LOCAL MANAGEMENT INSTRUCTION LMI/OD/OPS/SYST/003

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

Approved for: Implementation by- - - - - - - - - -signed - - - - - - - - - - - - - - - - - -- -GM, Dadri Date:

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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LMI APPROVAL DOCUMENT

Title of LMI PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS LMI/OD/OPS/SYST/003 OD/OPS/SYST/003 Issue No. : 1 Date : December 1993 Prepared By Ravindra Kumar Jangid Engr(Operation) Ashutosh Anshu Engr(Operation) Hare Ram Singh DGM(Operation) Signature: - - - - - - - - - -- - - - - - Rechecked By S. S. Sen AGM(Operation) Signature: - - - - - - - - - -- - - - - - Reviewed By Siva Rama Krishnam AGM(O&M-TH) Signature: - - - - - - - - - -- - - - - - Approved By P. R. Dahake GM Signature: - - - - - - - - - -- - - - - - Date of issue 13.09.2011

Document code Original/Ref. document

Checked By

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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TABLE OF CONTENTS S.No. 1. 2. 3. 4. 5. 6. 7. 8. CONTENT INTRODUCTION SUPERSEDED DOCUMENTS SCOPE DIRECTIVE/PROCEDURE RECORDS IMPLEMENTATION REFERENCE DOCUMENTS REVIEW PAGE NO.

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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1.0 INTRODUCTION
Prime movers can be damaged beyond repair by excessive overspeeding. This can result from: i) The governor failing to arrest the speed rise after load is rejected, and ii) Failure of the overspeed tripping devices, or iii) Mechanisms sticking, or iv) The release of stored energy to the prime mover.

2.0 SUPERSEDED DOCUMENTS

None

3.0 SCOPE:
This is applicable to 500 MW steam turbines and TD BFPs drive steam turbines installed at NTPC Dadri Stage-II.

4.0 DIRECTIVE
Overspeeding should be restricted to the absolute minimum magnitude, duration and frequency necessary to ensure safety of the Prime mover. The failure of prime movers following excessive overspeeding results from the increased centrifugal forces. However any overspeeding results in higher, and therefore undesirable, stresses in the rotating assemblies. DEFINITION OF OVERSPEED An overspeed is a speed greater than the maximum rotational speed value prime mover can achieve when under normal Governor Control. KWU turbines are provided with an on line-testing device for checking the healthiness of overspeed protection device. To prevent overspeeding of 500 MW turbines, the healthiness of protective devices are to be tested and ensured during: 1) Normal operation 2) After an overhaul or long shutdown 3) While shutting down the unit.

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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4.1 During normal operation:

The following tests shall be done during normal operation of the unit:

Procedure: Exercising Turbine stop and control valves: The stop and control valves of the turbine are the final control elements governed by the protective devices. The testing of these valves in conjunction with testing of protective devices ensures that all elements, which might respond on turbine trip, are tested for their ability to function reliably. Each stop valve is tested together with its associated control valve through ATT. Only one valve assembly may be selected and tested at a time. Grid frequency shall be above 49 Hz. I) Turbine shall be in EHC and Load control mode with CMC and frequency influence off. II) Turbine Load shall be maintained 400 MW or less for testing of MS valves & > 200 MW for HRH valves. III) Select the valve group to be tested. IV) Start the SGC program for valves testing. First the control valve closes. When the control valve is completely closed, the stop valves starts closing. Once stop valve is completely closed, the reverse process starts. After the valves return to their normal positions, carry out testing for other valves. During testing if any control valve is not closing fully, physically attempt should not be made to close the corresponding stop valve. Test of this set of valves is to be abandoned. The reason for not closing is to be investigated and corrected immediately. -Responsibility: DGM(C&I) / DGM (TMD) Overspeed trip device oil injection test: The healthiness of this device can be tested by either of the following method: - From control room by operating the automatic turbine tester. - From local turbine governing rack. I) From control room through ATT: Start the overspeed devices test program. Record the turbine speed, test oil pressure (local) at which the strikers actuate. Confirm the alarm in alarm page when the trip acts. The observations are to be recorded in Protection check register. -Responsibility: UCE II) From local turbine governing rack: Release testing device for operation. Inhibit trip by keeping test valve (LHS) pressed down. a) Pressurize test oil circuit by turning test signal transmitter hand wheel. b) Note the turbine speed and test oil pressure at which the strikers operate. Confirm alarm in control room. c) Depressurize test oil circuit by turning test signal transmitter hand wheel in opposite direction.

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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d) Reset the overspeed trip device to operating position by depressing the reset valve (RHS Test valve). Verify aux. trip fluid pressure is as before start of the test. Slowly release reset valve. e) Release test valve. Record turbine speed, and test oil pressure at which the strikers have acted in Protection check register. -Responsibility: UCE If the oil injection test results are not satisfactory, the cause shall be investigated immediately and if not resolved, the turbine shall be taken out of service immediately and actual overspeed test done. If actual overspeed test is successful, then until oil injection test gear is rectified, actual overspeed test shall be done every 3 months. -Responsibility: DGM (O)/ DGM (TMD)/DGM(C&I) Under base load or part load conditions, frequency correction or/and frequency influence are "on", the load will vary many times during the day depending on grid frequency thus ensuring healthiness of speed governor and control valves. Turbine shall always be rolled through EHC, such that the governor shall always be active to control the speed from the lowest speed. -Responsibility: UCE Healthiness of hydraulic controller shall be checked every month by taking it into service for 1 hour on 10th / 11th of every month and recorded in UCE log book. -Responsibility: UCE

4.2 After an overhaul or long shutdown

The following are to be carried out after an overhaul or long shutdown (> 1 month): Sl. Test No. 1 To establish smooth operation of stop, control and governor valves before rolling. Steam tightness test of turbine control valves. Method Precautions Responsibility Records

Governing characteristics to be checked over the full range of operation of the valves.

Care to be DGM.(O.) & taken to ensure DGM(TMD) steam is not admitted into the turbine.

Protocol to be made

2.

Reset turbine and open stop valves. Observe turbine speed. Turbine speed should not increase by more than 30 rpm.

This is to be DGM.(O.) & done only after DGM(TMD) reaching rolling parameters and TG on barring gear.

Protocol to be made.

3.

Overspeed trip To be test by oil through

done To be done at DGM.(O) & ATT 3000 rpm DGM(TMD)

Protocol to be made.

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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4.

from before synchronizing the machine Healthiness After resetting the To be done with DGM.(O) & of remote trip turbine, trip from main steam DGM( C&I) device. control room. line in Ensure both devices depressurized have tripped (both condition. channels). Correctness of Shaft speed should turbine speed be measured with indicators tachometer/strobosc ope and compared with speed indicator readings in control room. Shaft speed to DGM (MTP) be measured & DGM(C&I) and compared at 3000 rpm. This is to be done before synchronization.

injection.

program local.

or

Protocol to be made. (This is a part of turbine protection check) Measured and indicated speeds to be recorded in communication Register

5.

Any deviation in any of the above test results shall be corrected before unit is synchronized. -Responsibility: DGM.(Oprn.),DGM(C&I) / DGM(TMD)

4.3 While shutting down the unit:

The following tests shall be done while unit is being shut down as per indicated frequency of testing: Sl. Test No. 1. Steam tightness of control valves Method Frequency testing of Responsibility Records

2.

Overspeed trip.

Tightness of the control valves can be proven by establishing a motoring condition while shutting down Raising turbine speed to permissible overspeed and conforming tripping of the turbine.

Once in a year.

DGM.(Oprn.) & DGM(TMD)

Test results shall be recorded in SCE log book.

Every 12 months. Immediately after carrying out any maint. work on overspeed trip gear.

DGM.(Oprn.) & DGM(TMD)

Protocol to be made.

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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When unit is being shut down the steam tightness of the control valves shall be proved by establishing a motoring condition. - Gradually reduce unit load to 100 MW, with matching boiler firing. - Reduce throttle pr. to 100 Ksc. - Charge HP/ LP bypass. - Reduce load gradually to less than 2.5 MW and hold. Turbine shall trip after a time delay of 15 sec. Otherwise trip the turbine as prolonged operation below 2.5 MW can damage turbine. -Responsibility: DGM (O) Failures to establish a motoring condition shall be brought to the attention of General Manager before turbine is returned to service. Failure to establish motoring shall be investigated and understood before the machine is allowed to return to service. -Responsibility: DGM (TMD) Over speed trip: Precondition: - Turbine should be warm enough to have achieved more than 80 % of full load expansions. - Healthiness of overspeed trip device has been confirmed by oil injection testing within 15 days and more than 1 day prior to carrying out actual overspeed test. - Two independent speed indicators shall be available for the test. One the speed indicator (Control room & turbine governing rack) and the other a digital tachometer at local. - Generator circuit breaker and field breaker shall be open. - While de-synchronizing from grid, motoring condition shall be established. TEST PROCEDURE: - Turbine controls shall be continuously manned during the test. The person manning the turbine shall trip the turbine if the speed exceeds 3350rpm or as decided by DGM (O) and DGM (TMD). - A person familiar with its operation shall man the manual emergency trip device at turbine governing rack, and, he shall continuously monitor the speed on digital tachometer. Should any abnormality be observed or if turbine speed exceeds 3350 rpm, or, as decided by DGM (O) and DGM (TMD), he shall trip the turbine. - Trip turbine after load reduction, allow coasting down to barring gear. - Reset turbine and roll to 3000 rpm. - Raise starting device to a position such that it does not inhibit speed rise with speeder gear. - Raise turbine speed further from governing rack, by raising speeder gear to 100 %. - After ensuring healthiness of turbine, raise turbine speed by operating over speed knob. - Note the speed at which turbine trips along with corresponding primary oil pressure. All protocols are to be made in Protection Interlock test Register

Procedure: i) Steam tightness of control valves:

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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Drive Turbines of BFPs: Actual over speed testing of TDBFP drive turbines shall be carried out every 12 months. After cooling the BFP and turbine, remove coupling between turbine and BFP, and, coupling between Turbine and gearbox. Roll turbine to 3000 rpm and hold at this speed until turbine metal temperature stabilizes. Increase the turbine speed to maximum possible from control room. Further increase turbine speed to overspeed trip value from turbine governing rack by operating overspeed device. Note the speed at which turbine trips. The procedure for main turbine is applicable to TDBFP turbines also. -Responsibility: DGM.(O) If for any reason, actual overspeed test is not carried out once in 12 months, approval of Director (Operation) shall be taken for continuing the unit in operation. -Responsibility: DGM (TMD)

5.0 REFERENCE DOCUMENTS

This LMI is based on OD Procedure for testing to avoid excessive over speeding of prime movers OD/ODS/SYST/003 dated Dec1993.

6.0 RESPONSIBILITY
Responsibility to implement this LMI lies with DGM (O).

7.0 RECORDS
The records shall be maintained as required in referral LMI.

8.0 REVIEW
The GM (Dadri) will be responsible for reviewing this LMI after 2 years or as necessary.

PROCEDURE FOR TESTING AND MAINTENANCE TO AVOID EXCESSIVE OVERSPEEDING OF PRIME MOVERS

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