LMI/OD/OPS/SYST/003/014.

1
REV.1 ,DECEMBER 2008
OVERSPEEDING OF STEAMTURBINES OF (STAGE-1) 200 MW UNITS

CONTENTS

Sl.No. Page

1.0 INTRODUCTION 4

2.0 REFERENCE DOCUMENTS 4

3.0 SUPERSEDED DOCUMENTS 4

4.0 SCOPE 4

5.0 DIRECTIVE 4

6.0 OVER SPEED TESTING PRECAUTIONS 6

7.0 TESTING PROCEDURES & FREQUENCY OF TESTING 7

8.0 REVIEW 9

9.0 DISTRIBUTION LIST 10

Page 3 of 10
 LMI/OD/OPS/SYST/003/014.1
REV.1 ,DECEMBER 2008

OVERSPEEDING OF STEAMTURBINES OF (STAGE-1) 200 MW UNITS

1.0 INTRODUCTION

Stage-1 ANSALDO Turbine is a tandem – compound, reheat unit with

double flow LP Turbine. It has nozzle governing which is of electro
hydraulic type. There are two emergency stop valves & six control
valves for HP turbine and two stop valves & two control valves for IP
Turbine. The combined critical speeds of Turbine Generator Unit are
1786 & 1987.

2.0 REFERENCE DOCUMENT

OD/OPS/SYST/003, DECEMBER 1993

3.0 SUPERSEDED DOCUMENTS:

LMI/OD/OPS/SYST/003/014.1 18.11.1994

4.0 SCOPE

Applicable to 200 MW Turbo-generators (St-1).

5.0 DIRECTIVE : The over speeding of Turbine can result from :

I. The governor failing to arrest the speed rise after the load is
rejected.

II. Failure of the over speed tripping devices.

III. Valve Mechanisms sticking.

IV. The release of stored energy to the Turbines .

The excessive overspeeding will result in failure of Turbine

due to increased centrifugal forces. It also results in
Page 4 of 10
 LMI/OD/OPS/SYST/003/014.1
REV.1 ,DECEMBER 2008
higher & undesirable stresses in the rotating assemblies. So,
over speeding shall be restricted to the absolute minimum
magnitude, duration & frequency necessary to ensure safety of
the Turbines.

The tripping of Turbines on overspeeding is to be ensured in the

following ways:

I. By checking the healthiness of governing system and the

associated valves.

II. By doing the over speed tests at regular intervals. (oil

injection)

III. Checking the tripping of the machine by actual over

speeding of the prime mover.

5.1 DIRECTIVES FOR CHECKING THE HEALTHINESS OF

GOVERNING SYSTEM AND VALVES:

I. After overhauls and after long shutdown, all the emergency stop
valves, reheat stop valves, HP control valves and reheat control
valves are to be operated through their full range of operation.
(i.e. 0 to 100 %) – for checking free valve operation. A
protocol has to be maintained.
Resp: DGM(O)
II. During normal running of units, the operation of emergency
stop valves, reheat stop valves and control valves are to be
checked for full closing and opening and freeness of control
valves. This is to ensure that sticking of the valves is not there.
The load is to be kept around 95 % of the full load (190 MW),
Required assistance is to be provided by C&I.
Resp: UCE
Frequency - Once in a week full close operation,
(Every Monday A Shift) other days partial closing.
This is to be recorded in the log books of Turbine
Desk Engr. and UCE.
Page 5 of 10
 LMI/OD/OPS/SYST/003/014.1
REV.1 ,DECEMBER 2008
III a) During rolling of Turbine, the steam tightness of the HP
Control Valves and reheat control valves must be ensured
preferably once in six months by charging the steam up to these
valves in the presence of Turbine Maintenance. The
observation is to be recorded in the Log Book. If any passing is
observed this is to be brought to the notice of GM ( R )and
AGM (O&M) in writing.
Resp: SCE
III b) During shutdown of Turbine, the turbine should be unloaded
fully by closing the HP control valves and reheat control
valves. It is to be ensured that the turbine is not accelerating.
In case if it does not happen and turbine is accelerating , that
should be brought to the notice of General Manager ( R ) and
the problem should be sorted out before taking back the turbine
in to service.
Frequency: During planned shutdown / once in 6 months.
This is to be recorded in UCE & SCE log books.

6.0 OVER SPEED TESTING PRECAUTIONS:

I. The persons doing the test must be aware of the maximum speed (3380
RPM) at which the prime mover may be run and the need to limit over
speeding to the minimum duration.
Resp: DGM (O)
II. Before carrying out an over speed test on Turbine Generator precautions
must be taken to ensure that the field breaker is open and the machine is
in de-excited condition.
Resp: DGM(O)
III. The on load overspeed testing equipment (oil injection overspeed test)
should not be operated immediately before the actual overspeed test, to
avoid the freeing of the overspeed trip gear giving an artificial result
Resp: DGM(O)
IV. Before carrying out an over speed test, precautions must be taken to
limit the supply of steam to the minimum necessary, approx 30 % of
Boiler load (180 T/Hr). The machine should be warmed up sufficiently

Page 6 of 10
 LMI/OD/OPS/SYST/003/014.1
REV.1 ,DECEMBER 2008
so that casing expansions are at least 80 % of full load expansion.
(Approx. 18 mm).
Resp: DGM(O)
V. During over speed test after overhaul, shaft speed should be measured
with Stroboscope. The indicator readings and stroboscope readings are
to be compared. Previous overspeed trip values are to be examined for
reference.

Resp:DGM(O)/(MTP)

VI. The manual emergency trip must be manned by U.C.E. who can see
clearly the speed achieved and who will trip the turbine if the maximum
permissible speed is exceeded or if there is any abnormality in the
turbine. This person must be in direct communication with the person
controlling the speed of the turbine. Maximum allowable speed is 3380
RPM.
Resp: DGM(O)

7.0 TESTING PROCEDURES & FREQUENCY OF TESTING:

A: During normal running, the overspeed testing should be done once in a

month by oil injection method. The test can be done either from remote or
local.

I. REMOTE:
a) Check that the Turbine speed is around 3000 RPM.
b) Press the ‘Lock out’ button so that the actual tripping of the machine
does not occur. Ensure ‘Locked out’ LED is lit on the ATRS panel.
c) Press the ‘Oil Trip’ button and observe that the annunciation
“Hydraulic Overspeed / Turbine Emergency Trip” is appearing along
with LED indication of MTD ‘Trip’. Stop pressing “Oil Trip” button.
d) Then press the “Reset” button so that the annunciation and MTD
is reset ( MTD “Reset” indication LED appears) and the “lock out” is
released (after 10 to 13 seconds)
Resp: Turbine Desk Engr.
Page 7 of 10
 LMI/OD/OPS/SYST/003/014.1
REV.1 ,DECEMBER 2008

II. LOCAL :
a) Pull, turn clockwise and hold the lockout handle in the turbine front
pedestal. Check for lockout indication in the front pedestal.
b) Open the oil valve and see that overspeed trip is acting indicated by
MTD lever coming out.
c) Close the oil valve.
d) Pull, turn the reset handle anticlock wise and ensure that the
overspeed trip is reset. Indicated by lever going in.
e) Release the lockout handle to its original position.
Resp: UCE

B. AFTER OVERHAULING:
The actual overspeeding of the turbine is to be done after Turbine OR
governing system overhauling. The precondition is that casing
expansion should be at least 80 % of normal full load expansion.(i.e.
Approx. 18 mm)

STEPS:

a) Reduce the load on the unit to less than 10 MW after aux’s supply change
over to station.
b) Slowly close the control valves fully, ensure zero MW on the machine and
desynchronize the machine by opening the main and middle breakers of
Generator.
c) De-excite the machine by opening the field breaker of Generator.
d) See that turbine is running at 3000 RPM by adjusting the HP / LP bypass
valves position.
e) The local operator is to be positioned near the front pedestal to watch the
speed. (with Two Way communication).
f) Then the overspeed button in the ATRS console is to be pressed
continuously and speed rise to be observed both in UCB & Local
g) The speed at which the turbine is tripping with the annunciation ‘Hydraulic
overspeed / Turbine trip’ is to be noted both in local & UCB.
Page 8 of 10
 LMI/OD/OPS/SYST/003/014.1
REV.1 ,DECEMBER 2008
h) Incase the Turbine is not tripping around 3300 RPM (110 %) it is to be seen
that Electrical back up protection is acting at a speed of 3360 RPM (112 %).
or else trip the turbine at 3370 RPM.
i) If the Turbine is not tripping even at 3360 RPM trip the Turbine from push
buttons on turbine desk or from local. The matter is to be brought to the
notice of General Manager immediately. The turbine should be brought into
service again only after rectification of the problem.

Resp: SCE / UCE

D. ELECTRICAL OVER SPEED TESTING (Simulation) :
During every overhaul the speed channel output of the turbine can be
increased (by simulation) and it can be observed at what speed (in
ATRS console) the electrical protection (112 % over speed) is acting.
Frequency: After every overhaul prior to turbine start-up.
Resp: UCE
All the three testings are to be recorded in the UCE and Desk
Engineers Log books.
At any time if the on load overspeed test device fails to give
satisfactory indications, the cause must be investigated immediately
and if not resolved, the turbine should be taken out of service and an
actual overspeed is to be done and is to be repeated once in a every
three months till the on load overspeed testing is made available.
Resp: DGM (OPN)
If for any reason, it is not possible or practicable to carry out an actual
overspeed test at least once in every 12 months, it should be brought to
the notice of General Manager explaining the reasons for not carrying
out the test and formal dispensation from Director (OPERATION)
should be sought on each and every occasion.
Resp: AGM (O)

8.0 REVIEW:
HOD(O) will be responsible for reviewing this document on a 3 yearly
basis, or as and when required.

Page 9 of 10
 LMI/OD/OPS/SYST/003/014.1
REV.1 ,DECEMBER 2008

DISTRIBUTION LIST

1. HOD (O)

2. GODAVARY INTRANET

REVIEW RECORDS

S.NO DATE REVIEWED BY SIGNATURE

Page 10 of 10