 3'88EE 35-734133 January 25, 1994 O" BALTIMORE CAS & ELECTRIC CO.

F.M. CONTRACT 35-734133 Aan FM,PAIED G. Monahan wrLE 200 HOUR RATING QUALIFICATION TEST REPORT AFFBWED ,

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TABLE OF CONTENTS

SUMMARY

OF QUALIFICATION Ti.ST RESULTS Page 3 QUALIFICATION TEST PROCEDURE 10560978 Appendix A ENGINE POWER PARTS INSPECTION CHARTS Appendix B

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O TEST EQUIPMENT DATA Appendix D 6

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(" F.M. CONTRACT 35-734133 ,. l spont sr G. Monahan 200 HOUR RATING QUALIFICATION TEST REPORT st

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PURPOSE -

The purpose of the 200 Hour Rating Qualification Test was to prove that the emergency diesel engines at Baltimore Gas & Electric Co. (af ter conversion to turbo blower series) can operate at the following load rating:

3500 kW @ 900 rpm - 200 hour0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> rating This is net kW load after subtracting all parasitic loads; i.e., engine driven pumps.

DISCUSSION-The engine used for the test was Baltimore Gas & Electric (F.M. Contract 70C026) engine S/N 38D885002TDSM12. This engine was converted to turbo blower series configuration and completely rebuilt with new power components, including cylinder liners, main bearings, pistons, piston rings.

The engine was givan a complete inspection during the rebuild. This inspection hb included checking for wear, improper assembly, broken springs, etc. Also, bearing clearances and end float and gear backlash were checked. Injection pumps were inspected and recalibrated. All components were found to be in good condition and ready for the test.

To wear in the new power components, the engine was given the Wearing In Run per Engineering Dvg. 16 113 660. Following the wear-in, the Standard Final Acceptance Run per Engineering Instructions 4406FM was performed. Rated load for these tests was the continuous ratin of 3000 kW at 900 rpm. The engine was then visually inspected.

The generator used for the test is a Lcuir. Allis Model TGZDJ S/N 502564RI. Efficiency curves for this generator are included in Appendix D. All test instrumentation was calibrated prior to tests and a list of instrumentation used is included in Appendix D.

RESULTS OF 200 HOUR RATING TEST The endurance test at the 200 hour0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> rating was commenced on December 8,1993. Tne test engine was loaded to 4869 net bhp at 900 rpm. This load is the required horsepower to generr. tor 3500 net kW at 0.8 lagging power factor.

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.The test engine operated at 4869 net hp for 207 hours0.0024 days <br />0.0575 hours <br />3.422619e-4 weeks <br />7.87635e-5 months <br /> on a continuous basis. A complete line of engine data was recorded each hour and firing pressures were measured onco every 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />. See Appendix C for engine test logs. During this period, no f engine shutdownr occurred due to (ngine failure or malfunction.

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200 HOUR RATING QUALIFICATION TEST REPORT #

The engine was shut down three times during the test. The first shut own occurred after the first 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, when the engine was shut down in order to replace a test indicator cock (firing pressure test valve) which was stuck in the open position.

Af ter 35 hours4.050926e-4 days <br />0.00972 hours <br />5.787037e-5 weeks <br />1.33175e-5 months <br />, the engine was shut down to repair an oil leak at the generator bearing thermocouple. And after 85 hours9.837963e-4 days <br />0.0236 hours <br />1.405423e-4 weeks <br />3.23425e-5 months <br />, the engine was shut down to inspect the generator bearing insulation monitoring device brush. The total elapsed time during the 3 shutdowns was approximately 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />.

RESULTS OF POST TEST INSPECTION Af ter the test, all power components were removed and the engine was inspected for signs of wear or distress. Post-test inspection charts of the power components are 1 included in Appendix B. Results of the inspection are sunanarized below.

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LINERS All liner bores were inspected and were well within the condemnable limit of 8.145 h

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inches diameter. Several cylinders showed an increase in diameter of approximately

.001" in the exhaust port area. Cylinder #12 showed some elongation of the bore of up to .002" in the athwartship direction. This evidence of somewhat accelerated wear is  ;

as expected under the increased rating run during this test.

PISTONS AND PISTON RINGS Visual inspection of the pistons showed no areas of significant distress. Piston ring gaps on upper and lower pistons increased by up to .016". Although they were well within the condemnable limits, the piston compression rings were replaced for the 2000 hour0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br /> test. No compression rings or oil control rings were broken.

PISTON WRIST PINS. INSERT BUSHINGS. AND CONNECTING ROD BUSHINGS Visual inspection of these parts revealed no signs of unusual wear aad all pieces were reinstalled.

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_200' HOUR RATING QUALIFICATION TEST REPORT Y[!dse .

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PISTON PIN FLOATING BUSHINGS The upper piston pin floating bushings were inspected and reinstalled. Some minor wear was indicated by a slight reduction in 0.D. and increase ~in I.D. No extrusion of the ,

bushing was indicated by inspecting the bushing length.

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' MAIN AND CONNECTING ROD BEARIf g Inspection of the aluminum bearings showed significant distress on both connecting rod and main bearings. 'All upper and lower connecting rod bearings were replaced. All upper main bearings and #4, #10 and #13 lower main bearings were replaced.- The bearings that were removed were out of specification on bearing crush and free spread.

CONCLUSIONS The test engine operated for 207 hours0.0024 days <br />0.0575 hours <br />3.422619e-4 weeks <br />7.87635e-5 months <br /> e the 200 hour0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> contract rating of 3500 kW. The tests were completed without engine malfunction or failure and, therefore, the engine's capability to operate at the proposed ratings was successfully demonstrated.

The condition of the power components after the test showed soma accelerated wear as expected due.to the increased. loading. None of the parts were worn to'the extent of

. causing reduction in load carrying capacity of the engine.

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APPENDIX A I i

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F.M. CONTP.ACT 35-734133 j BALTIMORE CAS & ELECTRIC CO.

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INCREASED RATING QUALIFICATION TEST

REFERENCE:

(A) F.M. CONTRACT 35-734133 BALTIMORE CAS & ELECTRIC CO. ORDER NO. 85380GS .

. (B) F.M. CONTRACT 35-700026 (C) BC&ESPEChFICATIONSP451.REV.2

. I. GENERAL TEST REQUIRENENTS A. THE ENGINE USED FOR DIE SUBJECT TEST WILL BE BALTIMORE CAS &

ELECTRIC (F.M. CONTRACT 700026) ENGINE S/N 38D885002TDSM12. THIS ENGINE WILL BE CONVERTED TO TURBO BLOWER SERIES CONFIGURATION, REBUILT WIDI NEW POWER PARTS AND INSPECTED TO ENSURE DIAT ALL COMPONENTS ARE IN C00D WORKING CONDITION.

B. TEST INSTRUMENTATIDA USED FOR DIE TEST MUST BE WITHIN THE CALIBRATION DATE ISSUED BY THE QUALITY CONTROL DEPARTMENT.

C. TEST LOGS USED SHALL BE FORM BF4445. A MINIMUM OF 1 COMPLETE LINE OF DATA SHALL BE RECORDED FOR EACH HOUR OF ENGINE OPERATION. FIRING PRESSURES SHALL BE RECORDED ONCE EVERY 8 HOURS OF ENGINE OPERATION.

DIE FOLLOWING ENGINE PARAMETERS SHALL BE RECORDED:

i AIR RECEIVER PRESSURE

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AIR RECEIVER TEMPERATURE CRANKCASE VACUUM EXHAUST TEMPERATURE (CYLINDER)

EIHAUST TEMTERATURE (COMBINED)

EIHAUST PRESSURE FROM TURBOCHARGER FUEL OIL HEADER PRESSURE FUEL CONSUMPTION JACKET WATER TEMP. TO ENGINE JACKET WATER TEMP. FROM ENGINE LUBE OIL PRESSURE. PUMP DISCHARGE LUBE OIL PRESSURE. UPPER HEADER W&*:::aL" L"l't."Es."A"" :LY: '*M;27,93;;;

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l .. ' 8FS249 LUBE OIL TEMPERATURE. TO ENGINE LUBE OIL TEMPERATURE, FROM ENGINE l TURBO COMPRESSOR DISCHARGE TEMP.

TURBO SPEED DURING ALL TESTS. THE FOLLOWING PARAMETERS SIL*.LL BE HELD TO WITHIN

, THE LIMITS AS SPECIFIED BELOW. ALL OTHER PARAMETERS ARE RECORDED

. FOR INFORMATION ONLY.

AIR RECEIV'ER TEMPERATURE -

130+ 180'F JACKET WATER TEMP. FROM ENGINE -

160-185'F LUBE OIL TEMP. FROM, ENGINE -

175-195'F D. ENGINE RATING INFORMATION

%. CONTINUOUS KW GEN. GEN. EFF. BHP RATING RAT _ING LOAD e 0.8 P.F. HEI REN 30 MINUTE 120% 3600 96.4 5008 900 200 HOUR 117% 3500 96.4 4869 900 2000 HOUR 110% 3300 96.4 4591 900 CONTINUOUS 100% 3000 96.3 4178 900 3/4 75% 2250 95.7 3153 900 l l l 1/2 50% 1500 9.4.5 2129 900 E. THE GENERATOR USED FOR THIS TEST WiLL BE A IAUIS ALLIS MODEL TGZDJ S/N.502564R1. GENERATOR WILL RUN ON-LINE WIDI WISCONSIN POWER. AND LIGHT COMPANY AND BE LOADED AT APPROIINATELY 0.8 POWER FACTOR.

SWITCHGEAR, EXCITER, ELECTRICAL G.iUGE PANEL AND ALL AUIILIARY EQUIPMENT WILL BE NORMAL PRODUCTION TESY EQUIPMENT.

F. ALL ADDITIONS OF LUBE OIL SHALL BE RECORDED DURING THE 2000 HOUR TEST. THE HOUR METER READING AND THE QUANTITY OF OIL ADDED SHALL BE RECORDED ON THE TEST LOG. .

II. PREPARATION FOR TEST A. THE ENGINE IS TO BE COMPLETELY REBUILT WITH NEW POWER COMPONENTS FOR

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THIS TEST. THE FOLLOWING NEW PARTS WILL BE INSPECTED AND CHARTED BEFORE INSTALLATION AND AGAIN AFTER COMPLETION OF ALL TESTS.

PART NO. OR B/M E. HMIE gl 16605621 1 BEARINGS '- MAIN. COMPLETE SET h 16609595 12 LINER ASSEMBLY .

16204302 24 N0ZZLE - INJECTION g 16609599 12- PISTON ASSEMBLY - LOWER 16609598 12 PISTON ASSEMBLY - UPPER

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• i B. A COMPLETE VISUAL INSPECTION OF THE ENGINE WIII BE PERFORMED BEFORE COMMENCING THE TESTS. THIS INSPECTION VILL BE PERFORMED UNDER THE

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SUPERVISION AND DIRECTION OF DIE R&D DEPARTMENT. )

1 C. AFTER REASSEMBLY AND FINAL INSPECTION, U{E ENGINE SHALL BE GIVEN THE I STANDARD F.M. WEARING IN RUN PER PROCEDURE 4404FM. FOLLOWING THE 1

WEAR-IN, DIE STANDARD FINAL ACCEPTANCE RUN PER PROCEDURE 4406FM )

SHALL BE PERFORMED. RATED IAAD FOR THESE TESTS IS DIE CONTINUOUS l RATING OF 3000. KW AT 900 RPM. UPON COMPLETION OF HIE FINAL ACCEPTANCE TEST. THE ENGINE SHALL BE GIVDi A VISUAL POST-TRIAL INSPECTION. ANY LEAKS OR OTHER MALFUNCTION OF THE ENGINE OR SYSTEM l

. SHALL BE REMEDIED AT THIS TINE.

III. UlDURANCE TEST @ 2000 HOUR RATING ,

A. THE ENGINE IS TO BE LOADED TO 3300 KW AT 900 RPM AND RUN ON A CONTINUOUS BASIS FOR 2000 HOURS. AW FORCED SIfUTDOWN DURING TEST WHICH REQUIRES ACCESS TO INTERNAL PARTS OF THE CRANKCASE WILL REQUIRE REVIEW BT ENGINEERING, Q.A., PRODUCI SERVICE AND CUSTOMER PRIOR TO CONTINUING TEST. ANY OTHER FORCED SHUTDOWN SHALL BE REPAIRED, IDENTIFIED ON TEST LOG, AND TEST RESUMED.

B. FOLLOWING UfE 2000 HOURS OF CONTINUOUS OPERATION, DIE EUGINE IS TO BE SHUT DOWN AND CIVEN A VISUAL INSPECTION UNDER U{E DIRECTION OF

'lHE R&D DEPARTMENT. THIS INSPECTION SHALL INCIEDE: FEELER GAUGE CHECK OF HAIN AND CONN. ROD BEARINGS, FEELER CAUGE CHECK OF WRIST PIN BUSHINGS, AND VISUAL INSPECTION OF PISTONS AND LINERS.

l C. ACCEPTANCE OF THIS TEST WILL BE BASED ON THE ABILITY OF DIE ENGINE TO CARRY THE 3300 KW LOAD FOR DIE PRESCRIBED 2000 HOURS. CONDITION AND WEAR OF ENGINE COMPONENTS ARE NOT TO BE GROUNDS FOR REJECTION OF THE TEST.

IV. ENDURANCE TEST @ 200 HOUR RATING A. THIS TEST IS.TO BE RUN ONLY UPON THE SUCCESSFUL COMPLETION OF WlE TEST AND INSPECTION SPECIFIED IN PARA. III.

B. THE ENGINE IS TO BE LOADED To 3500 KW t.ND DIIS LOAD MAIEAINED FOR A PERIOD OF 200 HotdS. ANY FORCED SilVTDOWN DURING TEST WHICH REQUIRES ACCESS TO INTERNAL PARTS OF THE CRANKCASE WILL REQUIRE REVIEW BY ENGINEERING, Q. A. , PRODUCT SERVICE AND CUSTOMER PRIOR TO ~

CONTINUING TEET. ANY OniER FORCED SHUTDOWN SEiLL BE REPAIRED, IDENTIFIED ON TEST LOG, AND TEST RESUMED.

C. UPON COMPLETING 200 HOURS AT 3500 KW, DIE ENGINE IS TO BE SHUT DOWN.

TIIE TEST IS CONSIDERED ACCEPTABLE IF BIE ENGINE COMPLETES 200 HOURS s OPERATION AT 3500 KW. ,

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e crue.*y V. DISASSEMBLY AND INSPECTION A. THE ENGINE 15 TO BE DIfASSEMBLED FOR REINSPECTION OF ME POWER PARTS LISTED IN PARt.. !!.A. THESE PARTS SHALL SE COMPLETELY Q{ARTED AND PHOTOGRAPHED, ANY PARTS THAT HAVE EECREDED THE WEAR LIMITS AS PUBLISHED IN THE F.H. INSTRUCTION MANUAL

• ENGINE WEAR. LINIT CHART" SHALL BE MARKED TO INDICATE WEIR CONDITION. THE CONDITION OF THE POWER PARTS IS NOT TO BE CROUNDS FOR REJECTION OF EI1HER ENDURANCE TEST. ,

B. IN ADDITION TO THE INSPECTION OF THE POWER CONPONENTS, A COMPLETE VISUAL INSPECTION OF THE ENGINE IS TO BE CONDUCTED UNDER THE SUPERVISION OF 1HC R&D DEPARTNENT. ANY SIGNS OF WEAR Ok OTHE ABNORMALITIES ARE TO BE NOTED ON THE TEST IhCS.

C. ALL TEST LOCS, INSPECTION CHARTS AND PHOTOGRAPHS ARE TO BE SUBHITTED TO PRODUCT ENGINEERING FOR ISSUANCE OF THE FINAL TEST REPORT.

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