AUTOMATIC TURBINE TESTING (ATT)

INTRODUCTION Under the present crunch of power crisis, the economy dictates long intervals between turbine overhauls and less frequent shutdowns. This warrants testing of equipments and protection devices at regular intervals, during normal operation. The steam stop valves and control valves along with all the protective devices on the turbine must be always maintained in serviceable condition for the safety and reliability. The stop and control valves can be tested manually from the location but this test does not cover all components involved in a tripping. Also, manual testing always poses a risk of mal-operation on the part of the operator, which might result in loss of generation or damage to machine components. These disadvantages are fully avoided with the Automatic Turbine Test. A fully automatic sequence for testing all the safety devices has been incorporated which ensures that the testing does not cause any unintentional shutdown and also provides full protection to turbine during testing. SALIENT FEATURES The Automatic Turbine Tester is distinguishable by following features: Individual testing of each protective device and stop/control valve assembly. Automatic functional protective substitute devices that protect turbine during ATT. Only its pretest is carried out without any faults i.e. if the substitute circuit is healthy, the main test begins. Monitoring of all programme steps for execution within a predefined time. Interruption if the running time of any programme step is exceeded or if tripping is initiated. Automatic re-setting of test programme after a fault Full protection of turbine provided by special test safety devices. Automatic Turbine Testing extends into trip oil piping network where total reduction of trip oil pressure due to actuation of any protective device, is the criteria for the satisfactory functioning of devices. During testing, general alarm or the cause of tripping is also initiated so that this part of alarm annunciation system also gets tested. Also, during testing, two electrically formed values of 3300 rpm take over protection of turbine against over speed. The testing system or ATT is sub divided in two functional sub-groups.
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Each sub-group contains the device and all associated transmission elements for initiation of a trip. AUTOMATIC TESTING OF PROTECTIVE DEVICES ATT sub group for protective devices covers the following devices. 1. Remote trip solenoid-1. 2. Remote trip solenoid-2. 3. Over speed trip device. 4. Hydraulic low vacuum trip device. 5. Thrust bearing trip device. During normal operation, protective devices act on the stop/control valves via the main trip valves. Whenever any tripping condition (hydraulic/electrical) occurs, the protective device concerned is actuated. It drains the control/aux. trip oil, closing the main trip valves. The closure of main Trip Gear drains the trip oil, causing stop/control valves to close. During testing, trip oil circuit is isolated and changed over to control oil by means of test solenoid valves and the changeover valve. This control oil in trip circuit prevents any actual tripping of the machine. However, all alarm/annunciation are activates as in case of an actual tripping. Refer Fig. ATT for protective devices broadly incorporates the following sub programmes: a. Preliminary test programme. b. Hydraulic test circuit establishment. c. Main test programme. d. Reset programme.

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ATT SAFETY DEVICES

Preliminary Test In preliminary test programme, the substitute circuit elements and the circuit are tested for their healthiness; the turbine is fully protected against any inadvertent tripping during ATT. If any fault is present; further testing is inhibited. During preliminary test, following steps are performed.

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Test solenoids (TSX) become energised. Build-up of control oil pressure upstream of changeover valve is monitored. Test solenoids de-energised one by one & drop of control oil pressure is monitored. If all steps are executed within a specified time period pre-test is said to be successfully.

Hydraulic Test Circuit Establishment If no fault is present during preliminary test; command is automatically given to establish hydraulic test circuit (substitute circuit). The hydraulic test circuit is responsible for the supply of control oil in trip oil circuits. The test solenoids valves are again energised building up the control oil pressure upstream of changeover valve. At this moment another solenoid (SVX) gets energised, draining control oil and creating differential pressure across the changeover valve, it assumes upper (test) position and annunciation is flashed to this effect. With changeover valve in its test position, control oil flows in the trip oil piping. After successful establishment of hydraulic test circuit command goes to initiate the main test, in which individual devices can be checked.

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Main Test During main test programme, the associated hydraulic test signal transmitter with the exception of remote trip solenoids provides the necessary signal to actuate protective devices. The protective device under test operates and drains the aux. trip oil. Turbine trip gear (main trip valves) is closed after trip oil pressure drains and associated alarms flash. Reset Programme The resetting programme automatically starts after the main test is over. The reset solenoid valves energise and supply control oil in aux. start-up oil circuit to reset main trip valves and protective devices, which have tripped from their normal positions. Once they return to their normal position, trip oil and aux. trip oil pressure can be built-up and monitored. If oil pressure is satisfactory, reset solenoids along with test solenoid valves and SVX get de-energised, deactivating hydraulic test circuit and resetting circuit. TESTING OF PROTECTIVE DEVICES The main trip valves and remote trip solenoid valves have already been discussed in previous chapters; hence the remaining ones will be taken up here. Over speed Trip Device Trip consists of two eccentric bolts fitted on the shaft with centre of gravity displaced from the shaft axis. They are held in position against centrifugal force by springs whose tensions can be adjusted corresponding to 110% - 111% over speed. When over speed occurs, the fly weights (bolts) fly out due to centrifugal force and strike against the pawl and valves, draining aux. trip oil pressure and tripping the turbine.

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HYDRAULIC TEST SIGNAL TRANSMITTER (HTT) FOR OVER SPEED TRIP DEVICE

During ATT, the hydraulic associated

I. II. III. IV. V.

Control Oil Test Oil Aux. Trip Oil Aux. Startup Oil Drain Oil

1. 2. 3. 4.

Limit switch (normal) Limit switch (test) Valve for Test Oil Actuator

(HTT) becomes 'on'; spool valve slowly moves down to gradually build-up test oil (control) pressure beneath the flyweights. At pre-defined test oil pressure fly weight one and two operate to actuate individual pawl and spool arrangements bringing in the associated alarm. For resetting, spool moves-up and when test oil pressure is fully drained, aux. start up oil (control oil from 'reset' solenoids) pressure resets the devices to their normal position.

test signal transmitter

Low Vacuum Trip Device With deterioration of vacuum, pressure builds-up over the diaphragm, the spool valve move down, causing valve also to move toward lower position. The aux. trip oil pressure drains, tripping main trip valves and the turbine stop/control valves. During ATT, after hydraulic test circuit is established, the HTT (Hydraulic Test signal Transmitter) gets energised and connects the space above diaphragm to atmospheric pressure through an orifice. The device operates, bringing in the associated alarm. As soon as reset programme starts, HTT is de-energised and vacuum trip device is automatically reset, Field adjustment facilities and checks have been provided when turbine is stationary and there is no vacuum in the condenser. Thrust Bearing Trip Device This device operates in case of excessive axial shift ( >0.6 mm) or excessive thrust pad wear. Two rows of tripping cams on the shaft engage with the pawl) under high axial shift condition. Valves spool moves up draining aux. trip oil and tripping the trip gear and turbine. During ATT, associated ATT solenoid is energised and test oil pressure is supplied to test piston valve. The piston rod actuates the pawl and spool valve assembly, bringing in the associated alarms. During resetting, HTT is de-energised and aux. start-up oil (control oil) resets the device back into normal position.

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AUTOMATIC TESTING OF STOP/CONTROL VALVES The combined stop/control valves are final control elements of the turbine governing system. They must be maintained in absolutely workable condition for safety and reliability of turbine. All the four stop and control valve assemblies are tested individually.

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During ATT of stop/control valves, they are actually closed. In order to prevent large fluctuations of initial pressure or load on the machine, it is essential that Electro Hydraulic Governor is in service and machine load is less than 160 MW and load controller is 'ACTIVE'.

As soon as test programme is initiated, the positioner motor of control valve servomotor's pilot starts. The control oil supply pressure beneath the servomotor piston drops and control valve starts closing. After the control valve is fully closed, command goes to energise solenoid valve (1). The trip oil pressure drains beneath the disc of stop valve servomotor piston. The stop valve closes. After the stop valve is closed, automatically a command goes to energise another solenoid (2). This supplies trip oil to the test valve such that test valve moves down gradually to admit trip oil pressure above the servomotor piston. As soon as piston sits on the disc, there is a sudden rise in trip oil pressure, which is sensed by pressure switches. After these solenoids (1) & (2) de-energise, the test valve moves up to admit trip oil beneath the disc and connecting the space on top of the piston to drain. This pressure difference causes the stop valve to open. Once the stop valve is opened, next command goes to the positioner motor to move in reverse direction; opening the control valve. All along this test, the other control valves are operated by the governor, so as to keep the load and pressure reasonably constant. Should any turbine trip occur during the test, all solenoids are de-energised and tripping takes place in the usual manner.

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TESTING SCHEDULE All important turbine components must be tested at regular intervals. The operating reliability and availability can only meet the high requirements if testing is undertaken at the scheduled times, as recommended below. Testing Intervals Tests are scheduled according to the following Testing Interval Categories. 1. Testing Interval 0 2. Testing Interval I 3. Testing Interval II 4. Testing Interval III 5. Testing Interval IV 6. Testing Interval V Fortnightly Quarterly Six-monthly Annually After operation interruptions more than 12 month After or during overhauls

Testing Interval Category 0 applies to devices, which can be tested automatically without interrupting operation. The tables show the allocation of the Testing Interval Categories to the test. Controller
System / Device Test Test Conditions Test Interval 0 I II III IV V

Operation Turbine controller Load shedding relay Bypass controller Pressure controller Oil temp controller Function Adjustment Function Function Load Rejection Standstill Standstill Load rejection Operation Load rejection Adjustment Standstill Function Function Operation Operation

x x

x X* x

x x x x x x x x

x X* x X* x x x

X*: Recommended; not required by manufacturer

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Sub loop Control of Pumps

Test Conditions

Test Interval O I II III IV V

Oil Pumps

Function Start-up Pressure

Shutdown Operation

x x

Valves
System / Device Test Test Conditions Test Interval O I II III IV V

Standstill Stop Valves Freedom of movement Leak Test Operation Operation ATT x Shutdown Start-up Standstill Control Valves LP Bypass Control Valves Extraction Valves Safety valves Vacuum breaker Freedom of movement Leak Test Freedom of movement Freedom of movement Actuating valves Function Operation Operation ATT x Shutdown / Start-up Standstill Operation Operation/ Standstill Standstill x x x x / x x

x x

x x

x x x

x x x x

Protection and Safety Devices

Main Trip Valves (Gear) Function Remote Trip Solenoids

Standstill Operation ATT Standstill Operation ATT x

x x

Function

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Over Speed Trips

Function Actuating value

Over speed after load operation Rated speed Rated speed ATT Standstill Operation ATT Standstill Standstill x

x x

Hydraulic Function Low Vacuum Actuating Trip value Electrical Function Low Vacuum Actuating Trip value Thrust Bearing Trip LP Bypass Condenser Protection Reverse Power Protection Fire Protection Function Function Actuating value Function Function

x x x x x

x x

ATT

Standstill Shutdown Shutdown

x x x

x x x

Safety Function Devices for Actuating Reverse Flow value Low Lub Oil Pressure Protection Device Too high Steam Pr. Too low Steam Pr. Protection Devices Function Actuating value Function Actuating value Function Actuating value

Operation

Standstill

Standstill

Standstill

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Alarms and Measuring Devices System / Device Test Test Conditions Test Interval O I II III IV V

Alarms for all system Digital Signal Transmitter Speed Pressure Temperature Expansion Vibration Oil Level Valve Position Measuring Devices

Function Actuating Value Function Actuating Value

Operation Standstill Standstill Operation x

x x

x x x x x x x x x x x x x x

Accuracy of indication

x Standstill x x x

Measurement of Important Operating Parameters

Test Interval II III IV V

Long Term Monitoring

Steam Pressure Steam Temperature. Steam Flow Internal Efficiency Condenser Leak Tightness Bearing Metal Temp. Expansion Vibration Oil Levels Oil Pressure Oil Temperature

x x x x x Operation x x x x x x x x x x x x

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