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COS-ISO-00-OGN/OPS/MECH/003

Rev. No.: 0 September 2001

OPERATION GUIDANCE NOTE

TESTING OF SAFETY AND


PROTECTIVE DEVICES
(KWU TURBINE)

CORPORATE OPERATION SERVICES

National Thermal Power Corporation Ltd.

NATIONAL THERMAL POWER CORPORATION


OPERATION AND MAINTENANCE FORMAL DOCUMENTATION SYSTEM

OPERATION GUIDANCE NOTE: COS-ISO-00-OGN/OPS/MECH/003


Rev. No.: 0

Date : September 2001

TESTING OF SAFETY AND


PROTECTIVE DEVICES
(KWU TURBINE)

Approved for
Implementation by ..
Director (Operation)
Date: ..
Enquiries to: Head of Corporate Operation Services

Testing of Safety and Protective Devices (KWU Turbine)


Contents
SN Title

Page No.

1. INTRODUCTION
2. SUPERSEDED DOCUMENTS
3. TESTING INTERVAL
TABLE - TESTING OF SAFETY & PROTECTIVE DEVICE (KWU TURBINE)
4. TESTING INSTRUCTION - I
Testing the Overspeed Trips by Oil Pressure
5. TESTING INSTRUCTION - II
Overspeed Testing of Overspeed Governors

1
1
1
3
4

6. TESTING INSTRUCTION - III


Testing the Main Trip Valve
7. TESTING INSTRUCTION - IV
Exercising the Main Trip Valve and Control Valves
8. TESTING INSTRUCTION - V
Testing the SOP Valves and Control Valves with the Automatic Turbine Tester
9. TESTING INSTRUCTION - VI
Exercising the Extraction Valves
10. TESTING INSTRUCTION -VII
Checking the Settings of Governors and Control Valves

10

11. TESTING INSTRUCTION - VIII


Testing the Leakage of the Stop Valves and Control Valves
12. TESTING INSTRUCTION - IX
Speed Monitoring Device
13. TESTING INSTRUCTION - X
Testing the Automatic Starting of Auxiliary Oil Pumps and DC Bearing
Oil Pumps
14. TESTING INSTRUCTION - XI
Testing the Hydraulic Low Vacuum Trip
15. TESTING INSTRUCTION - XII
Testing the Electric Low Vacuum Trip
16. TESTING INSTRUCTION - XIII
Testing the Thrust Bearing Temperature
17. TESTING INSTRUCTION - XIV
Testing the Differential Protection of Extraction Valves
18. TESTING INSTRUCTION - XV
Testing Fire Protection Devices

20

19. REVIEW

35

12
14
17
18

22
24

26
28
30
31
32

Page No.1
COS-ISO-00-OGN/OPS/MECH/003
Testing of Safety and Protective Devices (KWU Turbine)

Testing of Safety and Protective Devices (KWU Turbine)


1.0

INTRODUCTION
This guidance note aims at streamlining the testing modes and procedures of
various turbine testing devices of KWU turbines, recording of test results and
rectification of defects. This document is a continuation of the already issued
operation directive - OD/OPS/SYST/006 titled Testing of Turbine Protection
Devices.
Testing instructions-1-9 of this document are meant for testing devices of KWU
turbines which protect from overspeed and are designed as a supplement to the
earlier issued operation directive OD/OPS/SYST/003 titled Procedure for
Testing and Maintenance to Avoid Excessive Overspeeding of Prime Movers.

2.0

SUPERSEDED DOCUMENTS
Nil

3.0

TESTING INTERVALS

3.1

Test Classes
The testing of safety, protective and monitoring devices must be carried out at
regular intervals. The tests are divided into various classes (1-4) and various
subgroups (5-8)
The intervals between tests vary according to the classes.

3.2

Test Class

Recommended Testing Interval

Maximum Testing Interval

2 weeks

4 weeks

1 month

2 months

3 months

1 year

1 year

Test Class Subgroups


Additional tests should be carried out during each shutdown or start up where
operational availability and the shut down or start-up programs permit. These tests
may eliminate the need to carry them out at another time. Whenever possible, the
tests should be carried out when shutting down the machine, because the operating
conditions are then very similar to those during continuous operation. Also, any
defects discovered by the tests may be rectified during the following shutdown
period.

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Page No.2
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Testing of Safety and Protective Devices (KWU Turbine)
Interruptions in operation provide another opportunity for testing the functioning of
all valves and fittings.
Extra-careful testing of all equipment in conjunction with setting up is required
after repairs or overhaul.
The following are the test class subgroups (5-8)

3.3

Subgroup

Tests

Testing during shutdown

Testing during start-up

Testing during shutdowns of between 4 & 24 hrs.

Testing during overhauls or repairs

Records of Tests
Records must he kept of all tests and should contain the following data :
Date of test
Result of test
Trip value (if detectable)
New settings

3.4

Testing Intervals
The table on the next page gives the testing intervals for the safety, protective and
monitoring devices.
In the case of turbines fitted with automatic turbine tester (ATT), tests of the
protective devices and the valves must be carried out at intervals of two weeks.

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Page No.3
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Testing of Safety and Protective Devices (KWU Turbine)

Device or test

Test requirement
Rated speed

Load *

Group

TESTING OF SAFETY & PROTECTIVE DEVICE (KWU TURBINE)

Testing
instruc
tion
1 2 3 4 5 6 7 8
No.:
Testing interval **

Testing the overspeed trips

Overspeed
Testing the main trip valve and other
devices
Several valves with
testing devices
Several valves
without testing
devices
Testing the stop valves and control
valves with Automatic Turbine tester
Exercising the
stop valves and
control valves

Automatic tester

Oil pressure drop

Full travel at part load

Emergency stop valves


only

Rated speed

Exercising the extraction valves


Checking the settings of Governors and
control valves
Testing the leakage of stop and control
valves

Oil pressure switches

Low-oil pressure alarms

Hydraulic low vacuum trip

Automatic tester

Testing the thrust bearing trip

Differential pressure protection of


extraction valves

Fire protection devices

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Automatic tester

Electr. Low vacuum trip

II
III
III
IV
IV
V

Automatic starters for auxiliary oil


pumps

Control action as
sequence of Control
impulses
Control maintains
speed
Reverse power
protection

Speed monitoring device

VI
VII
VIII
VIII
IX
X
X
X
XI
XII
XIII
XIV
XV

Page No.4
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Testing of Safety and Protective Devices (KWU Turbine)
*

Test under load possible

**

Testing interval
2 to 4 weeks
1 to 3 months
3 months to 1 year
1 year
During shut-down

1
2
3
4
5
6

During start-up

7
8

Standstill 4 to 24 h
After inspection

A
B
C
D
E
F
F

Devices which protect from overspeed (control devices)


Protective for oil supply
Overpressure protections
Measuring devices
Miscellaneous
Fire protection devices

4.0

TESTING INSTRUCTION - I
TESTING THE OVERSPEED TRIPS BY OIL PRESSURE

4.1

Introduction
The overspeed trips are among the most important safety devices of the turbine
generator unit.
When the set overspeed value is reached, they initiate the turbine trip.
Closure of the emergency stop, control and extraction valves is caused by the
reduction of the auxiliary trip oil pressure and the trip oil pressure.
It is possible to perform a test without interruption of operation by using the
overspeed trip test device. The test oil pressure simulates the additional centrifugal
force, which would occur in the event of a genuine trip and would act on each of
the plunger shaped overspeed trip bolts.
As long as conditions such as rotational speed, oil temperature and freedom of bolt
movement, remain constant, the freedom of movement and consequently operating
reliability of the overspeed trips is ensured.

4.2

Testing Modes
The test must be performed at normal rated speed if the turbine is not running at
rated speed, the trip initiating pressures are altered.
Dropout of the main trip valve is included in the test procedure using the automatic
turbine tester.
Only the response of the overspeed trips and the initiating devices are tested in the
manual test using the overspeed trip test device.

4.3

Test Procedure
The procedure required for testing with the automatic turbine tester are explained in
a special set of test instructions.
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Page No.5
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Testing of Safety and Protective Devices (KWU Turbine)
The following operating procedures are to be carried out when testing manually
using the testing device:

Depress the left hand spindle of the overspeed trip test device fully and hold
it in this position until the test is completed (the valve prevents the trip
activation pulse from the overspeed trips from causing an actual trip.
Before increasing test oil pressure check whether adequate aux. start up oil
pressure is available for resetting after the test. For this press right hand side
knob (left hand side knob is already in pressed position) and see generation of
adequate aux. start up oil pressure. Afterwards release right hand side knob &
proceed for injecting test oil into the system.
Turn the handwheel of the overspeed trip test device in the clockwise
direction.
Observe the test oil pressure.

Read and record the trip initiation pressure.

After both the overspeed trips have operated, turn the handwheel of the
overspeed trip test device in the anticlockwise direction back to the starting
position.
At the same time, observe the drop in test oil pressure.

Re-latch the overspeed trip actuation devices by depressing the right hand
spindle of the test signal generator.
Observe that the auxiliary trip oil pressure has been reestablished.

4.4

If the auxiliary trip oil pressure does not increase, the relatching valve must
be operated again and held in position for approx. 5 seconds.

Release the left hand spindle of the test signal generator as soon as the
auxiliary trip oil pressure has been reestablished.

Before Execution of the test, the test oil pressure reading must be ensured for
zero.
The test must be repeated to ascertain that the overspeed trips operate at the same
test oil pressure as protocoled in the first commissioning. In case the test oil
pressure is observed to be higher by more than 0.2 kg/cm2 from first commissioning
values the machine should be stopped, inspected and the fault is rectified.
It should be noted that while the left-hand spindle of the test signal generator is
depressed, the overspeed trip cannot operate even if the turbine overspeeds due to
generator shutdown.
As the test is performed from the governor rack, the tester must notice any
change in the speed of the turbine and release the left hand spindle during the
test immediately if necessary.
Test Results and Action to be taken in the Event of Malfunctions.
Testing by means of the automatic turbine tester has reached satisfactory
conclusion when the testing circuit has been established, the overspeed trips
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Page No.6
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Testing of Safety and Protective Devices (KWU Turbine)
operate, all alarms in the general alarm annunciation equipment have responded
and no criteria alarms have appeared on the tiles of the automatic turbine tester.
Manual testing using the overspeed trip test device has reached a satisfactory
conclusion when the overspeed trips operate faultlessly at the previously recorded
test oil pressures.
Should both or any one of the overspeed trips do not operate at the previously
recorded pressure even after repeated testing then an off-normal condition exits in
the system which must be rectified.
In the event of spurious initiation of an overspeed trip, the test must be repeated at
shorter intervals than those specified in the 'Testing Intervals' until it is proved that
the overspeed trip operates faultlessly at the previously recorded pressure.
This recommendation is to be applied analogously to testing with the automatic
turbine tester as well.
4.5

Recording the Tests


A record of the tests must be complied giving the date and results (incl. response
pressure) of the test.

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Page No.7
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Testing of Safety and Protective Devices (KWU Turbine)
5.0
5.1

5.2

5.3

TESTING INSTRUCTION - II
OVERSPEED TESTING OF OVERSPEED GOVERNORS
Introduction
The overspeed governors are among the turbine generator's most important safety
devices when the overspeed limit value is reached they respond and the stop, control
and extraction valves are closed.
In addition to testing with the automatic turbine tester at rated speed, the overspeed
governor must be tested at overspeed at long intervals.
The test is absolutely necessary after inspection or work on the overspeed governors.
Testing Conditions
Before the overspeed test, the turbine generator unit is relieved of load and the generator
is isolated from the grid system.
The turbine generator unit's speed is increased up to the tripping speed of the overspeed
governors.
Testing of the overspeed governors should preferably be undertaken when the machine
has sufficiently warmed up (The turbine overall expansion has reached a value greater
than 80% of normal values). The on load testing should not be operated immediately
before the actual overspeed test to avoid the freeing of the gear giving an artificial
result.
Testing Procedure
Preparations :
Testing of the overspeed governors and the automatic trip gear with the automatic
turbine tester.
Examination of the operational speed indicator.
Determination of any discrepancy between indicated speed and system frequency.
Procedure :
Relieve turbine generator unit of a load.
Isolate generator from grid system
Engage hydraulic speed governor
Take electrohydraulic governor to limit setting and switch off.
Increase speed to 3210 rpm i.e. upto the control range of hydraulic governor.
Increase speed to 3330 15 rpm by operating the lever on hydraulic governor in
about 15 to 30 sec.
Observe and acknowledge annunciations given.
Determine and log tripping speed preferably with two speed measuring devices
operating independently of each other.
Check dropout of all actuating devices and automatic trip gear.
Examine whether both overspeed governors have tripped.
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Testing of Safety and Protective Devices (KWU Turbine)
Examine whether all stop and control valves have closed.
Decrease turbine generator unit speed to rated speed so that overspeed governor bolts
return to operating position before actuating device engages.
Close start-up and load limiting device.
When turbine speed drops low enough for the subloop control of the auxiliary oil
pump to respond, observe pump start up.
Cut in electrohydraulic governor.
Reduce speed setpoint of electrohydraulic speed governor below actual speed.
Open stop valves by means of the start up and load limiting device.
Open startup and load limiting device far enough for the speed governor to maintain
idling speed.
Drive turbine generator unit to rated speed with electrohydraulic speed governor.
Synchronise generator.
5.4

Test results and rectification of faults


The test is successfully completed if the overspeed governors respond perfectly at the
previously determined overspeed values.
If only one overspeed governor has responded, the test must be repeated, preferably
after several tripouts have been activated, by oil pressure at rated speed. The turbine
must in this event be driven from the maximum speed of the control range to the
tripping speed at a faster rate.
The following causes are amongst those possible in this case. The overspeed governor
settings are slightly staggered. The staggering is apparent if when tripouts being
activated by oil pressure, the second overspeed governor also responds, at a test oil
pressure slightly above the tripping pressure of the overspeed governor responding at
overspeed. In such a case no particular counter measures are necessary.
The second overspeed governor responds during the test when oil test pressure at a
considerably higher response pressure. Further operation of the turbine is only possible
after the non-responding overspeed governor has been overhauled and this should be
done as soon as possible, or the test must be performed every day until the nonresponding overspeed governor has been overhauled. The overhaul should be
performed as soon as possible.
If neither of the overspeed governor responds when the overspeed shown in the setting
record is exceeded the recommended value of (11 + 0.5) % the turbine generator unit
must be shut down and the cause of the malfunction must be sought.
If neither of the overspeed governor responds it is recommended to shut down the
machine and recheck / reset the overspeed bolts.
Along with the cause of overspeed governor and actuating device malfunctions already
mentioned, the following may additionally be involved.
Fretting corrosion (chaffing fatigue, frictional oxidation)
Corrosion due to unsuitable oil or foreign matter in the oil (Water and Dirt).
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Page No.9
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Testing of Safety and Protective Devices (KWU Turbine)
Gumming of the oil in the overspeed governors.
Loosening and shifting of the setting weights of the overspeed governors.
Some of the above mentioned irregularities may be a result of irregular testing of the
overspeed governors.
5.5

Recording of the test


The test must be recorded with the date and test result (tripping speed of each
overspeed governor & their resetting speeds).

National Thermal Power Corporation Ltd.

Page No.10
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Testing of Safety and Protective Devices (KWU Turbine)
6.0
6.1

TESTING INSTRUCTION - III


TESTING THE MAIN TRIP VALVE
Introduction
The main trip valve is the operating device for the trip oil circuit, which includes
the stop valves, and the oil supply to the turbine governor and is actuated by the trip
linkages of the overspeed trips, the thrust bearings trip and the low vacuum trip.
The main trip valve is held in as normal operating position by auxiliary trip oil
pressure and trips in case the trip oil pressure falls below a certain minimum value.
It is a very important component of the turbine protection system and must be
absolutely reliable in operation when actuated by any of the safety devices.
Consequently it must be tested at regular intervals to ensure that it functions
satisfactorily.
It is not allowed to continue operating the turbine if the main trip valve is
inoperative or defective.

6.2

Testing Requirements
The test can only be carried out with the turbine running if the automatic turbine
tester is used.
When the set is shut down the main trip valve can be tested by reducing the trip
oil pressure. The trip of the valve can be monitored by observing the auxiliary trip
oil pressure. The oil pressure at which trip occurs be ascertained and recorded.

6.3

Test procedure
When testing the remote turbine trip the overspeed trips, the thrust bearing trip and
the low vacuum trip with the turbine running and using the automatic turbine
tester, the main trip valve is also tripped and thus is tested under true operating
conditions. Hence, a test of any of these safety devices can be carried out in order
to demonstrate the satisfactory functioning of the main trip valve.
Switch on the automatic turbine tester with the keyswicth.
Switch on the subgroup control for the safety devices with pushbutton.
Select the device to be tested.
Start the test program with pushbutton.
Observe operation of the main trip valve.
Observe engagement of the main trip valve.
Acknowledge and cancel the alarm for "Main trip valve operated" from the
general alarm system.
Check the annunciator tile of the automatic turbine tester for fault alarms.
Switch off the automatic turbine tester with keyswitch.

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Page No.11
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Testing of Safety and Protective Devices (KWU Turbine)
To carry out the test with the turbine shut down the trip oil pressure must be
lowered until the main trip valve operates. The trip oil pressure can be reduced by
throttling the supply valve to the governor stand.
Engage the main trip valve within the starting and load limit devices.
Open the starting and load limit device to at least 50 - 60%.
Slowly reduce the oil pressure in the governor control oil system by closing the
shut-off valve.
Ascertain the pressure at which the main trip valve operates, record the reading
and compare with the value given in the settings record.
Engage the main trip valve by operating the starting and load limit device.
6.5

Results and Action to be taken if defective


A test carried out by means of the automatic turbine tester with the turbine running
may be regarded as successful if, when repeated several times the main trip valve
always trips immediately and satisfactorily and is subsequently re-engaged.
A test carried out with the turbine shut down may be regarded as successful if the
oil pressure at trip correspond to the value quoted in the settings record and the
main trip valve can be re-engaged by actuating the starting and load limit device
and allowing the auxiliary startup oil pressure to build up again.

6.6

Record of the tests


A record of the test must be kept giving the date and the results (oil pressure at
trip).

National Thermal Power Corporation Ltd.

Page No.12
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Testing of Safety and Protective Devices (KWU Turbine)
7.0

TESTING INSTRUCTION - IV
EXERCISING THE STOP VALVES AND CONTROL VALVES

7.1

Introduction
When the turbine is operated continuously, the stop valves, and frequently the
control valves too, remain at the same lift for prolonged periods.
Impurities from the steam and the ambient atmosphere are deposited on the valve
spindles.
They carbonize into hard deposits, which can seriously affect the free movement of
the spindles.
All stop and control valves must therefore be exercised regularly and cleaned of
deposits at the same time.

7.2

Testing Requirements
Exercising can be performed with the automatic turbine tester either while the
turbine is running or while it is shutdown. The following start conditions must be
satisfied or be simulated during testing with the turbine shut down.
Load < load limit for testing
(Reason: limited lift reserve of valve groups not being tested at the time).
Load controller in operation
(Reason: to keep the load on the running turbine constant by opening valve of
valve groups not being tested at the time).
Intercept valve lift > minimum lift
(Reason: an increase in the pressure level in reheat system must be avoided).
While the turbine is running, exercising can be effected manually, observing the
test sequence and the above conditions, with the devices of the automatic turbine
tester, e.g. when the tester itself is malfunctioning.
With the turbine shut down, exercising is effected by opening and closing the stop
valves via the starting and load limiting device, or after the valves have been
opened a trip is initiated to effect closure.
Note: There must not be any pressure in the supply steam lines when exercising
is carried out in this manner.

7.3

Test Procedure
Exercising by means of the automatic turbine tester, either with the turbine running
or shut down is described in testing instruction no .V.
With the turbine running, manual exercising is performed as follows:
Test load run up to < load limit for testing.
Check whether load controller is operating.
If necessary, switch on load controller.
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Page No.13
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Testing of Safety and Protective Devices (KWU Turbine)
Close control valve of valve group to be tested by means of valve test gear.
Close stop valve of valve group to be tested with test valve.
Open emergency stop valve with test valve.
Open control valve by means of valve test gear.
Exercising with the turbine shut down is carried out as follows:
Check whether there is any pressure in the supply steam lines.
Bring test valve of stop valves to open position.
Operate the starting and load limiting device through the following sequence:
- establish zero position
- open to full lift
- return to zero position
OR
Operate the starting and load limiting device through the following sequence:
- zero position
- open to full lift and
- initiate trip
Observe opening and closure of all stop and control valves.
7.4

7.5

Test result and actions to be taken in the event of malfunctions


Exercising carried out by means of the automatic turbine tester can be regarded as
successful if, after the test program has been completed, the tester disconnects and
there are no alarms on the tester tiles.
In the case of manual exercising with the turbine running, the stop valve being
tested may not close unintentionally (e.g. cutoff of valve during opening process).
All stop and control valves must move continuously for as long as the starting and
load limiting device is operated. Any defects discovered during exercising must be
rectified immediately, particularly, any which adversely affect the safety of the
turbine.
Recording of the test
A record of the tests must be kept giving the date and the result.

National Thermal Power Corporation Ltd.

Page No.14
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Testing of Safety and Protective Devices (KWU Turbine)
8.0

8.1

TESTING INSTRUCTION - V
TESTING THE STOP VALVES AND CONTROL VALVES WITH THE
AUTOMATIC TURBINE TESTER
Introduction
When the automatic turbine tester is used to test the stop valves and the control
valves, it allows:
Regular exercising and functional testing of the stop valves and control
valves
without interrupting operation with the object of increasing the
operational reliability.
It eliminates the possibility of inadvertent disturbances due to human error
when testing.
The automatic turbine tester must be operated at regular intervals.
The manual tests may then be limited to the tests which must be carried out after
overhauls, repairs etc.

8.2

Testing requirements
The stop and control valves may be exercised with the set either running or shut
down.
In both cases it is necessary for the following start conditions to be fulfilled.
Power output less than limited power output
Load controller in operation

8.3

If the test is performed when the set is not running these conditions must be
simulated and it is necessary for all valves to be depressurized
Note : When testing with the set shut down, care must be taken to ensure that
the steam lines are not under pressure.
If the main trip valve operates during testing due to actuation of one of the
protective devices the trip system will be depressurized.
It will not be possible to reopen one of tested valves after tripping the set.
For this reason the protection of the turbine during testing is continuous.
The closing time of the stop valves is taken as the criterion for their efficient
operation.
Testing procedure
Testing proceeds automatically after the automatic turbine tester has been switched
on and the test program has been selected and started.
For safety reason the keyswitch should not be switched on until immediately before
the test is to be carried out.
The test procedure is as follows:

Switch on the automatic turbine tester by means of the keyswitch.


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Page No.15
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Testing of Safety and Protective Devices (KWU Turbine)

Switch on subgroup control

Select the valve groups to be tested from the selector tile. (When several
valve groups are selected they will be tested automatically in sequence).

Start the test programme by means of push button.

Observe the sequence of the test program.


-

8.4

control valve closes


stop valve closes
stop valve opens
control valve opens

Observe proper operation of the load controller which should maintain the
load steady.

Check the annunciator tile of the automatic turbine tester for alarms.

When the last test program has been completed the subgroup control must be
switched off.

Switch off the automatic turbine tester by means of keyswitch.

The status of the program can be observed at the operation tile of the automatic
turbine tester by annunciations and indication lamps.
The signals, which appear when the program is proceeding normally, are shown.
Results and action to be taken if defective
At test carried out by means of the automatic turbine tester may be regarded as
successful if, after the test program has been completed the tester disengages and
there are no fault indications on the tester tile.
Internal and external faults in the automatic turbine tester for the valve being tested
are indicated on the tiles.
In the event of fault while a test program is running the reset program is started
automatically.
Once program has been started, it is not possible to stop the program until it has
been completed.
In the event of mechanical disturbances in the equipment or faults of the automatic
turbine tester the operating personnel can intervene to allow the program to
continue.
It is essential for such action to be taken immediately if a stop valve does not
reopen after being closed for testing or if a testing device for the control valves
does not return to its normal operational position.
Before opening the stop valve under test check the related control valve is closed.
Close the related control valve if necessary.
Open the stop valve by means of the test valve.
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Page No.16
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Testing of Safety and Protective Devices (KWU Turbine)
Reopen the control valve.
Any fault discovered during testing must be rectified as soon as possible
especially if the safety of the turbine is affected.
8.5

Recording of the test results


A record of the test must be kept giving the date and the result.

National Thermal Power Corporation Ltd.

Page No.17
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Testing of Safety and Protective Devices (KWU Turbine)
9.0
9.1

9.2

9.3

9.4

9.5

TESTING INSTRUCTION - VI
EXERCISING THE EXTRACTION VALVES
Introduction
Malfunction of the extraction check valve may lead to overspeeding of the turbine
due to flow back of steam from heaters.
Testing requirements
The exercising of the check valves may be carried out only with the set running,
being verified by observing the position indicator. The position of check valve at
different loads should be observed and logged for future reference to ascertain its
free movement.
When the set has been shut down, the check valves may be inspected for proper
closing.
Test procedure
The steam flow causes constant movement of the check valves. Observation of the
position indicators will show whether the valves have adequate freedom of
movement at varying unit loads.
Results and action to be taken if defective
The test is successful if the check valves move under the action of the steam flow
changes.
Record of the tests
A record of the tests must be kept giving the date and the result.

National Thermal Power Corporation Ltd.

Page No.18
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Testing of Safety and Protective Devices (KWU Turbine)
10.0 TESTING INSTRUCTION - VII
CHECKING THE SETTINGS OF GOVERNORS AND CONTROL VALVES
10.1 Introduction
The satisfactory functioning of the turbine governing system depends to a large
extent on the accuracy of the control valve operating sequence and the interrelated
settings of the various components of the system. The settings of such governor
components as the bellows and the starting and load limit device need to be
accurately related to the control signals and the governor characteristics could be
distorted if this relationship is altered gradually during the running of the turbine.
Consequently, it is necessary to check the settings of the governing system at
regular intervals.
10.2 Testing requirements
When the turbine is shut down it is possible to check all settings of the governing
system including the opening and closing of the extraction valves and, if applicable,
also the check valves in the cold reheat line. (Full Scale test).
The travel of the bellow of the hydraulic speed governor, the auxiliary secondary
oil pressure, the secondary oil pressures of the hydraulic amplifier and the lift of the
control valves can be determined in relation to the travel of the starting and load
limit device.
The setting record contains details of the original settings from commissioning or
the last overhaul. The values recorded during testing should be compared with these
original values.
With the turbine running, it is not possible to check all details of the governor and
valve settings, because movements may take place while the readings are being
taken. As an alternative, it is sufficient to keep a regular record of the secondary oil
pressures and all valve lifts (in %) at three or four specific values of load i.e. 60%,
80% & 100% load at rated parameters (Partial check). These readings can then be
checked against similar readings in the operating data record.
It is also necessary to record the actual voltage of the lift of the amplifier for
purposes of comparison.
10.3 Test procedures
Testing with the plant shut down is carried out as follows:

Close the test valves of the stop valves.

Operate the starting and load limit device until the secondary oil pressure rise.

Determine the secondary oil pressure collapse point of the governing system.

Raise the auxiliary secondary oil pressure in steps of 0.1 bar.

Take readings of all principal parameters as described in testing requirements.

Enter the test readings in a graph against the auxiliary secondary oil pressure
and compare it with the settings record.

Close the control valves with the starting and load limit device.
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Testing of Safety and Protective Devices (KWU Turbine)

Open the test valves of the stop valves.

10.4 Results and action to be taken in the event of discrepancies


Minor deviations in the settings values of the order of 3% of total lift of valve in
case of main steam valves and 10% in case of reheat valves have no serious effect
on the governor characteristic and can be neglected. In the range of valve settings
for no load operation the deviations should be smaller in view of the better
distribution of the steam flow. If the deviations should, in fact, prove to be greater,
the manufacturer should be informed immediately so that he may decide whether
adjustment of the governing system is necessary.
10.5 Record of the tests
A record of the test must be kept giving the date and the settings.

National Thermal Power Corporation Ltd.

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Testing of Safety and Protective Devices (KWU Turbine)
11.0 TESTING INSTRUCTION - VIII
TESTING THE LEAKAGE OF THE STOP VALVES AND CONTROL
VALVES
11.1 Introduction
During normal operations of the turbine and particularly after extended periods of
running, the cones and seats of the control valves and stop valves can become
damaged by foreign objects or by erosion. The result is that the controllability of
the turbine in the range below or at the rated speed is adversely affected, i.e. the
uncontrolled admission of steam can give rise to undesirable increases in speed.
During stratup, this situation can give rise to the speed remaining longer than
necessary in the critical range, because it is impossible to lower the speed of the
turbine.
When the leakage through the valves is exceptionally severe, it can cause
difficulties in synchronizing because the turbine speed is greater than the system
speed.
Slight leakage at the control valves which causes the speed of the turbine to
increase when the stop valves are opened is a normal feature of the valves
(balancing holes in the valve cone and clearance at the cone guides) and is therefore
not dangerous.
Leakage at the valves must be detected early and rectified as soon as possible in
order not to endanger the turbine or to adversely affect its availability.
Consequently, it is necessary to test the leakage of the hydraulically-operated main
steam valves at regular intervals.
11.3 Testing requirements
The leakage of the control valves and stop valves can be tested during start-up,
during short interruptions in running or when shutting down using the reversepower protection.
11.4 Test procedure
When testing the control valves during startup, the speed of the turbine when the
stop valves are opened and the control valves remain closed must not differ greatly
from the corresponding speed recorded during commissioning under the same main
steam conditions.

Speed governor must be in 0 position.

Control valves must be closed.

Secondary oil pressures must be lower than the pressure required to lift the
control valves.

Open the stop valves by means of the starting and load limit device.

Observe the speed increase and record the reading together with the main steam
conditions.
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Testing of Safety and Protective Devices (KWU Turbine)
When testing the stop valves during start-up, there must again be no excessive
increase in speed when the control valves are open and the stop valves are closed.

Starting and load limit device must be in the 0 position.


Test valves of the stop valves must be closed.
Speed governor in control must be in the 0 position.
Operate the starting and load limit device to the 100% position.
Set the speed governor reference value higher than the actual speed on the
turning gear.
Observe the speed increase and record the reading together with the main steam
conditions.
Set the speed reference value to 0.
Close the control valves.
Set the starting and load limit device to 0.
Open the test valves of the stop valves.

The leakage of the control valves can be tested as follows during short interruptions
in operation or when shutting down.

Unload the turbine.


Close the control valves by means of the speed setter.
Observe the closure of the valves and the reduction of the secondary oil
pressure.
Observe the operation of the reverse-power relays,
Check the tripping of the generator circuit breaker by the reverse-power
protection.
For operation of the reverse-power relays to be satisfactory, the leakage of the
control valves must remain within permissible limits.
11.4 Results and action to be taken if defective
A test carried out during start-up may be regarded as successful if the speed does
not increase. A test carried out when shutting down or during a brief interruption in
running is successful if the reverse-power protection functions properly.
If excessive leakage causes the control of speed to be unsatisfactory when
running at no load and with the control valves and stop valves closed, the turbine
must not continue in service until the defect has been rectified.
11.5 Record of the tests
A record of the tests must be kept giving the date and results.

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Testing of Safety and Protective Devices (KWU Turbine)
12.0 TESTING INSTRUCTION - IX
SPEED MONITORING DEVICE
12.1 Introduction
The speed of the turbine must be monitored
During normal continuous operation.
After load rejections
During start up
When shut down
During turning gear operation
The maximum permissible speed must not be exceeded and operation of the
turbine is not allowed in speed ranges in which the following occur.
Critical speeds or
Blade resonances
12.2 Speed Monitoring System
The turbine is equipped with
An electrical speed indicator which measures the speed from 0 to 3600 R.P.M.
and
Primary oil pressure indication (Bears a definite relationship with speed as per
speed / pressure curve)
The primary oil pressure cannot be used for speed measurement in the lower speed
range due to the speed/pressure relation limitation. The primary oil pressure at and
near normal speed must be recorded during initial commissioning and subsequently
on quarterly basis.
12.3 Testing Requirements
The primary sensors shall be checked at standstill.
Healthiness of wear rings etc of primary oil pump.
During running the following shall be checked & compared.
At idling speed comparison of speeds by using stroboscope.
On load, with grid frequency.
As three out of four Hall probes are used for electrical speed measurement, their
looseness, gaps etc shall also be checked in standstill condition.
12.4 Test Procedure
During Planned Shut Down
Inspect & record the number of magnets in the Halls generator disc and polarity
of magnets incase speed differences are noticed prior to planned shut down.
Inspect the primary oil pump components.
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Testing of Safety and Protective Devices (KWU Turbine)
Check for cleanliness of orifice in the suction of the primary oil pump.
During normal operations
Check Halls probes (All four) for healthiness with respect to installation and
controls.
Compare the electrically measured speed with stroboscope at idling speed.
Under synchronised conditions compare speed with grid frequency.
Compare primary oil pressure as per speed pressure curve.
12.5 Testing results and rectification of faults
The speed measuring devices (electrical & hydraulic both should show matching
and consistent readings under condition listed in introduction:
In the event of mismatching, malfunctions, measures must be taken immediately to
rectify the fault to prevent operation of turbine at speed higher than rated.
12.6 Test Record:
A record must be kept giving the date, conditions during test and results.

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Testing of Safety and Protective Devices (KWU Turbine)
13.0 TESTING INSTRUCTION - X
TESTING THE AUTOMATIC STARTING OF AUXILIARY OIL PUMPS
AND DC BEARING OIL PUMP
13.1 Introduction
The oil supply to the bearing during operation at rated-speed, during run up and
run-down, and during turning gear operation must be safe-guarded.
One of the auxiliary oil pumps will start as soon as the lube oil pressure drops to the
set value of the subloop control.
The standby pump will start if the first pump fails to operate or the pressure
continues to drop.
Auxiliary oil pump failures, loss of their power supply, failure of their subloop
control, or any other failure which results in the lube oil pressure reaching a preset
lower limit which will cause the DC bearing oil pump to start.
Correct operation of the subloop controls for the auxiliary oil pumps and the DC
bearing oil pump are required to protect the bearings from damage.
For this reason the subloop controls should be tested at every suitable occasion i.e.
when shutting down the turbine.
13.2 Testing Requirements
Testing of the subloop controls during operation with rated speed can only be
carried out by means of special measures. Since the oil pumps have redundancy,
testing during operation is not absolutely necessary.
It is sufficient to test subloop control of the auxiliary oil pumps during shut-down
of the turbine.
Testing of the subloop control of the auxiliary oil pumps is recommended during or
after each extended shut-down.
13.3 Test procedure
If the testing of the subloop control of the auxiliary oil pumps occurs during shut
down of the turbine only one pump can be tested at a time.
Care must be taken to ensure each of the auxiliary oil pumps are tested according to
the testing recommendations.
A testing schedule should be established to fulfill this requirement.
Test procedure:
Select auxiliary oil pump to be tested according to test schedule.
Set the respective control switch to ensure that only the auxiliary oil pump
which has been chosen will start during test.
Shut-down turbine.
Observe speed and oil pressure drop.
Observe start of the auxiliary oil pump.
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Testing of Safety and Protective Devices (KWU Turbine)
Record starting pressure and turbine speed at which the auxiliary oil pump
started.
If the subloop control fails to start the auxiliary oil pump at the set oil pressure,
the pump must immediately be started manually.
During turbine standstill the testing of the subloop control of the auxiliary oil
pumps and the DC bearing oil pump can be carried out as follows:
Preconditions
Oil system depressurized
Subloop control switched off.
Testing procedure
Switch on subloop control.
Observe starting of all pumps which should have been started by the subloop
control.
Automatic start of the DC bearing oil pump by subloop control can also be carried
out during turbine standstill as follows:
Preconditions
Auxiliary oil pump in operation.
Oil system pressurized.
Subloop control of auxiliary oil pumps switched off.
Subloop control of the DC bearing oil pump switched on.
Testing procedure
Shutdown auxiliary oil pump manually.
Observe start of the DC bearing oil pump.
Start auxiliary oil pump
Stop DC bearing oil pump.
13.4 Results and actions to be taken if defective
All tests described above are successfully completed if the auxiliary oil pumps or
the DC bearing oil pump are started without failure by the respective subloop
controls.
The turbine must not be operated with defective subloop controls for the auxiliary
oil pumps and especially for the DC bearing oil pump. Any defects or deficiencies
must be corrected immediately.
13.5 Record of the tests
A record of the test must be kept giving the date and the results.

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Testing of Safety and Protective Devices (KWU Turbine)
14.0 TESTING INSTRUCTION - XI
14.0 TESTING THE HYDRAULIC LOW VACUUM TRIP
14.1 Introduction
The hydraulic low vacuum trip guards against excessive loss of vacuum in the
condenser due to continued inflow of steam in the event of failure of important
auxiliary systems in the condensing plant, e.g. the circulating water supply system,
and overheating of the condenser and the exhaust section of the turbine is
prevented.
When the tripping pressure is reached, the low vacuum trip reduces the auxiliary
trip oil pressure and thus causes closure of the main trip valves, control valves and
extraction valves.
The low vacuum trip must be tested at regular intervals by means of the automatic
turbine tester.
14.2 Testing modes
By means of the automatic turbine tester, the low vacuum trip can be tested while
the turbine generator is running.
The low vacuum trip can be tested during turning-gear operation when vacuum is
pulled in the condenser. It is done, by reducing the condenser vacuum and
simulating the primary oil pressure. The primary oil pressure is simulated by
screwing in to the limit the stop screw for the primary oil piston.
Testing can also be carried out even if there is no vacuum in the condenser during
shut down, by means of a special vacuum pump.
This test is done during initial adjustment, during routine, precise checks of the set
point, and after repairs to the equipment or overhaul of the entire plant.
14.3 Test procedure
The procedures required for testing with the automatic turbine tester are explained
in a special set of test instructions.
The following procedure is adopted for testing during turning gear operation by
alteration of the condenser vacuum.
Adjust the absolute pressure in the condenser to less than 0.1 bar by means of
the normal vacuum pump.
Close the test valves of the emergency stop valves
Operate the starting and load limit device to 40%
Unscrew the cap of the low vacuum trip stop-screw
Screw in the primary oil piston stop-screw of the low vacuum trip to the limit
Reduce the condenser vacuum
Record the functioning and response pressure of the low vacuum trip
Observe the drop in the trip fluid pressure
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Testing of Safety and Protective Devices (KWU Turbine)
Observe the response of the alarms (low vacuum trip and main trip valve
operated)
Increase the condenser vacuum
Acknowledge and cancel the alarms.
Actuate the main trip valve, using the starting and load limit device
Open the test valves
Unscrew the stop screw for the primary oil piston of the low vacuum trip, and
lock it in position
Replace the cap and screw it down so that it is oil-tight.
Testing with vacuum produced by a special vacuum pump is done if the vacuum
system at the time of testing or setting of the low vacuum trip, is not yet ready for
use, or if the vacuum in the condenser cannot be reduced this manner of conducting
the test required extensive preparations.
The following additional procedures are required:
Blank off the control pulse line to the condenser, using a closure disc since, for
safety reasons, an isolating device is not provided.
Use a hose line to connect the condenser low vacuum trip system (which has
been disconnected from the condenser) to a special vacuum pump.
Connect an additional pressure-measuring device (U-tube) to the system (which
has been disconnected from the condenser)
Produce an absolute pressure of less than 0.1 bar in the low vacuum trip system
Carry out the rest of the procedure as for "testing with in condenser vacuum
when shutdown"
14.4 Test results and action to be taken in the event of malfunctions
Testing with the automatic turbine tester has reached a satisfactory conclusion
when low vacuum trip and the associated alarms in the general alarm equipment
respond and no fault alarm is shown on the annunciator tile of the automatic turbine
tester.
For the other tests, the actual setting must correspond to the required setting.
14.5 Recording the tests
A record of the tests must be kept with date and response pressures and notes as to
the proper functioning of the equipment.

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Testing of Safety and Protective Devices (KWU Turbine)
15.0 TESTING INSTRUCTION - XII
TESTING THE ELECTRIC LOW VACUUM TRIP
15.1 Introduction
The electric low vacuum trip prevents the pressure in the condenser from increasing
to an inadmissible level as a result of a continued supply of steam after outage of
important auxiliary units of the condenser plant, e.g. the cooling water supply
equipment. It also protects the condenser and the exhaust section of the turbine
against overheating.
When tripping pressure is reached, the electric low vacuum trip initiates turbine trip
by actuating the remote trip solenoid valves, causing the stop, control and
extraction valves to close.
The electric low vacuum trip must be tested at regular intervals.
15.2 Testing Conditions
The electric low vacuum trip can be tested during operation of the turning gear,
once air has been removed from the condenser, by increasing the pressure in the
condenser.
Testing during standstill and no condenser vacuum is performed by using a
special vacuum pump to vary the simulated condenser pressure.
This test is carried out after initial setting, during regular and rigorous set point
checks as well as after repair work carried out on the equipment or overhauls of the
entire plant.
15.3 Testing Procedure
The following procedures must be carried out the when testing during operation
of the turning gear by varying condenser pressure.
Using normal-operation vacuum pump, set absolute condenser pressure at less
than 0.1 bar.
Close test valves of stop valves.
Run up start-up and valve lift limiter to 40%
Increase condenser pressure
Record function and response pressure of the electric low vacuum trip.
Observe drop out of automatic trip gear.
Record appearance of annunciations (electric low vacuum trip and automatic
trip gear activated).
Reduce condenser pressure by starting up normal operation vacuum pump and
gland steam supply.
Acknowledge and cancel alarms
Engage automatic trip gear with start-up and valve lift limiter.
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Testing of Safety and Protective Devices (KWU Turbine)
Open test valves of stop valves.
Testing with the vacuum produced by a special vacuum pump is carried out if the
condenser plant is not operational when the low vacuum trip is being tested or set,
or if the pressure in the condenser cannot be raised. This type of testing requires
extensive preparation.
The following additional procedure must be carried out:
Use closure disc to cut of pulse line to condenser, as for safety reasons no
isolating device is available.
Attach flexible tubing from the electric low vacuum trip system, isolated from
the condenser, to a special vacuum pump,
Connect an additional pressure gauge (U-tube) to the system isolated from the
condenser,
Using a special vacuum pump, produce an absolute pressure of less than 0.1 bar
in the low vacuum trip system,
Perform the remaining steps as for "Testing during operation of the turning gear
with condenser pressure"
Finally dismantle extra equipment used for this test and remove closure disc to
re-establish pulse line.
15.4 Test Results and Rectification of Faults
The setpoints must correspond with the desired settings during testing performed
during operation of the turning gear or during standstill and no condenser vacuum
by means of a special vacuum pump.
15.5 Record of the Test
A record of the test must be kept giving date, response pressures, or statements to
effect that the equipment is functioning properly.

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Testing of Safety and Protective Devices (KWU Turbine)
16.0 TESTING INSTRUCTION - XIII
TESTING THE THRUST BEARING TRIP
16.1 Introduction
The purpose of the thrust bearing trip is to prevent consequential damage in the event
of irregularities or damage to the thrust bearing. It is actuated as soon as the axial
displacement of the shaft within the thrust bearing exceeds a maximum value.
The reduction of the auxiliary trip oil pressure and the trip oil pressure causes the stop,
control and extraction valves to close.
The thrust bearing trip must be tested by means of the automatic turbine tester at
regular intervals. Further more, the thrust bearing trip must also be tested during
overhauls.
16.2 Testing Conditions
Testing of the thrust bearing trip while the turbine is running is carried out with the aid
of the automatic turbine tester.
Testing with the turbine shut down can only be carried out after the bearing housing
cover has been opened. The trip link is then released manually to check the freedom of
movement of the releasing device and the engaging of the trip link. During overhauls
or replacement of the thrust bearing, the linkage clearances must be checked and, if
necessary, corrected.
16.3 Test procedure
The steps to be performed for testing with the automatic turbine tester are given in a
separate testing instruction.
For testing with the turbine shut down, the procedure is as follows:
Open the bearing housing cover. (Note: Avoid the loss of oil).
Actuate the trip link manually
Observe operation of releasing device
Check presence of annunciation (Thrust bearing trip released) on annunciation
equipment
Re-engage releasing device valve manually;
Acknowledge and cancel annuniciation
Close bearing housing cover.
16.4 Test result and rectification of faults
The testing has been successful if:
The thrust bearing trips releasing device activates the automatic trip gear when
being tested with the automatic turbine tester.
The valve trip link re-engages correctly.
In the event of malfunctions, measures must be taken immediately to rectify the fault.
16.5 Test record
A record must be kept of the test, giving the date and result.
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Testing of Safety and Protective Devices (KWU Turbine)
17.0 TESTING INSTRUCTION - XIV
TESTING THE DIFFERENTIAL PRESSURE PROTECTION OF
EXTRACTION VALVES
17.1 Introduction
Under certain circumstances such as a rapid reduction of the load on the turbine, a
tripout or disturbance in the steam supply system fed from the turbine, it is possible
for steam or a steam/water mixture when conditions are very adverse-to flow back
through the extraction lines into the turbine. The admission of this relatively cold
steam to the cylinder would give rise to excessive temperature gradients, which
would cause damage. For this reason, check valves are fitted in the extraction lines
to prevent the reverse flow of steam. In extractions where the danger of reverse
flow is particularly acute, the check valves incorporate a control system, which
closes the valves as soon as the pressure differential of the flow of steam away from
the turbine falls below a certain minimum value. These control systems, which
incorporate differential pressure switches, must be tested regularly.
17.2 Testing requirements
The control systems for monitoring the differential pressure at the extraction valves
can be tested at any time during operation of the turbine.
17.3 Test procedure
The test is affected by equalizing the pressure on both sides of the differential
pressure switch.
Extraction valve is open,
Close shut-off valves,
Open the equalizing valve,
Observe the reduction of the pressure differential,
Observe closure of the extraction valve,
Close the equalizing valve,
Open the shut-off valves - as near as possible simultaneously.
17.4 Results and action to be taken if defective
The test may be regarded as successful if the extraction valve closes as soon as the
pressure differential falls below the set value. In the event of any irregularities,
open the vents. Before repeating the test wait until the condensate level has built up
to the condensate drain vessels.
17.5 Record of the tests
A record of the tests must be kept giving the date and the results.

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Testing of Safety and Protective Devices (KWU Turbine)
18.0 TESTING INSTRUCTION - XV
TESTING THE FIRE PROTECTION DEVICES
18.1 Introduction
When severe oil leaks occur there is an acute danger of fire, the fire protection
measures must be initiated immediately. Their object is to prevent any further
discharge of oil from the leak or to reduce it to a minimum while the turbine is
running down. The functions and operation of the fire protection devices are
described in detail in the Turbine Manual. The fire protection devices must be
tested as frequently as possible, i.e. during turbine shut-down, to ensure that they
are functioning satisfactorily.
18.2 Testing requirements
The fire protection devices can only be tested while the turbine is under shutdown.
Testing involves reducing the pressure in all hydraulic control protection systems
so that a turbine trip would be inevitable when the test is to be carried out with the
machine running.
18.3 Test procedure
The following operating conditions must be established before all tests are carried
out.
Auxiliary oil pump A or B running.
Turbine speed greater than 70 rev/min.
Starting and load limiting device at a load setting at which the auxiliary starting
oil pressure is reduced.
Main-trip gear set.
Test valves of stop valves in close position.
Stop valves closed.
The following tests are carried out:
TEST 1: Testing the functioning of the fire protection devices by operation of fire
protection switches 1 and 2.
TEST 2: Testing the functioning of the fire protection devices by operation of fire
protection switch 2 only.
TEST 3: Testing the functioning of the fire protection devices by operation of the
pushbutton on solenoid valve 1.
TEST 4: Testing the functioning of the fire protection devices by operation of the
pushbutton on solenoid valve 2.
The Procedure for TEST 1 is as follows:

Operate fire protection switch 1


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Testing of Safety and Protective Devices (KWU Turbine)

Check whether all fire protection measures listed in Fig.-1 are initiated
automatically.
Component

Function initiated

Remote trip 1

On

Remote trip 2

On

Emergency shut-off valve

Close

Vacuum breaker

On

Fig.1 Fire protection measure by operation of fire protection switch 1

Check the alarm and condition annunciations listed in Fig.2 which must
appear after operation of the fire protection switch 1.
Component

Function
initiated

Remote trip

Type of
annunciation

Annunciation

On

Alarm main trip valve operated

Emergency shut-off
valve

Closed

Desk operating control closed

Solenoid Valve 1

Tripped

Desk operating control closed

Solenoid Valve 2

Tripped

Desk operating control closed

Vacuum breaker

On

Desk operating control closed

Fig.2 Alarm (A) and condition (C) annunciations after operation of Fire
Protection Switch 1

Operate fire protection switch 2

Check whether all fire protection measure listed in Fig.3 are initiated
automatically.
Component

Function initiated

Auxiliary oil pump 1 (SLC AOP-1)

Protection Off

Auxiliary oil pump 2 (SLC AOP-2)

Protection Off

Automatic starter for shaft lift oil pump (SLC JOP-1, JOP-2)

Off

Emergency oil pump (EOP)

On

Automatic starter for Emergency oil pump (SLC EOP)

Off

Automatic starter for turning gear (SLC Turning Gear)

Off

Automatic starter for shaft lift oil pump (SLC JOP-1)

On

Fig.3 Fire protection measure after operation of fire protection switch 2

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Check the alarm and condition annunications listed in the following table which
must appear after operation of fire protection switch 2.
Function initiated

Annunciation

Type of
annunciation

Auxiliary oil pump 1

Protection Off

Desk operating control OFF

Auxiliary oil pump 2

Protection Off

Desk operating control OFF

Shaft lift oil pump


(JOP-2)

On

Desk operating control ON

Emergency oil pump

On

Desk operating control ON

Component

Fig.4 Alarm (A) and condition annunications(C) after operation of fire


protection switch 2

Check the reduction of oil pressure in the systems

After testing, normal operating conditions are restored as follows:

Cancel the auxiliary oil pump OFF command

Select auxiliary oil pump A or B

Switch on the auxiliary oil pump automatic starter

Stop emergency oil pump

Cancel the memory function of solenoid valves

Check that emergency shut-off valve opens

Switch on the automatic starters for shaft lift oil pump and turning gear valve.

The Procedure for TEST 2 is as follows:

Operate fire protection switch 2

Check whether all fire protection measures listed in figs. 1 and 3 are initiated
automatically.

Check that the alarms and condition annunications listed in figs. 2 and 4
appear.
NOTE: Operation of Fire Protection Switch 2 also initiates the Functions of
Fire Protection Switch 1.

If the test is satisfactory restore normal operating conditions.

The procedure for TEST 3 is as follows:

Establish the operating conditions for performance of the test

Operate the Pushbutton on solenoid valve

Check that emergency shut-off valve closes


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Testing of Safety and Protective Devices (KWU Turbine)

Check that the turbine trip operates

Check that all alarm (A) and condition (C) annunications for the components
included in the test are given.

The procedure for TEST 4 is the same as that for TEST 3 with the exception of
operating of the push-button on solenoid valve.
18.4 Results
The tests are satisfactory if

All control functions are satisfactorily carried out after operation of fire
protection switches 1 and 2, fire protection switch 2 and pushbuttons of
solenoid valves.

All alarm and condition annunications for the components controlled by the
fire protection switches are satisfactorily given.
Any malfunctions discovered during testing could, under real conditions lead to
costly damage and plant outages. Therefore, when a malfunction is found,
immediate action must be taken to ensure the satisfactory functioning of the fire
protection devices.
Testing of the fire protection devices must be logged together with the date and
result of the test.
19.0 REVIEW
The Head of Corporate Operation Services, will be responsible for reviewing this
document on a 3-yearly basis or as necessary.

National Thermal Power Corporation Ltd.

Document for Distribution to:


CONTROLLED
I. Power Stations
1. General Manager
2. General Manager
3. General Manager
4. General Manager
5. General Manager
6. General Manager
7. General Manager
8. General Manager
9. General Manager
10. General Manager
11. General Manager
12. General Manager
13. General Manager
14. General Manager
15. General Manager
16. General Manager
17. Addl. General Manager(I/C)
18. Addl. General Manager(I/C)
19. Addl. General Manager(I/C)
20. Addl. General Manager(I/C)
21. Addl. General Manager(I/C)
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Rihand
Vindhyachal
Kahalgaon
Farakka
Dadri (Coal & Gas)
Unchahar
Korba
Ramagundam
Badarpur
Talcher Kaniha
Singrauli
Kawas
Kayamkulam
Anta
Simhadri
BALCO Captive
Talcher Thermal
Auraiya
Jhanor Gandhar
Faridabad
Tanda

UNCONTROLLED
II. Regional Head Quarters
22. Executive Director (NR), Lucknow
23. Executive Director (SR), Hyderabad
24. Executive Director (WR), Mumbai
25. Executive Director (ER), Patna
26. Executive Director (NCR), NOIDA

III. Corporate Head Quarter


27. STA to CMD, SCOPE, New Delhi
28. STA to Director (Technical), SCOPE, New Delhi
29. STA to Director (Operations), SCOPE, New Delhi
30. STA to Director (Commercial), SCOPE, New Delhi
31. STA to Director (Projects), SCOPE, New Delhi
32. Executive Director (OS), EOC, NOIDA
33. Executive Director (Engg.), EOC, NOIDA
34. General Manager (R&D), NOIDA
35. Concerned Group Heads in Operation Services, CC

IV. Head of O&M


36. Singrauli

37. Korba

38. Ramagundam

39. Farakka

40. Vindhyachal

41. Rihand

42. Kahalgaon

43. Dadri(Coal)

44. Unchahar

45. Talcher Kaniha

46. Talcher Thermal

47. Badarpur

48. BALCO Captive

49. Auraiya

50. Anta

51. Kawas

52. Jhanor Gandhar

53. Dadri (Gas)

54. Kayamkulam

55. Faridabad

56. Simhadri

57.Tanda
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