ML20043F670

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Training Material for E-111 Emergency Diesel Generator Course, Instructor Manual (3-16), Table of Contents
ML20043F670
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Issue date: 02/12/2020
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Office of the Chief Human Capital Officer, Woodard Corp
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Gary Callaway
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Emergency Diesel Generator Instructor Manual EMERGENCY DIESEL GENERATOR COURSE INSTRUCTOR MANUAL TABLE OF CONTENTS CHAPTER CONTENTS PAGE 0 Introduction to the Course 3 Introduction to the Training School Facilities, with Walkaround Session 1 4 1 Diesel Generators as Emergency Power Sources 5 2 Introduction to Diesel Engines 6 Walkaround Session 2, Introduction to Diesel Engines 7 3 Diesel Engine Construction 11 H-O Session 3A, Crankshaft(s)-Bearings, End Float, Web Deflection, and Vibration Damper 13 H-O Session 3B, Pielstick Engine Cylinder Heads, Valve Operating Mechanisms, Cylinder Water Jacket, Main Bearings, Piston, and Connecting Rods 15 H-O Session 3C, Engine Crank-Lead and Fuel Injection Timing for the OP Engine 18 4 Combustion Air, Fuel, and Exhaust Systems 22 Walkaround Session 4, Combustion Air, Fuel, and Exhaust System 25 H-O Session 4A, Combustion Air Turbochargers, and Scavenging Blowers 27 H-O Session 4B, Fuel, Injection Pump, and Fuel Injection Nozzles 29 5 Engine Lubrication System 31 Walkaround Session 5, Engine Lubrication System 33 Rev 3/16 1 USNRC HRTD

Emergency Diesel Generator Instructor Manual TABLE OF CONTENTS - (CONTINUED)

CHAPTER CONTENTS PAGE 6 Engine Cooling Systems 35 Walkaround Session 6, Engine Cooling Systems 37 7 Diesel Engine Starting Systems 39 Walkaround Session 7, Direct Air Injection System 41 8 Diesel Engine Controls and Governing 43 Walkaround Session 8 45 9 Generator, Exciter, and Voltage Regulation 47 Walkaround Session 9, Generator, Exciter, and Voltage Regulation 49 10 Emergency Diesel Generator Control and Monitoring 51 11 EDG Testing and Monitoring 53 12 EDG Performance Monitoring and Maintenance 54 13 Emergency Diesel Generator Case Studies 56 14 Some Other Engines 58 Rev 3/16 2 USNRC HRTD

Emergency Diesel Generator Instructor Manual INTRODUCTION TO THE COURSE 0.1 Learning Objectives

1. To become acquainted with the instructors, each other, and the training school facilities.
2. To gain an overview of the planned course presentation methodologies and schedule.

0.2 Instructor Presentation

  • Introduction of staff and students.
  • Provide an overview description of the course including objectives, course presentation methodology, description of facilities, security regulations, other administrative details, attendance sheets, and student course evaluations.
  • Discuss facilities to be used, smoke-free status, safety regulations, first aid equipment present, accident reporting, personal protective equipment for labs (Hands-On sessions), tornado alarm and response to shelter, fire alarm and evacuation to muster location, notice that weekly drills are conducted.

0.3 Student Handouts

  • Students complete filling out Student Information sheets that were provided as they entered the classroom, and pass them for collection.

0.4 Student References

  • Instructor Manual
  • Introduction PowerPoint slide show presentation
  • Supplementary Course Materials: course schedule, local area information, etc.
  • Fairbanks Morse Training School facilities Rev 3/16 3 USNRC HRTD

Emergency Diesel Generator Instructor Manual INTRODUCTION TO THE TRAINING SCHOOL FACILITIES 1.0 Learning Objectives Conduct a walkaround narrated tour of the training school, of its diesel engines, major engine components and assemblies, test stands, and equipment to enable students to:

1. Gain a basic understanding of the 2- and 4-stroke cycle diesel engine construction, components, assemblies, and systems.
2. Gain a basic understanding of the relationship of these components and systems to each other and the way they operate to produce output horsepower.

1.1 Instructor Presentation The instructor will conduct a walkaround narrated tour in which he identifies and describes the following:

  • Motorized, rotatable cut-away of the 2-stroke cycle Opposed Piston (OP) engine
  • Motorized, rotatable cut-away of the 4-stroke cycle ALCO engine
  • Non-motorized OP engine with air distributor, operable emergency trip mechanism
  • 16-cylinder ALCO engine with accessories, open inspection ports, partial cutaways
  • Two cylinder section of a 4-stroke cycle Pielstick PC2.5 engine, with cutaways
  • Components for various large diesel engines including turbochargers, scavenging blowers, pumps (fuel transfer, fuel injection, lube oil, and jacket water), cylinder head assemblies, pistons, governors, injection nozzles, duplex filters, crankshafts, connecting rods, bearings, flexible drive gears, vibration dampers
  • High pressure fuel pump and injection nozzle test stands for fuel spray tests
  • Various failed engine components, to illustrate damage and causes
  • EDG generator with its covers removed to show internal components 1.2 Student References
  • Instructor Manual
  • Fairbanks Morse Training School facilities Rev 3/16 4 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 1 DIESEL GENERATORS AS EMERGENCY POWER SOURCES Classroom Instruction 1.1 Learning Objectives Effectively present Chapter 1 materials to enable students to understand the following:

1. The regulatory basis for NPPs to have redundant power systems (onsite, offsite), and key criteria applicable to them.
2. Three fundamental performance requirements for EDGs. (Instructor: Contrast with the three broad design attributes of Independence-Redundancy-Testability.)
3. Why diesel engines are used as prime movers for EDGs, instead of other engine types. (Instructor: Contrast with other engines such as gasoline, gas turbine.)
4. Overview of key regs, codes, guides, standards that apply to emergency power systems, and how they're used by licensee.
5. The Major components of a diesel generator system. (Instructor: Using Figure 1-1 is an opportunity to make brief comments about various parts of the system, to clarify their function and / or mention case histories that will be covered in later Chapters.)

1.2 Instructor Presentation The instructor will make a 22-slide PowerPoint presentation developed from Chapter 1 learning objectives, text, and illustrations. This begins with an overview of basic NRC regulatory requirements for NPP redundant emergency power systems. Fundamental performance requirements for EDGs are described and related to core protection criteria.

An overview of applicable Codes, regulations and industry standards including 10 CFR 50, RG 1.9, and IEEE 387 will be given. Licensee use of these documents in Safety Analysis Reports, Technical Specification, operating procedures, and other commitments will be discussed. The question, Why is the Diesel engine used instead of other types of prime-movers? will be answered. Finally, the component parts of an EDG system including its support systems will be reviewed, illustrated by a block diagram, and discussed.

1.3 Student References

  • Instructor Manual
  • Chapter 1 PowerPoint slide show presentation (22 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 5 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 2 INTRODUCTION TO DIESEL ENGINES Classroom Instruction 2.1 Learning Objectives Effectively present Chapter 2 materials and conduct Walkaround instruction to provide an introduction to (see, touch) EDG components and assemblies, to enable the students to:

1. Explain the basic energy conversion process involved in operation of a diesel engine.
2. Differentiate the operating principles of 4-stroke versus 2-stroke cycle diesel engines.
3. Identify selected basic terms applicable to the design and operation of a diesel engine.
4. Describe the basic heat/power balance that exists during operation of a diesel engine.

2.2 Instructor Presentation The instructor will make a 52-slide PowerPoint presentation developed from Chapter 2 learning objectives, text, and illustrations. This presentation will illustrate and explain the items below. Then, to reinforce this theory, Walkaround 2 will be conducted following the classroom PowerPoint presentation.

  • The combustion process
  • How chemical energy in fuel oil is converted to heat but not work;
  • How combustion is achieved in a diesel engine and converted into shaft output HP
  • Heat in-heat out balance in a diesel engine
  • Differences in the design and construction of the 2-stroke cycle OP engine vs. the 4-stroke cycle ALCO engine. Likewise for the OP and the EMD 2-stroke cycle engine.
  • Typical features of the 4-stroke cycle Pielstick engine
  • Engine design parameters, such as BHP, Torque, BMEP, displacement, speed (RPM and piston speed) and the relationships between these factors.

2.3 Student References

  • Instructor Manual
  • Chapter 2 Power Point slide show presentation (52 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 6 USNRC HRTD

Emergency Diesel Generator Instructor Manual WALKAROUND SESSION 2 INTRODUCTION TO DIESEL ENGINES 2.0 Introduction This walkaround session will be coordinated with the classroom presentation of Chapter 2.

2.1 Learning Objectives Effectively present the rotatable cutaway 2-stroke cycle OP engine and rotatable cutaway 4-stroke cycle ALCO engine and their associated components, to enable the students to:

1. Identify major features of the 2-stroke cycle OP and 4-stroke cycle ALCO engines.
2. Identify the primary systems and components of the OP and ALCO engines.
3. Understand function of primary features and components of OP and ALCO engines.
4. Operate the rotatable cutaways for self-learning.

2.2 OP Engine Rotatable Cutaway Explanation The instructor will first use the rotatable Fairbanks Morse Opposed Piston 2-Stroke Cycle engine. Each power train component will be identified in its stationary position. The engine will be slowly rotated and periodically stopped as the instructor explains how each system and component is functioning and its purpose. Slow rotation-stop-explain presentations will continue until the engine has completed its 2-stroke cycle. This will be repeated until all student questions have been answered and comprehension seems assured.

The instructor will move the students to the cutaway rotatable 4-stroke cycle ALCO engine.

The same sequence of instruction will be conducted as on the OP engine.

Using the Operating Display Models (Cutaways), demonstrate the operation of the engine, including its crankshaft, connecting rod and piston motion, opening and closing of air and exhaust ports, and timing of the engine events. Point out specific concepts in each engine:

1. Uniflow air through the cylinder
2. The oil path into the engine, through the main bearings, into the connecting rod bearings, up through the connecting rod drilling, into and through the wrist pin bearing and into the piston for cooling of the under crown on the piston. Point out the concept of cocktail shaker action, used in most diesel engine piston crown cooling.
3. Explain OP engine crank-lead: The lower crankshaft is ahead of the upper crankshaft in reaching its inner most and outer most positions. Crank-lead controls engine timing by controlling the points air intake and exhaust ports open and close. Explain the six events in each engine cycle, determined by piston motion in the cylinder, as follows:

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  • Exhaust ports open to expel the burnt gases
  • Air ports open to bring in fresh air charge to scavenge exhaust from cylinder.
  • Exhaust ports close to trap the air in the cylinder. The period of time between exhaust ports closing and air ports closing supercharges the cylinder to intake manifold pressure.
  • Piston compression of the air charge in the cylinder, sufficient to ignite the fuel.
  • Injection of fuel as the pistons approach inner dead center.
  • Combustion pressure in the cylinder cause the pistons to be forced outward during the power stroke. The power stroke ends when the exhaust ports open, allowing the cycle to begin again.
4. Point out that the events described above occupy only one revolution of the engine crankshaft and 2 strokes of the piston (therefore a 2-stroke cycle engine).
5. Show the injection pump, tappet assembly, and the injection nozzles. Show how the fuel rack positions the injection pump plunger to control the amount of fuel injected into the cylinder through the injection nozzle. Show the relationship of the cam shaft to the tappet housing.
6. Point out the other items attached to the cylinder liner, such as the water inlet and outlet connections, air start valve, and cylinder test cock.
7. Show the piston rings and explain how compression rings seal the combustion space and oil rings control the distribution and consumption of oil in the engine cylinders.
8. Using the non-motorized OP engine with front compartment cutaway, show the governor control system that positions the fuel injection pump racks. Also the air-start distributor with its supply from the starting air header and how its rotation connections supply pilot air to sequentially open each cylinder air-start check valve, for starting.

Show the camshaft timing chain and its adjustments, plus the over-speed governor assembly and how it trips to shut off fuel to the engine when an over-speed occurs.

Using the ALCO 4-stroke Cycle Engine Operating Display Model (Cutaway), demonstrate operation of the ALCO engine, including its crankshaft, connecting rod and piston motion, openingclosing of the air and exhaust valves, and the timing of the engine events. Point out specific 4-stroke cycle concepts of this engine design:

1. The oil path into the engine, through the main bearings, into the connecting rod bearings, up through the connecting rod drilling, into and through wrist pin bushings and into the piston for cooling under its crown, similar to the OP engine.
2. Explain the cam shaft and its relation to the crankshaft. The camshaft controls the timing of the engine by controlling the points at which fuel injection occurs and the air intake and exhaust valves open and close. Explain events in the engine cycle by the motion of the pistons in the cylinder. They are as follows:

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  • Air valve opens when the piston is at its top dead center (TDC) to bring in the fresh air charge and allow air to scavenge the cylinder of the exhaust products.
  • Exhaust valve closes and air is pulled into the cylinder as the piston moves toward bottom dead center (BDC). If engine is turbocharged, the cylinder is supercharged during this process.
  • Air valve closes when the piston is at BDC, to trap the air in the cylinder.
  • Compression of the air charge, as the piston moves toward TDC, to a temperature sufficient to ignite the fuel.
  • Injection of fuel as the pistons approaches TDC.
  • Pressure in the cylinder causes the piston to be forced outward during the power stroke. The power stroke ends when the exhaust valves open near BDC.
  • Piston travels to TDC and in the process pushes the spent exhaust gases from the cylinder, allowing the cycle to begin again.
3. Point out that the events described above occupy two revolutions of the engine crankshaft with 4 strokes of the pistons (therefore a 4-stroke cycle engine).
4. Show the injection pump, valve tappet assembly and the injection nozzle. Show how the fuel rack positions the injection pump plunger to control the fuel injected into the cylinder through the injection nozzle. Show the relationship of the cam shaft to the valve tappet housing.
5. Point out the other items attached to the cylinder liner and cylinder head, such as the water inlet and outlet connections and the cylinder test cock.
6. Show the piston rings on the piston and explain how the compression rings seal the combustion space and how the oil rings control the distribution and consumption of oil in the engine cylinders.
7. Show the engine governor and the over-speed governor assemblies and how they tie into the fuel control system. Explain the gear drive between the crankshaft and the cam shaft and point out the fact that the camshaft turns at half engine speed (4-stroke cycle engine).

During these demonstrations, cover the following points:

1. Barrel Faced compression rings, typical
2. Chrome Plating on Piston Crowns
3. Crankshaft balance weights
4. Compression ratio Turbo engines versus non-turbo
5. Typical compression and firing pressures, and fuel ignition temperature
6. Need for cooling the intake air on Turbocharged engines Rev 3/16 9 USNRC HRTD

Emergency Diesel Generator Instructor Manual Using other display models and cutaways, show and discuss the following items:

1. Typical lube oil pump assembly with relief valve
2. Typical Water Pump assembly, including seals and tell-tale drip port
3. Typical Fuel pump and Fuel Injection Pump assembly/parts (jerk pump)
4. Typical Turbocharger assembly
5. Typical OP blower assembly
6. Various types of Torsional Damper assemblies
7. Flexible drive gears to minimize shock loading 2.3 Student References
  • Instructor Manual
  • Motorized models of the cutaway OP and ALCO engines
  • Non-motorized OP engine with front cutaway
  • Major components and assemblies including the following:

Lube oil pumps Water pumps Fuel oil pumps Turbochargers OP blowers Torsional dampers

  • Fairbanks Morse Training School facilities Rev 3/16 10 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 3 DIESEL ENGINE CONSTRUCTION Classroom Instruction 3.1 Learning Objectives Effectively present Chapter 3 materials then conduct Hands-On to enable students to:

1. Describe the basic construction and identify the loads imposed on the structural components of a diesel engine.
2. Describe the basic construction and function of major rotating and reciprocating components of a diesel engine.
3. Describe the basic construction and state the function of the cylinder head, valves, and related components of a diesel engine.
4. Describe the basic construction and the purpose of camshafts, cam followers, and valve operating mechanisms.

3.2 Instructor Presentation The instructor will make a 52-slide PowerPoint presentation developed from Chapter 3 learning objectives, text, and illustrations. It will include the dynamic forces created by combustion and power train operation, and the engine containment structures and components which resolve these forces to permit reliable production of shaft output HP.

The instructor will present and discuss the following topics:

  • The magnitude of the dynamic forces created by combustion peak firing pressure in an engine cylinder
  • The balancing / offset of combustion in other cylinders of a multi-cylinder engine
  • The inertial effect of rotating engine and generator components on resolution of forces
  • How engine structure and structural components contain and resolve the dynamic forces and loads to produce shaft output power
  • The magnitude of peak combustion temperatures in an engine cylinder
  • How the high combustion temperatures are contained and resolved by the engine as shaft output horsepower and waste heat.

To put classroom theory into practice, the instructor will use engines and components in the school in conducting Hands-on (H-O) Sessions 3A, 3B, and 3C.

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Emergency Diesel Generator Instructor Manual 3.3 Student References

  • Instructor Manual
  • Chapter 3 Power Point slide show presentation (53 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 12 USNRC HRTD

Emergency Diesel Generator Instructor Manual HANDS-ON SESSION 3A CRANKSHAFT(S) - BEARINGS, END FLOAT, WEB DEFLECTION, AND VIBRATION DAMPER 3A.0 Introduction This hands-on session will be coordinated with the classroom presentation of Chapter 3.

3A.1 Learning Objectives Effectively present Session 3A materials using the OP operating model cutaway engine and display models of major engine components and assemblies to enable the students to understand:

1. Where the crankshaft is located and how it is supported in the engine on its bearings and their support structures.
2. Functions of engine bearings including their assembly, disassembly, and measurements.
3. Crankshaft loading, motion, and proper alignment.
4. Torsional vibration and how vibration dampers work.

3A.2 Instruction Presentation Engine Bearings and Crankshaft End-Float and Deflection Show examples of the various bearings in the Opposed Piston Engine. Most main bearings are of the same design. Some are special to meet the specific requirements of the engine. The engine has a thrust bearing on each of the crankshafts. These require special treatment and must have a clearance in order to operate. These bearings increase in clearance over time as they or the engine crankshaft wears. It is necessary to check for the clearance (end-float) in these bearings periodically. Demonstrate and have the students measure crankshaft end float.

The thrust bearings also control the back-lash in the vertical drive gear train. Excessive wear in the bearings results in excessive wear in the vertical drive gears due to increasing gear backlash. Demonstrate the method to determine the gear backlash. Have students measure the backlash.

Demonstrate the correct use of a dial indicator and allow students to determine the crankshaft web deflection using a dial indicator installed between the prick marks on the crankshaft webs of the last engine crankshaft throw on the lower crankshaft. Explain the importance of checking the crankshaft web deflection in determining that the engine bearings, crankshaft, and the generator are properly aligned.

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Emergency Diesel Generator Instructor Manual Vibration Damper Assembly Disassemble and reassemble monofiler type vibration dampener assembly. Inspect pins and bushings for wear, excessive galling, etc. Reassemble dampener being sure correct parts are used in matched positions. Explain operation of vibration dampeners in the engine. Observe several types of dampers available in the work and demonstration area.

Some are hydraulically dampened while some while some are dampened with rubber bushings or silicone fluids.

3A.3 Student References

  • Instructor Manual
  • The 6-cylinder OP engine
  • OP Engine Field Service Procedure
  • Major components and assemblies as follows:

Air start distributor and air start check valve Vertical drive gear assembly Vibration dampers Engine bearings Crankshaft web deflection gage

  • Tools and equipment as required
  • Fairbanks Morse Training School facilities Rev 3/16 14 USNRC HRTD

Emergency Diesel Generator Instructor Manual HANDS-ON SESSION 3B PIELSTICK ENGINE CYLINDER HEADS, VALVE OPERATING MECHANISMS, CYLINDER WATER JACKET, MAIN BEARINGS, PISTON, & CONNECTING RODS 3B.0 Introduction This hands-on session will be coordinated with the classroom presentation of Chapter 3.

3B.1 Learning Objectives Effectively present Session 3B materials using the cutaway 4-stroke cycle Pielstick engine and its components to enable the students to understand:

1. The 4-stroke cycle PC cylinder head assembly including its intake and exhaust valves.
2. The PC engine cylinder and water jacket assembly.
3. The PC main bearing assembly.
4. The PC piston and connecting rod assembly.

3B.2 Instructor Presentation Pielstick Cylinder Head, Valves and Operating Mechanism The instructor will demonstrate how the air intake and exhaust valves, located in the cylinder head, operate from the cam shaft on the demonstration stand. Demonstrate how the injection pump is supported by the cam housing and operated by the injection cam on the camshaft.

The instructor will disassemble the exhaust valve housing from the cylinder head, after removing the valve rocker support and rocker arms. Disassemble the exhaust valve from the housing. Remove the intake valve(s) from the cylinder head. Replace gaskets and O rings and reassemble the parts to the cylinder head.

The instructor will discuss the differences between the PC2 and PC2.5 cylinder head assemblies.

The instructor will show the PC4 model cylinder head and disassemble the head in layers to show the complexity of a typical cylinder head casting with its fire deck (the part that sees cylinder pressures/temperatures) and with its passages for cooling water and oil feeds for the rocker assemblies, etc.

The students will disassemble a cylinder head assembly at the direction of the instructor.

This consists primarily of the following steps:

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1. Remove the nuts on the studs that retain the valve rocker arm support. Remove the rocker arm support and its attached mechanism.
2. Remove the nuts on the studs that retain the exhaust valve cages and remove the exhaust valve assemblies.
3. Remove the spring keepers from the top of the intake valves using the spring compressor assembly. Remove the keepers, retainers and springs. Remove the intake valves from the cylinder head.
4. On the exhaust valve cages, use the spring compressor to depress the valve pushrods to the point that the keepers can be removed. Remove the keepers, retainers and springs. Remove the exhaust valves from the cage assemblies.
5. Inspect the parts as required/directed.
6. Reassemble the valves and valve cages to the cylinder head. Reassemble the valve rocker mechanism and torque the nuts and studs as required/directed.

The instructor will also cover valve lash adjustments and other checks using the operational display model of the cylinder head and valve mechanism.

Using the 2-cylinder PC assembly, the instructor will show the flexible drive gears that drive the camshaft from the crankshaft. Discuss how the flexible drive works (a series of springs between the hub and the gear parts, with hydraulic dampening).

Pielstick Cylinder Liner - Jacket Assembly Using the Pielstick 2-cylinder engine, the instructor will show the cylinder liner and jacket assembly fits into the cylinder block and how cooling water enters the liner jacket at the bottom outside edge and proceeds up through and around the jacket and out into the cylinder head assembly through jumpers. The student will observe a cylinder liner and water jacket parts disassembled.

Pielstick Main Bearing Assembly Using the Pielstick engine and a section of the crankcase, the instructor will show how the main bearing are installed into the engine and tell how the bearings are installed and how the bearing cap is torqued or loaded into the crankcase assembly using the hydraulic piston assembly.

The instructor will point out that lube oil is vital not only to lubricate this and other bearings but also to conduct heat away from the bearings.

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Emergency Diesel Generator Instructor Manual Pielstick Piston and Connecting Rod Assembly The students, with the assistance and direction of the instructor, will disassemble a Pielstick 2-piece piston and remove the crown from the aluminum skirt and piston and connecting rod assembly. The following steps are involved: (With the piston crown sitting on the floor)

  • Remove the keeper rings from the ends of the wrist pin, in the piston wrist pin bore.
  • Remove the wrist pin and pull the connecting rod out of the piston.
  • Examine the wrist pin, the wrist pin bushings in the connecting rod and the wrist pin bores in the piston.
  • Remove the nuts from the studs that hold the piston skirt to the piston crown. Pull the piston skirt from the piston crown.
  • Examine the fits on the piston and in the crown. Examine the O seal ring. Examine the oil feed holes in the piston to be sure they are clear.
  • Reassemble the piston to the crown and tighten and torque the nuts.
  • Reassemble the connecting rod into the piston and install the wrist pin and retaining clips. See that the piston moves freely on the connecting rod.

3B.3 Student References

  • Instructor Manual
  • The cutaway PC engine
  • Major components and assemblies as follows:

PC cylinder head, cylinder, and main bearing assemblies for student disassembly PC piston and connecting rod assembly

  • Tools and equipment for student disassembly
  • Fairbanks Morse Training School facilities Rev 3/16 17 USNRC HRTD

Emergency Diesel Generator Instructor Manual HANDS-ON SESSION 3C ENGINE CRANK-LEAD AND FUEL INJECTION TIMING FOR THE OP ENGINE 3C.0 Introduction This hands-on session will be coordinated with the classroom presentation of Chapter 3.

3C.1 Learning Objectives Effectively present Session 4 materials using the OP operating model cutaway engine and display models of major engine components and assemblies to enable the students to:

1. Understand the reason for crank-lead in the OP engine.
2. Understand how crank-lead is measured and set using the vertical drive gears.
3. Check fuel injection pump height, set for proper injection timing (applicable to all engines) 3C.2 Instructor Presentation Crank-lead Session Using the motorized OP engine operating display model, demonstrate crank-lead in timing the engine exhaust and intake ports opening and closing during the 2-stroke cycle.

Using the non-motorized OP engine assembly, explain how crank-lead is checked and set.

Show the students location of the following engine features:

  • The flywheel and flywheel pointer
  • The timing flat on the upper and lower crankshafts
  • The vertical drive gear assembly
  • Engine-level-check flange The exercise to check the crank-lead consists of the following steps:
1. Check to see that when the lower crankshaft is at inner dead center, the following conditions are observed.
1) The timing flat is vertical (90o from the horizontal level). Adjust for any engine out-of-level per the block check above.
2) The flywheel pointer is at zero position. Adjust the pointer as required.

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2. Turn the engine in the normal direction of rotation until the upper crank timing flat is vertical (or matches the angle of the block check).
3. Check the flywheel point to see that it is at the proper crank-lead angle. Note: In the direction of rotation, the lower crank should lead the upper crank.
4. Explain how crank-lead can be changed.

Injection Timing Session Using the OP display model, the instructor will demonstrate how the cams on the camshaft operate the injection pump through the tappet assemblies.

There are two steps in setting the injection timing. One is to be sure that the injection cam is in the correct position with respect to the lower crankshaft. The other is to see that the point of injection pump plunger covering the fill port at the right time in the engine cycle.

The first setting is done by checking/setting the high cam point with respect to the lower crankshaft position for the correct engine timing (this affects all engine cylinders). The second step is accomplished by shimming the injection pump so injection occurs at the correct time for that cylinder. The first timing is checked on the number 1 pump on each side of the engine. The second timing (shimming) must be accomplished for both pumps on each cylinder. Field Service Procedure No. 3 is used for checking and adjusting timing.

NOTE: Crank-lead must be set properly before performing the following checks / settings!

This exercise is to set / reset the injection pump high cam position. The required steps are:

1. Remove the discharge fitting, check valve and spring on the #1 Opposite Control Side (OCS) injection pump.
2. Install the stroke gage on the #1 OCS pump.
3. Turn the flywheel in the normal direction of rotation until the stroke gage lines align with the plunger line going in a downward stroke. STOP when the lines are aligned.
4. Record the flywheel pointer reading at which alignment was found.
5. Continue to turn the engine (in direction of normal rotation) until the stroke gage goes all the way down and comes back up until the lines are again aligned. STOP when the lines are aligned.
6. Record the flywheel pointer reading at which this second alignment was found.
7. If the first number is between say 340 and 360, then subtract the recorded number from 360 and add that difference to the other number. Then, divide that result by 2.

Add this number to the first number (and subtract 360) or subtract it from the second number to obtain the position of the high point of cam. If the first number is greater than 0, then add the two numbers and divide by 2 to get the high point of cam number.

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8. Move the stroke gage to the #1 Control Side (CS) pump and repeat steps 1 through 7.
9. If the CS cam does not match the OCS cam, slip the CS cam sprocket the number of degrees to match up with the OCS cam. If the CS cam is too far advanced, this means that the CS high cam figure is a lower number than the OCS high cam figure.

To change, loosen the four (4) nuts or capscrews one turn on the CS sprocket and turn the flywheel in rotation to number of degrees change desired.

10. Repeat Steps 4 through 7 as required to match the figures.
11. If the CS cam is too far retarded, this means the CS high cam number reads higher than the OCS high cam figure. To change, loosen the four (4) nuts or capscrews one turn on the CS sprocket, and turn the flywheel against rotation the number of degrees change desired.
12. Repeat Steps 4 through 7 as required to match the figures.
13. With both camshafts reading the same high cam number, you now have to set the high cam to agree with the technical manual setting. To do this, rotate the external timing device to get 43 degrees high cam after Inner Dead Center (IDC). Turn the nut counterclockwise to advance timing, (making the high cam number lower). Turn the nut clockwise to retard the timing, (making the high cam number higher). NOTE: One turn on the timing nut equals 1.5 degrees.

The above steps put the high point of cam in the correct position which influences the timing on all of the cylinders. It is also necessary to check the point of port closure on the injection pumps to time each cylinder. To do this, do the following steps:

1. Using the same stroke gage as used in the steps above, turn the engine in its normal direction of rotation to the point of high cam for the respective cylinder. See the engine firing order chart for the order for setting the injection pump heights.
2. With the cam for that cylinder at high point, the end of the stroke gage plunger should be flush with the end of the tool.
3. Measure the amount of protrusion or amount of recess of the gage plunger. If there is a protrusion, then additional shimming is required. If the gage plunger is recesses, then shims must be removed.
4. Remove the injection pump assembly from the tappet assembly.
5. Determine the thickness of the present shim pack and add or subtract the shims as determined in step 3. Always try to obtain the minimum number of shims that will result in the desired shim pack thickness.
6. Reinstall the injection pump and again check the stroke gage. If the exact number of shims cannot be obtained, its better that the plunger be slightly recessed at high cam.

Rev 3/16 20 USNRC HRTD

Emergency Diesel Generator Instructor Manual In this exercise, it is only necessary to demonstrate this technique on one injection pump.

In actual practice, this must be done for each injection pump on both sides of each cylinder on the OP engine. Similar procedures are applicable to other engines. First, the cam must be timed to the crankshaft and then the pump must be timed to the individual cylinder cam.

3C.3 Student References

  • Instructor Manual
  • The operating model of the cutaway OP engine
  • OP Engine Field Service Procedures Nos. 1 and 3
  • Crank-lead gage and bubble type protractor
  • Cylinder stroke gage
  • Tools and equipment as required
  • Fairbanks Morse Training School facilities Rev 3/16 21 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 4 COMBUSTION AIR, FUEL, AND EXHAUST SYSTEMS Classroom Instruction 4.1 Learning Objectives Effectively present Chapters 4 materials and conduct H-O instructions to enable the students to:

1. Describe the relationship between the intake air charge and fuel delivery in the development of power in a diesel engine.
2. Identify the major components of the diesel engine air intake and exhaust systems and state the purpose of each.
3. Identify the major components of a diesel engine fuel system and state the purpose of each.
4. List the functions that must be performed by the components of a diesel engine fuel injection system.
5. Describe the construction and explain the operation of a typical diesel engine fuel injection pump.
6. Describe the construction and explain the operation of a typical diesel engine fuel injection nozzle.
7. Describe the construction and explain the operation of a unit type diesel engine fuel injector.
8. Describe how the diesel engine governor operates to control the fuel delivery to the cylinders of a diesel engine.
9. Describe the exhaust system functions, construction, and operation.

4.2 Instructor Presentation The instructor will make a 58-slide PowerPoint presentation developed from Chapter 4 learning objectives, text, and illustrations. The instructor will include the inter-relationship between fuel, combustion air, and the governor control of fuel delivery to the cylinders for the engine to produce output shaft HP.

The instructor will illustrate and explain the following: The fuel, air, and exhaust systems in detail including all components and their functions; the engine governor control of fuel oil delivery through the linkage of the governor actuator arm to the cylinders fuel pump racks; the importance of freedom of movement of the fuel rack. Linkage connecting the governor to the rack and provisions for adjustment will be shown.

Rev 3/16 22 USNRC HRTD

Emergency Diesel Generator Instructor Manual The instructor will explain the combustion air system functions. Illustrate and explain the combustion air system from outside air through the intake structure, screens, filters, silencer, piping, into the turbocharger or blower, the air header/manifold through valves/ports into the combustion chamber. Emphasize the importance for proper design and functioning of all air system components. Emphasize need for clean, undiluted air supply. Cover de-rating factors for inadequacies in combustion air supply to the engine.

Discuss engine rating as influenced by engine combustion air temperature air deficiencies (altitude, contaminates, intake pressure drop).

To put classroom theory into practice, the instructor will present and discuss engine actual components of the combustion air supply system including the following:

  • Air inlet filter and silencer (often combined)
  • Air Intake piping
  • Air Intake blower (non-turbo OP and EMD engines)
  • Combustion air intercooler (aftercooler) and on-engine piping The instructor will Illustrate and explain the exhaust system components, from exhaust ports / valves, exhaust manifold, turbocharger(s), through exhaust silencer and piping system (and exhaust system outlet missile barrier). Explain exhaust system cooling of manifold (on non-turbo engines) and exhaust belts and turbochargers (on turbo engines).

The instructor will cite problems with exhaust system, including causes of high back pressure and influence on engine performance. Illustrate types of exhaust manifolds, turbocharging, turbocharger drive / boost systems, etc.

During walk-around students will have opportunity to examine exhaust system components, including 2-stroke cycle exhaust-ported cylinder liners, 4-stroke cycle exhaust-valved cylinder heads, gear drives, camshafts, and turbochargers.

The instructor will explain the fuel system, covering the following components and aspects:

  • Fuel specifications
  • Fuel storage and transfer
  • Fuel day tank
  • Engine-driven fuel pump (booster pumps) and fuel headers, relief valves, etc.
  • Fuel injection pumps
  • Fuel Injectors, spray patterns, etc.
  • Fuel injection timing.

Rev 3/16 23 USNRC HRTD

Emergency Diesel Generator Instructor Manual The instructor will illustrate components in the classroom and in labs / display area.

Utilizing the 2-stroke cycle engine model, conduct a hands-on walk-down locating and identifying all fuel system components from the incoming fuel lines to the injectors. Cover hand movements of the governor output shaft and the fuel rack linkages, illustrating the over-travel required for start-up and acceleration and under-travel required to assure shutdown. Show how the engine camshaft activates the fuel injection pump at the proper time. The instructor will show how rack adjustments are made to balance the fuel to each cylinder. Discuss how fuel pump shim adjustments are made to make minor changes in fuel injection timing. Cover operation and change-out of duplex fuel filters.

The instructor will discuss fuel specification requirements for nuclear service, including storage, cleanliness, biological growths, cetane number requirements, etc.

The instructor will give examples of failure modes and known diesel failures from the fuel vendor to the diesel engine combustion chamber. Cover supplier qualifications, receipt validation, periodic sampling, tank cleaning, and specific fuel criteria of manufacturers.

Controls, indicators, and trips will also be discussed.

To put classroom theory into practice, the instructor will use engines and components in the school in conducting Hands-on Session 4A and 4B.

4.3 Student References

  • Instructor Manual
  • Chapter 4 Power Point slide show presentation (58 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 24 USNRC HRTD

Emergency Diesel Generator Instructor Manual WALKAROUND SESSION 4 COMBUSTION AIR, FUEL, AND EXHAUST SYSTEMS 4.0 Introduction This walkaround session will be coordinated with the classroom presentation of Chapter 4.

Learning Objectives Effectively present Walkaround Session 4 using the OP and ALCO engines and operating model cutaway engines, and the display models of major engine components, to enable the students to understand:

1. The appearance and function of the air combustion system and its components.
2. The appearance and function of the fuel oil system and its components.
3. The appearance and function of the exhaust system and its components.

4.1 Instructor Presentation Combustion Air System The instructor will use the OP engine cutaway to illustrate and explain the combustion air system and the combustion air intake manifold that would connect to the supercharger, turbocharger, intake air piping, filters, and silencers. He will explain the flow of combustion air into each engine cylinder.

The instructor will use cutaway blower and its component parts to illustrate how they function to pressurize combustion air and scavenge exhaust gases.

The instructor will use the cutaway turbocharger and its component parts to illustrate their function in converting high temperature exhaust gases into pressurized engine intake combustion air.

The instructor will use the cutaway dry air filter and its components, as well as the cutaway oil bath air filter and its components, to illustrate their features and functions.

Fuel Oil System The OP engine cutaway will be used to illustrate the flow path of fuel oil in the engine.

The instructor will use the cutaway fuel oil transfer pump to illustrate its component parts and their functions.

Rev 3/16 25 USNRC HRTD

Emergency Diesel Generator Instructor Manual The cutaway fuel supply pump will be used to illustrate component parts and their functions.

The instructor will use the ALCO engine to illustrate the following:

  • The governor-to-fuel-rack linkage including the individual adjustable linkage to each engine cylinder fuel injection pump fuel metering gear.
  • How each cylinder fuel injection pump stroke is controlled by a cam on the engine camshaft.

The instructor will use the dual cutaway fuel oil filter and the cutaway fuel oil strainer to illustrate the component parts of each and their functions.

The instructor will use a cutaway fuel injection pump to illustrate component parts and their functions in metering and supplying fuel to the injection nozzle.

The instructor will use the cutaway fuel injection nozzle to illustrate component parts and their function in the injection process.

Exhaust System The instructor will use the OP engine cutaway to illustrate:

  • The flow path of exhaust gases from each cylinders exhaust ports to exhaust manifold.

The instructor will use the turbocharger cutaway to illustrate how hot exhaust gases drive the turbine to produce pressurized intake combustion air.

The instructor will use the muffler cutaway to illustrate how its baffles reduce noise.

4.3 Student References

  • Instructor Manual
  • Operating model of the cutaway OP and ALCO engines
  • Cutaway components listed above
  • Tools and equipment as needed
  • Fairbanks Morse Training School facilities Rev 3/16 26 USNRC HRTD

Emergency Diesel Generator Instructor Manual HANDS-ON SESSION 4A COMBUSTION AIR TURBOCHARGERS AND SCAVENGING BLOWERS 4A.0 Introduction This hands-on session will be coordinated with the classroom presentation of Chapter 4.

4A.1 Learning Objectives Effectively present Session 4A materials using the OP turbochargers and cutaway scavenging blower to enable the students to:

1. Understand the basic components and assemblies that makeup the turbocharger, and their functions.
2. Gain more knowledge from instructor presentation of the cutaway scavenging blower.

4A.2 Instructor Presentation Turbochargers The instructor will use a turbocharger cutaway to explain how the turbocharger works and its major components. Disassemble and reassemble an OP engine turbocharger. Show the models of other types of turbochargers available. Discuss the following parts of the turbocharger:

  • What the turbine does and how it derives its energy from the exhaust flow
  • What the compressor does and how it is driven
  • What the nozzle ring is for and how its area is changed to control the output of the turbocharger.
  • What the diffuser is and its purpose in generating output pressure from air velocity
  • What the ring catcher does
  • The bearings and lubrication (internal or external types)

Scavenging Air Blower Using the cutaway blower, the instructor will discuss its construction and operation. Its gear drive from the engine and mounting on the engine will be shown.

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Emergency Diesel Generator Instructor Manual 4A.3 Student References

  • Instructor Manual
  • The 2-cylinder model of the cutaway OP engine
  • Major components and assemblies as follows:
  • Scavenger blower cutaway
  • Tools and equipment for student disassembly
  • Fairbanks Morse Training School facilities Rev 3/16 28 USNRC HRTD

Emergency Diesel Generator Instructor Manual HANDS-ON SESSION 4B FUEL INJECTION PUMPS, FUEL INJECTION NOZZLES 4B.0 Introduction This hands-on session will be coordinated with the classroom presentation of Chapter 4.

4B.1 Learning Objectives Effectively present Session 4B materials using the PC2 and PC2.5 engine components and the PC engine display model to enable the students to understand:

1. The disassembly/assembly and test of fuel injection pumps and how they operate.
2. The disassembly/assembly of fuel injection nozzles and how they operate.

4B.2 Instructor Presentation Injection Pumps and Injection Nozzles At the instructors direction, students will dissemble a PC engine injection pump. After disassembly, pump parts will be examined and explained. Pump operation and how the fuel quantity is changed will be discussed. The instructor will disassemble the Pielstick injection nozzle, inspect it, then reassemble and test it. The relationship of the injection pump to the cam shaft and tappet assembly will be explained and demonstrated.

Injection Nozzle Assemblies At the instructors direction, students will disassemble the injection nozzles provided.

Several students may be assigned to do so on several different nozzle types simultaneously. The instructor will direct which parts are to be inspected and how an inspection is carried out. The students will then be instructed on how to reassemble the nozzles, generally in the reverse order to their disassembly. After the nozzles are reassembled, the nozzle assembly will be attached to a nozzle test stand and pump the hand pump to make the nozzle pop open. The nozzle should open at or slightly above a specified pressure and spray fuel in the form of a fine mist. The instructor will point out that when the pressure is relieved, the nozzle should not leak. Also, the nozzle should pop shut and not leak as the pressure is increased even though it has not yet popped.

Students will be cautioned to keep their hands away from the nozzle tip when pop testing the nozzle. The fuel comes out of the nozzle at a high enough pressure to cause injury to the fingers or hand.

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Emergency Diesel Generator Instructor Manual 4B.3 Student References

  • Major components and assemblies as follows:

PC2 engine injection pumps, injection nozzles, and connecting rods PC2.5 engine injection pumps and injection nozzles

  • Tools and equipment as required
  • Fairbanks Morse Training School facilities Rev 3/16 30 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 5 ENGINE LUBRICATION SYSTEM Classroom Instruction 5.1 Learning Objectives Effectively present Chapter 5 materials and conduct Walkaround to enable students to:

1. Define lubrication and the types of friction.
2. State the functions of the diesel engine lubrication system.
3. Identify major components of the typical diesel engine lubrication system and trace the flow path of lubricating oil through the engine.
4. State the purpose and describe operation of the lubrication oil keep-warm and pre-lube system(s) as are commonly used on nuclear application diesel engines.

5.2 Instructor Presentation The instructor will make a 27-slide PowerPoint presentation developed from Chapter 5 learning objectives, text, and illustrations.

The instructor will explain and illustrate engine lubrication systems. Discuss manufacturers lube oil spec requirements. Explain purposes of lube oil systemto lubricate moving parts, remove heat from pistons and bearings, etc. Explain the following system components:

  • Engine sump for storage of oil
  • Engine driven lube oil circulating pump (and auxiliary pumps)
  • Lube oil heat exchanger and temperature control valve (AMOT)
  • Lube oil keep-warm system the pump, heater and piping
  • Controls and instrumentation to monitor performance, alarms, and shut down engine The instructor will discuss bearing types, and also the various types of friction: sliding and rolling (both dynamic) versus static friction, which has a higher coefficient of friction.

The instructor will discuss crankcase vacuum / pressure: purpose, importance, monitoring.

The instructor will provide specific examples of diesel failures attributed to improper oils, lack of lubrication, too much lubrication, and/or malfunction of the oil supply components.

To put classroom theory into practice, the instructor will use engines and components in the school in conducting Walkaround 5.

Rev 3/16 31 USNRC HRTD

Emergency Diesel Generator Instructor Manual 5.3 Student References

  • Instructor Manual
  • Chapter 5 Power Point slide show presentation (28 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 32 USNRC HRTD

Emergency Diesel Generator Instructor Manual WALKAROUND SESSION 5 ENGINE LUBRICATION SYSTEM 5.0 Introduction This walkaround session will be coordinated with the classroom presentation of Chapter 5.

5.1 Learning Objectives Effectively present Session 5 materials using the OP and ALCO operating model cutaway engines and display models of major engine components and assemblies to enable the students to:

1. Become familiar with the appearance, location, function, and operation of the lube oil system and its components.

5.2 Instructor Presentation Lube Oil Flow Path The instructor will use the rotatable cutaway OP to show the oil flow paths, as follows:

  • From engine lube oil sump through the engine-driven oil pump to the thermostatic valve then either through the lube oil cooler or directly to the duplex oil strainer / filter
  • From the header(s) to and from the turbochager and back to the engine
  • From the header to the main bearing caps then through drilled passages to the crankshaft journals and connecting rod bearings
  • Through the connecting rod drilled passages to piston wrist pin bearings and through holes into the piston cocktail shaker, with its drain back to the sump The instructor will discuss the pre-lube keep-warm oil system and its components, and also point out the fact that engine cylinder(s) can become hydraulically locked so the engine will not start (and could be seriously damaged). Manufacturers recommend that cylinder test cocks be opened and the engine rolled over prior to all planned starts, to purge cylinders of possible lube oil / water. (Licensees procedures must assure cocks are always re-closed.)

Discuss the possibility of lube oil accumulation in exhaust manifolds, causing seepage and lube oil fires outside the manifold. Fire may also occur inside the exhaust manifold, posing the threat of turbocharger damage from the blowtorch effect.

The instructor will show differences in the 4-stroke cycle engine lube oil flow paths which include lubrication of the cylinder head valve rocker arm assemblies.

Rev 3/16 33 USNRC HRTD

Emergency Diesel Generator Instructor Manual Based upon typical oil consumption rates for OP and ALCO engines, the instructor will tell students how much lube oil engines will consume at rated load each day/week, how and when lube oil sump level should be checked, and how to add lube oil to the sump of a running engine. Crankcase exhauster location, power, and discharge will also be covered.

The instructor will show the location, function, and operation of the crankcase sump pressure relief blowout covers and how the covers are checked for proper operation.

Components The instructor will show cutaways and discuss the functioning of the following components:

  • Thermostatic valve
  • Pressure relief valve
  • Duplex filters/strainers
  • Main bearing cap showing drilled oil passages
  • Crankshaft showing drilled oil passages
  • Connecting rod drilled oil passages
  • Piston drilled oil passages to the cocktail shaker and its drain back to lube oil sump
  • Oil cooler
  • Piston with oil control rings 5.3 Student References
  • Instructor Manual
  • Operating model of the cutaway OP and ALCO engines
  • Other cutaway components listed above
  • Tools and equipment as required
  • Fairbanks Morse Training School facilities Rev 3/16 34 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 6 ENGINE COOLING SYSTEM Classroom Instruction 6.1 Learning Objectives Effectively present Chapter 6 materials and conduct Walkaround Session 6 to enable the students to:

1. State the purpose of a diesel engine jacket water cooling system.
2. Identify the major components of a typical diesel engine jacket water cooling system and describe their operation.
3. State the purpose and describe operation of jacket water keepwarm systems commonly used on NPP diesels.
4. State the purpose of a diesel engine intercooler (aftercooler) water cooling system, identify its major components, and describe their operation.
5. Identify other cooling requirements, such as engine room cooling.

6.2 Instructor Presentation The instructor will make a 13-slide PowerPoint presentation developed from Chapter 6 learning objectives, text, and illustrations.

The instructor will illustrate and explain the engine jacket water cooling system. Include manufacturers basis of rating for the EDG which specifically includes requirements for the coolant and BTU heat removal.

Instructor will show the flow path of jacket water to and from the heat exchanger (cooler) through the piping, temperature control valve, pump, and into the various passages within the engine cylinder block and cylinder head. Show specific differences for the OP engine and other typical diesel engines. Include turbocharger and exhaust manifold cooling.

The instructor will emphasize the importance of cooling water quality, treatment and quantity at the maximum temperature permitted. Discuss instrumentation and control of the jacket water system. Provide specific examples of diesel failure caused by system inadequacies, improper coolant, and / or malfunction of cooling system components.

The instructor will explain the effect of anti-freeze (Ethylene or Propylene Glycol) mixtures on the performance of the cooling system. Discuss other items that influence radiator cooler performance of the cooling system such as air re-circulation, lack of cleanliness, corrosion, scale build-up, high ambient air temperature, etc.

Explain the purpose of the air intercooler system, and requirements of the intercooler water system. Discuss engine room heat, sources of heat, and need for proper ventilation.

Rev 3/16 35 USNRC HRTD

Emergency Diesel Generator Instructor Manual To put classroom theory into practice, the instructor will use engines and components in the school in conducting Walkaround Session 6.

6.3 Student References

  • Instructor Manual
  • Chapter 6 PowerPoint presentation slide show (13 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 36 USNRC HRTD

Emergency Diesel Generator Instructor Manual WALKAROUND SESSION 6 ENGINE COOLING SYSTEMS 6.0 Introduction Walkaround Session 6 will be coordinated with the classroom presentation of Chapter 6.

Learning Objectives Effectively present Session 6 materials using the OP and ALCO operating model cutaway engines and display models of major engine components and assemblies to enable the students to:

1. Become familiar with the appearance, location, function, and operation of the engine cooling system.

6.1 Instructor Presentation Jacket Water Cooling System The instructor will illustrate and explain the jacket water system with its flow paths through the engine and around its components in the removal of waste heat from the engines.

The instructor will use the rotatable cutaway 2-stroke cycle OP to illustrate and explain the following jacket water flow path:

  • From the radiator/cooler to the jacket water head tank and to the suction of the jacket water cooling pump
  • From the pump to the engine cooling water header(s) with their flow of cooling water into the engine block for cooling the block and the individual cylinder liners
  • Back into the cylinder block
  • Around the exhaust belts
  • Heated water from the engine and its components flow into a common return header.
  • The return path from the heated water header to a 3-way thermostatic valve which directs the water through either the radiator / cooler or back to the inlet header if the water doesnt need cooling.

Show circulating keep-warm system components including their location and power supply.

The instructor will use the rotatable cutaway 4-stroke cycle ALCO to cover differences in cooling water flow from that of the OP engine, including into and out of the cylinder heads.

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Emergency Diesel Generator Instructor Manual 6.2 Components The instructor will show cutaways and discuss the functioning of the following components:

  • Jacket water pump
  • Thermostatic valve
  • Jacketed water cylinder liners and direct contact cylinder liners
  • Pielstick cylinder head to show water passages from the block through the cylinder head, around the valves and fuel injector and adjacent to the firing face, to remove combustion heat
  • Radiator / cooler
  • Instructor Manual
  • Operating model of the cutaway OP and ALCO engines
  • Cutaway components listed above
  • Tools and equipment as required
  • Fairbanks Morse Training School facilities Rev 3/16 38 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 7 DIESEL ENGINE STARTING SYSTEMS Classroom Instruction 7.1 Learning Objectives Effectively present Chapter 7 materials and conduct Walkaround to enable students to:

1. Describe requirements for starting a nuclear service Emergency Diesel Generator.
2. Identify the components and describe operation of a direct air injection, compressed air diesel engine starting system (aka air over piston start system).
3. Identify the components and describe operation of an air motor type, compressed air diesel engine starting system.
4. Identify the components and describe operation of a typical starting air supply system used in a nuclear plant application.
5. Identify the components and describe operation of an electric diesel engine starting system for a nuclear application diesel engine.

7.2 Instructor Presentation The instructor will make a 35-slide PowerPoint presentation developed from Chapter 6 learning objectives, text, and illustrations.

Present a detailed description of the three different types of starting systems, as follows:

  • Electrical starting system, including starting motor(s), bendix starter engagement drives, batteries, and control system.
  • Air motor starting system, including air starting motor(s), bendix starter engagement drives, air compressor(s), air storage tank(s), check valves, and control valves.
  • Air-over-piston starting system, including air start distributor and check valves, air manifolds, air compressor(s), air storage tank(s) and control valves.

During presentation of the direct air-over-piston starting system, the instructor may pass around the smaller components of this system to the students to enhance understanding of the components. It may include a cutaway air-start solenoid valve, cutaway air distributor, and cutaway cylinder air-start check valve.

To put classroom theory into practice, the instructor will use engines and components in the school in conducting Walkaround Session 7.

Rev 3/16 39 USNRC HRTD

Emergency Diesel Generator Instructor Manual 7.3 Student References

  • Instructor Manual
  • Chapter 7 Power Point slide show presentation (35 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 40 USNRC HRTD

Emergency Diesel Generator Instructor Manual HANDS-ON SESSION 7 DIRECT AIR INJECTION SYSTEM 7.0 Introduction This Hands-on session will be coordinated with the classroom presentation of Chapter 7.

7.1 Learning Objectives Effectively present Session 7 materials using the OP and ALCO operating model cutaway engines and display models of major engine components and assemblies to enable the students to understand:

1. How the direct air-over-piston starting system operates including its components and their location on the engine.

7.2 Instructor Presentation Air Start System Components Utilizing the cutaway OP and ALCO engines, the instructor will conduct a Walkaround presentation to identify the location of the air starting system and its components. Starting air will be traced from its input to the air valve, back to the main starting air header:

  • The starting air distributor with its lines to the pilot valve on each cylinders air start check valve
  • The line to the governor boost cylinder The instructor will discuss each application of starting air to these components and show cutaways of the components.
  • Air admission valve
  • Starting distributor
  • Governor boost cylinder Air Start Distributor The instructor will demonstrate the operation of the air start distributor by applying air pressure to the inlet fitting and then will demonstrate the operation of the individual cylinder valves by turning the cam. Students will observe how the valves operate as the cam turns.

Rev 3/16 41 USNRC HRTD

Emergency Diesel Generator Instructor Manual Air Start Distributor - (continued)

Students will be shown how the cylinder air start check valve operates when a signal is received from the air start distributor. The instructor will explain how these components operate to put air into the cylinder to cause the engine to rotate in the starting process.

The air-over-piston starting system develops a surprising amount of power while the EDG system is getting up to speed, contributing to the fast start capability of this diesel engine design. The magnitude of this effect will be characterized for students.

The air start distributor on some early models of engines was mounted on the front of the upper crankshaft. The instructor will show the display model with this configuration.

The instructor will show a sectioned air start check valve and will also demonstrate the operation of the air start check valve by applying pressure to the pilot piston.

Finally, the instructor will demonstrate how to determine if the air start cylinder check valve is not performing its check valve function during engine operation.

7.3 Student References

  • Instructor Manual
  • OP engine cutaway
  • ALCO engine cutaway
  • Tools and equipment as required
  • Fairbanks Morse Training School facilities Rev 3/16 42 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 8 DIESEL ENGINE CONTROLS AND GOVERNING Classroom Instruction 8.1 Learning Objectives Effectively present Chapter 8 materials and conduct Walkaround to enable the students to:

1. Describe the functional relationship between the engine control governor and the fuel injection system.
2. Explain how the engine control governor senses changes in generator load and compensates by regulating fuel delivery to the injectors.
3. Describe primary components of governing systems, their features and functions.
4. Explain how the terms "isochronous" and "droop" apply to EDG engines.
5. Describe how the EDG is synchronized with the grid for periodic test loading.
6. Explain rack boost and how it provides for faster starts.
7. Describe the overspeed trip, how it functions to shut down the EDG even during emergency loading, and its manual reset.
8. Understand advantages and disadvantages of digital systems.

8.2 Instructor Presentation The instructor will make a 41-slide PowerPoint presentation developed for the Chapter 8 learning objectives, text, and illustrations.

The instructor will explain engine governing systems. The means by which engine speed is controlled during start-up, acceleration, steady state run, load changes, and shutdown will be described. Both manual and automatic control will be covered.

The instructor will explain the basic Woodward mechanical / hydraulic governor by showing how the various linkages, springs, spool valve, pistons, and fly-weights interact to regulate engine fuel supply through the injection pumps. Explain interactions with engine load changes, with and without droop. Show a droop diagram and explain droop function.

The instructor will explain the basic Woodward electric / hydraulic governor. Cover the MOP, EGA, 2301A, MPU, and DRU adjustment and inputs. Explain how the electric /

hydraulic governor provides faster response to speed / load changes via sensing and control circuits. Describe how it governs with the mechanical / hydraulic governor as a backup in case of failure, and vice versa Rev 3/16 43 USNRC HRTD

Emergency Diesel Generator Instructor Manual The instructor will discuss governor adjustments and governor failures and improper root cause analyses, which have led to degradation and to inoperability of the EDG. Discuss fuel rack / governor boost systems including governor linkage binding.

The instructor will explain digital governing systems, including both the Woodward 2301D and the 723. The advantages and disadvantages of licensees converting existing analog systems to digital will be discussed, as well as the pros and cons of selecting a digital governing system for a new plant installation.

The instructor will discuss and explain the purpose of the separate mechanical over-speed governor / trip mechanism, included in all EDG installations.

To put classroom theory into practice, the instructor will use engines and components in the school in conducting Walkaround Session 8.

8.3 Student References

  • Instructor Manual
  • Chapter 8 PowerPoint slide show presentation (41 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 44 USNRC HRTD

Emergency Diesel Generator Instructor Manual WALKAROUND SESSION 8 DIESEL ENGINE CONTROLS AND GOVERNING 8.0 Introduction This Walkaround session will be coordinated with classroom presentation of Chapter 8.

8.1 Learning Objectives Effectively present Session 8 materials using the governors, governor cutaways, and governor linkage to enable the students to:

1. Become familiar with basic Woodward mechanical / hydraulic governor for EDGs.
2. Become familiar with the basic Woodward electric / hydraulic governor for EDGs.
3. Become familiar with the governor-to-fuel-rack linkage.

8.2 Instructor Presentation Mechanical / Hydraulic Governor Utilizing the mechanical / hydraulic governor and its components on the test floor, the instructor will conduct the following training:

  • Illustrate the rotating flyball governor operation and its output.
  • Illustrate the power piston output with its pressurized oil input port, with opening amount which is controlled by the flyball governor output.
  • Illustrate the power piston output to the governor output shaft.

Electric / Hydraulic Governor Utilizing the electric / hydraulic governor and its components on the test floor, the instructor will conduct the following training:

  • Illustrate the governor housing / case with its oil reservoir and pressurizing oil pumps.
  • Illustrate the magnetic null balance control with its off-null output for control to the loading piston.
  • Illustrate the loading piston with its pressurized oil input port and power output to the governor output shaft.
  • Illustrate the MOP, EGA, 2301A, MPU, and DRU control boxes and discuss how they control the electric / hydraulic governor.

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Emergency Diesel Generator Instructor Manual (Electric/ Hydraulic Governor continued)

  • Illustrate both the mechanical / hydraulic and electric / hydraulic governors housed in the same case. Describe how either can control the governor output shaft depending on the position of the floating lever connection between them, and their differences in speed settings.
  • Illustrate the purpose and use of controls on the front of the governor case.

Utilizing an engine on the test floor with fuel-rack linkage, the instructor will conduct the following training, applicable to both types of governors:

  • Illustrate governor-to-fuel-rack linkage with its many angular joints having potential for binding and, therefore, the need for periodic inspection, testing, and lubrication.

8.3 Student References

  • Instructor Manual
  • Woodward mechanical / hydraulic governor, Woodward electric / hydraulic governor, and governor output power linkage.
  • Fairbanks Morse Training School Tools and equipment, as required Rev 3/16 46 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 9 GENERATOR, EXCITER, AND VOLTAGE REGULATION Classroom Instruction 9.1 Learning Objectives Effectively present Chapter 9 materials and conduct Walkaround to enable the students to:

1. Describe the functions of the generator, exciter, and voltage regulator.
2. Identify the major components of the generator, exciter, and voltage regulator.
3. Explain the purpose of the Generator Differential Fault Protection system
4. Describe key considerations for connecting generator and engine, to protect bearings and engine crankshaft.
5. Describe how diesel engine operation relates to the power demand on the generator.

9.2 Instructor Presentation The instructor will make a 54-slide PowerPoint presentation developed for Chapter 9 learning objectives, text, and illustrations. The basic physics involved in the creation of voltage and current in conductors moving through a magnetic field will be explained, and illustrated with diagrams of a simple generator. That will be expanded into three-phase alternating current generation as in EDGs used for nuclear plant applications.

It will be explained that the energy output of a generator is controlled by adjusting current in the generator field winding. The field winding current is ultimately controlled by the voltage regulator which monitors the generator terminal voltage and increases or decreases the generator field current, as required to maintain the generator output voltage within allowed limits. The closed loop relationship between generator electrical output and engine fuel input will also be covered.

The instructor will discuss types of excitation systems including the Portec digital system with its advantages and disadvantages. Generation terminology will be discussed, along with construction of generator and exciter components and their physical assembly into a complete generator. Illustrate by one-line diagram a typical generator all the way from its voltage regulation input through the exciter into the generator and out to power loads through its circuit breaker.

To put classroom theory into practice, the instructor will use engines and components in the school in conducting Walkaround Session 9.

Rev 3/16 47 USNRC HRTD

Emergency Diesel Generator Instructor Manual 9.3 Student References

  • Instructor Manual
  • Chapter 9 Power Point slide show presentation (54 slides)
  • FM generator
  • Fairbanks Morse Training School facilities Rev 3/16 48 USNRC HRTD

Emergency Diesel Generator Instructor Manual WALKAROUND SESSION 9 GENERATOR, EXCITER, AND VOLTAGE REGULATION 9.0 Introduction This Walkaround session will be coordinated with classroom presentation of Chapter 9.

9.1 Learning Objectives Effectively present Session 9 materials using the Fairbanks Morse emergency diesel generator to enable the students to:

1. Become familiar with the EDG generator configuration, components locations and their functions
2. Understand the alignment of generator shaft with crankshaft and alignment of the generator rotor within the generator stator
3. Understand the need for proper connection from external exciter through generator brushes and slip rings to generator field windings
4. Understand the need for insulation of generator end bearing from ground
5. Understand the need for periodic inspections and tests of slip rings, brushes, windings, bearing, and alignment 9.2 Instructor Presentation Using the Fairbanks Morse EDG generator on the test floor, the instructor will conduct the following training:
  • Identify the generator frame. Discuss how a generator like this would be mounted on a diesel engine-frame-to-frame and shaft-to-shaft.
  • Show how the generator stator is mounted within the frame with its power leads brought out.
  • Show how the generator field pole pieces are mounted on the rotor and its mounting to the generator power input shaft.
  • Identify and discuss the generator stator to rotor air gap.
  • Discuss air gap functions and importance of its concentricity.
  • Show how the slip rings are mounted to the generator shaft and are connected to the generator field.
  • Show how the brush rigging is mounted above the slip rings.

Rev 3/16 49 USNRC HRTD

Emergency Diesel Generator Instructor Manual 9.2 Instructor Presentation - (continued)

  • Show the brush holders, spring clips, and brushes and discuss their alignment, curvature, condition, and how to measure brush pressure.
  • Show where the input from the external exciter is connected into the brush holders.
  • Show the generator outboard (inboard) bearings and the need for alignment, lubrication, and isolation from ground.
  • Show the generator shaft input coupling to the diesel engine. Discuss the need for proper alignment and mounting to the engine.
  • Discuss periodic inspections and tests of the generator including slip rings, brushes, windings, bearings, and alignment.
  • Discuss potential problem areas, indications of problems, and tests.

9.3 Student References

  • Instructor Manual
  • Fairbanks Morse EDG
  • Tools and equipment as required
  • Fairbanks Morse Training School facilities Rev 3/16 50 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 10 EMERGENCY DIESEL GENERATOR CONTROL AND MONITORING Classroom Instruction 10.1 Learning Objectives Effectively present Chapter 10 materials and conduct informal Walkaround if needed to address any remaining questions from this or related presentations. This chapter will include the following materials:

1. Describe the functions of the control system in starting, running, and shutting down the diesel engine.
2. Describe the various parameters to be monitored in order to ensure proper operation of the engine and generator.
3. Explain how the engine controls sense essential engine parameters and control these in operation of the engine.
4. Identify the key components of the engine protection system and state the purpose or describe the function of each.
5. Recognize various control components of this system, how they are put together, and the various ways they could fail.
6. Recognize signs of component deterioration, impending failure, or actual failure.
7. Explain generator loading onto the engine.

NOTE: A number of these items and additional EDG materials previously covered with a view toward understanding underlying theory (chemistry, physics, mechanics, etc.) will be covered in subsequent chapters from a different standpoint, that of assuring these systems are tested, monitored, and maintained such that EDG problems previously occurring at NPPs are not repeated.

10.2 Instructor Presentation The instructor will make a 28-slide PowerPoint presentation developed for Chapter 10 learning objectives, text, and illustrations. Control and instrumentation systems will be covered, including both manual and automatic control arrangements for the EDG. This will include discussion of starting, acceleration, voltage generation and regulation, loading, steady state operation, and transient response. In a general manner, EDG monitoring, voltage regulation, protective trips, bypasses, etc. will be covered.

The instructor will discuss instrumentation, control, and monitoring with state-of-the-art digital technology and components, and contrast this to using older analog technology and associated components. Advantages and disadvantages of converting analog systems or components to digital will be discussed, as well as possible use of digital for new EDGs.

Rev 3/16 51 USNRC HRTD

Emergency Diesel Generator Instructor Manual The instructor will cover the regulatory requirements for engine trips for over-speed and generator differential faults. All others protective trips (low lube oil pressure, high jacket water temperature, etc.) are by-passed when in emergency mode, unless provided with redundant logic, individual sensor annunciation, and means to separately test each one.

The instructor will explain that systems vary greatly between the various plants, depending on the specifications as enumerated by the various consulting engineering firms that were involved at each plant. Certain general principles always applied.

10.3 Student References

  • Instructor Manual
  • Chapter 10 Power Point slide show presentation (27 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 52 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 11 QUALIFICATION, SITE ACCEPTANCE & SURVEILLANCE TESTING Classroom Instruction 11.1 Learning Objectives Effectively present Chapter 11 materials to enable the students to better understand:

1. How EDGs are type-qualified for nuclear power plant service,
2. EDG supplier's installation, set-up, and initial run (at the site).
3. Licensees pre-operational tests to verify EDG performance, establish baseline data.
4. The licensees ongoing surveillance testing of EDGs.
5. "A typical surveillance run" on the grid. (Instructor: Focus on the "nuts and bolts" of an EDG surveillance run, including control of KW and KVAR load when on the grid.)

11.2 Instructor Presentation The instructor will make a 40-slide PowerPoint presentation developed for Chapter 11 learning objectives, text, and illustrations. The following topics will be discussed:

  • Manufacturers type test qualification of initial production EDGs of a particular design, construction, and rating.
  • Manufacturers subsequent lesser test requirements for production EDGs that are the same as previously type tested
  • Licensees on-site installed EDG qualification verification and pre-operational tests required to declare operability.
  • Licensees periodic surveillance and surveillance tests to assure continuing operability of EDG units.
  • Licensees routine surveillances and verifications between monthly surveillance tests to provide continuing assurance of EDG operability.

11.3 Student References

  • Instructor Manual
  • Chapter 11 PowerPoint slide show presentation
  • Fairbanks Morse Training School facilities Rev 3/16 53 USNRC HRTD

Emergency Diesel Generator Instructor Manual Chapter 12 EDG PERFORMANCE MONITORING AND MAINTENANCE Classroom Instruction 12.1 Learning Objectives Effectively present Chapter 12 materials to enable students to have working knowledge of:

1. The difference between Prescriptive (periodic) and Predictive (condition-based) EDG maintenance and how licensees have benefitted from the trend to Predictive.
2. An overview of the key regulatory requirements for maintenance including the NRC Maintenance Rule.
3. Monitoring, trending, and analysis of key EDG parameters including specific engine and support system values during runs as well as the fuel oil, lubricating oil, cooling water, etc.
4. The importance of baseline data, parameter trending, competent analysis, and follow up to assure effectiveness.
5. The necessity for observations before, during, and after EDG runs and also in conjunction with any maintenance on (or even in the vicinity of) the EDG.
6. Some applications of EDG monitoring systems including the human senses.
7. Information on the contribution of each EDG subsystem to failure rate.

12.2 Instructor Presentation The instructor will make a 56-slide PowerPoint presentation developed for Chapter 12 learning objectives, text, and illustrations. These topics will be presented and discussed.

  • How the licensees maintenance program has evolved from the predictive calendar based to the current predictive condition based methodology.
  • How this change has increased EDG availability and reliability
  • Overview of NRC Maintenance Rule and related NRC documents
  • Licensees need to trend maintenance related EGD parameters
  • Licensees need to establish and maintain baseline values for each parameter within an acceptable band width
  • Typical EDG parameters included in a licensees trending program
  • Examples of catastrophic EDG failures that could have been prevented trending data
  • Some EDG condition inspection methodologies Rev 3/16 54 USNRC HRTD

Emergency Diesel Generator Instructor Manual 12.3 Student References

  • Instructor Manual
  • Chapter 12 Power Point slide show presentation (57 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 55 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 13 EMERGENCY DIESEL GENERATOR CASE STUDIES Classroom Instruction 13.1 Learning Objectives Effectively present Chapter 13 materials to enable the students to better understand:

1. Various failure scenarios involving emergency diesel generators and support systems.
2. The significance and safety implications of individual licensee LERs, other documents.
3. The potential reliability impact of occurrences beyond the EDGs boundaries.
4. The potential unintended consequences of events in the vicinity of the EDG such as maintenance / cleaning activity or fire suppression system actuation.
5. Possible shortcomings in the licensees operational or maintenance procedures for EDGs and their support systems.
6. The likely effectiveness of licensee corrective actions for EDG failures.
7. Aging issues and other ongoing concerns regarding EDG systems.

13.2 Instructor Presentation The instructor will make a 71-slide PowerPoint presentation developed for Chapter 13 learning objectives, text, and illustrations. Case studies will illustrate:

  • What happened? - End result
  • Why did it happen? - Root cause
  • What corrective actions were required?
  • What was done to prevent reoccurrence?
  • What lessons were learned?
  • Reporting / evaluation documents The instructor will present case studies not already covered during other chapters / sessions.

Case studies will include EDG operational anomalies or failures involving the following:

  • Woodward Governors actuators, digital reference units, and associated equipment
  • Loss of Preferred Power Source (LOOP) for safety related components and systems
  • Postmaintenance failures that led to EDG or support system failures
  • Recent findings during component design basis inspections
  • Degraded grid voltage failures of supporting systems and/or equipment
  • Fairbanks Morse Opposed Piston diesel engine lube oil leakage / fire problems
  • Various events involving ALCO, EMD, Nordberg, SACM, other EDG engines Rev 3/16 56 USNRC HRTD

Emergency Diesel Generator Instructor Manual 13.3 Student References

  • Instructor Manual
  • Chapter 13 PowerPoint slide show presentation
  • Fairbanks Morse Training Center facilities Rev 3/16 57 USNRC HRTD

Emergency Diesel Generator Instructor Manual CHAPTER 14 SOME OTHER ENGINES Classroom Instruction 14.1 Learning Objectives Effectively present Chapter 14 materials to enable the students to:

1. Recognize basic similarities and differences between various engines that power EDGs at nuclear power plants.
2. Use the tabulation at the end of this chapter to identify EDGs and associated equipment at each nuclear power plant.

NOTE: Except for the EMD, engines in this chapter are orphans no longer produced and for which support service and parts are problematic. For some, only one or two NPPs may have them. Very little information is available for them so the data in this chapter is limited.

14.2 Instructor Presentation The instructor will make a 58-slide PowerPoint presentation developed for Chapter 14 learning objectives, text, and illustrations. Design similarities, differences, and other relevant observations will be made for the following engines in US NPP EDG service:

  • Cooper
  • Nordberg
  • Worthington
  • SACM
  • DeLaval The instructor will explain and discuss unique differences between the engines including their advantages, disadvantages, and known problems.

14.3 Student References

  • Instructor Manual
  • Chapter 14 Power Point slide show presentation (58 slides)
  • Fairbanks Morse Training School facilities Rev 3/16 58 USNRC HRTD
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