API-612 Special Purpose Steam Turbines overspeed test.

The standard specify that the tolerance on overspeed trip values is 1% and for mechanical overspeed devices,the overspeed trip test should be conducted three times to attain three consecutive non trending values that meet this criterion. My question:what is the meaning of the expression "three consecutive non trending values"? That expression simply tells you that they should be from minimum three speed ramps up to the trip. And when looking at results, they should not be trending in the sense that the trip speed either steadily increases nor decreases. Like 19710, then 19834 and third 20123, or 17345, then next 17322 and then 16978. What must be acceptable is 19710, then 20123 and a final 19834. Just a cluster of readings that is not trending away. If you do have a trend, you need to repeat to make sure it does not. Thanks for the replies.One more question. What should be the frequency of uncoupled overspeed test for steam turbines(API612) with 1-Electronic governors 2-Mechanical overspeed devices. All our special purpose staem turbines(12nos) covered by API-612 are still with mechanical overspeed device. I don't know if API-612 specifies how the trip speed should be measured, but the shipyard here had a very expensive lesson on the proper way to do it...... They were setting the overspeed on an overhauled turbine generator. The built-in tachometer had a 2.5:1 gear which the calibration lab didn't take into account, so the installed tach was reading 2.5 times low. When setting the overspeed, a strobotach was used to determine the speed. The guy reading the strobe looked at the installed tach, dialed in the strobe to about that speed and adjusted it to freeze the shaft. Unfortunately, he was reading 1/2 that shaft speed. Apparently, the trip speed was very low (because they were actually reading 1/2 the shaft speed) so they kept adding shims to the overspeed to raise the trip speed. Where 1/16" of shims usually did the trick, they had over 1" and they still thought the unit was tripping too low. In actuality, the turbine was running at nearly twice its normal speed! This process came to an aburpt end when the generator rotor expanded so much that it hit the stator. The turbine shaft fractured on the coupled end and the overspeed mechanism went flying off the shaft. Miraculously, nobody was hurt in the process but it did cost $6.5 million to repair the generator. The local instructions have been modified to require the use of an optical tach for setting overspeeds. If using a strobe, be sure to follow the steps to ensure you're seeing rotation rate and not a harmonic or sub-multiple. Jon Spintelligent Labs Does anyone can tell me if there's any standard or code defining minimum overspeed values to factory test new steam turbine rotors for a power plant (170 MW, 2044psi, 1000F, 3600 rpm): 105, 110 or 120% of nominal speed?

For how long must be maintained this speed? Thanks in advance for yout help.
Javier Guevara E. Projects, Mechanical Engineer

12 Jul 10 7:17 I have never heard of any Code or Standard for FAT speed test. I have seen the customers bid spec include such a test. If I had to spec, the design of the controls should have an emergancy peak speed value. that is peak speed following a full load rejection WITH a 100% failure of the governor valves, so that valve closure is intiated at emergancy trip speed. thus the peak speed is nomally just over 120% rated. a hold for 3 minutes is what I seem to recall Mililani (Mechanical) There are two sorts of overspeed protection, electical and mechanical. Machanical, a bolt on a spring,the faster you turn the further out the bolt goes , at the setpont tit hits a finger and dumps the hydraulic system closing the stop valve. An electronic OS system looks at a speed pickup or a tachometer and then trips a solenoid that dumps the hydraulic system. The OEM should have supplied settings and a procedure for the overspeed test.

byrdj (Mechanical)

19 Jul 10 9:43

19 Jul 10 17:25 Mililani, I believe the OP is asking about a spin test of a bare rotor. Any steam turbine would have to have testing of the overspeed trip protection system. But, this is not relevant to his question. I reviewed our specifications for turbines and found no requirement for a spin test above running speed. For large turbines, we would perform the balance at full running speed. We would have a full test of the overspeed trip protection system at the OEM shop and again once the turbine is installed.

JJPellin (Mechanical)

Johnny Pellin

20 Jul 10 12:24 All steam turbine and generator rotors (large or small) need to be factory tested at overspeed. My steam turbine-generator specs always include a factory test at 120% of rated speed. I recommend holding at 120% speed long enough to obtain stable vibration readings. These readings should not exceeed the allowable vibration at rated speed by more than 100%. For generator rotors, the winding needs to be checked for shorted turns with a flux probe during overspeed testing. For turbine rotors, a visual inspection is necessary after overspeed to ensure no blading or shroud distress occurred during the test. Best of luck!

stgrme (Mechanical)

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