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Steam Turbine Description

Automatic Turbine Tester Stop and Control Valves

same hydraulic conditions during testing as would be the case in the event of actual turbine trip, as the action of the protective devices is simulated by the solenoid valve (MAX61 AA211 and 212). The steam side conditions during testing are somewhat more severe than during actual trip, as the pressure downstream of the stop valve can not drop off during closure because the control valve is closed. This means that the steam pressure acting on the valve spindle against the spring closure force is greater than in the event of normal trip. The automatic turbine tester intervenes only in the oil circuits normally used in valve servomotor actuation. Trip oil is used to actuate the test valves (MAX47 AA011 and 012) and to reset and open the stop valves. Thus closure of the valves can not be impeded in the event of a genuine trip during testing, regardless of the stage which the test has reached. This also applies to the control valves, as the ATT does not interrupt the secondary oil circuit and secondary oil can thus be depressurized in the normal manner in the event of a trip. Features of Automatic Turbine Tester The ATT has the following features: 1 Separate part-testing of each valve assembly. 2 Time-related monitoring of all program steps, and their implementation. 3 Interruption due to running time exceeded or turbine trip. 4 Automatic reset of test program after a fault. 5 Protection of the turbine during testing provided by special test protective circuits. Setting Data The setting data for the pressure switches used to monitor the individual valve movements are listed in the setting record Pressure Switch settings. The actual set values are logged in the Commissioning Test Record. The test running times, etc., are entered in the functional diagram.

The following description refers to a standard stop and control valve assembly. The same text applies analogously to both the emergency stop and HP control valves. The valve assembly described is drawn in the closed position (ready for start-up). General The emergency stop and HP control valves of the turbine are the final control elements actuated by the protective devices. It is, therefore, equally important that these, as well as the protective devices, should function reliably. The testing of these valves in conjunction with testing of the protective devices, as already described in Automatic Turbine Tester, General ensures that all elements which must respond on turbine trip are tested for their ability to function reliably. Each stop valve is tested together with its associated control valve. The automatic turbine tester is designed so that only one valve assembly may be selected and tested at any time. Test Requirements To avoid turbine output changes and initial pressure variations due to the closing of the control valve under test during testing, the electro hydraulic turbine controller must be in operation prior to testing. To facilitate compensation by the controller, the closing time of the control valves is relatively long, and to enable initial pressure to be maintained constant, testing is only permissible when the turbine output is below a certain value. Special Conditions during Testing The emergency stop and HP control valves may only be tested if no other ATT subgroup is running. During testing the selected control valve (MAA 10 and 20AAOO2) is closed completely by means of motor operated actuator (-AAOO2M) acting on pilot piston (KAO6) parallel to pilot value (KAO5). This result in a closing movement simulating that which occurs when the associated secondary oil pressure drops. The resultant, constant slow closing movement is necessary in order to keep the output constant. Thus the conditions for actuation of the valve are the same during testing as during normal actuation by the controller. The stop valves, which are held in the open position by trip oil pressure during normal operation, are subjected to exactly the

Test Selection Units There are 2 combined Emergency stop and HP control valves each of which is tested as a separate unit and has a separate selection push-button on the ATT control panel. They are as given below:

Selection1 :Emergency stop and control valve, left Selection 2 : Emergency stop and control valve, right Test Procedure Start of Test The test starts with the selection of subgroups by pressing the On/Off push-button. The subgroup remains On until it is switched off after the program is concluded. When one subgroup program is running, the other subgroup is blocked. The On/Off signals. push button also acknowledges

The running time for closure of the control valve is monitored. If the control valve is functioning properly, it will close within the preset running time. Closure of Stop Valve Then the solenoid valve (MAX61 AA211 and 212) is energized. This allows trip oil to flow to the space below changeover pilot valve (MAX61 AAO11 and 012), which moves into its upper end position and connects the space below piston disc (KA02) with the drain. The pressure in this space drops rapidly and is monitored by pressure switch (MAX51 CP223, 228). When the pressure at this pressure switch has dropped slightly below the break-away pressure of piston disc (KA02), monitoring of the stop valve closure time starts. The associated limit switch (-CGO01 E) annunciates entry of the valve into its closed position, thus making it possible to monitor the valve closing action for completion within the maximum permissible running time. Opening of Stop Valve Next, solenoid valve (MAX47 AA211 and 212) is energized (test position) and trip oil is admitted to the control surface of the piston in the test valve MAX47 AA011 and 012. The piston moves into its lower end position against the spring force, thus permitting trip oil to flow to the space above piston KA01 of the stop valve servomotor. This piston is forced downwards by pressure of the trip oil, thereby tensioning the spring between piston KA01 and piston disc KA02 and finally pressing against piston disc KA02. Up to this point the trip oil pressure above piston KA01 is relatively low, being equal to the spring force acting against it. The spontaneous pressure rise when piston KA01 has made contact with piston disc KA02, and thus on completion of the spring tensioning action, is detected by pressure switch (MAX51 CP222, 227). If all conditions are fulfilled within this relatively long monitoring period, solenoid valve (MAX61 AA211 and 212) is deenergized (operating position), so that trip oil is once again able to flow to test valve (MAX47 AA011 and 012) and the drain is blocked off again. The buildup of trip oil pressure is monitored by pressure switch (MAX51 CP221, 226). When the pressure is sufficiently high, the stop valve is opened by de-energizing solenoid valve (MAX47 AA211 and 212) (operating position). Test valve (MAX47 AA011 and 012) switches over, admitting trip oil to the space below the piston disc KA02 and after a certain amount of further travel of test valve, slowly connects the space above

Selection If the test requirements have been fulfilled, the valve, assembly (e.g. emergency stop and HP control valve, left) to be tested is selected by switching in the subgroup by pressing the selection push-button. A separate selection push-button is provided for each valve assembly. Only one selection may be made at a time. Selection of a further test is not possible until the program already selected has ended. Operation Push-button The test run is started by pressing the Operation push button in the Stop and Control valves tile. Shutdown Push-button

This push-button can abort the current unit test and introduce the reset program, which has priority over the test program.
Lamp Test Push-button All lamps on the panel are tested by pressing the Test push-button. Closure of Control Valve If all the test requirements have been fulfilled and the selection and operation push-buttons pressed, the control valve (MAA 10 and 20AAOO2) is closed by means of the associated actuator (test motor -AAOO2M). Operation of the actuator (KA01) is continued until limit switch (-CGO02C) and limit switch (-AAO02M S72, S73) on the actuator is tripped to annunciate that the control valve being tested is in closed position. During this time, the turbine output controller compensates for the effects of closure of the valve being tested on the turbine output by opening the remaining control valves.

piston KA01 with the drain. The resultant pressure difference causes the tensioned piston relay to open the stop valve. As soon as the open position is reached, the full trip oil pressure builds up. This is monitored by pressure switch MAX51 CP223, 228 and by limit switch -CGO01 D. Testing of the stop valve is now completed. Re-Opening of Control Valve If the conditions are fulfilled within the specified monitoring period, the control valve is reopened. The motor of positioner -AAO02M is operated in the opening direction. Positioner -AAO02M moves the control valve into its original position in the reverse sequence to the closing action. Again the initial pressure and output are kept constant by the appropriate controller. Operation of positioner AAO02M is continued until, after a certain amount of over travel, it has positively ceased to influence the controller. This position is detected by limit switch -AAO02 MS61 or -AAO02 MS62. If the control valve is functioning properly, it will open within the preset running time.

Cancellation of Selection On conclusion of testing of each valve assembly, the selection is automatically cancelled and the program is shut down. Interruption due to Running Time Exceeded The reset program is automatically initiated if the running time for any step in the test program is exceeded. If any running time is exceeded during the reset program, the program halts. In either case, the alarms Fails signal and Time overrun are generated. If the Faults in ATT alarm is displayed, the fault lies in the automatic tester itself. Interruption due to Turbine Trip If electrical turbine trip is initiated during testing, all solenoid valves are deenergized and posltioner -AAO02M is returned to its extreme position and the program cancelled. All equipment associated with the automatic turbine tester are automatically returned to their normal position.