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Effective December 6, 2006, this report has been made publicly available in accordance with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export Administration Regulations. As a result of this publication, this report is subject to only copyright protection and does not require any license agreement from EPRI. This notice supersedes the export control restrictions and any proprietary licensed material notices embedded in the document prior to publication.

Basler SR8A Voltage Regulators for Emergency Diesel Generators

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WARNING: Please read the License Agreement on the back cover before removing the wrapping material.

Technical Report

Reduced Cost

Plant Maintenance Support

Equipment Reliability

Basler SR8A Voltage Regulators for Emergency Diesel Generators1011109

Final Report, December 2004

EPRI Project Manager J. Sharkey

EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA 800.313.3774 650.855.2121 askepri@epri.com www.epri.com

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIESTHIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM: (A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR (B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT. IMPORTANT NOTICE USE OF THIS DOCUMENT IS VOLUNTARY. IT IS NOT INTENDED FOR REGULATORY OR ENFORCEMENT PURPOSES. IT IS OFFERED FOR CONSIDERATION AND USE BY MEMBERS OF NMAC. USE OF THIS DOCUMENT AND ITS CONTENTS BY ANYONE OTHER THAN THOSE FOR WHOM IT IS INTENDED IS NOT AUTHORIZED. THIS DOCUMENT IS BASED ON CONSENSUS OF UTILITY PERSONNEL, WITH INPUT FROM THE MANUFACTURER AND OTHER CONTRIBUTORS. THERE MAY BE OTHER TECHNIQUES OR MEANS OF PERFORMING THE WORK OR ACTIVITIES DESCRIBED IN THIS DOCUMENT. QUESTIONS CONCERNING USE OF THIS MATERIAL SHOULD BE DIRECTED TO EPRIS NUCLEAR MAINTENANCE APPLICATIONS CENTER (NMAC). ORGANIZATION(S) THAT PREPARED THIS DOCUMENT EPRI

ORDERING INFORMATIONRequests for copies of this report should be directed to EPRI Orders and Conferences, 1355 Willow Way, Suite 278, Concord, CA 94520, (800) 313-3774, press 2 or internally x5379, (925) 609-9169, (925) 609-1310 (fax). Electric Power Research Institute and EPRI are registered service marks of the Electric Power Research Institute, Inc. EPRI. ELECTRIFY THE WORLD is a service mark of the Electric Power Research Institute, Inc. Copyright 2004 Electric Power Research Institute, Inc. All rights reserved.

CITATIONSThis report was prepared by Nuclear Maintenance Applications Center (NMAC) EPRI 1300 W.T. Harris Boulevard Charlotte, NC 28262 Principal Investigator J. Sharkey This report describes research sponsored by EPRI. The report is a corporate document that should be cited in the literature in the following manner: Basler SR8A Voltage Regulators for Emergency Diesel Generators, EPRI, Palo Alto, CA: 2004. 1011109.

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REPORT SUMMARY

This report contains information to help utilities address emergency diesel generator voltage regulator issues. Background Over 40% of domestic U.S. nuclear power plant emergency diesel generator (EDG) voltage regulators are obsolete. EDG voltage regulators, typically of 195060 vintage, have recently experienced aging and obsolescence issues that have created a heightened awareness among nuclear utilities because of the threat to overall EDG performance. The industrys situation is complicated by parts shortages and limited or nonexistent manufacturer support. It is noted that all Basler Model voltage regulators are not obsolete at this time (other than the systems provided by Basler to support the EMD Mag Amp design), and their line is currently supported by nuclear EDG manufacturers or distributors and a Basler teaming arrangement with a third-party company. Objectives To provide guidance on maintenance and maintenance-related issues of Basler SR8A voltage regulators in nuclear EDG service To provide maintenance guidance, including a description of specific voltage regulator systems; a review of failure history, tuning, troubleshooting, routine preventive maintenance tasks; and discussions of special maintenance tasks

Approach The project teams approach focused on addressing (1) industry-wide voltage regulator maintenance issues (provided under separate cover) and (2) specific issues relating to specific models of voltage regulators. The project team reviewed industry databases for EDG voltage regulator failure information and analyzed these data to identify common industry maintenance issues. The resultant maintenance issues were combined with the project teams own expertise in maintenance, training, and troubleshooting to develop discussions on voltage regulator failures/problems, testing, obsolescence, and good practices. Tuning and troubleshooting information was added based on the project teams extensive experience. Original equipment manufacturer (OEM) materials and existing training materials were used to develop the voltage regulator descriptions. This document was then reviewed by consultants and utility personnel responsible for EDG system and voltage regulator maintenance.

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Results This report is one of a series of reports (each under separate cover) that provides componentspecific information for five voltage regulators. This report provides information for the Basler SR8A voltage regulator; other reports provide information for the Portec (NEI Peebles) (EPRI product number 1011108), the Basler SBSR (EPRI product number 1011110), the EMD Mag Amp (EPRI product number 1011111), and the Basler SER-CB Voltage Regulators (EPRI report number 1011218). These reports describe each voltage regulator and its functional and support circuits. Details on tuning and guidance on bench testing are provided. Failures and problems, their respective solutions, and troubleshooting information are also provided along with guidance on specific obsolescence issues and preventive maintenance. An additional report, Emergency Diesel Generator Voltage Regulator Maintenance Issues (EPRI product number 1011232), provides generic guidance applicable to all nine models of voltage regulators in service at domestic U.S. nuclear plants. A review and analysis of industry failure data is provided. EDG testing practices are discussed along with their impact on voltage regulators, including post-maintenance testing, power factor testing, and droop operation. Information on obsolescence and vendor support is provided as well as specific information relating to voltage regulator systems that are obsolete, and actions that station personnel can take to address obsolescence. The report also discusses some general industry good practices. EPRI Perspective This series of reports provides users with several tools that they can use to cost-effectively address voltage regulator maintenance. Stations can use the provided troubleshooting guides, specific problems and solutions, tuning procedures, maintenance recommendations, and postmaintenance testing guidance to improve their EDG maintenance programs. Keywords Voltage regulator Static exciter Emergency diesel generator Diesel engine Electrical maintenance

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EPRI Licensed Material

ACKNOWLEDGMENTSVarious individuals and organizations provided substantive contributions to this report. NMAC would like to recognize the following for their contributions, reviews, and support of this document. The time and consideration of each are greatly appreciated. NMAC would especially like to recognize the technical contributions of Kevin Nichols and Robert Sawyers of ProTec, Inc., and Ted Bronson of Power Equipment Associates. Paul Banaszak David Blackwell Branko Boi Ted Bronson Alan DeGracia Clayton Erickson Harry Epstein Erban Green Rick Hermann Bill Hill Arvin Ho Jeff Keene Steve Kowalski Roger Kulavich Steve Laughlin Skip Lehman Kevin Nichols David Pederson Wayne Reynolds John Rosenberger Turkey Point Dresden Krko, Slovenija Power Equipment Associates Fitzpatrick Kewaunee IEN Engineering Diablo Canyon Columbia Generating Station Comanche Peak Exelon Pilgrim Clinton Station St. Lucie Quad Cities Consultant ProTec, Inc. Point Beach St. Lucie Surry vii

EPRI Licensed Material

Todd Sarver Robert Sawyers Alan Smith Jeff Warren Don Willis Laurentius Wyngaard Gary Yezefski

McGuire ProTec, Inc. Millstone Robinson Sequoyah Koeberg Nuclear Power Station Comanche Peak Basler Electric

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EPRI Licensed Material

CONTENTS

1 INTRODUCTION ....................................................................................................................1-1 1.1 1.2 1.3 Background..................................................................................................................1-1 Contents ..........................................................................................