ML20011D702
| ML20011D702 | |
| Person / Time | |
|---|---|
| Site: | Prairie Island  |
| Issue date: | 07/20/1988 |
| From: | Morzelle C ELECTRICITE DE FRANCE |
| To: | |
| Shared Package | |
| ML20011D695 | List: |
| References | |
| NUDOCS 8912280291 | |
| Download: ML20011D702 (16) | |
Text
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E X,P e# SPT .D. MATERIEL . ;
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i Electricit6 de France service stuces et projets Therminves et uvetterres 1e : ( 20 Jul11c: 1988 { l 3 kef.: E.H.M/l% 88.063 A i (M9/Yf l
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l ' 1 1 s , t i ! !. I kbre de pages : 10 Redacteur(s) : C. HOR?ELLE r t l lype de tranches(s) concern 6e(s) : REP 900 MW Nbre d' annexes : ' .} ,
' Titre : D05$1ER DE SUlVI DE QUALIFICATION (0$Q) .
GROUPES ELECTR0 GENES DIESEL * ' l
-l[]NlM [MA l / l BB j 063 j A GPE 1429Pl640[9998l ,
l Type de document : N01E TECHNIQUE , N Domaine(mots.c1Es): I Resume : Cette note fait la synthese des essais et snelyses qui permettent de conclure & la qualification des groupes electrogenes diesel du palier REP j l 900 MW. li . 6 e9 l Archivage su FTE : OU1 6 COPYRIGHT EDF EQT 19881 I Accessibilite : RE$1RE1H1C - Document ne pouvant sortir de la Direction de t! ; I l'Equipement sansTe'tTre ou bordereau d' envoi du Service 6metteur, 1 .
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c6m~plTm'entB'e I I ! I 1 I Direction 1 REAM : Monsieur HERAT 1 i i Opt Systemes et installation i SPT Hessine HM 1.ARUE I 1 l Opt Materiels 1 JEANNIN l i l Dpt Theorie I ouV1ER I !
.' lylli Chef de projet concerne 'I !
. 1 I Chef de division redactrice - I dont SEPTEN I
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I I Division GT : , bureau courrier I l ;
- documentation l l I I l l Division 50 rett Nucleaire (si note concerne la 50 rete) 1
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Pa e 3! , 6tPTEN E.M.M./MA UU.UDJ ,. j 00551CR DL SulVTbl 60AUFICA110H (BSQ) 6kOUPES tttCikO6thES b1E ___ b. I S, ,0, ...
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Pa.le.s t 4 I - EXPERIEN,CE INDUSTRIEtttE DU CONSTRUCTEUR 4 1.1. Hors du domaine nucleat,re
- 4 ,
1.2 . Dans le domaine_ nucleaire
- 11. DOCUMENT DE REFERENCE ,
- 5 111. ACTIONS DE QUAttflCA110N '
5 3.1. Qualification sismique
. 6 3.2 - Qualification icnetionnelle o
o.t.s . g>ge! ge,ogo,ve .ein,eyeg.,ptogiyug g gryne;,v1 pra) 3.2.2 - Essais,d;endurange,pratigu{s,en 1917,et 1918,6,Ggngevilliers 6 lug grguge,UD 45,AGO,V',20
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3.2.3 - [sga! pe,l}09 ((matraggs,pratigu{ 6 Crya! . 8 IV - QUALIFICA110N DE COMPOSANTS SENSIBLES 8 4.1 - Bie11es . 8 4.2 - 5eaments
. 8 4.2.1 - Choix d'un,cgmbugtib),e,1. haul in(ige,dg cetane 4.2.2 - gualificgtieg g'yng built 6logg,pguvoirdiagetoghegg y . FABRICATION EN USINE We 9
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Indice Page ' i sDF N01C D't1UDE l
'o A 4/1D
- ssp 1EN E.N.M./MA $8.063 1 D0551tR DC $UlVI DE QUAtlFICA110H (DSQ) GROUPES titCTROG i
I l de Suivi de Qualification. 050, s'appitque aux I l Le present Dossiergroupes electrogenes diesel de tranche des!I palie et & l' ensemble de leurs auxiliaires electriques et mecaniquet. 1 Par extension, il s' applique aux materiels suivants :
- Groupes d'Ultime Secours (4 moteur diesel) des tranches CPI . CP2 -
l qui, en raison de leur date plus recente d' installation, presentent. i par rapport aux groupes de tranches quelques ' modifications in61uc-tables, 044 A :
" mais de f aible importance", au sens de la note E reference des materiels mecaniques : pompes, turbines, diesels'. l
. Groupes diesel de tranche de Bugey et Fessenheim Les moteurs diesel de ces centrales sont des UD 45 - V 16 (A de SACH. alors que ceux du CP1-CP2 sont des UD 45 . V 20 i du f ait ;
~
, qu'ils ont 4 cylindres de moins, leurs vilebrequins, arbre ' alternateurs sont moins puissants tout le reste du materiel est ' identique et a b6i,6fic16 de l' ensemble des amt11 orations apport6es sux moteurs AGO V 20. . Le inattriel auxiliaire electrique est voisin de celui Hennequin, du CPI - CP2 et l est install 6 par le m6me sous-traitant de SACM :
- 1. svory_ truer twnut10tri e s nn rnwetourtrno d '
1.1 . Hors du domaine nucleaire leur utilisation dans le domaine nucleaire, les
- Anterieurement 6 mot.eurs UD 45 ont ett largement employes en traction ferroviaire. .
2
. En version V 16, ces moteurs equipent les locomotives $NCF de la
.' serie 72 000 (91 locomotives,unecentainedemoteurs). >
I
- 1. , ,
- En version V 12, ils equipent les locomotives de la serie 63500(26 locomotives).
l\ Dans ce type d' application, ces moteurs supportent 800 000 km entre lji deux r6 visions g6nerales.
- Diverses versions de ces moteurs equipent depuis longtemps des L,
- centrales de production d'energie. .
1.2 - Dans_1e domaine nuc1Eaire 5 , En dehors d'EDF, de nombreuses socittes ont adopte les moteurs UD , 4 pour leurs centrales nucleaires. Ces moteurs existent donc enlaRFA Suisse. Hollande, Finlande, Suede. Espagne,Belgique, Coree du Sud t t i Chine va en installer et les flats-Unis, considerant que SACM es e , pratiquement le constructeur ayant la plus grande experience mondial - en centrales nuc16aires, s'interessent 8 ses fabrications, les utili s s'ateurs europ6 ens sont groupes en une *Societe des Utilisateurs e de groupes diesel SACM", qui se reunit tous les 18 mois pour 6 changer u ' retour d'exp6rience.
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EXP s .-SPT D . nM i t.rt o tt. ~~ Indice Page ' W NOTE 0' ETUDE A 's/10
- sLPtsN E.N.H./MA 88.063 00$$1ER DE $UlVI DE QUALIFitATION (05Q) Gil;UPES f t(C7P,0 GEN!S DIESEL s
I I
!! - 00CUMENi$ DE REFERENC_t les documents de rEffrence sont : *
- le C5176 C 007-00 Edition Septembre 1975 'Groupes electrogenes de j secours d'une puissance nominale de 4 MW pour les centrales nucle-aires". ,
i Ce document contient les directives pour l'etablissement d'un Dossier , d'identificatioq (01) du materiel., [.
- le D1 id m6me, date du 13/07/77 et mis a jour le 16/02/82 est disponible au SEPTEN et & la REAH. .
!!! - ACTIONS DE 00AllFICA110H Les actions de qualification ont ett mentes dans deux directions l elle est destinee 4 verifier la capacite du *
. Qualification sismique : materiel 4 r6 sister au seisme , 8 fonctionner pendan ' !
continuer a fonctionner apres un seisme.' . . ; u 6 finalif tratinn innetinnnollo
- Les actions de qualification fonctionne11es ont pour but I
. de verifier l' aptitude du rattriel & demarrer dans le temps requis de 10" et i prendre la charge en une minute environ ; '
, l
. de verifier l' aptitude du materiel 8 subir de nombreux cycles de ;
demarrages et prises de charge avec de courts temps & pleine charge ; i !
. de verifier son aptitude i des fonctionnements de plusieurs l centaines d'heures 6 pleine puissance
,i
. de verifier que les modifications apportees ont r6 solu les ,
l problemes de jeunesse constates sur les materiels. ! 3.1 - Qualification sismique
, l la qualification sismique concerne les groupes diesel alternateur de *
- tranche et tous leurs auxiliaires mecaniques et 61ectriques 4 l'excep-tion des installations de preparation d' air comprime de demarrage et -
des cheminees. Par contre, les dispositifs de stockage d' air comprim6 sont qualifies et les cheminees possedent & leur base un disque de rupture qui, ' en cas de ruine de la cheminee avec obstruction - du conduit, eclaterait et permettrait le fonctionnement du moteur diesel. Tous les materiels dont la masse et les dimensions permettaient le passage sur table vibrante & la $0PEHEA ontTRICASTIN, le spectre subi une qualification plus
?
directe, 2 spectres etant pris en compte : ! contraignant, et le spectre des 8 autres sites 00 sont implantees des ,
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tranches REP 900 MW. Les autres materiels et les reseaux de tuyauteries ont 6t6 qualifies par le calcul. *
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I l N01E D'E1UDE indice i tDF E.N.H./MA B8.063 A Pa$e 6/ 0 L stMEN [ l DOSSIER DE SulVI DE QUALIFICA110H (DSQ) GROUPES ELECTROG t l L' ensemble des dossicr$ relatifs 4 la qualification sismique se trouvela chargei 4 la Region d'Equipement Alpes F.arsellie 4 j Electricite. . I
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Les calculs de qualification ne peuvent pas avoir la coherence mathe. ! matique qu'on est en droit d'attendre sur les paliers plus recents. En , effet, le moteur UD 46 n'a pac 6te mod 6)(c6 & sa enneeptian et ses i pl6ces des materlaux principales ont fait l'objet de calculs de simple resista i calevis faits sont aussi complets que possible et il serait difficile j de vouloir les pousser plus loin. , i 3.2 . Qualification f onctionnelle 1 3.2.1 - hui de 600 (tmerrges, pratiqvt i Krymmti WA) i du 11/06/1980 av 11/12/1980 ! ;
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Un groupe electrogene UD 45 (AGO V 16) a subi 600 d6m . demarrages et les prises de charge ont 6te realists dans les condi-tions normales de fonctionnement en secours en centrale. , Le bon 6 tat du groupe a ett constate apres d6 montage. , I ' Les organismes suivants ont participe aux essais et & l'examen contre.
- dictoire apres demontage :
l l.
- Bureau Veritas I . TUV Norddeutschland
- TUV Stuttgart .
- Germanischer tioyd . ,
- KW 1
- SACM ,
Les rapports d'essais sont conserves d'une part dans le " bunker
- archives,, de la centrale de Krummel, RFA, d' autre part & Mulhouse a la '
SACM, oD 1'exemplaire confidentiel peut etre consuite (voir lettre 4 SACH & SEPTEN UD - 88/153 EP/EF du 25/03/1988) 3.2.2 - Essais, d,'endur,ance prat,1(ves ,en ,1977, ,et, }928, 4, Ge,nneyil,11ers sur , grou2' UD 45,AG0,V,20 l Les essais suivants ont ete pratiques par le Service de la Production Thermique, le SEPTEN et la Direction des Etudes et Recherches :
- Controle vibratoire : Essais Rapportfaits en decembre n*78.43.78.277 du GRPT 1977 '
l
-)
Region Parisienne )
- Essais de survitesse, prise de charge et d61estage :
Rapport n'78.43.78,248 du GRPT~ ; de la Region Parisienne '
)
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as 6 *,w. . EXPi* SPT, D fmTER8EL .. i f i . Indice f'*', ID' N01E D'E1UDE A Pa$e 8/ 0 , [ { ssp 1sN E.N.M./MA 88.063 DO5SIER DE SU1VI DE QUALIFICA110N (05Q) GROUPE5 ELECTROGENE : I i I La modification apportee aux bielles a donc ete agreet. Les documents principaux suivants, disponibles av $EPTEN,, font le . point sur ces estats : l
. Note Technique SEPTEN E SE FA B2.48 A du 12/01/1983 t
! I
- Expertise n' 448 DL 1 du 16/08/1982 (document SACM) ;
822 074 A du ~
- Rapport de contr61e du Bureau yeritas de Matt n' .
27/08/1982. ' ' 5 IV - OUAtlFICA110H DE COMP 05ANi$ $EHQB,L,ES
- 4.1 Bielle), ,
-[ tv po vu s eing vutytve 6v: swt usesset a wLe Juve Sv e s e nouenceit hetseva
, pour que le SEPT [N confie 4 la Otrection des Etudes et Rech
- V:- UD 45, calcui qui, & l'origine, n'avait cas 6t6 falt par le construe- .
teur SACM.-
' t.e calcui a montre que le nouveau dessin' des bielles 6talt satisfat-sant.
te document suivant, disponible au $EPTEN, fait le point sur la . k question
. Note Bertin N186 Ch 01 du 10/02/1986.
4.2 - Segments , L' analyse des incidents survenus sur la segmentation a conduit E0r A deux sortes d' actions preventives. 4.2.1 Chgix d'un, combustible,4 haut indice,de cetane Des essais faits & Chinon en 1986 ont montre que la pression maximle - atteinte dans un cylindre de moteur UD 45 passe de 137 bar bar avec pour un un combustible 6 indice de cetane sup6rieur 6 48 4 270 ' combustible 6 indice de c6tane de 411 or la Pression Maximalej normale est de 140 bar. Voir document SACM DL1028/86 du 15/09/1986, disponible a SACM et au SEPTEN. s Ce r6sultat a conduit & generaliser pour tous les groupes 61ectrog6net . de secours le gazole OTAN F 54, dont l'indice de c6tane 16 gal es , suptrieur & 48(51/52 enmoyenne). .
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; l EDF N01E D'E100E Indice Page * '
A 7/10
- StritN E.lt.M./MA 88.063 i
00551ER DE SU!VI DE QUAtlFICAll0li (050) GROUPES ELECTROGENES D t de 1000 >; Essais en r6gime dynamique comportant un fonctionnement
,l bevres du 8/06/1978 au 26/06/1976 :
3 periodes de marche continue separtes chacune par un arr6t ont 6te
.f f execut6es : ;
- 60 h 4 3,5 MW puis arret de 5 h 1
$0 h n 4 MW puis 400 h n 3,5 MW et arret de 5 h :
- 490 h 4 3,5 MW. .
I s
. Les essais d' endurance font l'ob,iet du rapport 78.43.78.257 du GRpT !
de la Region l'arisienne. t
- Enfin ont 6t6 ex6 cutes des essais de prise de charge et de d6 charge en reseau separe: rapport n' 78.43.78.261 du GRPT de la Region Parisienne.
Tous its procts verboux sont dispvnibits av SEPTCH, qui n'eLell 41 stye de l'organisation des essais. Ces essais se sont deroules de f acon I satisf aisante. Une soupape d'6chappement a ett endomagee 1 apres - > modification. ce genre d' incident ne s'est plus manifeste sur les moteurs en exploitation. , t 3.2.3 - Essai de,1500 deprrages,,pratigu) 4 Cruas i A la suite d'une rupture de bielle et de fissures de bielles survenues ,
& fessenheim puts 4 Bugey un essai d' endurance de 1500 demarrages ,
, consecutifs a 6t6 execute 4 la centrale de Cross. i Le but de cet essai etait double t l . ( tester si l' amelioration apport6e aux bielles (diminutior de la concentration de contraintes & un conge de raccordement) apportait une amelioration decisive dans les conditions les plus dures suppo- ' rtees par l'embiellage.
- tester si l' influence d'un grand nombre de demarrages 6 tait ou non un facteur determinant dans les incidents observes. "
Les essais ont 6te effectues en Avril-Mai 1982, puis le moteur essayle6 est retourne en usine et un examen contradictoire a eu lieu 25/06/1982. Contrairement aux essais de demarrage pratiques. & Krummel, le moteur ,, ne revenait pas & l'6 tat thermique de veille entre chaque demarrage. Les resultats globaux ont 6te les suivants :
- tous les demarrages ont 6te reussis 1 e
- toutes les pieces, apres examen, etaient dans les tolerances' d s pieces neuves, sauf les segments coup de feu trouves 6callies, et lee dispositifs de lancement qui avaient subi l'usure nonnale & attendr apres 1500 d6marrages.
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34 A **v-vo-- EXPr'SPT D.rtATEU EL tor Wii D't1VPL Indice Face ,
. 7'. A 9/10 ,.
. stMcN , I.H.Ji./M 40.063 .
00551ER DE SulVI DE QUAllflCA110N (05Q) GROUPE5 ELEC1ROGENES D
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4.7.2 . Qualificat!on d'une huile n long,pouvo!:,d'accroghtgg Partant de la constatetton qu'une hulle moteur traditionnelle ne reste pat accrochco tur los paroit d'uno chomico de moteur diesel au dell tf'une periode d'arrit 'd'une semaine i dix jours . temps largement
- inferieur 8 l'intervalle de 30 jours entre essais periodiques .. le
$EPIEN et ELF ont d6montre la possibilite de qualifier une hutie moteur pouvant maintenir un film d'huile sur les chemises pendant 30 ,
jours, film pouvant assurer un demarrage dans des conditions normales de graissage, On aurait donc une amelioration supplementaire, non strictement necessaire, mais tout de mim fort interessante.' . t I'$utkeest at en'uNR h6 I EdI fe N dkr N
- cette huile qualifi6e pour 720 h. Des essais sur moteur ont per '
ailleurs montr6 que ce lubrifiant etait parfaitement satisfaisant. Le Service de la Production thermique a - 6 titre experimental - de:idt d'utiliser cette huile sur le moteur du GUS de Cruss pendant une annte avant d'envisager une eventuelle generalisation. La description de qualification et les resultats sont donnes dans les -
- documents ELF :
<- "Lubrifiants pour groupes de secours des centrales nucleaires - ;
premiere partie, etude de laboratoire" et "deuxieme partie, Essal ' moteur PC 2 5". Ces documents sont disponibles au SEPTEN. y . FABRICATION EN U$lHE i L' opinion que l'on pe'ut porter sur la fabrication en usine chez $ACM ' et son sous traitant Hennequin, installateur des auxiliaires est globalenen'. f avorable. L' absolve necessite d'identite aux materiels modtle s'est imposee progressivement. Le debut des f abrications date de 1977, epoque 00 ce souci itait nioins evident tant chez les constructeurs qu'& EDF : les mises 4 niveau - n6cessaires ont eu lieu : de bons exemples sont constitues par les bielles, modifiees sur tous les groupes, par les injecteurs d'huile ' dont la fixation a 6tt reprise sur tous les groupes, par les soupapes. I l
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' EDF NOTE D' ETUDE A 10 l0 STHEN (.N.F./MA 88.063 t
,e DOSSIER DE SUlVI DE QUAllFICATION (DSQ) GROUPES EL !
C0riCLUS10NS {[ [. 4 e
. Les actions de qualification mentes sur les groupes elec '
ji culierement nombreuses. i! (
. La partie *calcul" de la qualification sismique represente l' optimum compte tenu des elements disponibles sur le moteur diesel proprement . ;
dit. ,
- l L.'. experience d.u...constructeur est parmi les plus impor
. ,1
. . . .. r . . m .. 4 .. !
- Le combustible utilise est le meilleur de sa cattgorie sur le marche
- l national. !
t Tout cect conduit & une situation globalement saine que deux types d' actions pourraient encore eventuellement amtliorer : ,
- generalisation d'une huile 4 long pouvoir daccro l
. qualification et installation d'un nouveau ty1e de regulateur ~' J capable de limiter 4 des valeurs tres faib'es les survitesses t
d6marrage Starting) : et de se preter 8 des procedures de "demar - ressort du service de la Production Thermique. ' Nous proposons donc de considerer que les groupes electrogenes diese
& moteur SACM UD 45 et leur environnement mecanique et tiectrique ont i subi un ensemble suffisant d'epreuves avec de bons resultats et qu'ils sont donc qualifits pour le service demande.
t h h v i t WV11
E.N.M/MA 00.voJ A cnotit pens 4 v. .. '_Trehslation of EDF Docucent Ref: datod 20 July 1988 DIESEL GEN SET QUALIFICATION REPORT . Date: 20 July 1988 Ref : E.N.M/MA 88.063 A CMo/VF I I Department: MATERIELS Number of pages : 10 Author (s): C. MORZELLE , Type of plant concerned: REP 900 MW Number of annexes:
Title:
DIESEL GEN SET QUALIFICATION REPORT 1 I Type of document: TECHNICAL REPORT Rsference (key-words): Summary: This report is the synthesis of tests and analyses which permit a conclusion regarding the qualification of the REP 900 MW plant diesel gen sets. 1 I I I COPYRIGHT EDF EQT 1988 1
! Archive to FTE: YES Document may not leave from the Directioni 1Accessibilityt RESTRICTED -
ide L' Equipment without a letter or transmittal sheet from the I ltransmitting Department. l I I I _ -- _. . l
l'TranslationofEDFDocumentnet: r.. a . n i n a oo.vva a v.w i . 4- yor . .. I datbd 20* July 1988 DIESEL GEN SET QUALIFICATION REPORT - EDF INTERNAL CONTROL PAGE 4 f i 4 e e 4
E.N.M/MA 80.O'J J A GMD/tr pago a 96 av (
'Tran'sIction of EDF Docu ent Ref: ; ,doto'd 20 July 1988 l DIESEL GEN SET QUALIFICATION REPORT .
I
SUMMARY
l Page , I 4 I - INDUSTRIAL EXPERIENCE OF THE MANUFACTURER i 4 1.1 - Outside the nuclear fields 7 4 i 1.2 - Inside the nuclear field 1 5 II - REFERENCE DOCUMENTS 5 III - OUALI"ICATION ACTIONS 5 3.1 - Seismic auslification 6 3.2 - Functional cualification 6 3.2.1 - 600 start test, carried out at Krummel (Germany) 3.2.2 - Endurance test, carried out in 1977 and 1978 at Gennevilliers on the UD 45 V20 gen set 7 3.2.3 - 1500 start test, carried out at Cruas i 8 IV - QUALIFICATION OF CRITICAL COMPONENTS 8 4.1 - Connectinn Rods 8 4.2 - Rings , 9 4.2.1 - Choice of a fuel with high cetane index 4.2.2 - Qualification of lub oil with lonn adhesion cuality 9 10 V - FACTORY FABRICATION t i 1
)
E.N.M/MA 88.063 A CMo/VF pago 4 or av Tronciation of EDF Docunent Roft
.dctod 20 July 1988 DIESEL GEN SET QUALIFICATION REPORT .
This Qualification Report, DSQ, is applicable to the 900 MW CP1 and CP2 plants diesel standby gen sets and to their associated electrical and mechanical equipment. By extension, it is applicable to the following materials:
- Ultimate Security Standby Sets (with diesel engines) of the CP1
- CPI plants which, due to their more recent date of installation, present, in comparison with the standby sets, some "needed modifications, but of small importance", in the opinion of the report C SC MA 87 044 At " Procedure for composition and administration of mechanical reference materials files 'pumpo, turbi'nes, diesels"
- Diesel standby sets of Bugey and Fessenheim The diesel engines of these power plants are UD 45 V16 (AGO V16) from SACM, while those of the CP1 - CP1 plants are UD 45 V20; due to the fact that the'y have 4 cylinders less, their crankshafts, camshafts and blocks are shorter but geometrically sim11ars their alternators are less powerful; all the remaining material is identical and have benefited from the improvements carried out on the UD45V20 (AGO V20).
The auxiliary electrical material is similar to that of CP1 - CP2 and is installed by the saine sub-contractor of SACM: Hennequin. I - INDUSTRIAL EXPERIENCE OF THE MANUFACTURER 1.1 - Outside the nuclear field Prior to their utilization in the nuclear fisid, the UD 45 engines have been employed largely in railway traction.
- In V16 versions, these engines equip the Series 72 000 SNCF locomotives (91 locomotives, a hundred angines).
- In V12 versions, they equip Series 63 500 locomotives (26 locomotives)
In this type of application, these engines run 800 000 km between two general overhauls.
- Different versions of these engines have equipped for a long time main power stations 1.2 - In the nuclear field Outside of EDF, numerous companies have adopted the UD45 engines l
for their nuclear power plants. These engines exist in Germany, Switzerland, Holland, Finland, Sweden, Spain, Belgium, South Korea; China is going to install sets.and.the United States, i unsidering that SACM is in fact the manufacturer having the l greatest world experience in nuclear power plants, is interested in its products. The European users are part of an "SACM user's , group", which meets every 18 months to exchange experience teedback. , 1
E.N.M/MA 88.063 A CMo/VF page 5 of 10 ucnslation of*EDF Docunent Reft
-dotod 20 July 1988
, DIESEL GEN SET QUALIFICATION REPORT ,
.I - REFERENCE DOCUMENTS The reference documents are:
- CST 76 C 007-00 September 1975 Edition " Emergency gen sets of 4 MW nominal power for nuclear power stations".
This document contains directives for establishment of an Identification File (DI) for the equipment.
- The DI itself, dated 13 Jul 77 and updated 16 Feb 82 is available at SEPTEN and at REAM.
s III - QUALIFICATION OPERATIONS The qualification operations have been conducted in two directions:
- Seismic qualifications it is destined to verify the capacity of the equipment to resist an earthquake, to function during an arthquake and to continue to function after an earthquake.
- Functional qualification The functional qualification operations have as a goal
. to verify the fitness of the equipment to start in the required time of 10 seconds and to take the load in about one minute;
. to verify the fitness of the equipment to undergo numerous start cycles and load steps within a short time to full load;
. to verify its fitness to function during several hundred hours at full load;
. to verify that the modifications carried out have resolved the infancy problems found on the equipment 3.1 - Seismic Qualification Seismic qualification involves the plant diesel gen sets and all its mechanical and electrical auxiliaries with the exception of '
the refilling of the compressed air starting receivers and the exhaust stack. On the other hand, the compressed air receivers are qualified and the exhaust stacks possess at their base a rupture disk which, in case of damage to the exhaust stack with obstruction of the conduit, would burst and permit functioning of the diesel engine. All materials for which the mass and-dimensions-permit testing on a shake table at SOPEMFEA have been submitted to direct the qualification, 2 spectres being taken into accounts TRICASTIN spectra, most constraining, and the spectra of the 8 sites where the REP 900 MW plants are built. The other materials and piping system have been qualified by calculation.
E.N.M/MA 88.063 A CMo/VF page 6 of 10 i Translatien of EDF Docucent Reft - !
~ dated 20 July 1988 l DIESEL GEN SET QUALIFICATION REPORT ,
The group of reports relative to seismic qualification are 2 J located in the Region d'Equipement Alpes Marseille under the responsibility of the Electricity Department. The qualification calculations may not have the mathematical l coherencethe thatUDone 45 expects from the more recent qualifications. engine initially has not been modeled and its ; In fact, ! j principal components were part of simple resistance calculations In all : of the materials (not finite element calculations). i cases, the calculations made are as complete as possible and it would be difficult to imagine pushing them further. , 3.2 - Functional Qualification t 3.2.1 - 600 start test, carried out at Krummel (West Germany) , from 11 JUN 80 to 11 DEC 80 A UD 45 (AGO V16) gen set has' undergone 600 consecutive starts,. with return to cold state between each start. All the starts and loadings have been carried out under the normal functioning , conditions during an emergency at the plant. The good condition of the gen set has been established after , disassembly. The following organizations have participated in the tests and the cross-examination after disassembly
- Bureau Veritas '
- TUV Norddeutschland ,
- TUV Stuttgart .
- Germanischer Lloyd
- KWU
- SACM The test reports are kept in one copy at the " archives storage" sf the Krummel station, West Germany, and one copy in Mulhouse at SACM, where the confidential report may be consulted (see letter SACM to SEPTEN UD - 88/153 EP/EF of 25 MAR 1988),
3.2.2 - Endurance tests carried out in 1977 and 1978 at Gennevilliers on a UD 45 AGO V20 - The f ollowing tests have been carried out by tile Thermic Production Department, SEPTEN and the Studies and Research , l Department l l
- Vibration monitoring: Starts made in December 1977 Report no. 78.43.277 of the Paris Region -
GRPT
- Test of overspeed, loading and unloading: :
Report no. 78.43.78.248 of the Paris i Region GRPT
~
- Tradslation o~f EDF Docu:ent Ref t E.N.M/MA,88.063 A CMo/VF pago 7 ot 10 dated 20 July 1988 DIESEL GEN SET QUALIFICATION REPORT ,
- Test under dynamic loading comprising 1000 hour operation from 8 JUN 1978 to 26 JUN 1978:
i 3 periods of continuous operation each separated by a stop have been executed: l
- 60 hrs, at 3.5 MW then stop of 5 hours ,
- 50 hrs. at 4 MW then 400 hours at 3.5 MW and stop of 5 hrs.
- 490 hrs at 3.5 MW f l
- The endurance tests are the subject of report 78.43.78.257 of :
the GRPT of the Paris Region, ; 6 i ~
- Finally, some separate tests of loading.and unloading on the :
grid have been executed: report no. 78.43.78.261 of the GRPT ! of the Paris Region ,
- All the verbal proceedings are available through SEPTEN, which j was in charge of the organization of the tests. These tests One exhaust valve was damaged; 1
- took place satisfactorily. after modification, this type of incident is no longer present ! on the engines in operation. 3.2.3 _1500 After a start tests carried connecting out atand rod rupture Crues unexpected appearance of connecting rod fissures at Fessenheim, then at Bugey, an endurance test of 1500 consecutive starts has been executed at ! the Cruas station.
. i The goal of this test was two part .
- to test if the improvement employed on the connecting rods (reduction of stress of a junction collar) resulted in a decisive improvement under the most severe conditions experienced by the connecting rod
- to test if the influence of a large number of starts was or t was not a determinative factor in the observed incidents The tests have been carried out in April-May 1982, then the tested engine was returned to the factory and a cross-examination took place on 25 June 1982. -
l Contrary to the starting tests carried out at Krummel, the engine did not come back to the previous thermic state between each start. , The overall results were the'following ,
- all the starts were successful; .
- all the parts, after examination, were within the tolerances of new parts, except the firing rings found scaly, and the ;
starting devices which had sustained the normal wear after.1500 starts.
-e ,, - - ~ -
E.N.M/MA 88.063 A CMo/VF pogo 8 of 10 -l
'Trahslatien of EDF Docucent Ref t
' dated 20 July 1988 DIESEL GEN SET QUALIFICATION REPORT . l The modification employed on the connecting rods have thus been l agreed upon. The following principle documents, available at SEPTEN, state the i position on the tests: '
- Technical note SEPTEN E SE MA 82.48 A of 12 Jan 1983;
- Survey no. 448 DL I of 16 Aug 1982 (SACM document); l
' i
- Inspection report of Bureau Veritas of Metz no. 822 074 A of 27 Aug 1982. .
IV - OUALIFICATION OF CRITICAL COMPONENTS . 4.1 - Connectinn Rods The problem observed on the connecting rods has been judged to , be sufficiently serious that SEPTEN requested the Studiesa and Research Department and the Bertin Company to carry out - finite element calculation on the UD 45 engine connecting rods, a calculation which, in the beginning, has not been made by the ' manufacturer SACM. The calculation showed that the new design of connecting rods , was satisfactory. The following document, available at SEPTEN, states the position on the question: ,
- Note Bertin NT 86 Ch 01 of 10 Feb 1986. ,
( 4.2 - Rings , The analysis of the incidents unexpectedly occurring on the ring was conducted by EDF with two sorts of preventative actions. t 4.2.1 - Choice of a fuel with high cetane index Some tests made at Chinon in 1986 have shown that the maximum pressuce attained in a UD 45 engine cylinder passes from 137 bar with a fuel of cetane index greater than 48 to 270 bar for
- a fuel with a cetane index of 41;-but the normal Maximum Pressure is 140 bar.
SeeSACMdocumentDLId28/86of15Sep1986,availableatSACM , and at SEPTEN. This result has lead to standardizing f or all emergency gen
- sets the diesel fuel OTAN F 54, for which the lawful cetane index is greater than 48 (51/52 on the mean). <
E v.-.
E.N.M/MA 88.063 A CMo/VF page 9 ot 10 dlation of*EDF Document Ref: yd 20 July 1988 )EL GEN SET QUALIFICATION REPORT , l L 2.2 - Qualification of lub oil with long adhesive properties l Proceeding from the findings that a traditional engine lub oil does not adhere to the inner valls of a diesel engine liner beyond a stopping period of a week to 10 days - time greatly , SEPTEN less than the 30 day interval between periodic tests and EDF have demonstrated the possibility of qualifying an engine oil able to maintain an oil film on the liners during 30 days, film able to assure a start in normal lubricating conditions. One would then have an additional improvement, not strictly necessary, but all the same.very interesting. An oil has been qualified - ELF DISOLA Special Emergency Gen Sets - the oil film is maintained 1050 hours and it has been Some decided to consider this oil qualified for 720 hours. tests on the engine have moreover shown that the lubricant was perfectly satisfactory. The Thermic Production Department has - as experimental qualification - decided to utilize this oil on the engine of the Ultimate Security Standby Set of Cruas during one year before considering an eventual standardization. The qualification description and the results are given in the ELF documents:
- " Lubricants for emergency gen sets cf nuclear power stations
- first part, laboratory study" and "second part, Engine test PC 2-5".
These documents are available at SEPTEN. _ V - FABRICATION IN THE FACTORY The opinion regarding fabrication at the SACM factory and its sub-contractor Hennequin, auxiliaries installer, is favorable overall. The absolute necessity of identity of the design materials is imposed progressively. The beginning of fabrication dates from 1977, an era when this , care was much less evident at manufacturers than at EDF: the necessary balancing of these has taken place : good examples given by the connecting rods, modified on all gen sets, by the lub oil injectors for which the fitting has been renewed on all gen sets, by the valves.
olation od EDF Document Ref: E.N.M/MA 88.063 A CMo/VF page 10 of 10 6 20 July 1988 lEL GEN SET QUALIFICATION REPORT , 1 CONCLUSIONS
- The qualification operations conducted on the diesel gen sets 4 of the REP 900 MW plants and on their auxiliaries have been particularly nunerous. . . .
- The " calculation" part of the seismic qualification represents j the optimum taking into account the available elements on the ;
~
g engine itself
?
- The experience of the manufacturer is among the greatest in the _
world in this type of utilization 4
- The fuel utilized is the best from its category on the national market.
All of this leads to an overall safe situation which two types of ~ actions would eventually still be able to improve:
- standardization on a lub oil with long adhesion property on all -
gen sets (subject to good experience on the Ultimate Security " Standby Set of Cruas), e .
- qualification and installation of a new type of governor capable of limiting to very small values the overspeeds at starting and to lend itself to some procedures for " soft starting" : this study, if it is judged necessary, would be .
4 from the Thermic Production department.
- We propose thus to consider that the diesel gen sets with SACM UD 45 engines and their auxiliary mechanical and electrical equipment have undergone a sufficient group of tests and examinations with good results and that they are thus qualified .
for the service intended. -- 4
.s.
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