Documente Academic
Documente Profesional
Documente Cultură
Overspeed Checks
BTCP/BTRF
Maintenance Work
Practice
No. 8041
Introduction
Scope
References
Table of
Contents/
Attachments
Rev. 4, 09/14
See Page
Introduction
Definitions
General Information
General Requirements
Responsibilities
Work Procedure
16
24
32
33
34
35
Page 1 of 35
Introduction, Continued
Safety, Health
and
Environmental
Precautions
General
Turbine casings are not normally designed for inlet steam pressure. To
prevent casing overpressurization it is important to open the exhaust isolation
valve(s) first and the inlet steam last when lining up a turbine. When taking a
turbine out of service one must close the inlet steam valve first and the
exhaust isolation valve last to prevent casing overpressurization.
NOTE: Leaking inlet steam isolation valves can cause casing
overpressurization when a turbine is isolated.
After closing the inlet steam isolation valve, then open a case drain and then
close the exhaust steam valve. If the casing pressure rises above exhaust
pressure then the steam inlet valve may be leaking potentially causing
casing overpressurization.
Overspeed
Testing
Turbine trip valve should not be left closed with the turbine inlet steam lined
up. This can damage the valve seats and prevent proper operation of the
overspeed trip system.
Rev. 4, 09/14
Only personnel trained per these procedures can perform turbine overspeed
tests.
Personnel must position themselves out of the line of fire during testing
(i.e., at the governor end of the turbine and not on either side next to the
coupling or turbine casing).
Page 2 of 35
Introduction, Continued
Safety, Health
and
Environmental
Precautions,
Continued
Overspeed
Testing,
Continued
The design of governors and overspeed trip systems differ between turbine
manufacturers. Therefore, peculiarities of each turbine must be understood
before working on the machine. Refer to the turbine manufacturer's
instruction manual and machinery equipment file for specific information about
proper adjustments and settings.
During testing if the turbine reaches a speed higher than the trip setpoint
(including tolerance), the turbine must be immediately manually tripped.
General Purpose (GP) Turbine - Typically smaller (less than 600 hp) turbines
used to drive pumps or other general purpose equipment.
Special Purpose (SP) Turbine - Typically larger (greater than 600 hp) turbines
used to drive compressors and other critical equipment. Special purpose
turbines are typically equipped with handwheel-type Trip/Throttle (T/T) valves
(sometimes called Gimpel valves) and electronic governors.
Definitions
Rev. 4, 09/14
Page 3 of 35
General Information
General Purpose
Turbines
Overspeed Trip
Testing Frequency
Acceptance
Criteria
Special Purpose
Turbines
Rev. 4, 09/14
Item
Description
Trip speed deviation from target trip speed by more than +5%.
For general purpose turbines that are tested when still coupled
up to driven equipment, the turbine must roll to a stop with trip
valve closed and full inlet steam pressure upstream of the trip
valve.
Overspeed trip occurring above the maximum trip speed for that
particular turbine.
Page 4 of 35
Item
Special Purpose
Turbines,
Continued
Overspeed Trip
Setpoint
Description
Continued
General Requirements
Item
Conditions Not
Requiring
Overspeed
Testing
Rev. 4, 09/14
Requirement
This document must be at the job site in the field and readily
accessible to those doing the test when overspeed test is performed.
Other Conditions
Requiring Turbine
Overspeed
Testing
Item
Requirement
A complete overspeed test is required if the trip bolt, trip weight, trip
spring, trip valve, trip linkages, knife edges or trip arms are replaced, or
any other component that may effect the functionality of the overspeed
trip system. If these parts are replaced during a shop repair, it is
preferred that the shop test the overspeed trip system in the shop as
part of the repair (it is recognized that this may not always be feasible).
The turbine overspeed setpoint must be in the range outlined in
Attachment 1 as demonstrated by a shop overspeed test prior to
reinstallation in the field.
NOTE: If a turbine has just been repaired and a shop
overspeed test was performed and witnessed by an
ExxonMobil representative, only one field test of the
overspeed trip system is required before the turbine
is returned to process.
Actions To Be
Taken When Any
Turbine Fails
Overspeed Test
Responsibilities
No.
Requirement
Mechanical FLS
Mechanical
(ExxonMobil and
Contractors)
Process
Machinery
Records Clerk
Rev. 4, 09/14
Page 6 of 35
Responsibilities, Continued
No.
5
Technical
Requirement
Provides technical recommendations when problems are identified.
NOTE: Additional details regarding roles and
responsibilities are provided throughout this
document.
Work Procedure
Section 1: General Purpose Steam Turbines to be Tested Uncoupled
Rev. 4, 09/14
Action
A turbine PM must be complete per MWP-8040 before overspeed testing to help insure that turbine hardware performs as
designed during overspeed testing.
Initial
____
Page 7 of 35
Inspection/
Overspeed Trip
Checks for
Turbines with
Small Bypass
Line, Continued
Prepare for
Overspeed
Testing
Step
Action
Prior to testing, obtain the Overspeed Trip Testing Data Sheet Initial
located per equipment tag in STRIPES. Verify that the
indicated operating speed, overspeed trip Setpoint and
overspeed trip Acceptance Range listed on the Data Sheet
agree with values given in Attachment 1 of this MWP AND with
the turbine nameplate information. If there is a discrepancy, do
____
not continue with the test, and contact the BTES Machinery
Technical Section to resolve the issue.
Rev. 4, 09/14
NOTE:
Initial
____
Initial
____
Initial
____
____
Page 8 of 35
Step
Action
Initial
____
Initial
____
____
WARNING:
IT IS VERY IMPORTANT THAT A REMOTE
READING TACHOMETER BE USED SO
PERSONNEL DO NOT HAVE TO STAND ON
EITHER SIDE OF THE TURBINE. DO NOT USE
TACHOMETERS WHICH REQUIRE
PERSONNEL TO HOLD THEM CLOSE TO THE
SHAFT AS THIS PUTS PEOPLE IN THE LINE
OF FIRE IF A FAILURE OCCURS.
Rev. 4, 09/14
Page 9 of 35
Action
Preparation steps -
Initial
____
WARNING:
A SHIELD MUST BE PROVIDED FOR VERTICAL
TURBINES THAT ARE TESTED UNCOUPLED.
Rev. 4, 09/14
____
Prepare for
Overspeed
Testing,
Continued
Step
Action
10
Reset the overspeed safety device, and manually trip it to verify Initial
that it operates properly. If the trip valve fails to close quickly
and fully (i.e. linkage sticking, binding, etc.), the turbine has
failed overspeed testing. Follow instructions in Attachment 4
____
for a turbine failing overspeed testing.
11
Initial
____
WARNING:
OPENING TURBINE STEAM INLET BLOCK
VALVE OR BYPASS VALVE WHILE THE
TURBINE STEAM DISCHARGE (EXHAUST)
VALVE IS CLOSED COULD OVERPRESSURE
THE TURBINE CASING AND CAUSE CASING
RUPTURE AND/OR PERSONNEL INJURY.
____
____
WARNING:
IF THE SMALL STEAM BYPASS IS ROUTED
AROUND THE AUTOSTART CONTROL VALVE,
DO NOT PROCEED WITH THIS TEST UNTIL THE
AUTOSTART VALVE IS BLINDED. IT IS UNSAFE
TO OPEN THE SMALL STEAM BYPASS
AROUND THE AUTOSTART VALVE IF THE
AUTOSTART INLET IS NOT BLINDED.
Rev. 4, 09/14
Page 11 of 35
Manually Trip
Overspeed
Device
12
Action
Crack open small steam bypass around turbine steam inlet
valve (this could be the closed inlet steam block valve or
blinded autostart valve) to SLOW ROLL and warm up the
turbine.
Initial
____
13
Manually trip the overspeed trip valve linkage. With the trip
Initial
valve tripped (in closed position), continue to slowly crack open
inlet steam using the small steam bypass and see if turbine
rolls above 50% of rated speed. If the turbine speed exceeds
50% of rated speed with trip valve closed and normal steam
pressure upstream of the trip valve, then the turbine has failed
overspeed testing. Follow instructions in Attachment 4 for a
____
turbine failing overspeed testing.
14
Initial
____
WARNING:
RESETTING OVERSPEED SAFETY TRIP
WITHOUT FIRST CLOSING ALL STEAM INLET
VALVES CAN RESULT IN UNCONTROLLED
TURBINE OVERSPEED.
Clear
Unnecessary
Personnel
Rev. 4, 09/14
15
Initial
____
16
Initial
____
Page 12 of 35
17
Action
Check governor operation as follows:
Initial
____
CAUTION:
Small steam bypass must be opened slowly
during testing by machinist under the direction of
Process. During testing all other sources of inlet
steam to the turbine shall be blocked using
isolation valves, or blinded to prevent unexpected
rapid acceleration of turbine.
Electronic
Governor
Rev. 4, 09/14
____
____
18
Initial
____
19
Initial
____
Page 13 of 35
Action
NOTE:
20
Rev. 4, 09/14
Initial
____
____
____
____
Page 14 of 35
20
Action
Continued
Initial
____
____
____
____
CAUTION:
Steam block valve must be closed before
overspeed safety trip is reset. Resetting the
overspeed trip safety device before ALL steam
inlet valves are closed can result in uncontrolled
turbine overspeed.
Reset Overspeed
Safety Trip
Return Turbine
Back to
Operations
Rev. 4, 09/14
21
Initial
22
Initial
____
23
Initial
____
24
Initial
____
____
Page 15 of 35
Step
Action
25
Initial
____
Governor
Adjustment
Under Load (If
Required)
26
Initial
27
____
Return the completed test Data Sheet to the Machinery Records Initial
Coordinator.
____
Overspeed Trip
Section 2: General Purpose Vertical Steam Turbines to be Tested Coupled
Checks for
Vertical Turbines Vertical turbines pumps that are tested when coupled to a pump are to be
That Cannot be
tested using this procedure. Special precautions are required for vertical
Uncoupled from
turbines because the turbine disc is in a horizontal plane making it difficult for
Driven Unit
personnel performing test to avoid being in the plane of the turbine disc. This
section provides required procedures for overspeed trip testing such turbines.
CAUTION:
This procedure can only be used on turbine driven equipment in
which operation of the pump at trip speed will not overpressure
piping between the pump and pump discharge valve used to throttle
pump. Contact BTES Area Machinery Engineer to determine if this
procedure can be applied to a particular piece of equipment.
Rev. 4, 09/14
Page 16 of 35
A turbine PM must be complete per MWP-8040 before overspeed testing to help insure that turbine hardware performs as
designed during overspeed testing.
____
Initial
Rev. 4, 09/14
Initial
Prepare for
Overspeed
Testing
Action
Initial
____
Page 17 of 35
Step
5
Action
Mechanically inspect the governor as follows:
Mount
Tachometer
Initial
____
____
Initial
____
Rev. 4, 09/14
Initial
____
Page 18 of 35
Step
7
Action
____
Continued
WARNING:
IT IS VERY IMPORTANT THAT A REMOTE READING
TACHOMETER BE LOCATED BEHIND THE
PROTECTIVE SHIELD SO PERSONNEL ARE IN A
SAFE LOCATION DURING TESTING DO NOT USE
TACHOMETERS WHICH REQUIRE PERSONNEL TO
HOLD THEM CLOSE TO THE SHAFT AS THIS PUTS
PEOPLE IN THE LINE OF FIRE IF A FAILURE
OCCURS.
Prepare for
Overspeed
Testing
10
Rev. 4, 09/14
Initial
Initial
____
____
Page 19 of 35
11
Action
Line up system for test as follows:
Initial
____
____
____
Bring Turbine to
SLOW ROLL
12
Crack open the steam inlet block valve to SLOW ROLL and
warm up the turbine.
Initial
____
Manually Trip
Overspeed
Device
13
Manually trip the overspeed trip valve linkage. With the trip
valve tripped (in closed position), continue to crack open inlet
steam and see that it rolls to a complete stop. If the turbine
speed does not roll to a stop with trip valve closed and normal
steam pressure upstream of the trip valve, the turbine has
failed overspeed testing. Follow instructions in Attachment 4
for a turbine failing overspeed testing.
Initial
14
Rev. 4, 09/14
____
Page 20 of 35
Clear
Unnecessary
Personnel
Check Governor
Operation
Throttle Pump
Discharge
Action
14
WARNING:
Continued
15
Initial
____
16
Initial
17
18
____
Initial
____
____
____
Initial
____
CAUTION:
Do not completely close the discharge valve or
pump could be damaged. If possible, monitor
total flow through the pump to maintain pump
above minimum flow.
Rev. 4, 09/14
Page 21 of 35
19
Initial
____
20
Initial
____
Check
Overspeed
Safety Trip
Operation
NOTE:
21
Action
Initial
____
Or
Where governor speed adjustment allows, increase
governor speed setpoint until turbine trips on
overspeed but don't exceed the maximum speed
outlined in Attachment 1.
NOTE:
Rev. 4, 09/14
____
____
Page 22 of 35
21
Action
Continued
Reset Overspeed
Safety Trip
Initial
____
____
____
____
Rev. 4, 09/14
Action
23
Initial
____
24
Initial
____
25
Initial
Initial
____
26
____
Rev. 4, 09/14
Page 24 of 35
Overspeed Trip Setpoint and Acceptance Range: The overspeed trip Setpoints
and Acceptance criteria for Special Purpose steam turbines are listed in
Attachment 2 of this MWP.
A turbine that trips above the maximum acceptable trip speed shown for this
turbine in Attachment 2 will be judged to have FAILED the test. Follow
instructions in Attachment 4 for a turbine failing overspeed testing.
Prepare for
Checks
Rev. 4, 09/14
Step
Action
Prior to testing, obtain the overspeed trip testing Data Sheet from Initial
the Compressor Maintenance Crew Planner. Verify that the
operating speed, overspeed trip Setpoint, and overspeed trip
Acceptance Range listed on the Data Sheet match the values
given in Attachment 2 of this MWP AND with the turbine
nameplate information. If there is a discrepancy, do not continue
with the test, and contact the BTES Machinery Technical Section ____
and the Compressor Maintenance Crew Planner to resolve the
issue.
NOTE:
Initial
____
Page 25 of 35
Check
Tachometer
Action
Ensure that Process has not used the T/T valve for energy
isolation.
Initial
____
Initial
____
Reset the overspeed safety device and manually trip the inlet
Initial
steam trip and throttle (T/T) valve to verify operation. If the T/T
valve does not trip satisfactorily, the turbine will be judged to
have FAILED the test. Follow instructions in Attachment 4 for ____
a turbine failing overspeed testing.
Initial
____
Initial
____
Initial
____
____
WARNING:
IT IS VERY IMPORTANT THAT A REMOTE
READING TACHOMETER BE USED SO
PERSONNEL DO NOT HAVE TO STAND ON
EITHER SIDE OF THE TURBINE. DO NOT USE
TACHOMETERS WHICH REQUIRE PERSONNEL
TO HOLD THEM CLOSE TO THE SHAFT AS THIS
PUTS PEOPLE IN THE LINE OF FIRE IF A
FAILURE OCCURS.
Rev. 4, 09/14
Page 26 of 35
8
Continued
Action
NOTE: Only a calibrated digital tachometer can be
used. Vibrating reed tachometer must not be
used for overspeed safety trip checks
because they do not provide reliable data.
This digital tachometer must be calibrated
annually and a record of the calibration kept
on file for 3 years.
Line Up System
Bring Turbine to
SLOW ROLL
10
Initial
____
11
Initial
____
12
Initial
____
13
Initial
____
WARNING:
OPENING TURBINE STEAM INLET BLOCK
VALVE OR BYPASS VALVE WHILE THE
TURBINE STEAM DISCHARGE (EXHAUST)
VALVE IS CLOSED COULD OVERPRESSURE
THE TURBINE CASING AND CAUSE CASING
RUPTURE AND/OR PERSONNEL INJURY.
Rev. 4, 09/14
Page 27 of 35
Manually Trip
Overspeed
Device
Clear Personnel
Check Governor
Operation
13
Action
Initial
____
____
Continued
14
Manually trip the throttle and throttle valve (T/T valve). If the
turbine rolls at a speed above 20% of the minimum governor
speed with the T/T valve closed with normal steam pressure
upstream of the trip valve, the turbine has failed overspeed
testing. Follow instructions in Attachment 4 for a turbine failing
overspeed testing.
Initial
15
Initial
____
16
Initial
____
17
Initial
____
18
Initial
19
____
____
____
____
Rev. 4, 09/14
____
Initial
____
____
____
Page 28 of 35
Action
NOTE:
20
Initial
____
____
Rev. 4, 09/14
Note the trip speed and observe that the T/T valve closes
rapidly and the turbine rolls to a speed less than 20% of ____
the minimum governor speed.
Repeat this test two more times for turbines that have no
mechanical overspeed shutdown system (for a total of
____
three tests).
Page 29 of 35
21
22
Action
Have I&E temporarily raise the electronic overspeed setpoint
200 rpm above the maximum rpm of the Trip Acceptance
Range shown in Attachment 2 for this turbine.
NOTE:
NOTE:
Rev. 4, 09/14
Initial
____
Initial
____
____
____
Page 30 of 35
Action
22
Continued
Reset Overspeed
Safety Trip
Initial
____
____
23
Have Process fully close the T/T valve, then reset the
overspeed safety trip.
Initial
____
24
25
If the turbine passes the overspeed test, repeat Steps 14, 15,
16, 17, 18, 19, 22, and 23 of this section two more times to
verify the turbine reliably trips within the Acceptance Range
(see Attachment 2 for Special Purposes Turbines).
Initial
26
Initial
____
27
Initial
____
28
Initial
____
29
Initial
____
____
Rev. 4, 09/14
Page 31 of 35
Attachment 1
(see note 2)
(rpm)
(rpm)
Min rpm
Max rpm
1200
1356
1290
1420
600
1800
2034
1940
2140
900
3600
4068
3870
4270
1800
(Other) Nr
Nr x 1.13
Nr x 1.075
Nr x 1.187
Nr x 0.5
Notes:
2) Tripping below the minimum rpm in the acceptance range does not constitute a failure of the
overspeed system and should not be reported as a failure of a safety critical device. This is because
tripping below the Trip Acceptance Range is a reliability issue and not a safety issue.
.
Rev. 4, 09/14
Page 32 of 35
Attachment 2
Special Purpose Steam Turbines Overspeed Trip Setpoint and Acceptance Range
Turbine
Trip "Setpoint"
(Lowest in "Train")
(rpm)
Min rpm
Max rpm
AS9 C-902
AS10 C351-B
BS4 C-904
BS4 C-905
CLEU3 C-30
DAU J-1
4375
3728
9000
8400
11,273
9160
5208
4100
9900
9400
12,400
10,076
5104
4018
9702
9212
12152
9874
5312
4182
10,098
9588
12648
10278
DAU J-1-A
FCCU2 J-101
FCCU2 J-102
FCCU2 J-10-C
FCCU2 J-10-E
FCCU2 J-4
FCCU3 C-301
9160
7481
10,129
4950
7100
8525
8000
10,076
8230
11,419
5445
7810
9047
8800
9874
8065
11191
5336
7654
8866
8624
10278
8395
11647
5554
7966
9228
8976
FCCU3 C-302
FCCU3 C-303
FXK C-303
HCU1 C-701
HF3 C-1-A
HF3 C-1-B
7913
7913
8061
5200
8900
8900
8704
8704
8867
5710
9800
9800
8530
8530
8690
5596
9604
9604
8878
8878
9044
5824
9996
9996
HF4 C-401-A
HF4 C-401-B
HF4 C-402
HU6 C-101
LPU C101
PFU C501
PLP C-1
7959
7959
9779
9975
3600
9000
5964
8755
8755
10,757
10,973
4158
11000
6560
8580
8580
10542
10753
4075
10780
6429
8930
8930
10972
11192
4241
11220
6691
PP3 STG-31
PP3 STG-32
PP3 STG-33
PP3 STG-34
GF1 C-251
FXK C-301
3600
3600
3600
3600
10,089
5100
3960
3960
3960
3960
11,099
5610
3881
3881
3881
3881
10876
5498
4039
4039
4039
4039
11321
5722
5100
5100
5100
5100
5100
5100
5100
5610
5610
5610
5610
5610
5610
5610
5498
5498
5498
5498
5498
5498
5498
5722
5722
5722
5722
5722
5722
5722
2
2
2
2
2
2
2
PP3
PP3
PP3
PP4
PP4
PP4
PP4
Note 1:
Note 2:
Note 3:
Note 4:
Note 5:
GTG-35
GTG-36
GTG-37
GTG-41
GTG-42
GTG-43
GTG-44
Note
1
1
1
1
1
1
These turbines are designed as special purpose turbines. They shall be tested using the procedures in Section 3 of this MWP.
The frequency of testing, however, shall be per Attachment 3 since they have installed spares.
These are "helper" steam turbines on Gas Turbine trains. They are built as General Purpose turbines and must be tested using
the procedures outlined in Section 1. However, since they are linked to the maintenance schedules of the Gas Turbine trains,
their testing frequency is as per the Special Purpose testing interval guidelines given in Section 3.
This turbine has a triple redundant electronic overspeed shutdown system and is not equipped with a mechanical overspeed bolt.
As a general guide - it is preferred that for any turbine equipped with both an electronic overspeed shutdown and a mechanical
overspeed shutdown, the electronic overspeed setpoint shall be set at 100 rpm or less than the mechanical overspeed setpoint.
Tripping below the Min rpm in the acceptance range does not constitute a failure of the
overspeed system and should not be reported as a failure of a safety critical device.. This is because
tripping below the Trip Acceptance Range is a reliability issue and not a safety issue.
Rev. 4, 09/14
Page 33 of 35
Attachment 3
General Purpose Turbines Overspeed Testing Interval Adjustment for
Turbines Passing Overspeed Test
Step 1
Step 2
Step 3
Step 4
Step 5
Turbine tested
and passes
overspeed
test.
Mechanical to communicate
successful testing to Machinery
Records Clerk. Machinery Records
Clerk to record data for successful
overspeed test in TIGER or SAP.
Data also to be tracked to
determine overspeed testing MTBF.
Mechanical shall also issue a
monthly report for turbine
overspeed testing for the Baytown
Complex.
Determine current
testing interval. See
below.
Responsibility Mechanical
Rev. 4, 09/14
6 months
1 year
2 years
3 years
4 years (maximum
interval)
1 year
2 years
3 years
4 years
4 years (i.e. no change)
New turbine
overspeed tested
when installed.
Page 34 of 35
Attachment 4
Action Steps to be Taken for a Turbine Failing Overspeed Test
Step
Action
Responsibility
Mechanical
Mechanical
Mechanical
BTES
Mechanical
Mechanical
Rev. 4, 09/14
No action required
Page 35 of 35