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Steam Turbine Safety and

Overspeed Checks

BTCP/BTRF

Maintenance Work
Practice
No. 8041

(Owner: BTRF/BTCP Technical Machinery


Second Line Supervisor)

Introduction
Scope

The purpose of this Maintenance Work Practice (MWP) is to provide mandatory


procedures to be followed to ensure steam turbines can be maintained and
operated safely. This MWP provides procedures for both "General Purpose" and
"Special Purpose" steam turbines. The second section addresses procedures
specific to General Purpose (GP) vertical turbines tested coupled up.

References

Table of
Contents/
Attachments

Rev. 4, 09/14

OIMS 6.3 Procedure 2 - SHE Critical Equipment, Availability Target


Determination
Topic

See Page

Introduction

Definitions

General Information

General Requirements

Responsibilities

Work Procedure

General Purpose Steam Turbines to be Tested Uncoupled

General Purpose Vertical Steam Turbines to be Tested Coupled

16

Special Purpose Steam Turbines

24

Attachment 1, Site General Purpose Steam Turbines Overspeed Trip


Setpoint and Acceptance Range

32

Attachment 2, Special Purpose Steam Turbines Overspeed Trip


Setpoint and Acceptance Range

33

Attachment 3, General Purpose Turbines Overspeed Testing Interval


Adjustment for Turbines Passing Overspeed Test

34

Attachment 4, Action Steps to be Taken for a Turbine Failing


Overspeed Test

35

Page 1 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

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.

Turbine speed must always be controlled in the range for which it is


designed.
WARNING:
OPERATION OF THE TURBINE AT A SPEED ABOVE THE
OVERSPEED SETPOINT CAN CAUSE DESTRUCTIVE FAILURE OF
THE TURBINE WHICH CAN CAUSE INJURY TO NEARBY
PERSONNEL.

Rev. 4, 09/14

In order to ensure personnel safety, it is important that this practice be


applied to BTCP/BTRF turbines.

Only personnel trained per these procedures can perform turbine overspeed
tests.

Nonessential personnel must be cleared from the area during overspeed


testing.

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Introduction, Continued
Safety, Health
and
Environmental
Precautions,
Continued
Overspeed
Testing,
Continued

A remote reading tachometer must be used during overspeed testing 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.

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 turbine speed must be controlled using a small steam


bypass valve. If the small steam bypass is routed around the turbine autostart
valve, then the autostart valve must be blinded or blocked and tagged "Do Not
Operate" during testing. This is done to prevent the autostart valve from
opening and causing rapid turbine acceleration.
NOTE: Some very small turbines with steam inlet lines less than 2" in
diameter do not have small steam bypasses. These are
controlled using the inlet steam valve.

Testing must be stopped if any safety concerns are identified or field


hardware prevents personnel from following this practice.

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

NOTE: For the purposes of overspeed trip testing requirements and


procedures, all Baytown Complex steam turbines to be treated
as "Special Purpose" are listed in Attachment 2 of this MWP.
Turbines not listed in Attachment 2 are to be considered
General Purpose turbines.

Rev. 4, 09/14

Page 3 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

General Information

General Purpose
Turbines
Overspeed Trip
Testing Frequency

Acceptance
Criteria

Special Purpose
Turbines

Rev. 4, 09/14

Item

Description

The minimum overspeed testing interval is 6 months. The maximum


test interval for the overspeed trip system is 4 years. The goal of this
turbine testing program is to progress all General Purpose turbines to
the maximum testing interval of 4 years. Attachment 3 outlines how to
adjust the test interval for General Purpose turbines passing overspeed
testing. (See below for the acceptance criteria for overspeed testing.)

The following problems shall be considered failures of general purpose


turbine overspeed protection systems:

Failure of the trip valve to close.

Sticking or binding trip bolt.

Sticking or binding linkage preventing the trip valve from closing.

Sticking or binding linkage slowing trip valve closure.

Overspeed trip occurring above the maximum trip speed.

Trip speed deviation from target trip speed by more than +5%.

For general purpose turbines that are tested uncoupled - speed


exceeding 50% of normal running speed with the trip valve
closed and full inlet steam pressure upstream of the trip valve.

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.

Any other condition found that would prevent the turbine


overspeed system from providing overspeed protection.

The following problems shall be considered failures of special purpose


turbines overspeed protection systems:

Failure of the trip valve to close.

Sticking or binding trip bolt.

Sticking or binding linkage preventing the trip valve from closing.

Sticking or binding linkage slowing trip valve closure.

Overspeed trip occurring above the maximum trip speed for that
particular turbine.

Trip speed varying by more than +/-2%.

Page 4 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

General Information, Continued

Item
Special Purpose
Turbines,
Continued

Overspeed Trip
Setpoint

Description

Trip not rolling to a speed less than 20% of minimum governor


speed after it is tripped with full inlet steam pressure upstream
of the trip valve with the turbine uncoupled.

Failure of any component in the electronic overspeed


protection system that would prevent the electronic overspeed
system from providing overspeed protection.

Any other condition found that would prevent the turbine


overspeed system from providing overspeed protection.

Continued

See Attachment 1 of this MWP for General Purpose Turbine overspeed


setpoint values.

General Requirements

Item

Conditions Not
Requiring
Overspeed
Testing

Rev. 4, 09/14

Requirement

Due to the critical nature of overspeed testing this document must be


read and understood by all involved when a turbine overspeed test is
performed; this includes process technicians and all machinists
participating.

This document must be at the job site in the field and readily
accessible to those doing the test when overspeed test is performed.

Each step must be initialed in the space provided prior to proceeding to


the next step (note that all steps do not apply to every turbine, put N/A
for steps not applicable).

Any problems found with overspeed trip systems shall be described


clearly and in detail by personnel conducting the test in the
documentation provided to the Machinery Records Clerk. This will
allow timely and effective problem identification and correction.

Testing of the overspeed system is not required if parts are replaced


that are not used in the overspeed system. Examples of parts that,
when replaced, would not require overspeed testing include the
governor, governor linkage, governor valve, carbon seals, bearings,
and oil rings.
Page 5 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

General Requirements, Continued

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

Attachment 4 provides mandatory steps to be taken for any turbine


failing overspeed testing.

Responsibilities

No.

Requirement

Mechanical FLS

Reviews this procedure with Machinist performing tests prior to


beginning work.

Mechanical
(ExxonMobil and
Contractors)

This is primarily a mechanical activity. Mechanical must perform


Preventive Maintenance (PM) checks prior to test and control turbine
speed during testing (under the direction of a Process Operator), and
document findings.

Process

Operates valves, ensures proper energy isolation, and issues permits.

Machinery
Records Clerk

Records and reports data, and updates intervals.

Rev. 4, 09/14

Page 6 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

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

Baytown Complex steam turbines, except those listed in Attachment 2 of this


MWP, are considered General Purpose Turbines and are subject to the
requirements of this section.

General Purpose Vertical Turbines tested "coupled up" are addressed in


Section 2 of this MWP.

Overspeed Test Procedure for GP Turbines Tested Uncoupled:


Inspection/
Overspeed Trip
Checks for
Turbines with
Small Bypass
Line

NOTE: The small steam bypass line is designed to provide


improved manual control of turbine speed. It is important for
personnel safety that the governor linkage and overspeed
trip valve checks be made as described below before
proceeding with overspeed testing.
Step

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued

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.

Ensure that equipment has been energy isolated.


NOTE:

Uncouple turbine from driven unit.

Visually inspect coupling flex element.

Rev. 4, 09/14

Prior to closing turbine exhaust valve, a


casing drain should be cracked open so
that leakage of the inlet steam block
valve can be detected when the turbine
is isolated. If steam is seen blowing from
the bleeder when the inlet and exhaust
valve are closed this is an indication that
one or both isolation valves are leaking.

NOTE:

Initial
____

Initial
____
Initial
____

If the turbine cannot be uncoupled from


the driven equipment, refer to the
Section 2 of this MWP.

Mechanically inspect the governor as follows:

For mechanical governors: Inspect governor to


Initial
governor valve linkage to confirm that the governor can
fully close the governor valve. Move linkage by hand
____
and verify linkage does not have excessive looseness
or slack at pivot points.

For hydraulic governors: Inspect governor to governor


valve linkage to confirm that the governor can fully
close the governor valve. Move linkage by hand and
verify linkage does not have excessive looseness or
slack at pivot points.

____

Page 8 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued
Prepare for
Overspeed
Testing, Continued
Mount
Tachometer

Step

Action

Visually inspect the overspeed trip linkage and system for


obvious damage or defects.

Mount digital test tachometer on turbine as follows:


NOTE:

Initial
____

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.

Mount optical sensor pointing at the coupling hub.


Stick tachometer target tape on the coupling so it is
directly in the line of sight of the digital tachometer.

Initial
____

Position tachometer remote readout device at the end


(not sides) of the turbine.

____

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued
Step
Prepare for
Overspeed
Testing

Action
Preparation steps -

Initial
____

Ensure that all normal lubrication checks have been


performed (i.e., turbine and governor oil levels are
OK).
NOTE:

Identify an escape route that allows


personnel involved in testing to exit the
area in the event that an uncontrolled
overspeed occurs. The escape route
shall be clear of obstructions and not in
the same plane as the turbine disc or
coupling. This route shall be
communicated to all involved so all can
quickly exit the area if needed. Testing
shall not proceed if a clear escape route
is not available.

WARNING:
A SHIELD MUST BE PROVIDED FOR VERTICAL
TURBINES THAT ARE TESTED UNCOUPLED.

In order to protect personnel performing the test, a


protective shield must be provided between the
position of personnel performing the test and the
turbine. This protective shield must, at a minimum,
consist of scaffolding with a double layer of wooden
scaffold boards to form a barrier. Other proven barrier
technology may be used as well (i.e., Kevlar covers
etc.).
NOTE:

Rev. 4, 09/14

____

If the vertical turbine utilizes a rigid


coupling between the turbine and pump,
follow the steps outlined in the General
Purpose Vertical Steam Turbines Tested
Coupled Section of this MWP for
overspeed testing coupled to pump.
Page 10 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued

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

Line up system for test as follows:

If the small steam bypass used to control turbine


speed is routed around the turbine autostart valve,
blind the inlet to the autostart valve or block (close
inlet or outlet isolation valve) the autostart valve and
tag "Do Not Operate" prior to testing. This is done to
be sure the autostart valve does not open during
testing and cause rapid turbine acceleration.

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.

Open turbine exhaust (outlet) block valve.


Ensure steam supply to turbine is dry.

____
____

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued
Step
Bring Turbine to
SLOW ROLL

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

Close the inlet small steam bypass and depressure (using


bleeders) the steam trapped in the line between the small
steam bypass line and the trip valve. When this is complete,
reset overspeed safety trip system. After resetting the
overspeed trip linkage, slowly crack open steam to the small
steam bypass and return turbine to SLOW ROLL
(approximately 500 to 1000 rpm).

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

Clear all unnecessary personnel away from turbine.

Initial
____

16

Personnel performing overspeed testing check must move to


position themselves out of line with the turbine wheel (away
from the sides of the turbine), but close to governor controls
and manual overspeed trip.

Initial
____

Page 12 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued
Step
Check Governor
Operation

17

Action
Check governor operation as follows:

Slowly open the small steam bypass valve until speed


is controlled by governor.

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

Verify satisfactory turbine operation with no abnormal


vibration.

____

Verify oil pressure is adequate (if applicable).

____

If necessary, adjust governor until tachometer indicates ____


normal operating speed.

18

If turbine has an electronic governor, contact I&E to bypass


electronic overspeed, or increase setpoint above mechanical
overspeed setpoint to allow mechanical overspeed trip testing.

Initial
____

19

Test electronic overspeed once to verify trip circuit operation


before proceeding with mechanical overspeed trip testing.

Initial
____

Page 13 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued
Step
Check
Overspeed
Safety Trip
Operation

Action
NOTE:

20

Be prepared to manually trip turbine or


release governor override if turbine exceeds
overspeed trip Acceptance Range.
Attachment 1 provides the range of
acceptable speeds for turbines of various
rated speeds (Nr).

Check overspeed safety trip as follows:

With the inlet steam valve closed or blinded and


exhaust valve fully open, slowly open the small steam
bypass valve until turbine just reaches normal
operating speed. Slowly override governor to
increase turbine speed until turbine reaches trip speed
outlined in Attachment 1.
If turbine speed does not reach overspeed trip RPM,
open small steam bypass valve 1/4 turn and repeat
this step again from the beginning.
During testing if trip speed cannot be reached, close
turbine hand valves to reduce steam flow
requirements and allow turbine to reach trip speed.
NOTE:

Rev. 4, 09/14

Initial

____

____

____

One attempt to adjust the trip bolt spring


tension as per the OEM Instruction Manual
may be made to correct the trip speed
setpoint.

If the turbine does not trip below the maximum


acceptable speed (see Attachment 1), immediately
manually trip the turbine. The turbine has failed the
overspeed test. Follow instructions in Attachment
4 for a turbine failing overspeed test.

____

Page 14 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued
Step
Check
Overspeed
Safety Trip
Operation,
Continued

20

Action

Continued

If turbine trips WITHIN the Acceptance Range, note


the trip speed and observe that the trip valve closes
rapidly and the turbine speed slows to below 50% of
normal operating speed (see, Attachment 1).

Initial
____

If the turbine DOES NOT slow to below 50% of


operating speed, the turbine has failed (follow
instructions in Attachment 4 for a turbine failing
overspeed test).

____

If the turbine passes overspeed testing, enter the trip


speed on the test Data Sheet for each test.

If turbine passes the overspeed test, repeat Steps 14,


15, 16, 17 and 20 two more times to verify turbine
reliably trips WITHIN the Acceptance Range (see
Attachment 1). Failure to meet any of the overspeed
testing acceptance criteria during any of these three
overspeed tests is considered to be a failure of the
overspeed trip system.

____

____

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

Close the inlet small steam bypass and depressure (using


bleeders) the steam trapped in the line between the small
steam bypass line and the trip valve. When this is complete,
reset overspeed safety trip system.

Initial

22

Have I&E rearm/adjust electronic overspeed if turbine has an


electronic governor.

Initial
____

23

Ensure that turbine is energy isolated.

Initial
____

24

Reinstall coupling and coupling guard. Remove blind from


autostart valve if installed.

Initial
____

____

Page 15 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 1, General Purpose Steam Turbines to be Tested Uncoupled,
Continued
Return Turbine
Back to
Operations,
Continued

Step

Action

25

Return turbine back to operations.

Initial
____

Governor
Adjustment
Under Load (If
Required)

26

If the governor speed setpoint was adjusted during testing, the


equipment shall be placed back in service and the governor
speed setpoint adjusted so the turbine runs at the normal
operating speed.

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

Testing frequency, overspeed trip Setpoints, and Acceptance Ranges for


"coupled" testing are identical to those outlined in Attachments 1 and 3.

Page 16 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2: General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Procedure for Vertical GP Turbines Left "Coupled":
Step

A turbine PM must be complete per MWP-8040 before overspeed testing to help insure that turbine hardware performs as
designed during overspeed testing.

____

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.

In order to protect personnel performing the test, one of the


following steps must be taken:

Initial

A protective shield must be provided between the


position of personnel performing the test and the turbine.
This protective shield must, at a minimum, consist of
scaffolding with a double layer of wooden scaffold
boards to form a barrier. Other proven barrier
technology may be used as well (i.e., Kevlar covers etc.). ____
NOTE:

Rev. 4, 09/14

Initial

Prepare for
Overspeed
Testing

Action

Identify an escape route that allows


personnel involved in testing to exit the
area in the event that an uncontrolled
overspeed occurs. The escape route shall
be clear of obstructions. This route shall
be communicated to all involved so all can
quickly exit the area if needed. Testing
shall not proceed if a clear escape route is
not available.

Ensure that equipment has been energy isolated.

Initial
____

Page 17 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2, General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Prepare for
Overspeed
Testing,
Continued

Step
5

Action
Mechanically inspect the governor as follows:

Mount
Tachometer

For mechanical governors: Inspect governor to governor


valve linkage to confirm that the governor can fully close
the governor valve. Move linkage by hand and verify
linkage does not have excessive looseness or slack at
pivot points.
For hydraulic governors: Inspect governor to governor
valve linkage to confirm that the governor can fully close
the governor valve. Move linkage by hand and verify
linkage does not have excessive looseness or slack at
pivot points.

Visually inspect the overspeed trip linkage and system for


obvious damage or defects.

Mount digital test tachometer on turbine as follows:


NOTE:

Initial

____

____

Initial
____

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.

Rev. 4, 09/14

Mount optical sensor pointing at the coupling hub. Stick


tachometer target tape on the coupling so it is directly in
the line of sight of the digital tachometer.

Initial
____

Page 18 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2, General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Mount
Tachometer,
Continued

Step
7

Action

Position readout device behind the protective shield.

____

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

Ensure that all normal lubrication checks have been performed,


[i.e., turbine and governor oil levels are OK and pump lubrication
is within normal limits (oil levels, oil mist flow if applicable)].

Initial

Line up pump suction. Line up pump discharge and observe


pump to be sure it does not rotate backwards. If pump rotates
backwards when discharge valve is opened, the check valve is
leaking. Repair check valve before proceeding with overspeed
testing. Line up seal flush system. Check pump for process
leaks.

Initial

____

____

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.

Page 19 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2, General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Step
Prepare for
Overspeed
Testing,
Continued

11

Action
Line up system for test as follows:

Initial
____

Ensure turbine inlet block valve to turbine is closed.


WARNING:
OPENING TURBINE STEAM INLET WHILE THE
TURBINE STEAM DISCHARGE (EXHAUST)
VALVE IS CLOSED COULD OVERPRESSURE
THE TURBINE CASING AND CAUSE CASING
RUPTURE AND/OR PERSONNEL INJURY.

Open turbine exhaust (outlet) block valve.

____

Ensure steam supply to turbine is dry.

____

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

____

Close the inlet steam valve and depressure (using bleeders)


Initial
the steam trapped in the line between the inlet steam valve and
the trip valve. When this is complete, reset overspeed safety
trip system. After resetting the overspeed trip linkage, slowly
crack open the inlet steam valve and return turbine to SLOW
____
ROLL (approximately 500 to 1000 rpm).

Page 20 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2, General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Step
Manually Trip
Overspeed
Device,
Continued

Clear
Unnecessary
Personnel

Check Governor
Operation

Throttle Pump
Discharge

Action

14
WARNING:

Continued

RESETTING OVERSPEED SAFETY TRIP


WITHOUT FIRST CLOSING ALL STEAM INLET
VALVES CAN RESULT IN UNCONTROLLED
TURBINE OVERSPEED.

15

Clear all unnecessary personnel away from turbine.

Initial
____

16

Personnel performing overspeed testing check must move to


position themselves out of line with the turbine wheel (away
from the sides of the turbine), or provide a protective shield
between them and the turbine wheel but close to governor
controls and manual overspeed trip.

Initial

17

18

Check governor operation as follows:

____
Initial
____

Slowly open the steam inlet valve until speed is


controlled by governor.

Verify satisfactory turbine and pump operation with no


abnormal vibration.

____

Verify oil pressure is adequate (if applicable).

____

If necessary, adjust governor until tachometer indicates


____
normal operating speed.

Throttle pump discharge using discharge block valve to reduce


flow through the pump. This reduces the load on the turbine.

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2, General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Step
Electronic
Governor

19

If turbine has an electronic governor, contact I&E to bypass


electronic overspeed, or increase setpoint above mechanical
overspeed setpoint to allow mechanical overspeed trip testing.

Initial
____

20

Test electronic overspeed once to verify trip circuit operation


before proceeding with mechanical overspeed trip testing.

Initial
____

Check
Overspeed
Safety Trip
Operation

NOTE:

21

Action

Be prepared to manually trip turbine or


release governor override if turbine exceeds
overspeed trip Acceptance Range.
Attachment 1 provides the range of
acceptable speeds for turbines of various
rated speeds (Nr).

Check overspeed safety trip as follows:

Have the Operator slowly open the smaller sized inlet


block valve bypass line (if available) to let steam into
the turbine to achieve normal running speed. If the
desired rpm cannot be achieved, close the bypass
and use the main valve. Machinist to slowly override
governor to increase turbine speed until turbine
reaches trip speed.

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

____

During testing if trip speed cannot be


reached, open turbine hand valves to
increase turbine horsepower.

If turbine speed still does not reach overspeed trip


RPM, throttle pump discharge further and repeat
overspeed test.

____

Page 22 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2, General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Step
Check
Overspeed
Safety Trip
Operation,
Continued

21

Action

Continued

Reset Overspeed
Safety Trip

If the turbine does not trip below the maximum


acceptable speed (see Attachment 1), immediately
manually trip the turbine. The turbine has failed the
overspeed test. One attempt to adjust the trip bolt
spring tension (as per the OEM Instruction Manual)
may be made to correct the trip speed setpoint.
Follow instructions in Attachment 4 for a turbine
failing overspeed testing.

Initial

____

If turbine trips WITHIN the Acceptance Range, note


the trip speed and observe that the trip valve closes
rapidly and the turbine speed slows to a complete
stop.

____

If the turbine DOES NOT slow to a complete stop, the


turbine has failed testing (follow instructions in
Attachment 4 for a turbine failing overspeed testing).

____

If the turbine passes overspeed testing, enter the trip


speed on the test Data Sheet.

____

If turbine passes the overspeed test, repeat Steps 14,


15, 16, 17, 18, and 21 two more times to verify turbine
reliably trips WITHIN the Acceptance Range (see
Attachment 1). Failure to meet the overspeed testing
acceptance criteria during any of these 3 overspeed
tests is considered to be a failure of the overspeed trip ____
system.
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.
22

Rev. 4, 09/14

Close the inlet steam valve and depressure (using bleeders)


Initial
the steam trapped in the line between the steam inlet valve and
the trip valve. When this is complete, reset overspeed safety
____
trip system.
Page 23 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 2, General Purpose Vertical Steam Turbines to be Tested Coupled,
Continued
Step
Reset Overspeed
Safety Trip,
Continued
Return Turbine
Back to
Operations

Action

23

Have I&E rearm/adjust electronic overspeed if turbine has an


electronic governor.

Initial
____

24

Return turbine and pump back to operations for service.

Initial
____

25

If the governor speed setpoint was adjusted during testing, the


equipment shall be placed back in service and the governor
speed setpoint adjusted so the turbine runs at the normal
operating speed.

Initial

Return the completed test Data Sheet to the Machinery


Records Coordinator.

Initial
____

26

____

Section 3: Special Purpose Steam Turbines

Steam turbines listed in Attachment 2 of this MWP, are considered Special


Purpose turbines and are subject to the requirements of this section.

This section contains requirements for overspeed trip testing of Special


Purpose steam turbines. Turbines to be treated as Special Purpose are listed
in Attachment 2 of this MWP. Turbines not listed in Attachment 2 shall be
treated as General Purpose turbines as per Sections 1 and 2 of this MWP.
See Acceptance Criteria for overspeed testing of Special Purpose turbines at
the beginning of this document.

Overspeed Trip Testing Frequency: All Special Purpose turbines shall be


overspeed trip tested during each unit turnaround or other extended unit
downtimes and during major turbine/compressor maintenance where the
turbine has been taken off-line and where it is practical to do so. Exceptions
to the above mandatory testing frequency may be made, if the turbine has
been overspeed trip tested and PASSED in the last 2 years prior to the time in
question, and if the turbine was successfully shut down by manually tripping
the turbine. ALL exceptions are contingent on review and approval by the
BTES Machinery Technical Section.
Deviation from the above testing frequency guidelines MUST be formally
approved by the deferral process outlined in SSS-4240. (See Notes in the
Attachment 2 of this MWP for specific exceptions to this testing frequency.)

Rev. 4, 09/14

Page 24 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 3: Special Purpose Steam Turbines, Continued

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.

Obtain necessary permits and verify energy isolation of turbine


and driven equipment. Uncouple turbine from driven equipment.
NOTE:

Prior to closing turbine exhaust valve, a


casing drain must be cracked open so that
leakage of the inlet steam block valve can
be detected when the turbine is isolated. If
steam is seen blowing from the bleeder
when the inlet and exhaust valve are
closed this is an indication that one or both
isolation valves are leaking.

NOTE:

Identify an escape route that allows


personnel involved in testing to exit the
area in the event that an uncontrolled
overspeed occurs. The escape route shall
be clear of obstructions and not in the
same plane as the turbine disc or coupling.
This route shall be communicated to all
involved so all can quickly exit the area if
needed. Testing shall not proceed if a
clear escape route is not available.

Initial
____

Page 25 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 3: Special Purpose Steam Turbines, Continued
Step
Prepare for
Checks,
Continued

Check
Tachometer

Action

Ensure that Process has not used the T/T valve for energy
isolation.

Initial
____

Ensure all normal lubrication, precautionary checks and


warm-up procedures have been performed.

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.

Correct any mechanical problems noted during Step 5 and


continue with procedure.

Initial
____

Verify proper operation of the local tachometer permanently


mounted on turbine.

Initial
____

Mount digital optical tachometer as follows:

Initial
____

Mount optical sensor pointing at the coupling hub.


Position readout device at operating station, safely
away from turbine wheel.

____

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 3: Special Purpose Steam Turbines, Continued
Step
Check
Tachometer,
Continued

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

Ensure Process opens exhaust valve for turbine per Unit


Initial
Operating Procedures. Have Process warm up steam inlet to
the closed inlet steam block valve, and then warm up the steam
line to the T/T valve. Line up turbine systems as required per
____
Process operating procedures to prepare turbine for operation.

10

Set turbine speed control instrumentation for control at local


panel or turbine governor.

Initial
____

11

Set governor at minimum governor speed.

Initial
____

12

Ensure trip/throttle (T/T) valve is closed.

Initial
____

13

Have Process bring turbine to SLOW ROLL as follows:

Slowly open turbine steam inlet block valve, leaving


steam lined up to closed T/T valve.

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 3: Special Purpose Steam Turbines, Continued
Step
Bring Turbine to
SLOW ROLL,
Continued

Manually Trip
Overspeed
Device

Clear Personnel

Check Governor
Operation

13

Action

Ensure Process slowly opens T/T valve until turbine


reaches SLOW ROLL speed.

Initial
____

Operate turbine at SLOW ROLL for time needed to


complete warm-up cycle per Unit Operating Manual.

____

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

Reset overspeed safety trip and return turbine to SLOW ROLL


speed using Step 13 above.

Initial
____

16

Clear all unnecessary personnel away from turbine.

Initial
____

17

Operator performing check must move to a position out of the


plane of the turbine wheels, but close to governor controls and
the manual trip for the T/T valve.

Initial
____

18

Check governor operation as follows:

Initial

19

Have Process open T/T valve as required to increase


turbine speed through critical speed until governor has
control at minimum governor speed.

____

Verify that the governor is successfully holding the


turbine at the minimum governor setting.

____

Verify satisfactory turbine operation with no abnormal


vibration.

____

Verify test tachometer is indicating turbine speed.

____

Increase the turbine speed to the Maximum Continuous Speed


(see Attachment 2) using the manual or local speed control.
Have Process open T/T valve further in small increments if
necessary to reach maximum continuous speed.

Rev. 4, 09/14

____

Initial
____

Verify turbine is operating normally.

____

Verify tachometer tracks the speed increase


accurately.

____

Page 28 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 3: Special Purpose Steam Turbines, Continued
Step
Check
Overspeed
Safety Trip
Operation

Action
NOTE:

20

Be prepared to manually trip turbine or lower


governor speed setpoint if turbine exceeds
overspeed trip Acceptance Range.

Test electronic overspeed to verify trip circuit operation before


proceeding with mechanical overspeed trip testing.

Initial
____

Most turbines have the electronic overspeed setpoint set


below the mechanical overspeed setpoint. If the
electronic overspeed setpoint is higher than the
mechanical overspeed then have I&E temporarily lower
the electronic overspeed setpoint 100 rpm below the
____
minimum rpm of the Trip Acceptance Range shown in
Attachment 2 for this turbine.
NOTE: For turbines with electronic and mechanical
overspeed shutdown systems, test the
electronic overspeed system once.
NOTE: For turbines with electronic overspeed
systems only (no mechanical overspeed), test
the electronic overspeed system three times.

Increase the turbine speed slowly to the electronic


overspeed setpoint and verify that the turbine trips at the
correct speed.

____

NOTE: If turbine has an electronic governor, use


governor to control turbine speed at all times
and have Process use T/T valve to limit steam
energy to turbine during uncoupled overspeed
testing by only opening T/T valve enough to
provide just enough steam flow to do
overspeed testing.

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 3: Special Purpose Steam Turbines, Continued
Step
Check
Overspeed
Safety Trip
Operation,
Continued

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:

Typically Baytown Complex electronic


overspeed trips have setpoints that are
LOWER than the mechanical overspeed trip
setpoint. If the setpoint is not increased, the
electronic trip will trip the turbine before the
mechanical trip engages.

NOTE:

If turbine has an electronic governor, use


governor to control turbine speed at all times
and have Process use T/T valve to limit
steam energy to turbine during uncoupled
overspeed testing by only opening T/T valve
enough to provide just enough steam flow to
do overspeed testing.

Check the mechanical overspeed trip as follows:

Rev. 4, 09/14

Initial
____

Slowly increase the turbine speed by increasing


governor speed setpoint. For turbines equipped with
hydraulic governors, this may require manually
overriding the governor.

Initial
____

If the turbine trips BELOW the Acceptance Range (see


Attachment 2), it will be necessary to make
adjustments to the trip bolt to correct the trip speed
setpoint.
If the turbine rpm EXCEEDS the Trip Acceptance
Range in Attachment 2 for this turbine without tripping,
immediately manually trip the T/T valve to shut down
the turbine. The turbine will be judged to have FAILED
the test. Mark the test Data Sheet as "FAILED."
Follow instructions in Attachment 4 for a turbine failing
overspeed testing.

____

____

Page 30 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Work Procedure, Continued


Section 3: Special Purpose Steam Turbines, Continued
Step
Check
Overspeed
Safety Trip
Operation,
Continued

Action

22
Continued

Reset Overspeed
Safety Trip

If the turbine trips WITHIN the Acceptance Range,


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.

Initial
____

If the turbine does not meet the acceptance criteria for


Special Purpose turbines, follow instructions in
Attachment 4 for a turbine failing overspeed testing.

____

23

Have Process fully close the T/T valve, then reset the
overspeed safety trip.

Initial
____

24

The turbine will be judged to have PASSED the test if it trips


Initial
within the Acceptance Range in Attachment 2 and the turbine
____
rolls to a speed less than 20% of the minimum governor speed.

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

When testing is complete adjust the electronic overspeed


setpoint back to the original setting.

Initial
____

27

Ensure equipment has been energy isolated.

Initial
____

28

Couple up the turbine and driven equipment.

Initial
____

29

Return the completed test Data Sheet to the Machinery


Records Coordinator.

Initial
____

____

** End of Maintenance Work Practice **

Rev. 4, 09/14

Page 31 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Attachment 1

Site General Purpose Steam Turbines Overspeed Trip Setpoint and


Acceptance Range
Operating Speed Target Trip "Setpoint"

Trip "Acceptance Range"

Max Allowable Speed After Trip

(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:

50% (Uncoupled) Stopped (Coupled)

1) Nr is the normal rated speed for the turbine.

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Attachment 2
Special Purpose Steam Turbines Overspeed Trip Setpoint and Acceptance Range
Turbine

Max Continuous Speed

Trip "Setpoint"

Unit and Tag

(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

Trip "Acceptance Range" (see note 5 below)

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

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

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.

Determine new test


interval and
communicate new
interval to
GEMs/TIGER
Coordinators. See
corresponding new test
interval below.

Update TIGER or SAP with


new test interval if different
from current interval.

Responsibility Mechanical

Responsibility - Mechanical and


Machinery Records Clerk

Responsibility Machinery Records


Clerk

Responsibility Machinery Records


Clerk

Responsibility GEMS/TIGER Coordinators

Rev. 4, 09/14

Current Test Interval

New Test Interval

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.

Test two times at


6-month intervals,
assuming testing
successful, then
increase interval as
shown above.

Page 34 of 35

Steam Turbine Safety and Overspeed Checks

Maintenance Work Practice No. 8041

Attachment 4
Action Steps to be Taken for a Turbine Failing Overspeed Test
Step

Action

Responsibility

Turbine tested and fails overspeed testing. Acceptance criteria


is provided in this document.

Mechanical

If turbine trip mechanism failed to trip within the acceptable


speed range, then one and only one attempt to adjust the trip
setpoint can be made to correct the problem without contacting
BTES. Adjustment of the trip bolt setpoint to pass overspeed
testing is still considered a failure of the overspeed trip system
and must be recorded by the Machinery Records Clerk and
reported in IMPACT.

Mechanical

Notify BTES area Machinery Engineer or Machinery Specialist


and Machinery Records Clerk that turbine failed testing.

Mechanical

BTES machinery engineer analyzes failure, determines root


cause, and recommends corrective action. Turbine shall not
be overspeed tested again until recommended corrective
action is taken.

BTES

Corrective action taken per BTES recommendation.

Mechanical

Turbine overspeed retested as per procedure.

Mechanical

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.

Machinery Records Clerk

If turbine fails overspeed testing again, return to Step 1.


8

Rev. 4, 09/14

Test interval is not changed for the next scheduled test


following correction of the problem and retesting.

No action required

Page 35 of 35