Emergency Diesel Generator Some Other Engines
14.0 SOME OTHER ENGINES • one for the four exhaust valves
• one for the unit fuel pump/injector
Learning Objectives
Unlike other engines, pushrods from the
As a result of this lesson, you will be able to: camshafts are not required.
1. Recognize basic similarities and Cylinders are directly opposite each other
differences between the engines that on this Vee engine. Connecting rods from
power EDGs at nuclear power plants. directly opposite side cylinders use a
common connecting rod journal without
2. Use the tabulation at the end of this offset by means of their mating fork-and-
chapter to identify EDGs and blade slipper assembly.
associated equipment at some nuclear
power plants. Lubrication cooling of the each piston
crown is accomplished by use of an engine
14.1 EMD EDG Engines
frame-mounted piston-cooling oil pipe that
is aligned with a hole in the piston carrier to
The EMD EDG engines are the General
send a jet stream of oil directly into the
Motors EMD 645 Series 2-stroke cycle 45o
piston cocktail shaker for crown cooling and
Vee engine. These engines have intake
wrist pin lubrication. The oil then drops
ports in the lower end of each cylinder liner
back into the crankcase.
and four exhaust valves in each cylinder
head.
Some design and performance data for the
EMD engine are provided:
During starting and up to approximately 40
percent load, cylinder exhaust scavenging
• Figure 14-1 is a cutaway cross section
and combustion air charging of the
of the EMD 645 engine. It provides
cylinders are supplied by the engine some perspective of engine con-
turbocharger which is gear driven until the figurations and component locations.
exhaust gases get hot enough to drive the
turbocharger faster than the drive gear. • Figure 14-2 is an EMD engine data
Then the drive gear is overridden (clutched sheet.
out).
14.2 Cooper EDG Engines
Each engine cylinder fuel pump and fuel
injection nozzle are combined into a unit The Cooper EDG engines are 4-stroke
type construction thereby eliminating the cycle Enterprise KSV V16 and V20 cylinder
need for high pressure fuel injection lines. engines. Cylinders on opposite sides of the
Vee are directly opposite each other. The
For each bank of this Vee engine, the cam use of articulating connecting rods permits
shafts are located above the cylinder the use of a single crankshaft journal
heads. From this location, they directly without offset for both cylinders. There is a
actuate two rocker arm assemblies: master connecting rod that provides the
bearing and transmits both connecting rod
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loads/power into the single crankshaft
journal. The master rod has a bushing Some design and performance data for the
bearing for the slave rod. The connecting Nordberg engine are provided:
rods and bearings are shown in Figure 14-
3. • Figure 14-9 provides general engine
data.
Cooper engines had 13 crankcase
explosion events attributed to lack of • Figure14-10 provides recommended
operating temperatures and pressures.
lubrication. These engines were designed
for continuous use with minimum oil
• Figure 14-11 is a cutaway cross
consumption. The lack of lubrication was
section. It provides some perspective
corrected by removal of the lower scraper of engine configurations and com-
ring on each piston and removal of wrist pin ponents locations.
bearing end caps.
14.4 Worthington EDG Engines
Some design and performance data for the
Cooper16- and 20-cylinder engines are The Worthington EDG engine is a 4-stroke
provided: cycle Vee engine. Opposite side cylinder
connecting rods use a single crankshaft
• Figure 14-4 provides KSV design data. journal and mount directly beside each
other.
• Two cutaway cross sections provide
some perspective of engine At the D. C. Cook Plant, the high pressure
configurations and components fuel injection lines from the injection pumps
locations. (See Figures 14-5 & 14-6)
to the injection nozzles have been prone to
cavitation erosion failures in sharp bends
• Figure 14-7 provides a bar graph of
made in routing the fuel lines from injection
engine timing. (Typical for 4-stroke
cycle engines) pumps to injection nozzles. This could be a
generic problem.
14.3 Nordberg EDG Engines
Some design and performance data for the
The Nordberg EDG engine is a 4-stroke Worthington engine are provided:
cycle Vee engine. It has a unique cam
shifting mechanism, which will shift • Figure 14-12 is a cutaway engine cross
section. It provides some perspective
combustion air inlet valve closure from its
of engine configurations and
initial 18 degrees ABDC to 28 degrees
components locations.
BBDC at engine full load. Actuator sensing
is of combustion air intake manifold • Figure 14-13 provides general engine
pressure. The actuator is operated by a data.
hydraulicly positioned linkshaft which
repositions the camshaft. The inlet valve • Figure 14-14 provides a circle timing
cams have an eccentric configuration. This diagram to show the timing of all
system is illustrated in Figure 14-8. engine events during the 4-stroke
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cycles of the engine. (Typical for other
4-stroke cycle engines.) • Figure 14-15 provides general engine
data.
14.5 SACM EDG Engines
• Figure 14-16 provides general
The SACM UD 45 V16 S5D engine is a 4- generator data.
stroke cycle engine at Calvert Cliffs and
Prairie Island nuclear stations. The Prairie Island configuration of Unit 2
SACM EDG D5 and D6 not known.
The Calvert Cliffs configuration has two
SACM engines connected in tandem to NRC NOV EA-02-068 cited Prairie Island
power a single 5400kw generator. There with a $60,000 penalty for failure to take
are two tandem units–one safety related action to address EDG problems in a timely
and one SBO unit. Each engine is manner.
provided with a Woodward 2301A electrical
governor and a Woodward EGB-35P 14.6 DeLaval EDG Engines
governor actuator, which permits engine
load sharing as they both power their The DeLaval EDG uses the 4-stroke cycle
common generator. IN-96-67 Vulnerability Enterprise RSV-V-16-4 engine.
of Emergency Diesel Generator to Fuel Oil/
Lube Oil Compatibility. Following Calvert The DeLaval engine like other EDG
Cliffs’ successful pre-op qualification testing engines is subject to large pressures and
of their new SACM safety related EDG, the forces as it operates. See Figure 14-16.
licensee performed progressive external to Consider the 17-inch diameter piston in the
internal and then to disassembly DeLaval engine. With 1500 psi peak firing
inspections of the engines. pressure, it must carry a peak load on each
piston of the of 340,000 pounds 225 timing
Extensive cylinder liner/piston skirt damage per minute. This load is transmitted from
was discovered. Root cause was a the piston through its wrist pin bearing to
chemical reaction between combustion the connecting rod bearings and then to the
blowby water into the crankcase and a crankshaft journal. The large forces of
diester in the synthetic lube oil acid- combustion are contained and resolved
neutralizing additives. This reaction formed within the engine by structural components.
hard deposits behind the piston rings which Fortunately a large percentage of these
led to cylinder/liner scuffing. The forces create useful work by their rotation
inoperable piston rings could have led to of the engine crankshaft to produce
early failures of the SACM EDG. A useable output power. However, when
significant amount of water is formed during some cylinders fail to produce their share of
the combustion of fuel. NRC IN 96-97. output power, the unbalanced forces can
be large enough to become destructive.
Corrective actions included engine repairs/ Some design and performance data for the
replacements and lube oil change to an DeLaval engine are provided:
API-CG-4 mineral-based oil recommended
by the root cause analysis team.
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• Figure 14-17 provides general engine
data.
• Figure 14-18 provides a cross sectional
illustration of the DeLaval articulating
connecting rod assembly. It provides
some perspective of engine con-
figurations and components locations.
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Figure 14-1 EMD Engine Cross Section
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Figure 14-2 EMD Engine Service Data Sheet
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Figure 14-3 Cooper Engine Connecting Rods & Bearings
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Figure 14-4 Cooper Engine Service Data Sheet
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Figure 14-5 Cooper Engine Cross Section
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Figure 14-6 Cooper Engine Cross Section
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Figure 14-7 Cooper Engine Timing Bar Graph
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Figure 14-8 Nordberg Engine Linkshaft
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Figure 14-9 Nordberg Engine Service Data Sheet
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Figure 14-10 Nordberg Engine Operating Pressures & Temperatures
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Figure 14-11 Nordberg Engine Cross Section
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Figure 14-12 Worthington Engine Cross Section
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Figure 14-13 Worthington Engine Service Data
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Figure 14-14 Worthington Timing Diagram
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Figure 14-15 SACM Engine Service Data Sheet
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Figure 14-16 SACM Generator Service Data Sheet
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Figure 14-17 DeLaval Engine Service Data Sheet
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Figure 14-18 DeLaval Engine Articulating Connecting Rod Assembly
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