Manual Steam Turbine PDF

INSTRUCTION MANUAL
CAMPBELL'S SOUP
OHIO
INSTRUCTIONS FOR
569 HP
NON-CONDENSING STEAM TURBINE
TURBINE SERIAL NUMBER D6706

WELLSVILLE ORDER NUMBER C-34347
P.O. # M2018308I
SEPTEMBER 2011
Instruction Manual for
Single Stage 350, 500, and 700 Frame
Steam Turbines
Manual 107-A
How to Use This Manual
Dresser-Rand
SST 350, SST 500, and SST 700
Single Stage Turbine
Instruction Manual
March 2011 INSTRUCTION MANUAL 107

Revision A
How To Use This Manual SST Turbine Instruction Manual
Revision A SST Turbine Instruction

THIS MANUAL APPLIES TO SST 350, 500, AND SST 700 SINGLE STAGE
TURBINES.
This instruction manual contains installation, operation, and maintenance

instructions for the Dresser-Rand Turbine identified on the Turbine Data Sheet
included with this manual. It should be reviewed thoroughly by the user before
attempting to install and operate the turbine, and should be kept in a location
convenient to the user for ready reference during operation and maintenance.
WARNING
A complete reading of this manual by personnel in contact with

the steam turbine is essential to safety. INCORRECT
INSTALLATION, OPERATION, MAINTENANCE, OR PARTS
REPLACEMENT CAN RESULT IN INJURY TO PERSONNEL,
AND DAMAGE TO THE TURBINE, DRIVEN MACHINERY,
AND PLANT.
The Instruction Manual consists of 15 sections, as listed in the table of contents.

Each section is further broken down into subsections.
This is a general instruction manual, describing a standard ring oiled or pressure

lubricated turbine with hydraulic or electronic governors. The description and
illustrations contained herein may differ in minor details from the unit actually
supplied. All general installation, operation, and maintenance procedures are
applicable.
For turbines supplied with options such as forced or circulating lubrication

systems, alternative speed control systems, accessories, instrumentation, speed
reducers or other special configurations, refer to the appropriate accessory manuals
and turbine certified drawing package included in Appendix A and Appendix B
following this manual.
March 2011 Revision A 1

How To Use This Manual SST Turbine Instruction Manual
WARNING
Throughout this manual, it is assumed that the motive flow applied at

the turbine inlet is high-pressure steam. Therefore, the word “steam”
is used in reference to various aspects of turbine installation,
operation, and maintenance. For some specialized applications, high-
pressure gasses such as Freon, natural gas, or other vapors may
provide the motive flow. In these cases, it can generally be assumed
that the name of the gas in use may be used to replace the word
“steam.” The user of the equipment must address all hazards
associated with the nature of the specific motive flow in use with the
turbine. If flammable or toxic gasses are used as the motive fluid or if
oil vapor could be emitted, the user/installer must pipe leak-offs and
drains to a safe location. Explosive gas mixtures must not be used as
the motive fluid.
The instructions contained in this manual do not attempt to cover all details, nor
does it provide for every possible contingency to be met in connection with
installation, operation, or maintenance of the supplied equipment.
The supplying of instructions does not imply, in any manner, that Dresser-Rand
accepts liability for work carried out by a customer or contractor personnel.
Liability is limited to and as stated in our Terms and Conditions of Sale.
Should further information be desired, or should particular problems arise, the

matter should be referred to Dresser-Rand.
This manual is intended for use by personnel with a general knowledge of proper
operation and maintenance of steam turbines. Special training or the assistance of
a trained Dresser-Rand service representative is suggested for personnel with less
than a general working knowledge of this type of equipment.
All inquiries regarding installation, operation, maintenance, spare parts, or service

should be directed to your Dresser-Rand manufacturer’s representative, or to:
Dresser-Rand
Steam Turbine Business Unit
www.dresser-rand.com
800-828-2818
585-596-3100
Refer to Section M, Replacement Parts/Factory Service, for information on how to

request factory service or order replacement parts.
2 Revision A SST Turbine Instruction

SST Turbine Instruction Manual EU Compliance
EU Compliance
The following warning and notes apply only to turbines for which
compliance with European Union Directives has been specified.
NOTE
If there is a CE mark on this turbine nameplate it indicates

compliance with the ATEX Directive. Machinery Directive
Compliance and Machinery Directive CE marking of the turbine
and driven equipment is the responsibility of the assembler or
installer. See the Machinery Directive Declaration of
Incorporation
WARNING
ATEX Certified turbines will have a mark –c C X on the turbine

nameplate. This indicates that the turbine casing temperature
will become that of the motive fluid (steam or gas) inlet
temperature, this may exceed the ignition temperature of some
gasses. See the ATEX Directive Risk Assessment Summary
List accompanying the ATEX Declaration of Conformance.
NOTE
Refer to the Machinery Directive – List of Residual Risks and

ATEX Directive-Risk Assessment Summary List for warnings
related to EU Compliance.
Additional cautions and warnings are located throughout this

manual and in the Safety Precautions Section.
SST Turbine Instruction Manual Revision A 3

Table of Contents SST Turbine Instruction Manual
Table of Contents
How to Use This Manual............................................................................................................... 1
EU Compliance ............................................................................................................................. 3
Table of Contents.......................................................................................................................... 4
List of Figures................................................................................................................................ 13
List of Tables................................................................................................................................. 15
Safety Precautions ........................................................................................................................ 17
Section A Introduction and General Description.......................................................................... 25
A.1 Turbine Description ................................................................................................ 25

A.2 Construction ............................................................................................................. 25
A.3 Main Components .................................................................................................... 27
A.4 Factory Test ............................................................................................................. 36
A.5 Shipping Preparation/Crating ................................................................................... 37
A.6 Uncrating and Inspection ......................................................................................... 37
A.7 Short-term Storage................................................................................................... 38
A.8 Long-term Storage ................................................................................................... 39
A.9 Dresser-Rand Factory Service/Replacement Parts................................................. 41
A.10 Re-Rating and Upgrades ......................................................................................... 42
A.11 Nameplate Information............................................................................................. 43
Section B Technical Data............................................................................................................. 45
B.1 General..................................................................................................................... 45
B.2 Lifting ........................................................................................................................ 45
B.3 Alignment ................................................................................................................. 46
B.4 Thermal Growth........................................................................................................ 47
B.5 Lubricants................................................................................................................. 48

SST Turbine Instruction Manual Table of Contents
B.6 Major Fits, Clearances, and Rotor Balance Criteria.................................................49

B.7 Piping Forces............................................................................................................56
B.8 Bolt Torques and Materials.......................................................................................57
B.9 Sealants and Joint Compounds ...............................................................................58
B.10 Cooling Water to Bearing Housing Water Jackets ...................................................60
B.11 Steam Pressure and Temperature Limits.................................................................60
B.12 Steam Quality and Steam Purity ..............................................................................60
B.13 Turbine Rotor Data ...................................................................................................62
Section C Installation....................................................................................................................63
C.1 General .....................................................................................................................63

C.2 Foundation................................................................................................................65
C.3 Piping........................................................................................................................67
C.3.1 Piping Forces............................................................................................................68
C.3.2 Isolating Valves.........................................................................................................69
C.3.3 Full Flow Relief Valve ...............................................................................................70
C.3.4 Inlet Piping ................................................................................................................71
C.3.5 Exhaust Piping..........................................................................................................72
C.3.6 Piping Blow Down.....................................................................................................73
C.3.7 Steam Strainer..........................................................................................................73
C.3.8 Check Valve..............................................................................................................74
C.3.9 Expansion Joints ......................................................................................................74
C.3.10 Leak-Off Piping .........................................................................................................77
C.3.11 Gland Seal Leak-Off Piping – Vacuum Exhaust.......................................................78
C.3.12 Gland Seal Intermediate Leak-Off Piping – High Back Pressure Exhaust...............78
C.3.13 Drain Piping ..............................................................................................................81
C.3.14 Water Cooling Piping to Bearing Housing Water Jackets ........................................82
C.4 Alignment Requirements ..........................................................................................84
C.5 Couplings..................................................................................................................86
C.6 Preparation for Alignment.........................................................................................87
C.7 Compensation for Thermal Movement .....................................................................89
C.8 Cold Alignment Check ..............................................................................................91
C.8.1 Angular Alignment ....................................................................................................91
C.8.2 Parallel Alignment.....................................................................................................92
C.9 Grouting ....................................................................................................................93

C.10 Hot Alignment Check ............................................................................................... 94

C.11 Fire Protection .......................................................................................................... 95
C.12 Decommissioning..................................................................................................... 94
Section D Speed Control System ................................................................................................ 96
D.1 General..................................................................................................................... 96
D.2 Standard Governor................................................................................................... 96
D.3 Lubrication and Maintenance ................................................................................... 99
D.4 Speed Range and Droop Adjustment ...................................................................... 99
D.5 Optional Governors .................................................................................................. 99
D.6 Throttle Valve ........................................................................................................... 100
D.7 Throttle Linkage........................................................................................................ 102
D.8 Hand Valves ............................................................................................................. 102
Section E Overspeed Trip System............................................................................................... 105
E.1 General..................................................................................................................... 105

E.2 Warnings .................................................................................................................. 107
E.3 Description and Function ......................................................................................... 109
E.3.1 Overspeed Governor Cup Assembly ....................................................................... 109
E.3.2 Trip Valve ................................................................................................................. 110
E.3.3 Trip Linkage.............................................................................................................. 113
E.4 Trip System Operation ............................................................................................. 113
E.4.1 Manual Reset ........................................................................................................... 113
E.5 Adjustment of Trip Speed......................................................................................... 116
E.5.1 Trip Speed Setting.................................................................................................... 116
E.5.2 Magnetic Pickup Clearances ................................................................................... 117
E.6 Testing the Overspeed Trip Mechanism .................................................................. 118
E.6.1 General..................................................................................................................... 118
E.6.2 Overspeed Trip Test Procedure............................................................................... 119
Section F Lubrication System ...................................................................................................... 120
F.1 General..................................................................................................................... 121

F.2 Lubrication Requirements ........................................................................................ 122
F.3 Oil Ring Lubrication.................................................................................................. 123
F.4 Mist Oil System Lubrication...................................................................................... 124
F.5 Circulating Oil Cooling System................................................................................. 125

F.6 Pressure Lubrication System....................................................................................125

F.6.1 Design Parameters for Turbine Pressure Lubrication Oil Systems..........................126
F.7 Cooling Water to Bearing Housing Water Jackets ...................................................128
F.7.1 Bearing Housing Cooling Water Requirements .......................................................130
F.7.2 Governor Oil Cooling Water Requirements..............................................................130
F.8 Recommended Oil Sump and Bearing Temperatures .............................................130
F.9 Constant Level Oiler .................................................................................................131
F.10 Bearing Housing Oil Levels and Capacities .............................................................132
F.11 Maintenance/Oil Changes ........................................................................................132
F.12 Lubricating Oil Selection Guidelines.........................................................................133
F.13 Air Purge of Bearing Housings .................................................................................134
Section G Optional Gland Condensers, Eductors and Ejectors ..................................................135
Section H Optional Instruments and Controls ..............................................................................137
H.1 Sentinel Warning Valve ............................................................................................137

H.2 Pressure and Temperature Gauges.........................................................................137
H.3 Solenoid Trip.............................................................................................................138
H.4 Other Optional Instruments and Controls.................................................................138
Section I Start-Up and Operation .................................................................................................139
I.1 Warnings...................................................................................................................139
I.2 General 146
I.3 Turbine Installation and Start-Up Checklist ..............................................................145
I.3.1 Turbine Information ..................................................................................................145
I.3.2 Site Information.........................................................................................................146
I.3.3 Installation.................................................................................................................147
I.3.4 Start Up - Uncoupled ................................................................................................149
I.3.5 Start Up - Coupled ....................................................................................................150
I.4 Start-Up Procedure...................................................................................................152
I.4.1 Restoration of Turbine from Shipping Condition ......................................................152
I.4.1.1 Flushing/Filling of Bearing Housings ........................................................................152
I.4.1.2 Shaft Packing............................................................................................................153
I.4.2 Initial Start-Up Procedure .........................................................................................153
I.5 Turbine Vibration Limits............................................................................................156
I.5.1 Shaft Displacement Measured with Proximity Probes .............................................156

I.5.2 Bearing Housing Vibration ....................................................................................... 158

I.6 Testing the Overspeed Trip Mechanism .................................................................. 158
I.7 Governor Speed Adjustment.................................................................................... 158
I.8 Governor Droop Adjustment .................................................................................... 159
I.9 Hand-valve Adjustments .......................................................................................... 160
I.10 Shutdown ................................................................................................................. 161
I.11 Restart Procedure .................................................................................................... 162
I.11.1 Non-Condensing Turbines ....................................................................................... 162
I.11.2 Condensing Turbines ............................................................................................... 163
I.12 Standby Operation ................................................................................................... 165
I.13 Auto Start Operation ................................................................................................ 167
I.14 Manual Start Operation ............................................................................................ 167
I.15 Quick Start................................................................................................................ 168
I.15.1 Acceleration Rate ..................................................................................................... 168
I.15.2 Temperature Differential .......................................................................................... 168
I.15.3 General..................................................................................................................... 169
I.16 Function Check of Sentinel Warning Valve.............................................................. 170
Section J Maintenance, Maintenance Schedule and Inspection Schedule ................................. 172
J.1 Introduction............................................................................................................... 173

J.2 Maintenance and Inspection Schedule .................................................................... 174
J.3 Major Inspection ....................................................................................................... 176
J.4 Inspection Checklist ................................................................................................. 176
J .4.1. Protective Devices and Steam Cleanliness ............................................................. 179
J.5 Factory Service ........................................................................................................ 180
J.6 Factory Replacement Parts...................................................................................... 181
Section K Troubleshooting........................................................................................................... 185
K.1 Introduction............................................................................................................... 183

K.2 Troubleshooting ....................................................................................................... 183
Section L Disassembly and Parts Replacement.......................................................................... 195
L.1 Warnings/Cautions................................................................................................... 195
L.2 General..................................................................................................................... 197

L.3 Turbine Case Upper Half Removal and Replacement............................................. 198

L.4 Carbon Ring Removal and Replacement.................................................................203

L.4.1 Carbon Ring Removal ..............................................................................................203
L.4.2 Carbon Ring Replacement .......................................................................................205
L.5 Casing Labyrinth Seal Removal and Replacement..................................................206
L.5.1 Casing Labyrinth Seal Removal ...............................................................................206
L.6 Turbine Bearing Removal and Replacement ...........................................................208
L.6.1 Sleeve - Type Journal Bearing Removal and Replacement ....................................208
L.6.2 Thrust Bearing Removal and Replacement .............................................................210
L.6.3 Ball-Type Journal Bearing Removal and Replacement ...........................................212
L.7 Bearing Housing Shaft Seal Removal and Replacement.........................................212
L.8 Bearing Housing Removal and Replacement ..........................................................215
L.9 Turbine Rotor & Turbine Wheel Removal and Replacement...................................215
L.9.1 Turbine Rotor Removal & Replacement...................................................................216
L.9.2 Turbine Wheel Removal and Replacement..............................................................217
L.9.3 Turbine Rotor Balancing...........................................................................................218
L.10 Nozzle Ring Removal and Replacement..................................................................218
L.11 Hand-valve Removal and Replacement...................................................................219
L.11.1 Hand-valve Removal ................................................................................................220
L.11.2 Hand-valve Replacement .........................................................................................220
L.11.3 Reassembly of the turbine rotor and upper half casing 221
L.11.4 Hand-valve Adjustment ............................................................................................221
L.12 Governor Removal and Replacement ......................................................................222
L.12.1 General .....................................................................................................................222
L.12.2 Governor Removal (Direct Drive) .............................................................................223
L.12.3 Governor Replacement (Direct Drive) ......................................................................224
L.12.4 Governor Removal (Gear Drive) ..............................................................................225
L.12.5 Governor Replacement (Gear Drive) .......................................................................225
L.12.6 Governor Drive Gearbox Removal ...........................................................................225
L.12.7 Governor Drive Gearbox Replacement ....................................................................227
L.12.8 Governor Valve Travel and Linkage Adjustment......................................................227
L.13 Trip and Throttle Valve Maintenance .......................................................................228
L.13.1 Valve Removal from Turbine ....................................................................................229
L.13.2 Woodward TG Governor Valve Travel Setting .........................................................232
L.13.3 Woodward TG-13L Governor with Fisher Control....................................................232
L.13.4 Alternate Governor Valve Stem Connection ............................................................234
L.14 Emergency Valve Maintenance................................................................................235

L.14.1 Governor Cup Removal ........................................................................................... 235

L.14.2 Governor Cup Replacement .................................................................................... 237
L.14.3 Trip Mechanism Disassembly .................................................................................. 238
L.14.4 Emergency Valve Travel .......................................................................................... 239
L.14.5 Emergency Valve Removal and Replacement ........................................................ 239
L.14.6 Trip and Throttle Valve and Steam Strainer............................................................ 241
Section M Replacement Parts/Factory Service ........................................................................... 242
M.1 Factory Replacement Parts...................................................................................... 242

M.2 Turbine Identification................................................................................................ 242
M.3 Parts Identification.................................................................................................... 242
M.4 Recommended Spare Parts..................................................................................... 243
M.5 Ordering Parts .......................................................................................................... 243
M.6 Factory Service ........................................................................................................ 244
M.7 Rerates..................................................................................................................... 244
M.8 Upgrades.................................................................................................................. 245
M.9 Factory Start-Ups ..................................................................................................... 245
M.10 Parts Catalog............................................................................................................ 245
Section N Miscellaneous.............................................................................................................. 249
N.1 Low Ambient Temperature Applications .................................................................. 249

N.2 Quick Start, Fast Start, Automatic Start ................................................................... 254
N.3 Standard Policy on Equipment Sound Levels ......................................................... 256
Section O Low Voltage Electrical Components ........................................................................... 257
O.1 Electrical Parts and Applications.............................................................................. 257

O.2 Electrical Component Removal and Replacement .................................................. 260
O.3 Electrical Certification and Standards ...................................................................... 261
O.4 Electrical Maintenance ............................................................................................. 261
O.5 Electrical Packaging................................................................................................. 262
O.6 Electrical Testing ...................................................................................................... 271
O.7 Programming of Electrical Devices .......................................................................... 274
O.8 Customer Responsibilities........................................................................................ 275
Section P User Notes and Maintenance Records .................................................................... 292

SST Turbine Instruction Manual

THIS PAGE WAS LEFT BLANK

INTENTIONALLY

SST Turbine Instruction Manual List of Figures
List of Figures
Figure A-1. Dresser-Rand SST, General View, Steam and Exhaust Ends............... 34
Figure B-1. Recommended Lifting Arrangement for Dresser-Rand SST Turbines ... 46
Figure B-2. Major Fits and Clearances, Standard SST-350 and 500 Turbines......... 50
Figure B-3. Major Fits and Clearances, Standard SST-500H Turbines.................... 56
Figure B-4. Major Fits and Clearances, Standard SST-700 Turbines ...................... 56
Figure C-1. Suggested Steam Inlet and Exhaust Piping Arrangement ..................... 69
Figure C-2. Unrestrained Expansion Joint (Not Recommended)……………………..74
Figure C-3. Expansion Joint With Tie Rods (Acceptable) ......................................... 75
Figure C-4. Expansion Joint W/Tie Rods Non-Condensing Operation (Preferred)… 75
Figure C-5. Expansion Joint W/Tie Rods Condensing Operation (Preferred)........... 76
Figure C-6. Short Runs to Exhaust Header .............................................................. 77
Figure C-7. Typical Gland Sealing System Without Gland Condenser..................... 79
Figure C-8. Gland Seal Intermediate Leak-Off Piping-High Back Pressure Exhaust 80
Figure C-9. Gland Leakage Ejector System ............................................................. 81
Figure C-10. Suggested Steam Inlet, Exhaust, and Drain Piping, Manual-start . ……83
Figure C-11. Suggested Steam Inlet, Exhaust, and Drain Piping, Auto-start.............. 83
Figure C-12. Coupling Misalignment Limits ................................................................ 85
Figure C-13. Alignment Using Dial Indicators ............................................................. 89
Figure C-14. Centerline Height VS Centerline Rise per Ambient Temperatures ........ 90
Figure D-1. Woodward Drive Coupled Arrangement ................................................ 98
Figure D-2. Woodward Oil Relay Governor Features ............................................... 99
Figure D-3. Governor Valve and Emergency Trip Valve......................................... 102
Figure D-4. Woodward Oil Relay Governor Features ............................................. 103
Figure D-5. Hand Valve Arrangement .................................................................... 104
Figure E-1. Typical Trip System Arrangement Diagram ......................................... 109
Figure E-2. Emergency Governor Cup Assembly................................................... 115
Figure E-3. Trip System ......................................................................................... 111
Figure E-4. Trip Valve ............................................................................................ 118
Figure E-5. Air Gap Between Signal Gear and Magnetic Pickup............................ 111
Figure F-1. Typical Bearing Case Water Piping Schematic for Ring Oiled Turbines
………………………………………………………………………………..129
Figure I-1. Radial Shaft Displacement .................................................................. 157
Figure I-2. Angular Misalignment Limits Curve ..................................................... 157

List of Figures SST Turbine Instruction Manual
Figure L-1. Case-Upper Half Removal ................................................................... 201

Figure L-2. Flange Bolt Torque Sequence ............................................................. 203
Figure L-3. Flange Bolt Torque Sequence, Series 700H........................................ 204
Figure L-4. Carbon Ring Assembly, Non-Condensing Turbines............................. 205
Figure L-5. Carbon Ring Assembly, Condensing Turbines .................................... 206
Figure L-6. Typical Carbon Packing Installation ..................................................... 208
Figure L-7. Labyrinth Seal Assembly ..................................................................... 209
Figure L-8. Nozzle Ring-To-Wheel Clearance........................................................ 202
Figure L-9. Bearing Housings With Inpro/Seals ..................................................... 217
Figure L-10. Hand Valve Assembly.......................................................................... 215
Figure L-11. Direct Drive Governor Assembly.......................................................... 226
Figure L-12. Gear Drive Governor Assembly ........................................................... 222
Figure L-13. Overspeed and Governor Valve Linkage ............................................. 224
Figure L-14. Throttle Valve Linkage ......................................................................... 226
Figure L-15. Governor Valve Travel Setting-Woodward TG Governor..................... 231
Figure L-16. Alternate Governor Valve Stem Connection ........................................ 236
Figure L-17. Governor Cup Assembly...................................................................... 238
Figure L-18 Trip Valve Lever Orientation-Trip Valve Open and Closed .................. 240
Figure O-1 Typical Electrical Schematic Tag Numbers for Wire Marking .............. 262
Figure O-2 Typical Tag Number Labels Attached to Junction Boxes..................... 263
Figure O-3 Standard ¾” Terminal Head................................................................. 265
Figure O-4 Enclosure Gasketing Details................................................................ 267
Figure O-5 Example of Conduit Routing, Non-Typical Application ........................ 268
Figure O-6 Cable Pull Tension and Capacitance Properties ................................. 271
Figure O-7 Location of Grounding Lug on Turbine Baseplate ............................... 283
Figure O-8 Grounding Lug on Turbine Soleplate ................................................... 284

SST Turbine Instruction Manual List of Tables
List of Tables
Table B-1. Major Fits, Clearances, and Rotor Balance Criteria- SST 350 ............. 50
Table B-2. Major Fits, Clearances, and Rotor Balance Criteria- SST 500.............. 51
Table B-3 Major Fits, Clearances, and Rotor Balance Criteria - SST 500H .......... 53
Table B-4. Major Fits, Clearances and Rotor Balance Criteria- SST 700............... 55
Table B-5. Bolt Material and Markings .................................................................... 57
Table B-6. Standard Bolt Torques for Turbine Bolting............................................. 58
Table B-7. Recommended Limits for Boiler Water .................................................. 61
Table B-8. Turbine Rotor Data for Standard Two-Row Wheel ................................ 62
Table C-1. Gland Intermediate Leak-off Piping--High Backpressure Exhaust ........ 79
Table F-1. SST-Sleeve Bearing Turbines, Cooling Water Requirement ............... 128
Table F-2. Recommended Oil Sump and Bearing Temperatures ......................... 130
Table F-3. Bearing Housing Oil Capacity .............................................................. 132
Table F-4. Bearing Housing Oil Levels ................................................................. 132
Table F-5. Viscosity Comparisons ........................................................................ 134
Table I-1. Turbine Sound Level Data ................................................................... 145
Table I-2. Axial Shaft Displacement Tilting Pad Thrust Bearings......................... 160
Table I-3. Bearing Housing Vibration ................................................................... 160
Table J-1. Suggested Maintenance and Inspection Schedule .............................. 174
Table J-1. Suggested Maintenance and Inspection Schedule (Cont.) .................. 176
Table J-2. Inspection Checklist............................................................................. 177
Table J-2. Inspection Checklist (Cont.)................................................................. 178
Table J-2. Inspection Checklist (Cont.)................................................................. 179
Table K-1. Troubleshooting Guide ................................................................. 184-195
Table L-1. Applied Bolt Torques for Case Flange Bolts ........................................ 203
Table L-2. Applied Bolt Torques Case Flange Bolts ............................................. 204


SST Turbine Instruction Manual Safety Precautions
Safety Precautions
This turbine has been designed to provide safe and reliable service within the
designed specifications. It is a pressure containing, rotating machine; therefore,
responsible and qualified personnel must exercise good judgment and proper safety
practices to avoid damage to the equipment and surroundings and/or possible
serious or painful injuries.
It is assumed that your company's safety department has an established safety

program based on a thorough analysis of industrial hazards. Before installing,
operating, or performing maintenance on the turbine, it is suggested that you
review your safety program to insure that it covers the hazards arising from rotating
machinery and pressure vessels.
It is important that due consideration be given to all hazards resulting from the
presence of electrical power, hot oil, high pressure and temperature steam, toxic
gasses, and flammable liquids and gasses. Proper installation and continued
maintenance of protective guards, shutdown devices, and overpressure protection
are also necessary for safe turbine operation. The turbine should never be operated
by bypassing, overriding, or in any way rendering inoperative, guards, protective
shutdown equipment, or other safety devices.
When internal maintenance work is in progress, it is essential that the turbine be

isolated from all utilities to prevent the possibility of applying power or steam to
the turbine. When performing internal turbine maintenance, always ensure that
isolating valves in the steam inlet and exhaust lines are locked closed and tagged,
and all drains are opened to depressurize the turbine casing and steam chest.
Precautions must also be taken to prevent turbine rotation due to reverse flow
through the driven machinery.
In general, you should be guided by all of the basic safety rules associated with the
turbine, driven equipment, and plant process.
This manual contains four types of hazard seriousness messages. They are as
follows:
DANGER: Immediate hazards that WILL result in severe personal injury or death.
WARNING: Hazards which COULD result in serious injury to the turbine operator and
others, or extensive damage to the turbine, driven equipment, or the surroundings.

Safety Precautions SST Turbine Instruction Manual
CAUTION: Hazards, which COULD result in damage or malfunction to the turbine or its
parts, leading to subsequent downtime and expense.
NOTE: A message to clarify or simplify an operation or technique, or to avoid a common

mistake.
DANGERS
DO NOT attempt to ADJUST, REPAIR, DISASSEMBLE OR

MODIFY this turbine WHILE IT IS IN OPERATION, unless such
action is expressly described in this instruction manual.
NEVER DISCONNECT the inlet or exhaust piping of the turbine

without first CLOSING and TAGGING the ISOLATING VALVES
and then OPENING DRAIN VALVES SLOWLY to relieve any
pressure with the turbine. Failure to do so may expose
PERSONNEL to SERIOUS INJURY if steam was to be
introduced into the piping or captured in the turbine. As an
added precaution, always install blank flanges on inlet and
exhaust lines after removing the turbine.
DO NOT REMOVE ANY COVERS, GUARDS, GLAND

HOUSINGS, DRAIN COVERS, etc. while the unit is
OPERATING.
Under no circumstances should the TRIP VALVE be blocked or

held open to render the trip system inoperative. Overriding the
trip system, and allowing the turbine to exceed the rated
(nameplate) trip speed, may result in FATAL INJURY to
personnel and extensive turbine damage. In the event the trip
system malfunctions, immediately SHUT DOWN the turbine
and correct the cause
NEVER BLOCK OR DISABLE THE TURBINE TRIP SYSTEM

OR ATTEMPT TO ADUST OR REPAIR IT WHILE THE
TURBINE IS OPERATING.

DANGERS (Cont’d)
This turbine is equipped with an OVERSPEED TRIP to protect

against dangerous over-speeding. It is absolutely essential that
the complete trip system be MAINTAINED in such a condition
that it will operate perfectly if required. It must be thoroughly
INSPECTED AND TESTED WEEKLY. Inspection must include
all elements of the trip system. Dresser-Rand Turbine
recommends that all TESTS BE RECORDED.
Keep body parts (fingers, hands, etc.) away from shaft,

couplings, linkage or other moving parts to prevent contact and
possible serious injury.
NEVER WEAR NECKTIES OR LOOSE CLOTHING while in

the proximity of the turbine or auxiliary equipment. These could
become entangled in the shaft, coupling, linkage or other
moving parts and cause serious injury.
A coupling guard must be installed at the coupling between the

turbine and driven equipment.
Wear proper eye protection when working on or around the

turbine.
The turbine must be grounded.

WARNINGS
Modification of, incorrect repair of, or use of non DRESSER-

RAND repair parts on this turbine could result in a serious
malfunction or explosion that could result in serious injury or
death. Such actions will also invalidate ATEX Directive &
Machinery Directive Certifications for turbines that are in
compliance with those European Directives. Refer to Section M
Replacement Parts/Factory Service.
Throughout this manual it is assumed that the motive flow

applied at the turbine inlet is high-pressure steam. Therefore,
the word “steam” is used in reference to various aspects of
turbine installation, operation, and maintenance. For some
specialized applications, high-pressure gasses such as Freon,
natural gas, or other vapors may provide the motive flow. In
these cases it can generally be assumed that the name of the
gas in use may be used to replace the word “steam.” The user
of the equipment must address all hazards associated with the
nature of the specific motive fluid in use with the turbine. If
flammable or toxic gasses are used as the motive fluid or oil
vapor could be emitted, the user/installer must pipe leak-offs
and drains to a safe location. Explosive gas mixtures must not
be used as the motive fluid.
DO NOT START OR OPERATE this turbine unless the

INSTALLATION has been VERIFIED TO BE CORRECT and all
pre-startup SAFETY AND CONTROL FUNCTIONS have been
CHECKED.
DO NOT START OR OPERATE this turbine, unless you have a

COMPLETE UNDERSTANDING of the location and function of
ALL COMPONENTS in the steam supply and exhaust systems,
including block and relief valves, bypasses, drains, and any
upstream or downstream equipment that may affect the flow of
steam to or from the steam turbine.

WARNINGS
DO NOT START OR OPERATE this turbine, unless you have a

complete understanding of the control system, the overspeed
trip system, the drain and leak-off systems, the lubrication
system, and all auxiliary mechanical, electrical, hydraulic and
pneumatic systems, as well as the meaning and significance of
all monitoring gages, meters, digital readouts, and warning
devices.
DO NOT MAKE ANY MODIFICATIONS OR REPAIRS that are

not described in this manual without consulting with and
approval of an authorized Dresser-Rand company
representative.
WHEN STARTING the turbine, BE PREPARED TO execute an

EMERGENCY SHUTDOWN in the event of failure of the
governor, overspeed control systems, linkage, or valves.
It is the USER’S RESPONSIBILITY to INSTALL A FULL-FLOW

RELIEF VALVE in the exhaust line between the turbine exhaust
casing and the first shut-off valve. This relief valve should be
sized to relieve the FULL AMOUNT OF STEAM THAT THE
TURBINE WILL PASS, in the event that the exhaust line is
blocked.
VERIFICATION of proper functioning and setting of the

OVERSPEED TRIP SYSTEM during initial start-up is
mandatory. This should be accomplished with the turbine
DISCONNECTED from the driven equipment. Turbine speed
should be increased SLOWLY in a controlled manner during
trip testing.
If the turbine is operated on a motive fluid other than steam due

consideration must be given to safety issues that might relate to
the medium used, including but not limited to the ignition,
explosion or poisoning of personnel.

WARNINGS
The surface temperature of the turbine and piping will become

that of the steam inlet temperature. This could exceed the
ignition temperature of some gasses. Therefore if the turbine is
installed where explosive gasses could be present it is the
user’s responsibility to insure that this does not create a
hazardous situation.
Steam quality must be DRY AND SATURATED OR

SUPERHEATED. There must be provision to REMOVE
MOISTURE AND CONDENSATE for the steam supply system
to AVOID DAMAGING the turbine. Steam purity should meet
or exceed American Boiler Manufacturers Association
Guidelines.

that of the steam inlet temperature. Personnel should wear
gloves and protective clothing to avoid burns.
Lighting must be provided in the installation to insure that

operators can see the turbine and its controls.
Should an explosion occur in the vicinity of the turbine it is the

user/installer’s responsibility to halt it immediately and/or limit
the range of explosive flames and explosive pressures to a
sufficient level of safety.
Shown below are turbine noise levels that were measured at

three feet (1 meter), while operating at a normal load and
exhausting to a positive back pressure. These noise levels are
not guaranteed and are published for informational purposes
only.
This noise data is based on test measurements that were taken

on similar equipment being operated on the factory test stand,
and have been extrapolated and/or corrected for background
noise as appropriate.

WARNINGS
When the turbine is operated under actual field conditions,

noise generated in or by the piping, foundation, base plate,
couplings, driven equipment, background and other sources,
can add significantly to the turbine noise level and to the overall
noise levels in the area.
It is recommended that the equipment user assesses the noise

level(s) of the completed installation and determines if
additional sound attenuation and/or hearing protection for
operating personnel are required.
Octave Band Frequency (HZ) - Expected Sound Pressure Levels

(dB – Ref. 2 x 10-5 N/m2)
Accoustic 63 125 250 500 1K 2K 4K 8K Expected Overall dBA
Insulation
YES 96 91 88 86 83 82 81 81 85
NO 97 92 90 89 87 85 84 84 88


INTENTIONALLY

SST Turbine Instruction Manual Introduction and General Description
Section A
Introduction and General Description
THIS MANUAL APPLIES TO SINGLE STAGE 350-500-700 TURBINES.
A.1 Turbine Description

Standard Dresser-Rand SST Turbines are single-stage, impulse-type turbines with a
two-row, velocity-compounded rotor and one row of stationary reversing blades
between the rotating blades. The rotor is contained within a horizontally split
(axially split) casing, with steam inlet and exhaust connections located in the lower
half of the casing assembly.
The rotor is supported between two sleeve bearings and positioned axially by a ball
thrust bearing or tilt pad thrust bearing, or it is supported between two ball bearings
and positioned axially by a ball thrust bearing. Other variations of the turbine
include extended inlet pressure and temperature constructions and/or a high back
pressure construction.
Steam enters the turbine casing after first passing through the built-in steam
strainer, the throttle valve and the overspeed trip valve. The turbine inlet casing
incorporates the nozzle ring, which contains several individual steam nozzles.
Some of these nozzles are controlled by hand-valves for partial load or overload
conditions. Steam flowing through the nozzles expands and is directed at high
velocity against the rotating blades of the first row on the turbine rotor. After
passing through the first row, stationary reversing blades redirect the steam against
a second row of rotating blades. The steam is then discharged into the exhaust
casing and from there into the user’s exhaust piping at the exhaust system pressure.
Optionally, the turbine may be supplied with a single row rotor, in which the case
stationary reversing blades are not provided.
A.2 Construction
Dresser-Rand SST Turbines are ruggedly constructed, suitable for a wide range of
mechanical drive applications and comply with all basic API-611 and NEMA
SM23 requirements.

Introduction and General Description SST Turbine Instruction Manual
The casings, valve body, shaft, wheel, blades, nozzles, valve components, and
fasteners are constructed of high-grade alloy steel, stainless steel, and carbon steel,
assuring a long and dependable service life.
Depending on the steam conditions, horsepower, and speed, materials used in

turbine construction may vary. Always consult the turbine data sheet or nameplate
on the turbine before connecting it to a steam inlet or exhaust, to ensure that the
turbine is rated for the prospective conditions. Never run the turbine in excess of
the maximum allowable speed, maximum inlet or exhaust pressure, maximum inlet
temperature, or above the rated horsepower, as specified on the nameplate.
WARNINGS
Materials used in turbine construction (steel, stainless steel,

special alloys) vary with steam conditions, speed, and power.
These materials were selected according to the original rating
of the turbine. NEVER attempt to RE-RATE a turbine without
the assistance of a Dresser-Rand manufacturer’s
representative and/or the factory. MISAPPLICATION of
materials COULD result in serious equipment damage and/or
personal injury.
Never CONNECT the turbine to inlet or exhaust sources of

UNKNOWN PRESSURE OR TEMPERATURE or to sources
whose pressure or temperature EXCEED limits stated on the
NAMEPLATE.
Some Dresser-Rand turbines can be re-rated for different steam conditions, powers,
and speeds. Consult your Dresser-Rand manufacturer’s representative or the
factory for further information.
CAUTION
For turbines which will be subject to ambient temperatures of

–30°C (-20°F) or less, review and comply with all requirements
outlined in “Low Ambient Temperature Application of Single
Stage ASTM A216-WCB Carbon Steel Pressure Casing Steam
Turbines” in the “Miscellaneous” section of this instruction
manual.

A.3 Main Components

Your steam turbine is a single stage impulse type machine. A cut-away view of a
single stage turbine with a Woodward direct-drive speed governor is shown in
Figure A-1. Following is a description of the major components that comprise
the turbine.
Inlet Flange, 21. The standard SST turbine inlet flange for connection to the steam
supply is part of the over-speed Venturi trip. Flange type, size and material are a
function of the steam conditions and customer specifications. Refer to the certified
drawings in Appendix A following this manual.
Governor, 3. The main purpose of the governor is to maintain the set turbine
speed. The mechanical governors used for single stage turbines are direct
acting units mechanically linked to the governor lever for control of the
governor valve. Each governor is factory set to the customer’s specifications
for a specific speed range. The electronic governors maintain turbine speed
through the use of an actuator. The actuator adjusts the governor valve in
response to the signal received from the electronic governor. The Woodward
PG and UG governors are gear driven. For turbines with a Woodward
governor, Woodward bulletins, which describe operating characteristics and
maintenance instructions, are provided in Appendix B.
Trip & Throttle Valve. A single stage turbine may include a trip and throttle
valve, which is mounted between the turbine casing and the inlet steam line. It
normally houses both a throttle valve and over-speed trip valve. The overspeed trip
valve is a mechanically actuated valve which interrupts the supply of steam to the
turbine during an over-speed condition or other emergency, thereby bringing the
turbine to a complete stop. In the event of over-speed, the valve is activated by the
over-speed governor cup, which is attached to the turbine shaft inside the governor
housing. In the event of other emergencies, the valve can be activated using the
manual trip lever or an optional remote trip.
Governor Valve. The governor valve is automatically controlled by the speed

governor to admit the proper amount of steam required to maintain the speed for
which the governor is set. When the turbine is not operating, the valve is open,
unless options have been selected to close the valve when the turbine is tripped.
If your turbine has a special control system, a diagram is given in Appendix A.
Emergency Valve. The emergency valve, is automatically closed to shut

down the turbine on over-speed conditions, and manually when the trip
lever is unlatched. Some optional systems to automatically close this valve and

shut down the turbines are as follows: (Refer to Appendix A & B for turbines
with this equipment.)
Low oil pressure trip — on turbines with a pressure lubricating system.
Low air pressure trip — using the customer's air supply.
Solenoid trip.
High back-pressure trip.
Emergency Over-speed Trip Cup, 17. An emergency overspeed governor

assembly, located in a cup on the steam end of turbine shaft shuts down the turbine
when the turbine speed reaches the set trip-out speed. (Refer to turbine data sheets for
tripping speed of your turbine.) The trip mechanism is factory set and should require
no further adjustment. However, the tripping speed may be raised or lowered within
small limits. Procedures for this adjustment are given in section E-5.
Hand Valves, 16. Hand-operated nozzle control valves allow maximum efficiency at part
loads; rated load at reduced steam pressure, or operation at overload capacity. The valves
permit adjustment of the nozzle area to that which most closely conforms to the correct area
required by the steam flow for a particular load condition, thus reducing throttling.
Performance characteristics relating to the use of hand valves for your turbine are given on
the turbine data sheets.
As the steam leaves the governor valve it fills the steam chamber supplying the nozzle
ring. In the wall between this steam chamber and the nozzle ring are openings or ports
through which steam is fed to certain nozzles or groups of nozzles. In order to permit
the adjustment of the nozzle area as stated above, valves may be placed in as many of
these ports as is practical or required with the exception of one. This one port is under
control of the governor controlled inlet valve at all times. The hand valve ports are num-
bered, starting with the port located at the lowest point in the steam end and
proceeding in a clockwise direction. Thus, if a hand valve is furnished in the first port
it is designated as hand valve No. 1, in the second port, No. 2, etc. The valves must
be opened in their numerical order for best operation.
The hand valves cannot be used as throttling valves. They should be either fully opened or
fully closed. A valve that is partly open will soon have a damaged seat due to steam erosion. This
condition is better known as "wire drawing." However, when putting the unit into opera-
tion, do not close a valve tightly until the turbine is up to operating temperature and all parts
are evenly heated.
The reason for this is that the material of the valve stem is subject to greater thermal
expansion than the turbine casing, and if the valve is closed tightly when cold, it may
lock the valve in the closed position making it difficult to open.

Main Bearings, 19. The turbine rotor is carried on two main bearings, which are
designated as the steam end and exhaust end bearings. The bearings are babbitted
sleeve type, with shoulders on the ends to maintain their axial position. A stop pin
prevents them from rotating with the shaft. Ball bearings also are main bearing options as well
as rare applications of tilt-pad bearings.
Thrust Bearing, 18. A ball or shoe type thrust bearing, located on the steam end of
the turbine shaft, prevents axial movement of the turbine rotor beyond designed
limits, (See Appendix A for the type of thrust bearing in your turbine.) The bearing
is properly positioned on the turbine shaft with shims at the factory and should
require no adjustment. However, it should be noted that the shims are responsible
for the proper nozzle-to-turbine wheel clearance. This is illustrated in Figure L-8
page 223. In pressure lubricated systems, the bearing operates in a continuous oil
bath. For ring oiled turbines, the ball thrust bearing receives the necessary oil
supply from the same oil ring that supplies oil to the main bearings.
Oil Rings, 12. For turbines without a pressure lubrication system, an oil ring,
located inside a slot in each main bearing, provides for lubrication of the main
bearings and the thrust bearing. During operation, the rings, which revolve freely
on the shaft, dip into the oil reservoir and carry oil up onto the shaft where it is
distributed to each main bearing. The thrust bearing, located inside the shell of the
steam end main bearing, receives its lubricating oil from this same action.
Shaft Packing, 7, 13. Carbon or labyrinth rings are provided at each end of the
turbine where the shaft passes through the turbine case. The turbine data sheets
specify the type and number of packing rings in your turbine, and the longitudinal
section drawing in Appendix A demonstrates the typical installation. Procedures
for replacement are given in Section L.5.2.
On non-condensing (back pressure) machines, the packing limits and controls the
flow of steam along the shaft. On condensing machines, the packing controls the
entrance of air into the casing at the packing glands where the pressure inside the
turbine case is less than atmospheric.
The carbon rings are individually separated in compartments formed by corrosion

resistant steel spacers. The partition rings are located in annular grooves in the
packing cases. The carbon rings seal by being forced against the spacers and by
being a clearance fit along the shaft. The rings are made in three sections and kept
from rotating by a stop on each ring. The ends of the ring segments are kept in
contact with each other by interlocking the ends. A stop prevents the assembly
from rotating.

Labyrinth packing is essentially a multiple tooth-throttling device, assembled

concentrically with the shaft. The rings, which are made of corrosion resistant steel,
are assembled in four segments with each joint numbered to facilitate identification
during replacement. The rings are located in the packing case by means of machined
shoulders.
Gland Sealing Systems. All condensing turbines have a gland sealing system to prevent air
from being drawn into the turbine casing through the packing glands. A typical schematic of
a sealing system, without a gland condenser arrangement, is shown in Figure C-6. If your
turbine requires a gland condenser system, a piping diagram with operating instructions is
included in Appendix A, along with a description of the major components that comprise the
system.
Pressure Lube Systems. For turbines with a pressure lube system, an oil piping or
schematic drawing for your turbine is provided in Appendix A. Ring oiled turbines
equipped with a separate, pressure lubricated, gear box may not require a diagram.
A typical schematic diagram of this system is shown in Figure 6. Since all turbines with
an integral gear box are pressure lubricated, this information, if applicable, is also
given in Appendix A. Turbines with pressure lube systems, that do not have an
automatic-start auxiliary oil pump, have oil rings to ensure lubrication of the bearings
during start-up, low speed operation and shut-down.
Oil Filter or Strainer. Either a strainer or an oil filter is provided in all pressure
lube systems. The filters are of the replaceable element type. A drop in normal oil
pressure may be an indication that the filter or strainer is clogged.
Twin filters with a transfer valve will allow changing an element without shutting
down the turbine. The twin units have a fill valve that should be used to fill the
side being placed into service, before the transfer is made. NOTE: Coolers and
filters are individually vented and the by-pass valves have been opened at start-up
or when any maintenance has been done on either component.
Certain systems, using a single element filter, incorporate a by-pass valve

arrangement to allow maintenance on the filter without shutting down the turbine.
In general, two basic types are employed; one system uses three separate valves
(Figure A-X, view A) and the other system uses a single two-position valve (3-way
or 4-way), shown in views B and C.
The two position valves are never closed. They are either positioned open to the
filter (normal operation), or open to by-pass (maintenance position). The shutoff
valve downstream of the filter in view B must be closed during maintenance. In
the three-valve arrangement, two valves are in series with the filter and one valve is
parallel. For normal operation, the two series connected valves are open; the

parallel-connected valve is closed. For filter maintenance, the three valves are set
opposite their normal position.
Main Oil Pump. The pump can be direct-drive or gear driven from either the
turbine shaft, gear shaft, or governor shaft, depending on the application. (See
Appendix A). No adjustments or special maintenance is required. For motor
driven main oil pumps, see turbine data sheets for electrical requirements.
Auxiliary Oil Pump (Motor Driven). Usually controlled automatically by a

pressure switch to start and stop at certain line pressure (See Turbine Data Sheets.)
A test valve in the system allows simulating a low oil pressure condition to check
operation of the pump. The pump should be tested at regular intervals.
Auxiliary Oil Pump (Steam Driven). Steam to drive the pump is controlled
automatically by a regulator valve. When oil line pressure is sufficient, the valve is
closed and the pump is inoperative. If oil line pressure drops, the regulator valve
opens and steam is admitted to drive the pump. A test valve allows simulating a
low-pressure condition to check operation of the pump. NOTE: it is important that
the pump exhaust is piped to atmosphere, and that the exhaust line be properly
drained.
*Low Oil Pressure Trip. The low oil acts to shut down the turbine when oil
pressure drops to an unsafe limit. (See turbine data sheets). The device is mounted
on the steam end of the turbine and consists basically of a spring loaded bellows,
bellows stem, and a spring loaded plunger rod (See Appendix A). Bearing system
oil pressure keeps the device linked to the turbine trip latch. If bearing system oil
pressure decreases the device releases the trip latch and the turbine is shut down.
On certain turbines, oil pressure must be established in the system before the
emergency valve can be latched open.
*Low Air Pressure Trip. The air pressure trip allows shutting down the turbine
from a remote control. The device is identical to the low oil pressure trip described
in the preceding paragraph, except that facility air pressure in place of bearing oil
pressure keeps the device linked to the turbine trip latch.
*Turbines with the optional trip and throttle valve do not utilize a separate low
oil/low air pressure trip. This is a “built-in” feature of the trip & throttle valve
design.
Solenoid Dump Valve. In systems with a low oil/air pressure trip device, a
solenoid dump valve allows the shutting down of the turbine from a remote
location. The valve, when activated, opens and dumps system oil back to the
reservoir or air pressure to atmosphere. This creates a low oil/air pressure

condition and the turbine is shut down. (See turbine data sheets for electrical
requirements and valve position when energized/de-energized.)
Circulating Systems. The circulating system is the next step up from the ring oil system
with water-cooling. This system is used when oil temperature in the bearing housings could
exceed 180°F (82°C). This elevated temperature is normally caused by an increase in
shaft/bearing rubbing speeds and/or elevated inlet or exhaust steam temperatures being
transmitted from the wheel casing to the bearing case itself.
The circulation system is basically a ring lubrication system, the difference being
that a shaft driven, direct drive pump, which circulates oil out of the bearing cases for
additional cooling, has been added. At high exhaust temperatures, an external oil cooler
is added to the system.
The pump supplied with this system is a positive displacement gear type pump. It is
mounted on the shaft at the exhaust end of the turbine. The upper half of the exhaust
end bearing case serves as a housing for the pump. The same pump is used regardless
of turbine rotation. The pump may be mounted off the turbine shaft at the steam
end when design allows.
A standpipe or overflow port is located at each bearing case to maintain the correct
oil level.
The circulating lube system has very limited options and is not an API system.
Figures A-1, Dresser-Rand SST Turbine, General View, Non-Drive End, & A-2,
Dresser-Rand SST Turbine, General View, Drive End, show major components, as
seen on the exterior of a standard turbine. Each major component is described in
detail below.
The Dresser-Rand manufactured Throttle Valve is contained in the steam chest or

valve body upstream of the over-speed trip valve. It controls the amount of steam
entering the turbine and thereby determines the speed and power produced by the
turbine.
Optional constructions may include separate throttle and/or over-speed trip valves
or other equipment configurations. Refer to the certified drawings in Appendix A.
Trip Linkage (not visible). This linkage connects the overspeed trip valve to the
trip mechanism inside the governor mounting housing. The trip linkage is activated
by the turbine shaft mounted over-speed trip collar, the manual over-speed trip
lever or an optional electric or electric/pneumatic trip actuator

Immersion Heater. For turbines operating in an extreme environment, an optional

thermostatically controlled immersion heater may be provided in the main oil tank to
heat the oil prior to start-up and to maintain a suitable temperature during operation. If
your turbine has this equipment, a supplementary description and parts list is provided
in Appendix B. Operating procedures for this equipment are given in Section F.
Immersion heaters are not available on circulating lube systems.
Probes and Proximitors. An axial movement probe provides a means of

monitoring thrust bearing wear and radial probes monitor shaft vibration. For turbines
equipped to monitor vibration and axial displacement of the shaft, a probe assembly drawing
and an electrical wiring and layout drawing are provided in Appendix A with sup-
plementary instructions on the monitoring equipment.
In certain designs a key-phasor probe, shown on the electrical wiring and layout
drawing, is provided as an instrumentation reference point. The key-phasor is a separate
probe that may be axially or radially mounted.
LEGEND FOR FIGURE A-1
1. Turbine Shaft 12. Oil Rings (2)

2. Governor Lever 13. Packing Case Leakoffs (2)
3. Woodward TG Governor 14. Turbine Wheels
4. Steam End Bearing Case 15. Turbine Case
5. Sentinel Warning Valve 16. Hand Valve
6. Exhaust End Bearing Case 17. Overspeed Cup
7. Carbon Packing Rings 18. Thrust Bearing
8. Steam Chest 19. Main Bearings (2)
9. Steam Strainer 20. Exhaust
10. Governor Valve Stem 21. Inlet
11. Trip Lever

Figure A-1. Dresser-Rand SST, General View, Steam and Exhaust Ends

Governor Lever, 2. This is the linkage between the governor and governor valve.
Over-speed Trip Lever, 11. The overspeed trip lever is part of the trip linkage,
allowing manual activation of the over-speed trip valve. Optional electric or
electric/pneumatic trip actuators and/or limit switches may be provided to work in
concert with the overspeed trip lever.
Over-speed Trip Reset Handle. This handle is used to reset (open) the overspeed
trip valve, permitting recovery from an over-speed trip condition. When recovering
from a trip condition, the handle is initially opened slightly to permit pilot valve
operation, and then is opened fully to reset the valve.
Steam End Bearing Case, 4. SST turbines have one sleeve shaft support bearing
and a thrust bearing in this housing. SST turbines can also have two ball bearings
serving the same purposes. The overspeed trip mechanism is located in this
housing and the over-speed trip lever is typically is mounted on this housing. The
standard housing also contains an oil ring, seals, the oil reservoir and the cooling
water jacket. Standard construction includes a constant level oiler mounted on the
bearing housing, along with the oil filler/vent, oil drain plug, and plugs for cooling
water inlet and outlet openings.
Exhaust End Bearing Case, 6. SST turbines have one sleeve shaft support bearing
in this housing and can also have one ball bearing serving the same purpose. The
standard housing also contains an oil ring, seals, the oil reservoir and the cooling
water jacket. Standard construction includes a constant level oiler mounted on the
bearing housing, along with the oil filler/vent, oil drain plug, and plugs for cooling
water inlet and outlet openings. This housing is similar to the steam end bearing
housing.
Oil Level Gauge. The oil level gauge indicates the oil level in the bearing housing.
This level corresponds with a mark inscribed on the bearing housing. For turbines
with alternate lubrication systems this may not be included.
Constant Level Oiler. The constant level oiler is an oil reservoir that is set to
maintain a constant oil level in the bearing housing. For turbines with force feed
lubrication or circulating oil cooling systems, oil levels are established by other
means.
Gland Housings. Gland housings of the standard SST turbine contain carbon ring
seals that prevent steam from leaking along the shaft to atmosphere. Some steam
will escape past the carbon rings, lubricating them. This steam is conveyed by the
gland leak-off connection to a safe location. Alternate gland housing
configurations include labyrinth seals or mechanical seal designs.

Upper Case, 15. The upper case half contains exhaust steam and is the turbine
component that seals the turbine exhaust casing. It contains an eyebolt, used for
lifting the cover during turbine service. The eyebolt must not be used for lifting the
entire turbine.
Steam Chest, 8. The steam chest (or valve body) is the casing section containing
the high-pressure inlet steam. Steam enters the steam chest, travels past the trip and
throttle valve, trip valve, and through nozzles in the nozzle block.
Lower Case. The lower turbine case (exhaust casing) contains exhaust steam and
is integral with the exhaust flange. The exhaust casing supports the drive end
bearing housing.
Turbine Supports. The steam and exhaust end supports each consist of fabricated
steel or cast iron members that are bolted to the steam end and exhaust end casing.
The supports are drilled for mounting bolts and dowel pins that hold the turbine in
position and help maintain alignment with the driven equipment.
Exhaust Flange, 20. This flange connects the turbine to the user’s exhaust steam
line. Flange type, size, and material are a function of steam conditions and
customer requirements. Refer to the certified drawings in Appendix A.
Shaft Extension. This is the output shaft of the turbine, which is keyed to accept a
coupling.
Sentinel Warning Valve, 5. If specified, the turbine is supplied with a sentinel

warning valve. The valve will alarm when exhaust-casing pressure is excessive
(high). The valve warns the operator (by a whistle) only; it is not intended to
relieve the casing pressure.
A.4 Factory Test

All Dresser-Rand turbines are given a mechanical no-load run test at the factory
prior to shipment. The purpose of the test is to ensure the mechanical integrity of
the turbine and to adjust its controls, overspeed trip, and accessories, as required.
The standard test includes the following:
 Turbine is run on shop steam conditions at rated speed, maximum continuous

speed and just below the overspeed trip speed.

 Vibration levels are measured and recorded at each test speed.

 Turbine rotation & exhaust location are confirmed
 Governor and speed control operation are checked
 The over-speed trip is set and tested
 Turbine is checked for steam and lubrication leaks
 Sentinel warning valve is checked (if supplied)
 For SST turbines a post-test visual inspection of each bearing and sleeve
bearing journal is carried out. If evidence of wear, scoring, or overheating is
found, the cause of the defect is corrected, and the turbine is re-tested and
inspected.
A.5 Shipping Preparation/Crating

Turbines are prepared for shipment and short-term storage (six months) using the
following procedure. After testing, the turbine is allowed to cool and all moisture is
drained from casings and valves. It is then masked and painted. All unpainted
surfaces not inherently corrosion-resistant, such as exposed portions of the shaft,
are coated with a rust-preventative and/or wrapped. Flange covers are installed on
all open-flanged connections. Rust inhibitor is sprayed inside the turbine. Oil in
bearing housings is drained and these cavities are partially filled with a rust
inhibiting and vaporizing oil. The turbine is mounted on a heavy wooden skid, and
depending on the shipping destination, is placed in a wooden container, covered or
wrapped with plastic.
Just prior to crating, the turbine is given a final inspection by a quality inspector,
who checks for completeness and appearance. Photographs of every turbine and the
accessories shipped with it are taken and become a part of the factory order file for
the turbine.
Refer to Section A.8, Long-term Storage, for additional measures taken if the
turbine is prepared for long-term storage.
A.6 Uncrating and Inspection

Remove the packing material and check all items against the packing list. Ensure
that parts are not missing or damaged. Handle all parts carefully. If inspection
shows that the turbine has been damaged during shipment, contact the carrier and
file a claim immediately.
Take care to ensure that loose parts are not discarded with the packing material.

CAUTION
Do not lift on the turbine shaft, as this could damage seals

and/or bearings, or may bend the turbine shaft.
A sling under each end of the turbine case can safely raise the
turbine. Do not use the eyelet in the center of the turbine case.
This eyelet should be used only for lifting the upper half of the
turbine case.
Refer to Figure B-1, Recommended Lifting Arrangement for Dresser-Rand SST

Turbines.
A.7 Short-term Storage

Dresser-Rand turbines shipped to United States destinations are prepared for short-
term storage of up to six months. The turbine should be stored in a clean, non-
corrosive atmosphere and protected against damage, loss, weather, and foreign
material, such as dust or sand. The equipment should remain on its shipping skid,
with all preservatives and covering left intact. Indoor storage is preferred, where
the temperature and humidity are maintained at a level preventing condensation.
When stored outdoors, the turbine skid should be raised sufficiently so as to avoid
contact with excessive moisture.
CAUTION
For turbines which will be subject to ambient temperatures of

–30°C (-20°F) or less, review and comply with all requirements
outlined in “Low Ambient Temperature Applications of Single
Stage ASTM A216-WCB Carbon Steel Pressure Casing Steam
Turbines” provided in the “Miscellaneous” section of this
instruction manual.
Dresser-Rand turbines shipped to overseas destinations are prepared for short-term

storage of up to six months. The same general instructions stipulated for domestic
U.S. shipments also apply here.

A.8 Long-term Storage

Long-term storage is defined as storage exceeding six months to one year.
The following instructions apply to turbines that are to be prepared for long-term
storage because they are not to be operated in the near future.
Basically these instructions apply equally to new units prepared for long-term
storage in the field or to units that have been operated but are to be taken out of
service for long-time storage.
The unit should be removed from the installed location (disconnect all steam,
water, drain, and leak-off lines) and stored in a clean, dry building which is not
subjected to large changes in temperature or humidity.
Long-term storage must be carried out in a warehouse maintained at constant

temperature, thereby preventing condensation. As with short-term storage, the
turbine should be protected against damage, loss, weather, and foreign material
such as sand or dust. The turbine should remain on its shipping skid and be raised
sufficiently so as to avoid contact with excessive moisture.
The following is the Dresser-Rand long-term storage procedure. This procedure

should be performed on turbines that will be subjected to long-term storage, if they
were not so prepared at the factory. The procedure should be repeated after the first
12 months of storage and checked at six-month intervals thereafter:
a. Remove the inlet and exhaust flange covers and spray the interior of the turbine
with rust-inhibiting and vaporizing oil; then replace the covers securely. All
machined parts (including internal parts such as oil pump gears and shafts, pins,
linkages, pilot valves, thrust bearing parts, governor parts (except Woodward
governors), couplings, etc.) which are not painted should be coated with heavy
slushing compound; we recommend that the slushing compound purchased to MIL-
C-16173, Grade 1. All major oil companies can furnish such a slushing compound.
b. Partially fill bearing housings to a level corresponding to the bottom of the sight
glass with rust inhibiting and vaporizing oil. For SST turbines with sleeve type
bearings, coat the bearing and shaft journal surfaces with a rust preventative.
c. Fill governor with rust inhibiting and vaporizing oil. Woodward governors
should be filled to the top of the filler cup with the same type of lubricating oil
normally used in the Woodward governor. On units that have been operated in the
field, the old oil should be drained out and the Woodward governor should be
flushed with a clean light grade of fuel oil or kerosene before filling it with
lubricating oil.

d. Spray the exposed bonnet, seal blocks, and linkage areas of the trip and throttle
valve assembly with rust inhibiting and vaporizing oil.
e. Apply a rust-preventative coating on all exposed and machined surfaces of the

turbine. Do not apply this material to chrome plated areas of the turbine shaft. The
turbine rotor, the gear and pinion and the generator rotor can be stored in their
normal positions with the bearings in place; or they can be blocked up with wood
and the bearings removed for storage; or they can be removed from their normal
housings and blocked up for storage. In either case the journals should be carefully
cleaned, slushed and wrapped in waterproof, greaseproof, acid- free non-corrosive
paper (Sisal-Croft Fibreen or equal).
f. For turbines with carbon rings, after removing the upper case half, remove the
carbon rings, garter springs and stop washers. Coat the inside and machined
surfaces of the gland housings, along with casing and cover flanges exposed by the
removal of the upper case half, with rust-preventative grease. Reinstall garter rings
and stop washers on the shaft. Reassemble upper case cover onto the turbine. Store
the carbon rings separately and in original matched sets until the turbine is ready
for installation. This procedure will help protect chrome-plated areas of the turbine
shaft from corrosion damage. Turbines supplied with mechanical seals should not
have the seals disassembled. The outer surfaces of the seal may be coated to help
prevent external corrosion.
When prepared by Dresser-Rand for long-term storage, SST turbines have had the
carbon rings, garter springs, and stop washers removed as their removal helps
protect the shaft from corrosion. These components are packaged separately in a
box attached to the skid, and the turbine labeled with a long-term storage warning
tag. Installation of these components is necessary before the initial turbine start up.
Refer to Section L.4, Carbon Ring Removal and Replacement. The shaft packing
should be removed, tagged and prepared for storage. The packing ring segments
should be marked so that they can eventually be replaced in the turbine in their
control position.
Be sure that all water pockets are drained to eliminate danger of freezing). Piping
should be cleaned, dried and slushed.
To protect electrical insulation from vermin, the generator and exciter can be stored
in a vermin- proof housing. Do not get any slushing compound on the generator or
exciter insulation. Generator windings must be protected against absorbing
moisture.
It has been found that if a unit is stored in a clean dry building in which air is
circulated at approximately constant temperature it is not necessary to seal all

openings, and the slushing needs only to be moderate. If it is decided to seal all
openings (after the flanges are slushed), use the special paper mentioned in Item 3
backed up by wood or light sheet metal. Place a good grade desiccant or some other
drying agent in the enclosure and arrange to inspect it at intervals of several
months.
If the unit is to be stored in the open, or in an uncompleted building, or in a

building that is subjected to large temperature changes, special precautions should
be taken such as:
Cover the unit with a tarpaulin and protect it with planking if building construction
is progressing in the vicinity of the unit.
Inspect at shorter intervals to determine if the slushing compound needs replacing.
A.9 Dresser-Rand Factory Service/Replacement Parts

Dresser-Rand provides a wide range of services to all its customers, including in-
house factory rebuilding of turbines, factory trained field service personnel,
replacement parts interchangeability lists, optimum replacement parts inventory
recommendations, and replacement parts. Vital spare parts, such as carbon rings,
gaskets, bearings, and valve components, are available for next-day shipment.
Selected Dresser-Rand manufacturer’s representatives maintain factory-authorized

repair facilities at locations throughout the world.
WARNING

Modification of, incorrect repair of, or use of non DRESSER-

compliance with those European Directives. Refer to Section
M – Replacement Parts/Factory Service.
For assistance with service or spare parts, contact your local Dresser-Rand
manufacturer’s representative. Refer to Section M, Replacement Parts/Factory
Service, for additional information regarding identification of turbine parts.
A.10 Re-Rating and Upgrades

Most Dresser-Rand turbines can be re-rated for different steam conditions, speed,
or power. Contact your local Dresser-Rand manufacturer’s representative to
determine if a re-rate can meet your needs.
WARNING
Materials used in turbine construction (cast iron, steel, stainless

steel, special alloys) vary with steam conditions, speed, and
power. These materials were selected according to the original
rating of the turbine. NEVER attempt to RE-RATE a turbine
without the assistance of a Dresser-Rand manufacturer’s
representative and/or the factory. Misapplication of materials
COULD result in serious equipment damage and/or personal
injury.
Dresser-Rand turbines incorporate start-of-the-art technology and Dresser-Rand is

dedicated to making continuous improvements in its equipment to enhance
efficiency, maintainability and safety. In an effort to make improvements available
to owners of older Dresser-Rand steam turbines, the factory offers upgrade kits for
incorporating major design improvements into existing units. Consult your Dresser-
Rand manufacturer’s representative for information regarding factory upgrades.

A.11 Nameplate Information

The following information is included on the turbine nameplate.
Turbine Serial Number

Turbine Type (Model)
Power
Speed – RPM
Normal Inlet Pressure
Normal Inlet Temperature
Normal Exhaust Pressure
Maximum Inlet Pressure
Maximum Inlet Temperature
Maximum Exhaust Pressure
Calculated First Critical Speed
Maximum Continuous Speed - RPM
Minimum Allowable Speed – RPM
Trip Speed
Purchaser’s Equipment number – If Specified
CE Mark – Followed by Notified Body Number when ATEX Category 2 is
specified by Purchaser
EX Mark – Followed by ATEX Group, Category, Atmosphere and EN 13463-1
warning related to User/Installer determined Inlet Temperature.
Manufacture Date (on CE/ATEX units)
Manufacturer’s name and location


SST Turbine Instruction Manual Technical Data
Section B
Technical Data
B.1 General
Your Dresser-Rand single-stage turbine has been built specifically for your
application. Frame size, materials used in construction, nozzling, rotor
construction, and other items are based on steam conditions, power, and speed
specified in the original purchase order. This information is recorded in three
locations: 1) on the turbine nameplate; 2) on the turbine data sheet found at the
beginning of this manual; and 3) on the certified outline drawing found in
Appendix A. These documents also provide other important information, such as
installation dimensions, connection identification, connection sizes, weight,
component removal clearances, etc.
The turbine nameplate and data sheet specify the turbine serial number. This
number is a unique identifier for the turbine; it must be specified when ordering
replacement parts and in all correspondence with your local manufacturer’s
representative, the factory, and service personnel. The number is also stamped on
the horizontal flange of the inlet casing.
The following subsections discuss important technical considerations that must be

addressed when installing, operating, maintaining, or repairing the turbine.
B.2 Lifting
Turbines shipped on wooden skids should remain on their respective skids until
placement onto their permanent foundations. When a turbine is on its skid, the skid
should be used for lifting. Turbines shipped on base-plates can be lifted using
lifting provisions on the base-plate. Do not attempt to lift the turbine and base-plate
by lifting on the turbine or other base-plate mounted equipment.
When lifting the turbine itself, use slings extending around the steam chest and two
locations on the turbine casing, as illustrated in Figure B-1, Recommended Lifting
Arrangement for Dresser-Rand SST Turbines. Do not use the turbine shaft,
governor, or the cover (upper exhaust casing) eyebolt for lifting purposes. Lift
slowly and carefully to ensure stability and safety.
For correct sling selection, refer to the weights specified on the certified outline
drawing in the Appendix A.

Technical Data SST Turbine Instruction Manual
WARNING
Never attempt to LIFT the turbine USING the cover (upper

exhaust casing) EYEBOLT. This eyebolt is intended for lifting
the cover only. Using this eyebolt to lift the entire turbine
presents a SERIOUS SAFETY HAZARD.
Figure B-1. Recommended Lifting Arrangement for Dresser-Rand SST

Turbines
B.3 Alignment
Correct alignment of the turbine to the driven equipment is a primary consideration
in turbine installation. Improper alignment can result in vibration, as well as wear
and premature failure of bearings, seals, couplings, and shafts. Such failures can
occur not only in the turbine but in the driven equipment as well. Alignment should
be performed both under cold conditions and with the turbine at operating
temperature, using personnel experienced in turbine alignment. Refer to Section C,
Installation, for cold and hot alignment procedures. Alignment may be affected not
only by turbine positioning with respect to the driven equipment, but also by
thermal growth of the turbine, piping or the driven equipment, and by mechanical

forces imposed by the piping. All of these factors must be considered when
installing the turbine.
WARNING
Misalignment with driven equipment or overload due to driven

equipment could result in excessive wear and bearing failure.
This could create sparks or hot surfaces could ignite lubricant
or flammable gasses.
CAUTION
Never put a steam turbine into service without first carefully

ALIGNING it to the driven equipment under cold conditions and
then again at operating temperature. Failure to do so may
result in premature FAILURE of both TURBINE and DRIVEN
EQUIPMENT components.
B.4 Thermal Growth

Thermal growth of the turbine casing supports, inlet/exhaust piping, and driven
equipment may result in misalignment and/or application of external forces on the
turbine. To avoid vibration and premature wear/failure of bearings, seals, couplings
and shafts, along with distortion of the turbine casing, the thermal expansion of
mating components must be carefully analyzed and compensated for by careful
alignment (both hot and cold), as well as the use of flexible shaft couplings,
expansion joints in piping, and proper maintenance of these components.
Refer to Section C, Installation, for cold and hot alignment procedures.
Refer to Section C-7 (Compensation for Thermal Movement) for further

information.
Refer to Appendix A in your manual for turbine thermal growth data.
Concerning temperature differential on turbines with built-up rotors, the disc-to-

shaft allowance tends to decrease to unacceptable limits with a 200°F (93°C)
temperature differential between the disc and shaft. The existence of such a condition is
greatest at approximately five minutes after start-up, rather than immediately at start-up.
Loss of the shrink fit can result in axial or wobble movement of the disc on the shaft,

possibly resulting in turbine breakdown. The colder the unit at start-up, the greater the
probability of the temperature differential occurring. Since the utilization of forged discs
in lieu of plate discs allows a higher shrink fit, we normally recommend the customer
consider using forged discs.
In general, the subject of "quick," "fast" or "automatic" starting is not something

new in the steam turbine industry. Dresser-Rand has not decreased its engineering
standards for design of steam turbine shafts, bearings, or shrink fit of discs to shafts.
Reliability and durability are compromised by quick starting a turbine and will result in a
shortened overall turbine life. Frequent quick starts are particularly severe on bearings
and rotating elements. The more rapid the acceleration rate, the higher are the transient
loadings and the more severe are the loading effects. Dresser-Rand single stage
turbines with standard construction are suitable for start-up in five seconds provided the
following conditions are met:
1. The inlet side of the turbine steam line must be trapped.

2. Proper lubrication of bearings must be provided.
3. The inlet temperature of the steam shall not exceed 750°F (399°C).
4. The differential temperature between the inlet steam and exhaust steam shall not
exceed 350°F (177°C).
5. Back pressure shall be maintained on the casing during shutdown. (This in itself
is not a recommended operating condition due to possible shaft wire cutting or
carbon ring seal decay, but it will keep the casing warm.
6. The operating speed o f the turbine shall not exceed 6000 RPM.
7. The unit must be brought up under load.
B.5 Lubricants
The importance of using a proper lubricant cannot be over emphasized. High
quality turbo machinery oils are required. Dresser-Rand does not recommend
specific brands of oil. Turbine owners should consult reliable oil suppliers
regarding the proper selection of turbine oils. As a minimum, the selected oil
should be a premium quality rust- and oxidation-inhibited turbine or circulating oil
that will readily separate from water and have minimum tendency to emulsify or
foam when agitated at actual operating temperatures. Since the proper grade of
lubricant may not be available locally, it should be ordered in advance of the initial
start-up of the equipment.
Consult Section F, Lubrication for viscosity recommendations, bearing housing oil

capacities, oil levels, and maintenance of lubrication systems. In addition, a careful
review of the certified drawings in Appendix A must be made to insure any specific

lubricant requirement applying to the supplied equipment package are

accommodated.
B.6 Major Fits, Clearances, and Rotor Balance Criteria

Dresser-Rand steam turbines are precision machines. The fits of the turbine wheel
to its shaft, bearings on the shaft and in their housings, and other fits are selected
and controlled so as to ensure long, efficient, trouble-free operation, as well as ease
of maintenance.
Whenever a turbine is disassembled and reassembled for inspection or parts

replacement, factory fits and clearances must be checked and maintained. If parts
do not fit properly on re-assembly, the reason must be determined and the problem
corrected.
Some major fits and clearances are listed in Tables B-1 Major Fits, Clearances, &
Rotor Balance Criteria – SST 350 and 500, B-2 Major Fits, Clearances, & Rotor
Balance Criteria – SST 500H Turbine and B-3 Major Fits, Clearances, & Rotor
Balance Criteria – SST 700 Turbine. Other clearances are specified in the
appropriate subsection of Section L, Disassembly and Parts Replacement.
For overspeed governor trip setting see section L.14.1, for overspeed governor trip
linkage see L.14.3, for governor valve travel using Woodward PG and UG governors see
L.12.8 See L.14.4 for adjustment of the emergency valve travel.

Figure B2 - Major Fits, Clearances and Rotor Balance Criteria – SST 350
Table B1 - Major Fits, Clearances and Rotor Balance Criteria – SST 350

Table B-2. Major Fits, Clearances and Rotor Balance Criteria – SST 500

Figure B-3 Major Fits and Clearances, Standard SST 500 Turbine

Table B-3.Major Fits, Clearances and Rotor Balance Criteria – SST 500H

Figure B-4 Major Fits and Clearances, Standard SST 500H Turbine

Table B-4.Major Fits, Clearances and Rotor Balance Criteria – SST 700

Figure B-5 Major Fits and Clearances, Standard SST 700 Turbine
B.7 Piping Forces

Steam piping, if improperly designed or installed, can impose severe mechanical or
thermal forces and moments on the inlet and exhaust flanges of a steam turbine.
Such forces and moments can misalign the turbine with its driven equipment, or
distort the turbine casing, resulting in internal misalignment of the turbine shaft
with bearings, seals, and other components. Such misalignment can cause vibration
and premature wear or failure.
To prevent excessive piping forces or moments, the customer must ensure that the
piping is designed and installed so as to comply with NEMA SM-23, Section 8,

Allowable Forces and Moments on Steam Turbines. The maximum allowable

forces and moments are a function of pipe sizes and are tabulated in the certified
drawings in the Supplemental Documentation section, supplied at the end of this
manual. Additional piping information, including suggested piping layouts, can be
found in Section C, Installation.
B.8 Bolt Torques and Materials

The bolts used in Dresser-Rand turbines are carefully selected to ensure adequate
strength at the maximum temperatures and pressures the turbine is subjected to.
The following general application guidelines are used when selecting bolt
materials.
Turbine Construction Bolt Material Bolt Marking
A Steel inlet/iron exhaust casings

B7
Bolts on trip and throttle valves
B7
B Steel casings (below 775°F) (413°C)

B7
All pressure-containing
components B7 B7
Or
Steel casings (carbon moly) B16

above 775°F (413°C) B16
Table B-5. Bolt Material and Markings

WARNING
NEVER REPLACE THE ORIGINALLY SUPPLIED BOLT WITH

A SUBSTITUTE BOLT OF UNKNOWN OR LESSER GRADE.
DO NOT MIX BOLTS during assembly. Failure to use the
proper grade bolt could result in serious failure of pressure-
containing components
Torque ft-lbs. (N-m)

Inlet temp below Inlet temp above
Bolt or Nut 775°F (413°C) 775°F (413°C)
Size (Inches)
B-7 B-16
Bolt Grade
45,000 PSI 60,000 PSI
½ 53 (72) 71 (96)
5/8 106 (144) 141 (191)
¾ 188 (255) 251 (340)
7/8 303 (411) 381 (519)
1 455 (617) 606 (822)
1 1/8 667 (904) 889 (1205)
1¼ 937 (1270) 1250 (1695)
Table B-6. Standard Bolt Torques for Turbine Bolting
The above torques are based on the thread and nut or bolt seating areas being
lubricated with FEL-PRO C5-A high-temperature anti-seize compound or its
equivalent.
B.9 Sealants and Joint Compounds
The following sealants and joint compounds are recommended for the joined areas
specified.

WARNING
Follow the manufacturer’s instructions for application of

sealants and joint compounds. Insure that personnel are aware
of and take precautions to avoid any hazards described by the
manufacturer.
Applicable Joints and Recommended Sealants and Joint Compounds
1. All flanges and joints sealing steam at 600 PSIG (41.4 BAR) or less – Any of
the following:
Silver Seal
Turbo R and Temp-Tite String
Copaltite
Hylomar
Turboseal
Alinco or triple boiled linseed oil
Gortex Tape
Tem-Flex String Kit
Permatex #2 and #3
2. All flanges and joints sealing steam at greater than 600 PSIG (41.4 BAR):
Turbo R and Temp-Tite String

Copaltite and Temp-Tite
3. All flanges and joints sealing gas
Locktite Superflex Silicone Sealant
4. Bolt and Stud Threads – Either of the following:
Never-Seez
Fel-Pro C-5A
5. Bearing Housing Cover to Base
Locktite Superflex Silicone Sealant or other RTV style equivalent

B.10 Cooling Water to Bearing Housing Water Jackets

Depending on the service conditions and the type of lubrication system supplied
with the turbine, bearing housings may require water cooling to maintain an
acceptable bearing oil temperature. Refer to Section F, Lubrication, for cooling
water requirements.
B.11 Steam Pressure and Temperature Limits

The steam temperature and pressure limits of Dresser-Rand turbines are limited by
the materials used in construction and the design of valve bodies, casings, casing
joints, seals, gaskets, and bolts.
WARNING
NEVER CONNECT the steam turbine to inlet or exhaust

sources of UNKNOWN PRESSURE OR TEMPERATURE, or to
sources whose pressure or temperature EXCEED limits stated
on the NAMEPLATE.
Dresser-Rand turbines can be re-rated for different steam conditions, powers and
speeds. Consult your Dresser-Rand manufacturer’s representative or the factory for
further information.
B.12 Steam Quality and Steam Purity
WARNING
THE DEGREE OF STEAM CLEANLINESS TOLERANCE ON

CONTROL VALVE AND TRIP VALVE COMPONENTS IS
LIMITED AND DEPOSITS MUST BE PREVENTED.
Steam quality must be dry and saturated or superheated. There must be provision to
remove moisture and condensate from the steam supply system to avoid damaging
the turbine. Governor valves, trip valves, trip throttle valves, etc. must be capable of

closing in fractions of a second; and their movement cannot be impeded by deposits on

valves, seats, stems, etc. Deposits can form rapidly - as a result of improper water
treatment and/or entrainment of impurities in the steam supply.
The performance and reliability of a steam turbine can be adversely affected by the
admission of contaminated steam. When contaminants enter the turbine with the
steam supply, the usual result is the accumulation of deposits, which can be either
inert or highly reactive, depending on the contaminants present. If the
contaminants are reactive, they can cause serious damage by corrosive attack on
the turbine materials.
To avoid these deposits, adequate boiler water chemistry control and other
precautions are required along with the need for constant surveillance during
operation and inspections. When deposits or material attack are noted during
inspection, investigations into the nature and origin of the contaminants should be
conducted and a program for corrective action begun.
The boiler water limits shown in Table B-5, Recommended Limits for Boiler Water,
are recommended for Dresser-Rand steam turbines to avoid the likelihood of
adverse affects from deposits and harmful ions. These limits are based on
operating history and recommendations from various consultants.
Pressure at
Outlet of Total OH
Silica, Phosphate, Hardness, Chloride,
Steam Solids, Alkalinity,
ppm ppm ppm ppm
Generating ppm ppm
Unit, PSIG
0 – 150 2000 200 50 50 0 250
151- 450 1500 100 35 50 0 200
451 - 750 1000 60 25 25 0 150
750 - 900 750 55 10 25 0 50
Table B-7. Recommended Limits for Boiler Water

B.13 Turbine Rotor Data

Table B-7, Turbine Rotor Data for Standard Two-Row Wheel, provides basic
turbine rotor data. If further information is required, consult the factory.
Shaft Torsional
Rotor Moment Of
Stiffness
Frame Size Weight Inertia
lb-in / RAD (N-m /
lb (kg) lb-ft2 (kg-m2)
RAD)
SST 350 150 (68.0) 16.7 (0.70) 1.3 x 106 (1.47 x 105)
SST 500 220 (100.0) 47 (2.0) 5.1 x 106 (5.76 x 105)
SST 500H 230 (104.3) 47 (2.0) 4.7 x 106 (5.31 x 105)
SST 700 350 (158.8) 167 (7.0) 5.1 x 106 (5.76 x 105)
SST 700H 360 (163.3) 167 (7.0) 4.9 x 106 (5.53 x 105)
Table B-8. Turbine Rotor Data for Standard Two-Row Wheel
Notes:
1. For applications with Rateau rotors and/or non-standard shaft extensions,

consult the factory.

SST Turbine Instruction Manual Speed Control System
Section C
Installation
C.1 General
WARNINGS
Throughout this manual it is assumed that the motive flow applied at

the turbine inlet is high-pressure steam, therefore, the word “steam”
is used in reference to various aspects of turbine installation,
operation and maintenance. For some specialized applications,
high-pressure gasses such as Freon, natural gas or other vapors
may provide the motive flow In these cases, it can generally be
assumed, that the name of the gas in use may be used to replace the
word “steam.” The user of the equipment must address all hazards
associated with the nature of the specific motive flow in use with the
turbine. If flammable or toxic gasses are used as the motive fluid or
oil vapor could be emitted the user/installer must pipe leak-offs and
drains to a safe location. Explosive gas mixtures must not be used as
the motive fluid.
If the turbine is operated on a motive fluid other than steam due

consideration must be given to safety issues that might relate to the
medium used, including but not limited to the ignition, explosion or
poisoning of personnel.
The surface temperature of the turbine and piping will become that of
the steam inlet temperature. This could exceed the ignition
temperature of some gasses. Therefore if the turbine is installed
where explosive gasses could be present it is the user's responsibility
to insure that this does not create a hazardous situation.
The turbine must be properly grounded, thereby by preventing

electrical shock or sparks that could cause injury or ignition of
flammable gasses or liquids in the event of failure of electrical
accessories, driven equipment or the creation of a static electrical
charge.

Installation SST Turbine Instruction Manual
WARNINGS
If the turbine is supplied with oil mist lubrication oil mist could escape
from the bearing housing vents or constant level oiler. If there is the
possibility that these could be ignited by equipment of processes in
the proximity of the turbine they should be piped to a safe area.
Lighting must be installed in the installation area to insure that

operators can see the turbine and its controls.
Do not install the turbine where ambient temperature could be –20°

F or less unless this was specified in the original order and LOW
TEMPERATURE materials have been provided. Refer to Section F,
Lubrication System, for ambient temperature limits based on
lubrication.
Proper installation of the turbine and driven equipment is vital for successful
operation of the system. It is for this reason that competent, experienced personnel
should be employed during installation. Before installing turbine refer to the
certified drawings in Appendix A of this manual.
Dresser-Rand recommends that API Recommended Practice RP-686 be consulted

for additional guidance in regard to the installation of the turbine and driven
equipment package. It provides recommended procedures, practices and quality
assurance checklists covering the installation and de-commissioning of turbines,
compressors, fans, motors, gear reducers and pumps for use in petroleum,
chemical, gas industry and other facilities.
The following subsections, C.2 through C.11, provide basic installation and
decommissioning procedures. Follow them in the indicated sequence for complete
and correct installation. These recommendations and instructions are provided to
assist the purchaser and/or his contractor. Fully qualified labor, including qualified
supervision, is required for proper installation, start-up, and subsequent operation
of the equipment. The services of a Dresser-Rand serviceman are recommended for
the final on site installation review and the initial commissioning and start-up of the
turbine.
As a minimum the following steps must be carried out in sequence to achieve

satisfactory operation.

WARNINGS
NEVER CONNECT the steam turbine to inlet or exhaust

sources of UNKNOWN PRESSURE OR TEMPERATURE, or to
sources whose pressure or temperature EXCEED limits stated
on the NAMEPLATE.

a. Refer to the certified drawings in Appendix A and carefully read all

installation notes, piping connection details, dimensions and clearances, and
any other special data.
b. Provide a proper and adequate foundation for the turbine.
c. Provide a proper piping installation, in accordance with NEMA SM23, that

will accommodate pressure forces and thermal growth without imposing
excessive force on the turbine.
d. Remove all protective coatings and foreign matter from the turbine and all
piping. If the turbine was prepared for long-term storage, reinstall the matched
carbon ring sets, springs and washers into the turbine gland housings.
e. Refer to coupling alignment instructions supplied by the coupling

manufacturer, as well as those supplied in this manual.
f. Perform an accurate cold alignment.
g. Grout the base-plate or sole plate to the foundation, as required.
h. Carefully check hot alignment at operating temperature and adjust it, if

necessary, to establish accurate alignment.
i. Dowel turbine and driven machine in place to maintain proper alignment.
C.2 Foundation
WARNING

If the turbine is installed in a location where there is the

possibility of an earthquake this must be considered in the
design of the piping and foundation.
The foundation is one of the most influential factors governing overall reliability of
a turbine. A foundation must maintain alignment under all normal and abnormal
conditions. This includes the way a foundation is supported on the soil and/or
superstructure, soil settling, soil resonances, thermal distortion, piping forces, and
vacuum pull or pressure forces in expansion joints.
The turbine, gear reducer (if used), and driven equipment should all be mounted on
a common foundation.
Sufficient space should be provided around and above the foundation to allow for
proper installation and maintenance.
The foundation must minimize vibration by being as heavy as possible and non-
resonant. It is important that the turbine be isolated from external vibration. Neither
the foundation nor related support structure should be resonant within the operating
range of the turbine.
Vibration transmissions may occur from the unit to the surroundings, or vice versa;
vibration may also be aggravated by resonance at transmission frequencies. Piping,
stairways, and ducts may also transmit vibration, which should be prevented by
proper isolation.
A certified outline drawing is furnished with each Dresser-Rand turbine and is

included in this manual in Appendix A. This drawing includes dimensions for
locating anchor bolts, equipment weights, and general information required for
determining foundation dimensions and design.
A generous safety factor should be used when determining foundation thickness.

The foundation length and width should extend at least 6 inches (152 mm) beyond
the anchor bolts.
Anchor bolts must be positioned accurately and provided with sleeves. The sleeve
bore diameter should be approximately twice the bolt diameter, but should provide
not less than 1/2” (13 mm) clearance all around the bolt.
Carefully constructed templates are required to hold bolts and sleeves in position
while the foundation is cast. Templates are usually made of wood and secured to
the foundation forms. Experienced workers should be able to set anchor bolts to a
tolerance of 1/8” (3 mm) by locating and drilling holes in the template after they
have been secured to the braced forms.

Anchor bolts should be threaded at both ends and be of sufficient length to extend
one-and-a-half to twice the bolt diameter above the top of securing holes in the
base plate or the sole plate. The lower end of each bolt is enclosed in a sleeve and
passes through an anchor plate, where it is secured by a nut to which it is welded.
Anchor plates can be either washers or plates of cast iron or steel. They should
have a diameter or side dimensions of approximately twice to two-and-a-half the
outside diameter of the sleeves.
Notes:
1. Templates must be rigid enough to prevent bolts from shifting while the
concrete is being poured.
2. After concrete has been poured and before it has hardened, recheck positions
of the anchor bolts.
3. Allow a 1-1/2” (38 mm) gap above the top of the foundation surface for
grouting under edges of the base plate or sole plates.
C.3 Piping
WARNING
Improperly designed or installed piping can lead to turbine

misalignment and failure of the turbine or driven equipment. It
is the user/installers responsibility to insure that the piping
system is properly designed, installed and that it meets local
codes and regulations. All references to piping design in this
section are for reference only.

WARNING
If the turbine is installed in a location where there is the

possibility of an earthquake this must be considered in the
design of the piping and foundation.
Proper piping of a steam turbine is essential. Correctly designed and installed

piping contributes to safe, trouble-free operation and can improve ease of turbine
operation and maintenance.
Before installing any piping, installation personnel should read and become
thoroughly familiar with this section.
The effects of possible earthquakes should be taken into account when designing
the inlet and exhaust piping systems.
C.3.1 Piping Forces

Any pipe connected to the steam turbine casing, valves, gland housing, or bearing
housings can exert forces and/or moments on the turbine. This can misalign the
turbine with its driven equipment or distort the turbine casing, resulting in internal
misalignment of the turbine shaft with bearings, seals, and other components. Such
misalignment can cause vibration, premature wear or failure of bearings, seals,
couplings and shafts, and casing leaks.
Steam supply (inlet) and exhaust piping, being relatively large and subjected to
higher temperatures and pressures, can, if improperly installed, exert relatively
large forces and moments on a steam turbine. Leak-off, drain, lube, cooling water
and gland seal piping does not normally transmit significant piping forces.
To prevent excessive piping forces or moments, the customer must ensure that the
piping is designed and installed so as to comply with NEMA SM-23, Section 8,
Allowable Forces and Moments on Steam Turbines. The maximum allowable
forces and moments are a function of inlet and exhaust flange sizes. Flange sizes
are tabulated on the Certified Drawing appearing in Appendix A.
Piping forces can be reduced or eliminated with proper piping design, the use of
expansion joints, and correct piping support systems. Figure C-1, Suggested Steam
Inlet and Exhaust Piping Arrangement, suggests inlet and exhaust piping systems,
showing typical expansion joints, piping loops, and spring supports in the piping
system.

Optional constructions, which include third-party throttle and/or over-speed trip

valves or other equipment configurations, may require the use of additional supports.
Refer to the certified drawings in the Appendix A.
Refer to a separate sketch in Appendix A for the estimated thermal movement of the
inlet flange and exhaust flange. The estimated thermal movements of the inlet and
exhaust flanges are used in the design and analysis of the piping support system.
Figure C-1. Suggested Steam Inlet and Exhaust Piping Arrangement
C.3.2 Isolating Valves

Inlet and exhaust lines to a turbine must be provided with isolating valves. The
purpose of these valves is to isolate the turbine from inlet and exhaust systems,
allowing the turbine to be shut down, along with sealing inlet and exhaust lines if
the turbine is to be moved or serviced.
DANGER
NEVER DISCONNECT inlet or exhaust piping of the turbine

without first CLOSING and TAGGING the ISOLATING VALVES
and then OPENING DRAIN VALVES SLOWLY to relieve any
pressure within the turbine. Failure to do so may expose
PERSONNEL to SERIOUS INJURY if steam was to be
introduced into the piping or captured in the turbine. As an
added precaution, always install blank flanges on inlet and
exhaust lines after removing the turbine.
The inlet piping isolating valve should be installed immediately upstream of the
turbine. Refer to Figure C-1, Suggested Steam Inlet and Exhaust Piping
Arrangement.
The exhaust piping isolating valve should be installed immediately downstream of

the full flow relief valve. Refer to Figure C-1, Suggested Steam Inlet and Exhaust
Piping Arrangement.
C.3.3 Full Flow Relief Valve

An atmospheric relief valve must be installed between the turbine exhaust flange
and the first exhaust line shut-off valve (Refer to Figure C-1, Suggested Steam Inlet
and Exhaust Piping Arrangement). The purpose of this relief valve is to protect the
turbine casing from excessive exhaust pressure. The relief valve must be of ample
size to pass the maximum quantity of steam flowing through the turbine at the
maximum inlet temperature and pressure steam conditions without allowing the
turbine casing pressure to exceed the limit defined below. It is the user’s
responsibility to install the relief valve in the piping.
The full flow relief valve shall begin to open at 10% or 10 PSIG (69 kPag) above
maximum exhaust pressure, whichever is greater, for non-condensing turbines; and
at not more than 10 PSIG (60 kPag) for condensing turbines. The valve shall be
fully open with an additional rise in pressure not to exceed 10%. Refer to NEMA-
23, Steam Turbines for Mechanical Drive Service, for further details.

WARNINGS

RELIEF VALVE in the exhaust line between the turbine exhaust
casing and the first shut-off valve. This relief valve should be
sized to relieve the FULL AMOUNT OF STEAM THAT THE
TURBINE WILL PASS, in the event that the exhaust line is
blocked.
The optional SENTINEL WARNING VALVE, located on the

turbine casing, DOES NOT SERVE as a RELIEF VALVE. The
sentinel warning valve WILL NOT PASS SUFFICIENT STEAM
FLOW to relieve the turbine casing of EXCESSIVE EXHAUST
PRESSURE. The purpose of the sentinel warning valve is to
warn visually and audibly that excessive pressure is building in
the turbine exhaust casing.
C.3.4 Inlet Piping

As shown in Figure C-1, Suggested Steam Inlet and Exhaust Piping Arrangement,
inlet piping should come off the top of the steam header and form an expansion
relieving loop or other strain relieving device, before coming down to the turbine.
A valved condensate drain should be installed in the inlet line upstream of the
isolating valve, allowing condensate to drain prior to opening the isolating valve
and feeding steam to the turbine. Piping must be supported in such a manner as to
allow thermal growth of the turbine and piping, without imposing excessive forces
and moments on the inlet flange. Properly installed piping should mate squarely to
the turbine inlet flange, without any need to force flanges by twisting them into
alignment when connecting them.
The inlet line should be well lagged to prevent heat loss and to avoid burns.
Pipe sizes should be large enough to maintain rated steam pressure at the turbine
inlet flange under maximum load conditions. In determining pipe size, proper
allowance should be made for pressure drop due to long sections of pipe, elbows,
valves, or other fittings between the boiler and the turbine.
If wet or saturated steam is used, it is very important that piping be arranged so that
condensate cannot be carried over into the turbine. A steam separator of the proper
size, with a trap of ample capacity, should be installed before the turbine inlet. All
horizontal runs must be sloped up in the direction of steam flow, with drains at the
low points.

The importance of protecting the turbine against slugs of water cannot be

overemphasized. The issue is not “wetness” of the steam, but with condensate,
which is separated out as water. The harmful effects of water are:
1. Rapid erosion of blading and valves.
2. In the case of turbine wheels with inserted blades, water may have a hammer-
blow effect, tearing out the blades and destroying the rotor.
3. Governing is adversely affected.
4. The rotor may be permanently distorted and/or the turbine may be seriously
damaged.
5. A danger of thrust bearing failure and consequent destruction of the turbine.
C.3.5 Exhaust Piping

Figure C-1, Suggested Steam Inlet and Exhaust Piping Arrangement, shows
exhaust piping together with the full flow relief valve and support system. Note that
the exhaust line should slope down toward the header or create an overhead loop,
to prevent condensate at the header from flowing back toward the turbine. Valved
drains should be installed before and after the exhaust-isolating valve.
On each installation, the length of run, elbows, valves, and other fittings in the pipe
must be considered, together with all factors, which may cause back-pressure on
non-condensing turbines or reduced vacuum on condensing turbines, and a final
decision on piping size made accordingly. On non-condensing turbines, back-
pressure which is higher than what the turbine was designed for will cause
reduction of power and an increase in steam consumption. It may also cause gland
leakage, and in extreme cases, can rupture the turbine casing. On condensing
turbines, decreased vacuum will have an even greater effect on capacity and
economy.
The exhaust pipe must be installed and anchored so that no excessive stress is
placed on the turbine from either the weight of the pipe or its expansion and
contraction. In cases where such an arrangement cannot be made with certainty, an
expansion joint near the turbine can be useful in low pressure lines and is usually
required on large pipe sizes. The use of an expansion joint does not of itself avoid
undue stress. It is not as flexible as many people assume and when installed, it must
be properly aligned and not indiscriminately exposed to shear or torsion. In the
majority of applications, axial thrust created on the cross-sectional area of the
largest bellows, by internal pressure, must be restricted by the use of tie rods. They
are most effective when the expansion joint is used in shear, instead of tension or
compression. When used in either a vacuum or a pressure line, tie rods must be

arranged accordingly. They are useless where a joint moves under tension or
compression, as they bypass the joint and transmit pipe forces directly to the
turbine. Provision must be made to anchor the piping in such a way that excessive
forces will not be transmitted to the turbine during shutdown and operational
running. Connection to a header must be made at the top, never from the bottom or
side, and great care must be taken to avoid draining water back into the turbine. All
horizontal runs must be sloped away from the turbine exhaust connection.
Properly installed piping should mate squarely to the turbine exhaust flange,
without any need to force flanges by twisting them into alignment when connecting
them. The exhaust line should be well lagged to prevent heat loss and avoid burns.
C.3.6 Piping Blow Down

Newly constructed steam piping should be blown-down to remove scale, weld slag
and any other foreign material. Such material can cause severe damage if it enters
the steam turbine.
After inlet piping has been installed, but before connecting it to the turbine, steam
should be blown through the line and into the exhaust line to remove welding slag
and debris.
Refer to NEMA SM-23, Steam Turbines for Mechanical Drive Service or a reliable
piping contractor for a blow-down procedure.
CAUTION
INLET STEAM LINES MUST BE BLOWN DOWN PRIOR TO

CONNECTING them to the turbine. Debris and welding slag
can cause serious damage to valves, nozzles, and turbine
blading if allowed to enter the turbine.
C.3.7 Steam Strainer

Standard SST Dresser-Rand turbines are provided with integral inlet steam
strainers to prevent entry of foreign material into the turbine. Part of the throttle
valve is located in the same chamber with the steam strainer. The steam strainer
will allow small debris particles to pass through the turbine and does not preclude
the need for inlet piping blow-down prior to connecting the turbine. The steam
strainer should be removed and cleaned at least once a year and replaced at least
every three years or as needed.
When a turbine is supplied without an integral or separate y-type strainer, the

purchaser must install an appropriate steam strainer in the inlet steam piping.

C.3.8 Check Valve

Where a turbine exhausts or bleeds steam into another system, and a check valve
(commonly referred to as a non-return valve) is installed for prevention of reverse
flow to the turbine, adequate bracing must be installed to absorb any forces created
by water hammer effects occurring in the exhaust line downstream and acting on
the check valve. The maximum relief valve settings are found on the turbine data
sheets. The sentinel relief valve on the turbine case is a warning valve only.
C.3.9 Expansion Joints

Low pressure and vacuum lines are usually large and relatively stiff. It is common
practice to use an expansion joint in these lines to provide flexibility. If an
expansion joint is improperly used, it may cause a pipe reaction greater than the
one that it is supposed to eliminate. An expansion joint will cause an axial thrust
equal to the area of the largest corrugation multiplied by the internal pressure. The
force necessary to compress or elongate an expansion joint can be quite large, and
either of these forces may be greater than the limits for the exhaust flange. In order
to have the lowest reaction; it is best to avoid absorbing pipeline expansion by axial
compression or elongation. If it is found that expansion joints are required, it is
essential that they be properly located and their foundation rigid. Refer to NEMA
SM-23, Steam Turbines for Mechanical Drive Service or a reliable piping
contractor for steam piping system design and installation guidance.
See Figure C-2 Unrestrained Expansion Joint (not recommended).
Figure C-2. Unrestrained Expansion Joint (Not Recommended)
The axial thrust from the expansion joint tends to separate the turbine and the
elbow. To prevent this, the elbow must have an anchor to keep it from moving. The
turbine must also absorb this thrust, and in so doing, it becomes an anchor. This
force on the turbine case may be greater than the allowable force. In general, this
method should be discouraged.

Figure C-3 Expansion Joint with Tie Rods (Acceptable) below shows the same
piping arrangement as in the previous figure, except for the addition of tie rods on
the expansion joint.
Figure C-3. Expansion Joint with Tie Rods (Acceptable)
The tie rods limit elongation of the joint and take the axial thrust created by the
internal pressure so it is not transmitted to the turbine flange. The tie rods eliminate
any axial flexibility, but the joint is still flexible in shear, meaning that the flanges
may move in parallel planes. The location of this type of joint in the piping should
be such that movement of the pipe puts the expansion joint in shear instead of
tension or compression.
Figure C-4 Expansion Joint with Tie Rods for Non-condensing Operation
(Preferred) below is an arrangement frequently used, with tie rods as indicated.
Figure C-4. Expansion Joint w/ Tie Rods Non-Condensing Operation (Preferred)
This arrangement will prevent any thrust, due to internal pressure, from being
transmitted to the exhaust flange. It retains the axial flexibility of the joint and may
be used for either vacuum or pressure service.

Figure C-5. Expansion Joint w/ Tie Rods Condensing Operation

(Preferred)
Figure C-5 shows a suggested arrangement for a condensing turbine with an up exhaust. This
arrangement is recommended and frequently used. Due to the large exhaust pipe size normally
encountered on condensing turbines, the exhaust piping will be relatively stiff and an
expansion joint must be used at some point to take care of thermal expansion. An
unrestricted expansion joint placed at the exhaust flange of the turbine will exert an upward
or lifting force on the turbine flange, which in many cases is excessive. Figure C-5
provides the necessary flexibility to take care of thermal expansion without imposing a
lifting force on the turbine. The expansion joint is in shear, which is the preferred use. The
relatively small vertical expansion will compress one joint and elongate the other, which
causes a small reaction only and will be well within the turbine flange limits.
On smaller and high-pressure exhaust lines it is frequently better to rely on the flexibility of
the piping than on an expansion joint. Only after a careful analysis of the piping shows the
need for an expansion joint should they be used.
In order to have flexibility in piping, short direct runs must be avoided. By arranging the
piping in more than one plane, torsional flexibility may be effectively used to decrease the
forces.

Figure C-6. Short Runs to Exhaust Header
Figure C-6 shows a short direct run to an exhaust header. If the header is free to float in
a horizontal plane, thermal expansion of the exhaust line will put very little direct
thrust on the exhaust flange. If the header is fixed, the thermal expansion will tend to cause
either the turbine or header to move and may cause damage. If thermal expansion causes
the header to move in an axial direction it will transmit a force and moment to the exhaust
flange. Figure C-6 is not recommended, as it is difficult to prevent excessive forces
from being transmitted to the exhaust flange.
C.3.10 Leak-Off Piping
WARNINGS
Leak-off and drain connections of turbines operated on

flammable or noxious gas must be piped to a safe location to
avoid the possibility of ignition of the gas or poisoning of
operating personnel.
LEAK-OFF AND DRAIN LINES MUST NOT BE

INTERCONNECTED. A leak-off from a high pressure upstream
location connected to a steam chest drain or throttle valve leak-
off/drain could supply sufficient steam TO ALLOW THE
TRIPPED TURBINE TO CONTINUE RUNNING, since such an
interconnection would bypass the overspeed trip valve.

LEAK-OFF PIPES that are left UNCONNECTED will allow the

escape of HIGH TEMPERTURE STEAM that could cause
PERSONAL INJURY or contamination of lubricating oil.
Standard SST Dresser-Rand turbines are supplied with leak-off connections at the
gland housings, throttle valve, and overspeed trip valve. Leak-offs are piping
connections that allow steam leaking past seals to be carried away to a safe area.
Shaft and valve stem seals depend on some leakage for lubrication and to minimize
wear. Leakage is therefore acceptable and necessary.
The leak-offs must be pitched down and away from the turbine and connected to
open, unrestricted, separate, non-manifolded drain lines, which discharge to a safe
and visible area. There should not be any valves on leak-off lines. Leak-off piping
should be arranged to insure that no pressure build-up occurs in the system,
avoiding any low points where condensate could accumulate and may be connected
to a gland condenser, eductor or ejector. No vertical upward pipe runs are to be
included in leak-off piping. Unavoidable low points should be trapped.
On gas operated turbines, leak-offs must be piped to a safe area away from the
turbine site.
Locations and sizes of leak-off connections are shown on the certified drawing in
Appendix A.
Gland housings on turbines operating with vacuum exhaust or at high back pressure
require special Gland Seal leak-off systems.
For turbines operating with vacuum exhaust refer to Section C.3.11 Gland Seal
Leak-Off Piping-Vacuum Exhaust
Turbines operating with high back pressure may have intermediate leak-off
connections on their gland housings. Refer to Section C.3.12 Gland Seal
Intermediate Leak-Off Piping – High Back pressure Exhaust.
C.3.11 Gland Seal Leak-Off Piping – Vacuum Exhaust

On turbines exhausting to a vacuum, sealing steam at 5 to 10 PSIG (34 to 69 kPag)
pressures must be furnished through the carbon ring glands to prevent air from
entering the exhaust casing.

Figure C-7. Typical Gland Sealing System without Gland Condenser
If gland seal piping is not furnished with the turbine, sealing steam connections
should be piped via a common connection to the user’s steam supply. A
recommended piping diagram for gland seal piping is shown in Figure C-6 Gland
Seal Leak-Off Piping – Vacuum Exhaust.
Frame Relief Gauge Customer’s

Gauge Angle Control Valve
Composition Valve Valve Connection
Ashcroft
Kunkle No. 1009 1/2” pipe 12.7 mm
Cat. KGSC
Vogt No. 1971 3/8” Max. Press. 600
Fig. No. Range 30” Vogt No lbs. 750F 42.18
All Sizes 600 lbs. Steel 9.52 mm
40R to 30 lbs. 9871 Kg/Cm2 399C
272 Kg.
Stainless 760 mm to
Steel 2.109
Kg/Cm2
Table C-1. Gland Intermediate Leak-Off Piping—High Back Pressure

Exhaust

Turbines to be operated with high back pressure may have intermediate gland leak-
offs that must be piped to a steam header with a pressure not less than 35 PSIG
(241 kPag) and not exceeding 70 PSIG (483 kPag). This intermediate leak-off
piping must include, for start up purposes, an atmospheric vent with a shut off
valve near the turbine and a check valve installed between the vent and the steam
header to prevent back-flow. Do not connect the intermediate leak-off piping with
other leak-off connections. Refer to Figure C-8 Gland Seal Int. Leak-Off Piping
High Back Pressure Exhaust.
Figure C-8. Gland Seal Intermediate Leak-Off Piping-High Back Pressure

Exhaust
C.3.12 Gland Seal Intermediate Leak-Off Piping—High Back Pressure Exhaust

In certain turbines with a high exhaust back pressure, a gland leak-off system is used. Figure 8
shows a typical system using gland ejectors connected to the leak-off piping of both packing
cases. The ejectors maintain a constant vacuum in the gland packing case leak-off lines. When
the ejectors are shipped separate from the turbine, the piping leak-off connections from the
turbine are shown on the outline drawing, Appendix A. If gland ejectors are required for your
turbine, the specific part number is listed on the Appendix A contents sheet. On certain designs,
a drip drain connection is located adjacent to gland leak-off on each packing case. These drain
connections must be plugged.
For leak-off systems that use a gland condenser, a system schematic diagram with operating
instructions is included in Appendix A, along with a description of the major components that
comprise the system.

Figure C-9. Gland Leakage Ejector System
C.3.13 Drain Piping
WARNING
DRAIN PIPING flanges and valves must be SELECTED AND

INSTALLED BY EXPERIENCED PERSONNEL, taking into
account the MAXIMUM OPERATING STEAM PRESSURE
AND TEMPERATURE. Improperly designed or installed drain
systems could FREEZE, become PLUGGED AND RUPTURE,
causing serious personal injury or equipment damage.

Leak-off and drain connections of turbines operated on

flammable or noxious gas must be piped to a safe location to
avoid the possibility of ignition of the gas or poisoning of
operating personnel.
LEAK-OFF AND DRAIN LINES MUST NOT BE

INTERCONNECTED. A leak-off from a high pressure
upstream location connected to a steam chest drain or throttle
valve leak-off/drain could supply sufficient steam TO ALLOW
THE TRIPPED TURBINE TO CONTINUE RUNNING, since
such an interconnection would bypass the over-speed trip
valve.
Drains are low-point piping connections at valves and casings that allow release of
condensed water. Drains are opened before starting the turbine, to allow any
accumulated water to escape. They are left open during the start-up cycle to allow
water condensing in the cold casings to exit. Once the turbine reaches normal
operating temperature, drains should be closed.
The user must install drain valves when not supplied by Dresser-Rand.
Drains can be automated with properly sized steam traps, if desired. Refer to C-10
Suggested Steam Inlet, Exhaust and Drain Piping, Manual Start and Figure C-11
Suggested Inlet, Exhaust and Drain Piping, – Auto Start.
Sizes and locations of drains are shown on the certified drawing in the
Supplemental Documentation section, supplied at the end of this manual.
C.3.14 Water Cooling Piping to Bearing Housing Water Jackets

Depending on service conditions and the type of lubrication system supplied with
the turbine, bearing housings may require water cooling to maintain an acceptable
bearing oil temperature.
Refer to Section F, Lubrication, for cooling water application requirements,

suggested piping, water flow, pressure and temperature requirements, and oil sump
temperature.

Figure C-10. Suggested Steam Inlet, Exhaust and Drain Piping, Manual Start
Figure C-11. Suggested Steam Inlet, Exhaust and Drain Piping, Auto-Start

C.4 Alignment Requirements
Many problems experienced with turbines, gears, and driven equipment is due to
misalignment. Units must be properly supported and their alignment accurately and
permanently established if the installation is to be successful.
WARNING

CAUTIONS
ALIGNMENTS performed by the factory on turbines with gears

or other driven equipment mounted on base plates MAY SHIFT
during rigging or shipment. These alignments must be
RECHECKED before startup.
Never put a steam turbine into service without first carefully

ALIGNING it to the driven equipment under cold conditions and
then again at operating temperature. Failure to do so may
result in premature FAILURE of both TURBINE and DRIVEN
EQUIPMENT components.
Excessive vibration, bearing edge loading, and high shaft loads can result from
incorrect alignment. Factors affecting alignment can be settling of the foundation,
growth in shaft heights due to temperature changes, machine movement of either
unit with respect to the foundation due to vibration, worn bearings, or distortion of
the casing due to loads from connecting structures (such as piping). A dependable
turbine drive system requires that all of these factors be given proper attention prior
to and during alignment.
The turbine and driven equipment should always be aligned cold, checked later at
operating temperature, and re-aligned if necessary. Both shafts should be parallel
and their axes concentric so that there is no offset at operating temperature.
Two types of misalignment must be identified and corrected (if necessary) to be

within defined limits.

Angular misalignment occurs when shaft centerlines intersect at an angle.
Figure C-12 Coupling Misalignment Limits
Parallel misalignment occurs when shaft centerlines are parallel to each other, but
do not intersect.

As previously noted, alignment is influenced by the thermal growth of both the

turbine and the driven equipment. This must be compensated for during cold
alignment by calculating the growth of each machine and intentionally creating a
parallel offset that will disappear when the equipment is hot.
C.5 Couplings
WARNING
A coupling guard must be installed at the coupling between the

turbine and driven equipment.
When the coupling guard is to be installed, refer to the coupling

guard manufacturer’s instructions to insure that it does not
contact the running shaft or coupling which could cause a spark
that could ignite hazardous gasses in the environment in which
the turbine is installed.
CAUTION
Coupling weights should not exceed the allowable limits on the

coupling drawing without approval from Dresser-Rand. A
heavier than allowed coupling could create a lower critical
speed, which could cause excessive vibration within the
operating range of the turbine.
A flexible coupling is required to connect the turbine to the driven machine.

Couplings should be selected based on power, speed, and characteristics of the
driven machine, using selection and balancing guidelines established by the
coupling manufacturer.
Correct installation of the coupling hubs is vital to proper operation of the turbine
and driven unit; great care must be exercised in assembling hubs onto shafts.
Before mounting a coupling, check the coupling bore and shaft diameter with a
micrometer to determine that the interference fit is as specified by the coupling
manufacturer. Also, inspect the key and keyways, making sure that the key is a
drive fit into the shaft keyway and a push fit into the coupling hub keyway. The

key should also sit positively on the bottom of the shaft keyway, with clearance on
the top of the key to allow expansion within the hub keyway.
If the shaft key extends beyond the back of the coupling hub, the key should fill the
entire keyway. The exposed portion of the key must be removed so that it is flush
with the coupling back face and must be profiled flush to the circumference of the
shaft so that only the keyway in the shaft is filled, maintaining shaft balance. When
installing coupling hubs on shafts, it is important to heat them uniformly, taking
great care to avoid overheating. A recommended method is to use an oil bath with a
temperature control or an induction heater.
When fitting the coupling onto the shaft, it is helpful to have a chamfer on the sides
and top of the key, making alignment easy with the hub keyway. Also, a temporary
block should be used, to prevent the hub from sliding too far onto the shaft.
Do not use hammers to drive coupling hubs onto the shaft, as this would damage
the coupling, shaft, or bearings. As coupling hubs are frequently used for reference
in alignment, runout or eccentricity of hubs, which may be caused by damage to the
shaft, hubs, or badly fitted keys, must be avoided.
CAUTION
DO NOT drive the coupling on or off the shaft with a HAMMER.

The force of the hammer will damage the rotor locating bearing,
resulting in internal turbine damage.
NOTE
Axial clearance between the coupling hubs and shaft end faces
should be in accordance with recommendations of the coupling
manufacturer, when shafts are in their normal running
condition.
Lubricate the coupling as required, by following the coupling manufacturer’s

instructions.
C.6 Preparation for Alignment

Use the following procedure:

a. Clean turbine mating support surfaces and mount turbine on the foundation.
b. Do not connect the turbine to inlet and exhaust piping.
c. Disconnect the coupling by removing the coupling spacer (if provided) and
pulling coupling sleeves away from the hub.
d. Insert suitable shim packs between supporting surfaces of the turbine and/or
driven equipment and their respective mounting surfaces. It is important to
insert sufficient shims under the equipment so that shims can be removed to
lower either piece of equipment if required during hot final alignment. A
minimum of 1/16 inch (1.6 mm) is recommended.
e. Level and square the turbine with respect to the driven equipment.
f. Check for base distortion and improper shimming by placing dial indicators in
vertical and horizontal planes on the driven equipment, with the indicators
detecting turbine shaft movement. Each turbine foot anchor bolt should then be
loosened and tightened, while observing the dial indicator reading. Readings
should not exceed 0.003 in. (0.075 mm); if they are exceeded, the cause must
be determined. Repeat this procedure for driven equipment.
g. Check that all anchor bolts (i.e., turbine, driven equipment and supports) are
tightened.
h. Check coupling hub face runout using the following procedure:
1. Install dial indicator (refer to Figure C-13, Alignment Using Dial

Indicators) to read a point nearest to the outside circumference on the face
of one hub.
2. Rotate the shaft and hub on which the dial indicator is touching and record
the maximum and minimum indicator readings. Axial runout is the
difference between the two readings.
3. Re-position the dial indicator to read on the external outside diameter of

the same hub as in step 1 and measure coupling hub diametral runout, as
shown in Figure C-13, Alignment Using Dial Indicators.
4. Rotate hub and record the maximum and minimum indicator readings.
Lateral runout is 1/2 of the difference between the two readings.
5. Repeat steps 1 through 4 for the other coupling hub.

6. Any runout exceeding 0.0015 inch (0.038 mm) should be corrected by

reinstallation of the hub and keys or their replacement.
7. Hub runout values should be subtracted from the desired alignment

setting.
Figure C-13. Alignment Using Dial Indicators
C.7 Compensation for Thermal Movement

During initial alignment, allowances must be made for thermal expansion of the
turbine and driven equipment. The shaft centerline of each unit will rise when they
reach operating temperature. Therefore, the difference between the two anticipated
growths must be incorporated into the cold alignments so that the shafts will come
into alignment when operating temperature is attained.
CAUTION

Thermal movement varies significantly with inlet temperature,

load, ambient conditions and time. Final hot alignment of the
turbine to the driven equipment must be based on actual
measured shaft rise under steady state conditions (after at least
a two hour run time).
Figure C-14. Centerline Height VS Centerline Rise per Ambient

Temperatures
On steam turbines, steam temperatures and insulation of the turbine case, proximity
of packing leak-off lines to the supports and type of lagging enclosure affect the
support temperatures. The average support temperatures may vary from 130F to
160 F (approximate oil drain temperatures). Judgment will have to be exercised in
estimating the support temperature for the initial cold alignment. The curves in
figure C-14 may be useful for checking and also for telling the effect of an error in
the estimate of support temperature. Refer to the certified drawings in Appendix A
for the estimated thermal movement of the turbine shaft extension.

Thermal growth of the driven equipment, or its temperature change, must be

obtained from the driven equipment manufacturer.
The unit with the greater thermal growth must be set lower than the other unit, by
the difference between their thermal growths. Normally, the turbine has the greater
thermal growth.
CAUTION
The initial alignment established with this estimated thermal

growth is only approximate. An actual hot alignment must be
performed prior to putting the turbine into service.
C.8 Cold Alignment Check

Cold alignment must be completed at ambient temperature (turbine and driven
machine in cold condition) and in the proper sequence, with angular misalignment
corrected first, followed by correction of parallel misalignment.
C.8.1 Angular Alignment
a. Clamp a dial indicator to one coupling hub and place the finger (contact point)
against the finished face of the other hub, as shown in Figure C-13, Alignment
Using Dial Indicators.
b. Scribe a reference mark on the coupling hub at the point where the finger
touches the hub face.
c. Rotate both shafts simultaneously (in the direction they were designed to
operate), keeping the finger against the reference mark on the coupling hub.
Note the dial indicator reading at each one-quarter revolution.
d. Angular misalignment of the shafts must not exceed the coupling

manufacturer’s recommendations or a total indicator reading of 0.001 inch
(0.025 mm) for each radial inch of the coupling hub.
e. When the distance between coupling hubs does not permit the use of dial
indicators, angular misalignment can be established using one of the two
following methods:

1. Use feeler gauges to determine the gap between coupling faces at four
locations, 90 apart. Adjust the turbine or driven equipment to obtain
equal clearance within 0.001 inch (0.025 mm) between coupling faces at
each 90 location.
2. Use a dial indicator mounted on a flexible arm to measure run-out on the

back surface of the coupling hub, as shown in Figure C-13, Alignment
Using Dial Indicators.
C.8.2 Parallel Alignment

a. Mark both hub rims so that their relative positions can be maintained at all
times during the alignment check.
b. Mount the dial indicator on one of the coupling hubs and position the indicator
finger on the rim of the opposite coupling hub, as shown in Figure C-13,
Alignment Using Dial Indicators.
c. Scribe a reference mark on the machined diameter of the coupling hub at the
point of indicator finger contact, or align match marks on the hub rims.
d. Rotate both shafts at the same time, while retaining the indicator finger at the
reference mark and the two match points aligned.
e. Note indicator readings at 90 locations (90, 180, 270, 360). Remember to
zero the indicator at the starting point.
f. Repeat steps d and e two or three times to verify accuracy of readings.
In installations where there is excessive coupling gap (when a coupling spacer

is used), it may be necessary to make a reading correction when determining
vertical parallel misalignment.
g. Parallel misalignment must not exceed the coupling manufacturer’s

recommendations or a total indicator reading of 0.002 inch (0.051 mm).
When parallel alignment is complete, connect inlet and exhaust piping, and recheck
angular and parallel alignment thoroughly.
C.8.3 If using laser alignment tooling such as Rotalign, you can eliminate Section C.B.1
and C.B.2. Follow recommended instructions included in the laser alignment
tooling.

C.9 Grouting
When cold alignment is satisfactory (the turbine has been leveled, and the coupling
alignment has been checked), grout the base plate or sole plate to the foundation
using the guidelines specified below. (Epoxy grout procedures may differ--follow
manufacturer’s instructions.)
Mix a test batch of ready-to-use grouting material to verify that the material
overcomes settlement and drying shrinkage. This type of material is normally used
for clearances less than one inch in thickness, and where the size and shape of the
space make placement difficult.
Coarse aggregate is normally used for clearances over one inch (2.5 cm) in
thickness, where free passage of the grout will not be obstructed. One part of pea
gravel or pea stone may be added to two parts of the ready-to-use grouting material
to form coarse aggregate grout.
CAUTION
Do not disturb alignment by removing shims or wedges under

the base plate or sole plate.
Grouting must be done with all steam and exhaust piping disconnected from the
turbine.
When prepared grout mixes are used, follow the manufacturer’s instructions and
applicable safety precautions. Be sure that there are no air pockets in the grouting.
A suitable form should be built around the base-plate or sole plate before grout is
applied.
With either of the above-described mixes, use the minimum amount of water
required to create a flowable grout that completely fills the required space.
Excessive water causes segregation and bleeding.
Apply grout quickly and continuously to avoid the undesirable effects from
overworking.
Once the grout has acquired its initial set, all exposed edges should be cut off
vertically to coincide with the base-plate. Paint the grout with waterproof paint
after the grout has thoroughly dried, or apply plaster with Portland cement-sand
mortar. Do not connect the piping before the grout is thoroughly dry and
alignment has been rechecked.

C.10 Hot Alignment Check

After installation is complete, the grout is fully set, and the tightness of all hold-
down bolts have been checked, bring the turbine and driven machine up to
operating temperature (this normally takes about two hours run time), shut down
the unit, and make a careful and final check of the alignment using the procedure
outlined in Section C.8. This should be done as soon as possible after shut down, to
avoid erroneous readings due to cooling. Final adjustments should be made so that
both shafts are parallel and their axes concentric, resulting in zero offset at
operating temperature, consistent with the coupling manufacturer’s limits.
If the alignment is not satisfactory, check the following for possible causes:
a. Pipe strains distorting or shifting machines due to thermal growth (disconnect

piping and re-check alignment).
b. Springing of the base-plate or sole-plates by heat from the turbine, from a heat
source close to the turbine, or due to soft shims or partial shims.
c. Loose hold-down bolts.
d. Shifting of the entire structure due to variable loading, a change in the

foundation due to concrete curing, or improper grouting causing non-continuous
support.
When final alignment is satisfactory, dowel the turbine and driven equipment in
place to maintain proper alignment.
C.11 Fire Protection

All possible precautions should be exercised to avoid fire hazard to operating
personnel and equipment, particularly to the oil system. To guard against the event
of a serious fire around the turbine, the following protective features should be
provided at an accessible location near the unit.
Fire Extinguishing Equipment Type Best Suited for Oil Fires

Examples: Carbon Dioxide Multi-purpose Dry Chemical
Provision for emptying oil reservoir quickly by draining oil to waste or distant
storage.
A shut-off valve in the steam inlet line and in the steam inlet line to the turbo
auxiliary oil pump (if supplied).

C.12 Decommissioning
WARNING
Prior to commencing the decommissioning operation, ensure

that the inlet and exhaust stop valve are shut, locked out and
tagged to eliminate the possibility of inadvertent start-up during
the decommissioning operation.
The decommissioning procedure is as follows:
1. Remove bolts from the inlet and exhaust flanges.
2. Disconnect all turbine piping from permanently installed piping.

3. Drain oil from the bearing housings and the governor. Dispose of the oil
in an environmentally responsible manner.
4. Drain cooling water from the cooling system and bearing housings.
5. Remove carbon rings, springs and stops from the gland housings.
6. Remove coupling guard.
7. Disconnect drive half coupling from driven half coupling. Remove

spacer coupling if one is installed.
8. Remove hold down bolts/nuts from the base-plate.
9. Sling the turbine and move it to a position where the inlet and exhaust
are exposed.
10. Spray the internals with a rust preventative through all available
openings.
11. Coat the non-painted machined surfaces with a water-soluble rust

preventative.
Seal all flanged connections with a rubber gasket, steel plate and through-bolts and
nuts.
Move the turbine to the selected storage location suitable for this type of
machinery.

Speed Control System SST Turbine Instruction Manual
Section D
Speed Control System
D.1 General
Your Dresser-Rand turbine has been designed to produce the rated power, at its
rated speed, under the specified steam conditions. This information can be found on
the turbine nameplate, on the turbine data sheet at the beginning of this manual, or
on the certified drawings in the Appendix A.
When the turbine has been provided with a droop-type governor (WOODWARD
TG-13 governor or similar), and the load created by the driven equipment is less
than the rated power, the turbine would tend to run faster than the rated speed.
When the load is greater than the rated power, the turbine would tend to run slower
than the rated speed. Regulating the amount of steam admitted to the turbine can
counteract these tendencies. The governor and throttle valve provide this function.
The governor senses the speed, at which the turbine is running and opens or closes
the throttle valve; accordingly to maintain the turbine at its predetermined (set)
speed.
WARNING
Never operate the turbine with the governor or governor system

disabled.
D.2 Standard Governor

The basic hydraulic governor is the Woodward TG mechanical-hydraulic speed
control governor. The governor is attached to the governor mounting housing and
couples to the turbine shaft via a flexible coupling. The governor linkage connects
the governor to the throttle valve.

WOODWARD
PG, UG OR 3161
GOVERNOR
TURBINE
SHAFT
OVERSPEED
COUPLING GOVERNOR CUP
Figure D-1. Throttle Valve Features

BREATHER
SPEED ADJUSTING
SCREW
OIL LEVEL
INDICATOR
OUTPUT SHAFT
INPUT
SHAFT
DRAIN
Figure D-2. Woodward Oil Relay Governor Features
The instruction manual for the standard or optional governor is found in Appendix
B.
Figure D-2 shows external features of the Woodward TG Governor.
Breather--this is a vent for the oil reservoir and also serves as a plug for the oil
filler hole.
Oil Level Indicator--a sight gauge on the side of the Governor for checking the oil
level.
Speed Adjusting Screw--this screw, located on the rear of the Governor, increases
the turbine speed setpoint when turned clockwise.
Output Shaft--opens and closes the Throttle Valve via the throttle linkage.
Input Shaft--is connected to turbine shaft, sensing turbine speed.
Drain Plug--oil drain on the bottom of the Governor.

D.3 Lubrication and Maintenance

The hydraulic governor has a self-contained, 1.75 quart oil reservoir. Oil level can
be checked by viewing the oil level indicator on the side of the Governor.
The turbine is shipped with the governor reservoir filled with oil. Oil level should
be checked before starting the turbine and should be maintained at the proper level.
Oil should be changed according to recommendations in the Woodward manual,
included with this manual. If oil should become contaminated, quality
turbomachinery oil is recommended. Refer to Section F, Lubrication System, for oil
selection guidelines.
WARNING
Operating the GOVERNOR with DIRTY OIL or with a LOW OIL

LEVEL can cause the Governor to MALFUNCTION, resulting in
damage to the governor and possible overspeed causing
damage to the turbine and personal injury.
Refer to the governor manual for governor oil selection guidelines and for any
additional maintenance information.
D.4 Speed Range and Droop Adjustment

The hydraulic governor speed range is preset at the factory, with the purchaser’s
specified turbine rated speed within that range. The user, within the allowable
range of the supplied governor, may vary the speed set point by turning the speed
adjusting screw on the rear of the Governor. Clockwise rotation of the speed
adjusting screw increases turbine speed.
Droop, the variation in speed from no load to full load, can affect speed stability
and may need adjustment if the turbine hunts or surges. Refer to the governor
manual for details on droop adjustment.
D.5 Optional Governors

Dresser-Rand turbines can be supplied with a variety of optional governors,
depending on customer needs. If your turbine is equipped with an optional
governor, refer to the appropriate vendor manual in the Appendix B.
WARNING

NEVER attempt to START the steam TURBINE without first

reading about and UNDERSTANDING the GOVERNOR
CONTROLS.
D.6 Throttle / Governor Valve

The SST throttle/governor valve (refer to Figure D-1, Throttle Valve Features)
consists of a balanced Venturi valve sliding in a cage contained within the valve
body. The valve stem extends through the valve bonnet, which contains a set of
hardened bushings. The bushings are captured in the cover, which is provided with
a leak-off to direct any steam that escapes past the stem bushings away from the
valve. Drain holes at the bottom of the steam chest are used to connect piping,
which drains condensate from the valve. The turbine is shipped with pipe plugs in
the drain holes. Refer to Section C.3.10, C.3.11, C.3.12 and C.3.13, for leak-off and
drain piping recommendations.
The throttle/governor valve needs no regular maintenance other than replacement

of the stem bushings if leakage becomes excessive. Valve stem freedom of
movement should be checked prior to starting a turbine that has been out of service
for any significant length of time.
The steam strainer screen, surrounding the throttle valve cage, prevents
foreign matter from entering the turbine. If foreign matter does appear in the steam
chest, turbine nozzles exhaust casing, or if blading is damaged, then the steam
strainer may be defective. Foreign matter that gets past an intact steam strainer
generally has a small particle size, or it could come from within the turbine itself.
Optional construction may include separate throttle and/or over-speed trip valves or
other equipment configurations. Refer to the certified drawings in Appendix A.
When a turbine is supplied without an integral or separate Y-type strainer, the

purchaser must install an appropriate steam strainer in the inlet steam piping.

Figure D-3. Governor Valve and Emergency Trip Valve

Figure D-4. Woodward Governor Valve Linkage
D.7 Governor Linkage

The linkage between the governor and the throttle/governor valve needs no
lubrication or maintenance. However, it should be checked periodically for
freedom of movement and for worn parts.
D.8 Hand Valves

The steam turbine may be equipped with one or two optional hand-valves, located
on the steam chest. The purpose of the hand-valves is to allow the operator to open
or close passages to one or more of the turbine nozzles. Since the turbine is more
efficient when operating at the highest possible steam chest pressure, it is advised
to operate the turbine with the throttle/governor valve open as wide as possible,
while regulating power with the hand-valves. If operating at lower power is
necessary, this is accomplished by closing hand-valves one at a time until the
governor and throttle/governor valve are no longer capable of maintaining speed
(throttle/governor valve is wide open), and then opening one hand-valve. If the load
should increase while operating in this mode (more power is required), it will be
necessary to open additional hand-valves to maintain speed.

TURBINE
WHEEL
NOZZLE
RING
HAND VALVE
(OPEN POSITION)
Figure D-5. Hand Valve Arrangement
Hand-valves must be fully open or fully closed. Operation with a partially open
hand-valve is equivalent to throttling, meaning that efficiency is lower. It will also
cause steam cutting damage to the valve seats.
When closing hand-valves, close the valve furthest from the inlet flange first. Open
hand-valves using the opposite sequence. This will prevent interrupted flow from
nozzles to the blades, which will subject blades to unnecessary stress cycles and
could reduce turbine efficiency.

SST Turbine Instruction Manual Lubrication System
Section E
Overspeed Trip System
E.1 General
In the event of an overspeed condition, caused by a sudden loss of load or failure
of the speed control system, the supply of steam to the turbine must be quickly and
positively interrupted, preventing damage to or destruction of the turbine or driven
equipment and possible personal injury. The turbine has a fixed amount of stored
energy in the steam or gas already downstream of the trip valve at the time that the
trip valve is closed. The turbine converts that energy to rotating mechanical
energy and transmits it to the driven machine. As it does so, with no additional
energy entering the turbine, the turbine slows down and comes to a stop.
An overspeed trip valve, activated by the over-speed governor cup assembly and/or
electronic trip system, performs this function.
Per NEMA SM23, Steam Turbines For Mechanical Drive Service, normal turbine
trip speed is 15% over maximum continuous speed for NEMA A (Woodward TG)
governors and 10% over maximum continuous speed for NEMA D governors.
Maximum continuous speed is 5% over rated speed; therefore, trip speed is 16%
(NEMA D) or 21% (NEMA A) over rated speed. Occasionally the trip speed set
point may be lower or higher than normal due to a customer request and/or
technical reason. The factory trip setting speed appears on the turbine nameplate.
Standard SST turbines are supplied with an overspeed governor cup assembly
(refer to Figure E-2, Overspeed Governor Cup Assembly), located within the
mounting housing on the steam end of the turbine shaft, which contains a spring-
loaded weight, within which resides a speed-adjusting set-screw. The weight,
spring, and setscrew are selected and set at the factory so that the weight snaps out
of the bushing at a predetermined trip speed. This trip speed is recorded on the
turbine data sheet and the turbine nameplate.
When the weight snaps out of the overspeed governor cup assembly (refer to
Figures E-2, Trip System), it strikes the trip paddle, which in turn releases the trip
linkage, causing the trip valve to close. As turbine speed decreases, the weight is
pulled back into the bushing by spring action. The trip valve can then be manually

reset to the open position under full inlet pressure by first closing the throttle valve
and then latching the trip linkage using the reset handle.
Pressing down the manual trip lever, which protrudes from the bearing case, can
also trip the turbine.
SOLENOID
DUMP VALVE
(OPTIONAL)
LOW OIL TRIP AND

ALARM SWITCH
(OPTIONAL)
LUBE OIL
OR AIR
TO TURBINE
NOZZLES
Figure E-1. Typical Trip System Arrangement Diagram

E.2 Warnings
CAUTION
If the KW load on a turbine-generator cannot be reduced in the

normal manner, it indicates the possibility of unacceptable
deposits on the control valve components.
STUCK CONTROL VALVES ARE A DANGER SIGNAL THAT THE

TRIP VALVE MAY ALSO BE STUCK. UNDER THESE
CONDITIONS IT IS IMPERATIVE THAT THE GENERATOR LOAD
NOT BE REMOVED UNTIL THE TRIP VALVE IS CLOSED.
If the trip valve cannot be closed by normal means, then other valves in
the steam system must be used to cut off the steam supply to the
turbine.
THE UNIT CIRCUIT BREAKER SHOULD NEVER BE OPENED

WHILE LOAD IS ON THE UNIT AND TRIP AND THROTTLE /
GOVERNOR VALVES ARE INOPERABLE. FAILURE TO
FOLLOW THESE PRECAUTIONS COULD CAUSE A SEVERE
OVERSPEED WITH EXTREME DANGER TO THE TURBINE
AND OPERATING PERSONNEL.
DANGER

OR ATTEMPT TO ADJUST OR REPAIR IT WHILE THE

WARNINGS
TESTING, REPAIR AND MAINTENANCE of overspeed trip

systems must be performed only by trained and
EXPERIENCED PERSONNEL.
The OVERSPEED TRIP SYSTEM must always be TESTED

and adjusted, if necessary, when STARTING the steam
turbine.
The OVERSPEED TRIP SYSTEM must be TESTED WEEKLY

on turbines that operate continuously. This prevents build-up
of foreign material in the trip linkage and alerts the operator to
deterioration that may affect trip system performance.
The TRIP SYSTEM utilizes HEAVY SPRINGS; use CAUTION

when assembling or disassembling the mechanism.
The TRIP LINKAGE MOVES RAPIDLY WITH GREAT FORCE

when the turbine trips. Use CAUTION when ADJUSTING the
TRIP SYSTEM, MAINTAINING the turbine, or when
WORKING IN THE VICINITY of the OPERATING TURBINE.
WARNINGS
Always determine and CORRECT the cause of an

OVERSPEED TRIP BEFORE RESETTING THE VALVE AND
MECHANISM.

DO NOT SET THE OVERSPEED TRIP SYSTEM to a speed

HIGHER than the factory setting without first consulting the
factory.
E.3 Description and Function
E.3.1 Overspeed Governor Cup Assembly

The overspeed governor cup assembly (Figure E-2) consists of the following parts.
Legend:
90. Cup – Governor 94. Spring

91. Screw – Adjusting 95. Bushing - Weight
92. Set Screw 96. Ring – Retaining-Open type
93. Weight 97. Ring – Retaining-External type
Figure E-2. Emergency Governor Cup Assembly
The weight (93), which is contained via retaining rings (96 and 97) within the
emergency governor cup (90), is installed within a lateral hole in the emergency
governor cup body (90). The emergency governor cup assembly is installed on the

turbine shaft via key and set screw. The weight is heavy at the adjusting screw end
(upper part of Figure E-2, Emergency Governor Cup Assembly). As the shaft and
cup assembly rotates, centrifugal force tends to move the weight out of the cup,
compressing the spring (94). When turbine speed reaches the trip speed, centrifugal
force at the weight exceeds spring retention force, causing the weight to snap out,
tripping the trip linkage.
The speed at which the weight trips the linkage is a function of the weight (93),
bushing (95) shape and material, the spring rate of the weight spring (94), and the
position of the adjusting screw (91). The factory based on the desired trip speed
selects these components. In the field, trip speed is adjusted by changing the
position of adjusting screw (91). It is imperative that the setscrew (92) be tightly
turned into and locking the adjusting screw (91) from any movement. Refer to
Section E.5, Adjustment of Trip Speed, for adjustment and maintenance
instructions.
WARNING
Weight (93), spring (94), adjusting screw (91) and setscrew

(92) are a FACTORY-CONFIGURED SET, selected to obtain
the proper trip speed for a specific turbine. DO NOT MIX OR
INTERCHANGE THESE PARTS with similar parts from other
turbines or attempt to modify these components. Consult your
local Dresser-Rand manufacturer’s representative or the
factory if replacement parts are needed.
E.3.2 Trip Valve

The standard SST turbine trip valve (Figure E-3, Trip Valve, E-4 Trip System) is a
positive shut-off, force-actuated, sliding trip valve that is spring-loaded to ensure
fast action.
When the turbine is running, the trip valve is fully open, held in place by the trip
linkage (valve linkage lever (444), latch (445) and trip lever (490)), which is in
turn held by trip lever (583) action against the trip finger (584).

Figure E-3. Trip Valve
424 Washer
425 Retainer

426 Seat
427 Roll Pin
428 Valve
429 Stem
430 Cover
431 Cap Screw
432 Lock Washer
433 Plug
436 Bushing
437 Link
438 Set Screw
439 Packing
440 Gland Follower
441 Valve Spindle
444 Lever
1000 Valve Body
The trip linkage operates as follows:
Refer to Figures E-1, Typical Trip System Arrangement Drawing, E-2, Emergency
Governor Cup Assembly, E-3 Trip Valve and E-4, Trip System.
During trip valve reset, as the valve (428) approaches the fully open position, reset
handle (434) rotates trip lever and latch (444 and 445) into place with the knife
edge of the latch (445) into position into the slot on the trip lever (490). The trip
pin (577) then engages the trip lever (583), holding the valve in the open position.
There is a torsion spring, operating in the valve closing direction, applies tension to
trip pin (577). There is also a linear acting spring (510) that is pulling against lever
(444). This tension is transferred to the knife-edge, holding the linkage in the open
position. With the valve in the open position, inlet steam can now flow into the
turbine.
The trip valve can then be tripped, either manually or by an overspeed condition. If
overspeed occurs, the weight (93) will snap out of the weight bushing (95), striking
the trip lever (584), causing it to release trip lever (490). The trip shaft (441) is
rotated by retraction of torsion spring (510), extending the linkage, closing the trip
valve via stem (429) and link (437). The force of the longitudinal spring (510)
ensures positive closing of the trip valve.
When the system is tripped, a spring acting on pin (577) retracts, rotating lever
(490), thus allowing lever (444) and latch (445) to be pulled by spring (510) into
the closed position via the trip linkage, isolating the turbine from the steam supply.

DANGER
Under no circumstances should the TRIP VALVE be blocked or

held open to render the trip system inoperative. Overriding the
trip system, and allowing the turbine to exceed the rated
(nameplate) trip speed, may result in FATAL INJURY to
personnel and extensive turbine damage. In the event the trip
system malfunctions, immediately SHUT DOWN the turbine
and remedy the cause.
Refer to Sections C.3.10, C.3.11, C.3.12 and C.3.13 for recommended drain and
leak-off piping configurations.
Optional construction may include a separate overspeed trip valve. Refer to the
certified drawings in Appendix A.
E.3.3 Trip Linkage
The standard SST turbine trip linkage, set in motion by movement of the weight
(93) in the governor cup assembly (90) Fig. E-2 controls the closing of the trip
valve. The linkage also allows the valve to be opened and latched in the open
position via reset handle (434), Fig. E-4. The design clearance at the end of the
governor controlled steam valve(s) and trip or trip and throttle valve stems are required
to minimize steam leakage from the turbine.
WARNING
NEVER OPEN A CLOSED TRIP VALVE without first preparing

the turbine and driven equipment for operation.
E.4 Trip System Operation

For SST turbines supplied with the standard trip linkage, if the overspeed trip valve
is tripped shut and the turbine stopped, either from an overspeed trip condition or
manual activation of the trip lever, the trip valve must be reset manually, as
described below.
E.4.1 Manual Reset

Use the following procedure to manually reset the over-speed trip valve:

a. Close shut-off valve in inlet steam line as soon as possible after the turbine
trips.
b. Determine cause of the trip condition. It may be due to loss of the driven
machine load, a turbine fault, or a governor problem. Remedy the cause using
procedures detailed in Section K, Troubleshooting.
c. If the turbine is not at a complete stop, listen for weight retraction into the
weight bushing, or wait for turbine speed to drop to 75% of its rated value to
ensure resetting of the trip weight.
d. Lift reset handle (434 in Figure E-4) slightly (approximately 10-15 angular
degrees) to open trip valve (428 in Figure E-3).
e. When pressure in the valve body has bled off, continue lifting the reset handle
using minimal force, until the trip valve opens and the trip lever (490 in figure
E-4) latches on latch (445 in Figure E-4).
CAUTION
DO NOT try to FORCE or jerk open the TRIP VALVE.
g. Gradually open shut-off valve in inlet steam line to bring turbine up to normal
operating speed, allowing the governor to take control. Then open shut-off
valve to full open position and back off one-quarter turn.

Figure E-4. Trip System

E.5 Adjustment of Trip Speed
E.5.1 Trip Speed Setting
It may become necessary to change the factory speed setting of the trip system due
to a change in the normal operating speed of the turbine.
Refer to the following figures:

Figure E-1, Typical Trip System Arrangement Diagram
Figure E-2, Emergency Governor Cup Assembly
Figure E-3, Trip Valve
Figure E-4, Trip System
Figure M-2, Governor, Mounting Housing, and Trip Components
Figure L-15, Governor Valve Travel Setting, Woodward TG Governor
For SST turbines supplied with the standard emergency governor cup assembly,
adjusting the position of the adjusting-screw (91) inside the governor cup (90) can
change this setting. Use the following procedure to set turbine trip speed:
a. Test the over-speed trip system per the Overspeed Trip Test Procedure specified
in Section E.6.2. Record the speed at which the weight triggers the over-speed trip
valve, stopping the turbine. Close isolating valve in inlet steam line to prevent
accidental restart.
b. For turbines with a Woodward governor with overspeed test device (type TG,
PG-PL and PG-D) remove test device cover located on top or end of the governor
(refer to Woodward instructions in Appendix B.)
c. Slide the end of the operating rod into its socket and turn it slowly. The turbine
speed will increase to tripping, and the turbine will trip out. For type UG
governors, the over-speed pin is located adjacent to the “Woodward” logo. Raise
up on this pin to over speed the turbine.
d. Turbines with Woodward governors without the over-speed device: Pry open
the governor valve, being careful not to damage the linkage. When trip speed is
reached, the turbine will trip out.
e. Turbines with electronic governors (Tri-Sen, CCC, and Woodward) -- refer to

the instruction manuals located in Appendix B for correct operating and testing
procedures.

WARNING
FIELD CONFIGURABLE GOVERNOR
Any change to the control limits, such as (but not limited to)
speed, over-speed trip, control logic, other than “tuning” (see
governor manual) requires the prior written approval of
Dresser-Rand Company to assure that safe operating limits are
not exceeded. Failure to comply may result in damage to
property, serious injury or death to personnel.
The new trip setting should be approximately 21% above the rated speed for a
NEMA A (Woodward TG) governor and 16% above the rated speed for a NEMA
D governor.
f. Open inlet isolating valve and test turbine tripping several times after final
adjustment. If the trip speed is not repeatable within 2%, or if erratic operation
occurs, investigate and correct the problem before placing the turbine in normal
service.
If possible, carry out a daily check of the tripping mechanism during the first week
after adjustment, by over-speeding the turbine.
Optional construction may include an electronic overspeed trip system. Refer to

the certified drawings and the appropriate vendor instruction manual in Appendix
A and Appendix B for instruction on how to adjust the trip speed set point.
E.5.2 Magnetic Pickup Clearances

When supplied, maintaining the proper clearance between the magnetic pickups
(located on the turbine mounting housing) and the turbine shaft mounted signal
gear/device is crucial to the operation of the turbine electronic trip systems and
electronic governor systems. Refer to Figure E-5.
Prior to initial start up of the turbine, the clearances must be checked, adjusted and
the pickups locked into position.

As a part of the routine checking and testing of the turbine, the magnetic pickups
should be visually checked for damage and the clearances verified to be within
tolerance.
Figure E-5. Air Gap Between Signal Gear and Magnetic Pickup
E.6 Testing the Overspeed Trip Mechanism

E.6.1 General
Before testing the overspeed trip system, the turbine must be visually inspected for
defects. Pay particular attention to governor and overspeed trip components and
correct the defects prior to initiating any tests.
Exercising of the governor-controlled valves may be performed choking the trip or trip
and throttle valve. At the same time, the trip or trip and throttle valve is exercised.
WARNING
RAPID CLOSING OF VALVES SUPPLIED WITH THE

TURBINE IS ESSENTIAL TO PROTECT AGAINST
OVERSPEED AND POSSIBLE OTHER MECHANICAL
PROBLEMS.
DANGER


WARNING
The overspeed trip system may malfunction during testing. Use

caution when testing and be prepared to shut the turbine down
quickly with the inlet-isolating valve.
The overspeed trip system should be tested weekly to verify its operation, to
prevent build-up of foreign material on the trip linkage, and to alert the operator to
deterioration that may affect trip system performance.
Dresser-Rand recommends incorporation of testing into the plant

operating/maintenance program and the keeping of a log to record tests.
Any malfunction of the trip system should be investigated and corrected prior to
returning the turbine to service.
E.6.2 Overspeed Trip Test Procedure

Before testing of the overspeed trip system, the turbine must be visually inspected
for defects. Pay particular attention to governor and overspeed trip components and
correct any defect prior to initiating any tests.
Use the following procedure to test the SST Turbine over-speed trip system:
a. Start up the turbine per Section I.4.2, Initial Start-Up Procedure.
b. Manually trip the turbine by pressing on the trip lever (434). The over-speed
trip valve should close, shutting off the turbine steam supply and bringing it to
a stop. This confirms operation of the linkage and valve, but not the
emergency governor cup assembly. If the valve does not close, refer to Section
K, Troubleshooting. Otherwise, proceed to Step c.
WARNING

The TRIP LINKAGE MOVES VERY RAPIDLY and abruptly

through its full travel when the turbine is TRIPPED. To guard
against serious hazards to operating personnel, they must
STAY CLEAR OF THE LEVER.
c. Open and latch the overspeed trip valve according to Section E.4, Trip System
Operation.
d. Increase turbine speed using the governor speed adjusting screw or knob on
the governor until trip speed is reached. The turbine should trip within 2% of
the trip speed setting on the turbine nameplate, and come to a complete stop.
e. If the turbine fails to trip at a speed 5% greater than the trip speed setting,
manually trip the turbine by pressing down on the trip lever. Refer to Section
K, Troubleshooting, to determine why the turbine fails to trip properly.
Optional construction may include an electronic overspeed trip system. Refer to

the certified drawings and the appropriate vendor instruction manual for
instructions on how to test the overspeed trip system.
Section F
Lubrication System

F.1 General
Proper lubrication of turbine bearings and the governor is essential for long,
trouble-free service. Turbine oil must be clean, of the proper viscosity and
quantity, and maintained at the proper temperature. Oil levels should be checked
before starting the turbine and on a daily basis for turbines running continuously.
WARNING
Lack of lubricant or contaminated lubricant could result in

bearing failure. This could create sparks or hot surfaces, which
could ignite lubricant or flammable gasses.
CAUTIONS
Overloading the turbine drive shaft will cause the turbine to

slow down – possibly resulting in insufficient lubrication and/or
reduced function and damage to the driven equipment.
If the ambient temperature exceeds 110° F (43° C), cooling

water must be provided to the bearing housings to limit the
maximum temperature of the lubricating oil to 180° F (82°C). If
the ambient temperature falls below freezing a means must be
provided to maintain the lubricating oil in the bearing housings
to a minimum temperature of 130°F (54°C) and to prevent
cooling water from freezing and possibly cracking the bearing
housings.
Without immediate and constant oil feed, the heat generated by the shaft in the
turbine bearings, unless properly dissipated, can cause bearing failure. Oil ring
lubricated bearings receive immediate lubrication as the shaft begins to turn, so
long as the proper oil level is maintained in the bearing housings. With pressure
lubricated bearings, the lubrication system must be arranged such that oil fills the
supply lines and feeds the bearings when the shaft begins to turn.

F.2 Lubrication Requirements

Lubrication requirements are a function of the turbine type, exhaust temperature
and required operating speed range. In many cases, several lubrication options are
feasible at a given set of operating conditions with the selected method determined
by the user.
Major oil companies produce satisfactory oil for turbine use. It is advisable to consult
with your oil supplier for specific recommendations. As a minimum, the selected oil
should meet the following:
(a) Properly refined highly filtered mineral oil.
(b) Maximum metal wetting ability and ability to prevent the formation of rust on
metal parts bathed in oil. High stability toward oxidation and corrosion resistance may be
accomplished by the use of rust and oxidation inhibitors, or as a result of a particular
refining process.
(c) Free from acid or alkali.
(d) Best possible ability to separate rapidly from water.
(e) Minimum tendency to oxidize or form sludge when agitated at actual operating
temperatures when mixed with air and water.
(f) Minimum tendency to emulsify or foam when agitated with water and/or air.
(g) High viscosity index. A fluid with a high viscosity index can be expected to
undergo very little change in viscosity with temperature extremes and is
considered to have a stable viscosity.
CAUTIONS
CLEANLINESS is ESSENTIAL for long and trouble free service

from BEARINGS and GOVERNOR. Care must be taken to
ensure that no foreign material enters bearing housings, the
governor, and constant level oilers or oil reservoirs when
performing maintenance, checking oil, adding oil or making
adjustments.


The bearings are made to precision limits on a production basis. When bearing
clearances become excessive, new bearings must be installed. Bearing clearances
may be considered excessive when they become approximately 0.004”/0.101mm over
the normal maximum clearance. (Refer to the turbine data sheets for normal running
clearance of your turbine.) The bearings are longitudinally split to permit their removal
and replacement with the shaft in place. Procedures for replacements are given in
Section L-6.
The recommended bearing temperature limits are as follows:

Metal Temp. Oil Temp.
°F / °C °F / °C
Maximum Normal – Pressure Lube
Operating 220/104 180/82
Alarm 230/110 185/86
Shutdown 250/121 195/90.5
Maximum Normal – Ring Oiled
Operating 220/104 180/82
Alarm 265/129 185/86
Shutdown 270/132 195/90.5
Table F-1 Bearing Temperature Limits
F.3 Oil Ring Lubrication

The basic method of lubrication for SST turbines is oil ring lubrication. Carbon
steel oil rings running on the turbine shaft pick up oil from reservoirs in the
bearing housings. As the shaft and oil rings rotate together, oil flows from oil rings
onto the shaft, ultimately flowing into the bearings, providing lubrication. The
thrust bearing, located inside the shell of the steam end main bearing, receives its
lubricating oil from this same action. The oil level within bearing housings must
be maintained at a sufficient level to allow the oil rings to run in the oil. An oil
level that is too high results in oil leakage past the shaft seals. Oil rings cease to
rotate sufficiently when the shaft runs below 950 RPM, no longer providing
adequate lubrication. Therefore, the turbine should not be run at minimum
governor speeds less than 950 RPM unless for slow roll speeds of 500 RPM for
warm-up purposes.
SST frame turbines must have simple bearing cases, the ambient temperatures must
be below 110°F (43°C) and the cooling water supply must not exceed 100°F

(38°C) to qualify for ring oiled lubrication. Heat deflectors and air maze breathers
must be used when the maximum operating exhaust temperature exceeds 400°F
(204°C).
Cooling water for the bearing case is recommended for all ring-oiled turbines.
Approximately 2 GPM of fresh water at 90°F (82°C) or less is required for cooling
the lubricating oil for each bearing housing. Cooling water is recommended when
the temperature of the bearing case cap exceeds 150°F (82°C). Maximum allowable
water pressure is 75 PSIG (517 KPAG). See Figure 25 for a typical bearing case
water piping schematic for ring oiled turbines.
The cooling water connections to the oil cooler are shown on the outline drawing
or oil piping diagram in Appendix A. The turbine data sheets specify the required
volume. The water outlet piping should be arranged to discharge into an open sight
drain where the operator can observe it. A water leg of at least six inches in height
should be placed in the outlet line adjacent to the cooler to assure the cooler being
kept full of water.
CAUTION
DO NOT RUN turbines equipped with oil ring lubrication at

speeds LESS THAN 950 RPM. The OIL RINGS WILL NOT
OPERATE CORRECTLY at these speeds, causing BEARING
FAILURE due to lack of lubrication.
The presence of oil in the constant level oilers does not

necessarily mean that oil in the bearing housings is at the
proper level.
Note: There are certain speeds and temperatures where Dresser-Rand

allows operation without cooling water. (Synthetic oil is required.)
F.4 Mist Oil System Lubrication
WARNING

If the turbine is supplied with mist oil lubrication, oil mist could
escape from the bearing housing vents or oiler. If there is the
possibility that these could be ignited by equipment or
processes in the proximity of the turbine they should be piped
to a safe area.
The turbine may be lubricated by a facility mist oil supply. When a turbine
utilizes a system of this type, a diagram that shows turbine connections and piping
is provided in Appendix A.
F.5 Circulating Oil Cooling System
The circulating system is the next step up from the ring oil system with water cooling. This
system must be used when oil temperature in the bearing housings could exceed 180°F (82°C)
and/or the exhaust temperature exceeds 550°F (82°C). This elevated temperature is
normally caused by an increase in shaft/bearing rubbing speeds and/or elevated inlet or
exhaust steam temperatures being transmitted from the wheel casing to the bearing cases.
The circulating system is basically a ring lubrication system. The difference is that a
shaft driven direct drive pump which circulates oil out of the bearing cases for
additional cooling has been added. At higher exhaust temperatures, an external oil
cooler is added to the system.
The pump supplied with this system is a positive displacement gear type pump. It is
mounted on the shaft at the exhaust end of the turbine. The upper half of the exhaust
end bearing case serves as a housing for the pump. The same pump is used regardless
of turbine rotation. The pump may be mounted off the turbine shaft at the steam
end when design allows.
A standpipe or overflow port is located at each bearing case to maintain the correct
oil level.
F.6 Pressure Lubrication System

Force-feed (pressure) lubrication systems, mandatory on SST turbines operating
above 5000 RPM or when normal exhaust temperature is 650F (343C) or higher,
employ a positive displacement pump to draw oil from a reservoir which is then
cooled, filtered and delivered under pressure to the turbine bearings. The used oil
drains from the turbine bearing housings by gravity and flows back to the reservoir
to be reused.

Force feed lubrication system reservoir/console assemblies must be located so that

the oil drain piping between the turbine bearing housings and the reservoir’s oil
return connection slopes a minimum of 0.5 inches per foot (40 mm per meter).
CAUTION
The oil drains must be free flowing at atmospheric pressure.

Under no circumstances should the oil drains be pressurized or
have a vacuum applied. Horizontal pipe runs should be sloped
continuously, at least 0.5 inches per foot [40 mm per meter],
towards the reservoir.
Refer to instructions from the lubrication system supplier.
CAUTION
All lubrication oil piping tubing, and system components, that

have not been pre-charged, should be flushed prior to
assembly. The assembled lubrication oil system should be
flushed prior to turbine initial start-up.
F.6.1 Design Parameters for Turbine Pressure Lubrication Oil Systems

SST turbines supplied with sleeve bearings and a standard ball thrust bearing
require:
Normal Oil Supply Temperature = 120° F (49° C)
Normal Oil Supply Pressure = 20 – 25 psig (137 – 172 kPag)
Oil Filtration = 25 micron or better

Bearing Cases GPM Heat Load
Steam End Exhaust End

Simple/Simple 2 1 300 BTU/Min
HiCap/Simple 4 1 500 BTU/Min

W/Ball Thrust
HiCap/Simple 11 1 1000 BTU/Min

W/Tilt Pad Thrust
Refer to Section F.12, Lubricating Oil Selection Guidelines, and to the certified
drawings in Appendix A for a description of the supplied hardware, the specific
lubricating oil requirements, the oil flow, and the heat load applicable to the
purchased equipment package.
CAUTION
SST turbines supplied with a tilting pad thrust bearing or

turbines sharing lubrication with a gear reducer or driven
equipment, will require additional oil flow and heat load
capacity and may require the use of special viscosity
lubricants. Refer to the certified drawings in Appendix A for a
description of the lubricating oil system requirements.

F.7 Cooling Water to Bearing Housing Water Jackets
Tables F-1, Cooling Water Requirement, specifies when cooling water to bearing
housing water jackets is required. This requirement is based on the type of
lubrication system supplied with the turbine, the steam conditions, and the ambient
conditions. Refer to the certified drawings in Appendix A for specific cooling
water requirements for your turbines.
Lubrication Type Cooling Water to Bearing Cooling Water to

Housing Mandatory Bearing Housing
Optional
Standard oil ring X
Cooling water supply
temperatures must not
exceed 100°F (43°C)
Standard oil ring X
with circulating oil
Force feed X
Table F-1. Cooling Water Requirement
Cooling water for the bearing case for ring oiled turbines is recommended for all
ring-oiled turbines. Approximately 2 GPM of fresh water at 90°F (32°C) or less
is required for cooling the lubricating oil for each bearing housing. Cooling water
is recommended when the temperature of the bearing case cap exceeds 150°F
(65.5°C). Maximum allowable water pressure is 100 PSIG (690 KPAG).
Cooling of the bearing oil is accomplished by water jackets integral to the bearing
housings. Under severe service conditions such as high ambient temperatures,
partial load (high exhaust temperature) operation, and frequent shutdown (heat
soaking), the optional application of cooling water will assist in maintaining
recommended oil temperatures.
Cooling water should be piped into one of the lower connections on the bearing
housings and out from the upper connection on the opposite side. If
interconnection of water jackets on the two bearing housings is desired, connect
the outlet of the non-drive end bearing housing to the inlet of the drive end bearing
housing. Refer to Figure F-3, Cooling Water Piping with Interconnecting Pipe. All
unused bearing housing connections should remain plugged.
Valves should be included in the cooling water piping to control the flow of water
and allow it to be shut off. The ideal system would employ two valves—one

upstream of the bearing housing, acting as a shut-off valve, and one downstream to
control flow. This arrangement ensures that water jackets are filled with water and
allows water to be shut off without disturbing the flow adjustment. If one valve is
used, it should be downstream of the bearing housings.
Figure F-1.Typical Bearing Case Water Piping Schematic for Ring Oiled
Turbines
Flow should be adjusted to maintain bearing oil sump temperature in the normal
range shown in Table F-3, Recommended Oil Sump and Bearing Temperatures.
Refer to the certified drawings in Appendix A for the location of cooling water
connections on bearing housings.

Single stage ring oiled turbines require cooling water connections to the bearing
cases. See Figure F-3 for a typical bearing case water piping schematic for ring
oiled turbines.
Pressure Lube Turbines -- The cooling water connections to the oil cooler are
shown on the Outline Drawing or Oil Piping Diagram in Appendix A. The turbine
data sheets specify the required volume. The water outlet piping should be ar-
ranged to discharge into an open sight drain where the operator can observe it. A
water leg of at least six inches in height should be placed in the outlet line adjacent
to the cooler to assure the cooler being kept full of water.
F.7.1 Bearing Housing Cooling Water Requirements

Cooling water for bearing housings must meet the following specifications.
Flow Rate (per housing): 2 GPM (7.0 l/MIN)

Maximum Inlet Pressure: 100 PSIG (690 KPAG)
Maximum Inlet Temperature 90F (32C)
Water Quality: Clean, non-corrosive
F.7.2 Governor Oil Cooling Water Requirements

Refer to turbine data sheets for water requirements. During operation, admit cooling water
as necessary to maintain oil temperature, out of cooler, between 90°F and 180°F (32°C
and 82°C).
F.8 Recommended Oil Sump and Bearing Temperatures

Table F-3, Recommended Oil Sump and Bearing Temperatures, lists the
recommended temperature ranges for the turbine bearing oil sumps and the turbine
bearings during normal operation. In addition, the table defines recommended
alarm and trip set points for optional instrumentation.
Oil Sump Temperature— Bearing Temperature—

Operating Status F C F C
Normal Operation 180 82 220 104
Alarm 185 86 230 110
Trip 195 90.5 250 121
Table F-2. Recommended Oil Sump and Bearing Temperatures

For turbines operating in an extreme environment, an optional thermostatically

controlled immersion heater may be provided in the main oil tank to heat the oil prior
to start-up and to maintain a suitable temperature during operation. If your turbine
has this equipment, a supplementary description and parts list is provided in Appendix
B. Operating procedures for this equipment are given in Section A-12.
When ambient temperature is approximately at the freezing point 32°F (0°C) or
below, the thermostat should be set at its maximum heat setting prior to startup. The
heater selected by Dresser-Rand is limited to approximately 250°F (121°C) so that
there is no danger of carbonizing the oil.
When oil reaches a temperature where it will flow smoothly, approximately 100°F
(38°C) it should be circulated through the oil system. If the oil tank is not equipped
with a thermometer, the temperature may be monitored as the oil leaves the system
cooler. The cooling water for the oil cooler should not be turned on until the turbine is
operating and the temperature of the oil leaving the cooler is approximately 120°F
(49°C). After oil pressure is established and stabilized throughout the complete system, the
turbine may be started, as described in the Starting Procedure. During operation, the
thermostat may be initially set at its minimum setting. Periodic checks of the oil tempera-
ture can determine the requirement for adjustment.
Governor Heater--When ambient temperature is approximately at the freezing

point, 32°F (0°C) or below, the thermostat should be set at its maximum heat setting prior
to startup. When the oil in the governor reaches approximately 90°F (32°C), the
turbine may be started and the thermostat set at its minimum heat setting. It should
be noted that precise temperature of the oil for normal operation of the governor is not
critical, provided that the oil temperature is within the range of 90°F to 180°F (32°C to
82°C).
CAUTION
Do not allow COOLING WATER to COOL OIL SUMP

TEMPERATURE TO BELOW 130F (54C), as this may
interfere with the action of the oil rings or cause
ATMOSPHERIC MOISTURE to CONDENSE in the oil
reservoir.
F.9 Constant Level Oiler

Turbines lubricated with oil rings typically are equipped with constant level oilers.
The purpose of these oilers is to maintain the correct oil level in the bearing
housings. When applicable, instructions for constant level oilers may be found in
Appendix B.

F.10 Bearing Housing Oil Levels and Capacities

The following table shows the approximate oil quantities required to fill bearing
housings based on the SST turbine frame size. In addition, each constant level oiler
has a capacity of about 8 oz. of oil.
Frame Size Steam End Capacity Exhaust End Capacity

ALL SST’S 64 oz. (1.89 l) 64 oz. (1.89 l)
Table F-3. Bearing Housing Oil Capacity
The following table shows the required oil levels that should be maintained by
proper adjustment of constant level oilers. The oil level gauge on the side of the
bearing housing indicates the oil level. A mark inscribed on the lower-half bearing
housing indicates the proper oil level. If the mark is obscured, refer to the
following table.
Distance Below Bearing Housing

Frame Size
Horizontal Split in Inches
SST Simple Bearing Case Steam End 3.25 (8.26cm)
SST Simple Bearing Case Exhaust End 2.875 (7.30 cm)
Table F-4. Bearing Housing Oil Levels
For hydraulic governor oil requirements, refer to the governor instruction manual
in Appendix B.
F.11 Maintenance/Oil Changes

Oil levels in turbine bearing housings, the governor and/or optional oil reservoirs
should be checked daily.
Low point drains in bearing housings and oil reservoirs should be checked weekly
for water.
Establish an oil change frequency based on oil tests. Otherwise, oil in bearing
housings and oil reservoirs should be changed monthly; or earlier, if there is reason
to believe that the oil has been contaminated with water, dirt, or by overheating.
CAUTIONS

The presence of oil in the constant level oilers does not

necessarily mean that oil in the bearing housings is at the
proper level.
CLEANLINESS is ESSENTIAL for long and trouble free service

from BEARINGS and the GOVERNOR. Care must be taken to
ensure that no foreign material enters bearing housings, the
governor, and constant level oilers or oil reservoirs when
performing maintenance, checking oil, adding oil, or making
adjustments.
For hydraulic governor oil requirements, refer to the governor instruction manual
in Appendix B.
F.12 Lubricating Oil Selection Guidelines

 Reference Table F-6 -- Sleeve Bearing Turbine, Lubricating Oil Selection
Guidelines.
 Reference Table F-7 – Ball Bearing Turbine, Lubricating Oil Selection
Guidelines
The importance of using a proper lubricant cannot be overemphasized. High
quality turbine oils are required. Dresser-Rand Steam Turbine Business Unit does
not recommend specific brands of oil. Turbine owners should consult reliable oil
suppliers regarding the proper selection of turbine oils. As a minimum, the selected
oil should be of premium quality rust and oxidation inhibited turbo-machinery oil,
which will readily separate from water and have minimum tendency to emulsify or
foam when agitated at actual operating temperatures. EP additives are not
recommended. Since the proper grade of lubricant may not be available locally, it
should be ordered in advance of start-up time. Comparisons between different
viscosity grading systems are shown in Table F-6, Viscosity Comparisons.
CAUTION
For SST turbines sharing a forced-feed lubrication system with

a gear reducer or driven equipment, refer to the certified
drawings in Appendix A for a description of the lubricating oil
requirements.
Viscosity Requirements

VISCOSITY SSU
DESCRIPTION VALUES @ 100°F
Range Nominal
*Light Turbine Oil (LTO) ISO VG 32 130-180 150
**AGMA 1 / SAE 10W {Med) ISO VG 46 193-235 214
***AGMA 2 /SAE 20 ISO VG 68 284-347 315
****AGMA 3 / SAE 30 ISO VG 100 417-510 464
Typical Recommendations
* Pressure Fed Lubrication

** Pressure Fed Lubrication with Oil Rings Retained
*** Ring Oiled Lubrication or Units with Reduction Gear.
**** Mist Oil Lubrication or Units with Ball Bearings
Table F-5. Viscosity Comparisons
F.13 Air Purge of Bearing Housings

An air purge connection can be furnished as an option on the bearing housing for
the supply of low pressure, dry, filtered air or nitrogen. The positive pressure
(relative to atmospheric pressure) will prevent the intrusion of dust, moisture, and
other contaminants into the bearing housing. The supply pressure should not
exceed a 1-inch (25.4 mm) water column.

SST Turbine Instruction Manual Optional Gland Condensers, Eductors, and Ejectors
Section G
Optional Gland Condensers, Eductors, and

Ejectors
For some applications, optional ejectors, eductors or gland condensers may be
supplied with the turbine package for the removal and recovery of leakage past the
turbine shaft seals.
Motive flow is applied to the inlet of the educator or ejector, creating a slight
vacuum, which is applied at the turbine gland leak-off connections. The discharge
of the eductor, ejector and/or gland condenser is then typically returned to the
plant water system when the motive fluid is steam or a safe area when the motive
is fluid gas. These items normally ship loose for piping and installation by others.
Refer to the certified drawings and optional equipment manuals for details of any
items supplied with the turbine package.
SST Turbine Instruction Manual Revision A

135

INTENTIONALLY

SST Turbine Instruction Manual Optional Instruments and Controls
Section H
Optional Instruments and Controls
NOTE
Refer to Appendix B at the end of this manual for instructions

for accessory instruments and controls not manufactured by
Dresser-Rand.
H.1 Sentinel Warning Valve

If specified as an accessory (applies to turbines to be operated on steam only), the
turbine will be furnished with a sentinel-warning valve to alert the operator when
excessive pressure arises in the exhaust casing.
WARNINGS
The SENTINEL WARNING VALVE will ONLY WARN that

excessive pressure exists in the casing. It will NOT RELIEVE
THIS PRESSURE.

RELIEF VALVE in the exhaust line between the turbine
exhaust casing and the first shut-off valve. This relief valve
should be sized to relieve the FULL AMOUNT OF STEAM
THAT THE TURBINE WILL PASS, in the event that the
exhaust line is blocked.
H.2 Pressure and Temperature Gauges

If specified as accessories, the turbine will be furnished with inlet and exhaust
pressure and/or temperature gauges. Inlet and exhaust gages must be connected to
the user’s inlet and exhaust steam piping just upstream and/or downstream of the
turbine inlet and exhaust flange connections as appropriate. Steam chest pressure

Optional Instruments and Controls SST Turbine Instruction Manual
gages may be connected to a “T” connection installed into the turbine steam chest
drain piping. Gauges are maintenance-free and require no attention.
H.3 Solenoid Trip
WARNING
If the turbine is equipped with a solenoid overspeed trip system

it will be activated electrically, hydraulically, pneumatically or
with a combination of these power sources. If the required
power source is not activated or fails, the over-speed trip
system will not operate. The turbine cannot be tripped by this
system.
When specified, the turbine can be supplied with a solenoid operated trip system
for remote trip functions. The supplied components may include a solenoid
actuator, or a solenoid valve and pneumatic actuator. The action of the actuator
striking the turbine trip linkage disengages the knife-edges in the turbine trip
linkage, causing the overspeed trip valve to close. Trip signals to the solenoid can
be automatically or manually transmitted. Electrical power (and for systems with
pneumatic actuators air pressure) must be available for the operation of the remote
trip functions. Turbines may also include optional mechanical or proximity type
limit switches, which may be wired to signal a “turbine tripped” condition. Refer to
the certified drawings and appropriate vendor instruction manuals for specifics of
the trip system supplied with the Dresser-Rand equipment package.
Refer to turbine data sheets to determine whether solenoid valve trips out turbine (opens)
in energized or de-energized mode. Make sure valve is closed before starting.
H.4 Other Optional Instruments and Controls

When specified by the customer, other optional instruments and controls can be
supplied. Refer to the certified drawings and appropriate vendor instruction
manuals.

SST Turbine Instruction Manual Start-Up and Operation
Section I
Start-Up and Operation
I.1 Warnings
The operator should read Sections A through H of this manual to become familiar
with the turbine before attempting to start and operate it.
WARNINGS

that of the steam inlet temperature. This could exceed the
ignition temperature of some gasses. Therefore, if the turbine
is installed where explosive gasses could be present it is the
user's responsibility to insure that this does not create a
DO NOT START OR OPERATE this turbine unless the

INSTALLATION has been VERIFIED TO BE CORRECT and
all pre-startup SAFETY AND CONTROL FUNCTIONS have
been CHECKED.
DO NOT START OR OPERATE this turbine unless you have a

COMPLETE UNDERSTANDING of the location and function of
ALL COMPONENTS in the steam supply and exhaust
systems, including block and relief valves, bypasses, drains,
and any upstream or downstream equipment that may affect
the flow of steam to or from the steam turbine.
Should an explosion occur in the vicinity of the turbine it is the

user/installer’s responsibility to halt it immediately and/or limit
the range of explosive flames and explosive pressures to a
sufficient level of safety.
DANGERS

Start-Up and Operation SST Turbine Instruction Manual
NEVER WEAR NECKTIES OR OTHER LOOSE CLOTHING

while in the proximity of the turbine or auxiliary equipment.
These could be become entangled in the shaft, couplings,
linkage or other moving parts and cause serious injury.
Keep body parts (fingers, hands, etc.) away from shaft,

coupling, linkage or other moving parts to prevent contact and
possible serious injury.
Wear proper eye protection when working on or around the

turbine.
WARNING
Never operate the turbine with the governor or governor

system disabled.
CAUTION
If the ambient temperature exceeds 110F (43C), cooling

water must be provided to the bearing housings to limit the
maximum temperature of the lubricating oil to 180F (82C). If
the ambient temperature falls below freezing a means must be
provided to maintain the lubricating oil in the bearing housings
to a minimum temperature of 130F (54C) and to prevent
cooling water from freezing and possibly cracking the bearing
housings.
DANGER


WARNINGS
DO NOT START OR OPERATE this turbine unless you have a

COMPLETE UNDERSTANDING of the CONTROL SYSTEM,
the OVERSPEED TRIP SYSTEM, the drain and leak-off
systems, the lubrication system, and all auxiliary mechanical,
electrical, hydraulic and pneumatic systems, as well as the
meaning and significance of all monitoring gages, meters,
digital readouts, and warning devices.
When STARTING the turbine, be prepared to execute an

EMERGENCY SHUTDOWN in the event of FAILURE of the
GOVERNOR, OVERSPEED CONTROL SYSTEMS, linkage, or
valves.

that of the steam inlet temperature. Personnel should wear
gloves and protective clothing to avoid burns.

CAUTIONS

Turbines should not be subjected to temperatures in a non-

running ambient condition of less than 20°F (unless special
LOW TEMPERATURE has been specified and low
temperature materials have been provided.
Do not operate the turbine above the Maximum Continuous

Speed or below the Minimum Allowable Speed as shown on
the nameplate, for sustained periods of time.
WARNINGS
The turbine should NOT BE OPERATED unless a properly

sized, functional, FULL FLOW RELIEF VALVE or other
overpressure protective device has been installed UPSTREAM
OF THE SHUT-OFF valve closest to the TURBINE EXHAUST
LINE.
VERIFICATION of proper FUNCTIONING and SETTING of the

OVERSPEED TRIP SYSTEM during initial start-up is
MANDATORY. This should be accomplished with the turbine
disconnected from the driven equipment.

WARNINGS
Shown below are turbine noise levels that were measured at

three feet (1 meter), while operating at a normal load and
exhausting to a positive back pressure. These noise levels are
not guaranteed and are published for informational purposes
only.
This noise data is based on test measurements that were

taken on similar equipment being operated on the factory test
stand, and have been extrapolated and/or corrected for
background noise as appropriate.
When the turbine is operated under actual field conditions,

noise generated in or by the piping, foundation, base plate,
couplings, driven equipment, background and other sources,
can add significantly to the turbine noise level and to the
overall noise levels in the area.
It is recommended that the equipment user assess the noise

level(s) of the completed installation and determine if additional
sound attention and/or hearing protection for operating
personnel is required.
Octave Band Frequency (HZ) - Expected Sound Pressure Levels

(dB – Ref. 2 x 10-5 N/m2)
Accoustic 63 125 250 500 1K 2K 4K 8K Expected Overall dBA
Insulation
YES 96 91 88 86 83 82 81 81 85
NO 97 92 90 89 87 85 84 84 88
Table I-1. Turbine Sound Level Data

I.2 General
The following recommended start-up and operating procedures apply to the basic
turbine (ring-oiled, TG governor, without reduction gear). For information on any
optional equipment, refer to the appropriate vendor instruction manual in Appendix
B.
WARNINGS
None of the recommended start-up and operating procedures

contained in this manual shall be construed in any way as
relieving the user of his responsibility for compliance with the
requirements of any regulatory body, or for the exercise of
normal good judgment in the start-up, operation, and care of
the turbine.
If a coupling guard is to be installed, refer to the coupling guard

manufacturer’s instructions to insure that it does not contact
the running shaft or coupling which could cause a spark that
could ignite hazardous gasses in the environment in which the
turbine is installed.
To ensure trouble-free operation, the turbine must be:
a. Cleaned thoroughly prior to start-up and kept clean at all times.
b. Properly lubricated at regular intervals.
c. Subjected to regular checks for the correct functioning of protective devices.
d. Regularly inspected and maintained according to a scheduled preventive

maintenance program.
e. Operated according to the procedures specified in this instruction manual.

I.3 Turbine Installation and Start-Up Checklist

The following turbine installation and start-up checklist is provided as a guide on
the following pages. Although intended for use by Dresser-Rand servicemen, this
checklist is suitable as a guide for end-users as well.
Turbine Installation and Start-Up Checklist

I.3.1 Turbine Information
Customer _________________ Location ______________
Serviceman _________________ Customer Contact ______________
Start Date _________________ Complete Date ______________
Nameplate Data:
Turbine Driven Equipment

Serial Number _________________ __________________
Rated Speed [RPM] _________________ __________________
Overspeed Trip [RPM]________________ __________________
Power [HP] _________________ __________________
Governor Lube System

Manufacturer _________________ __________________
Serial Number _________________ __________________
Part Number _________________ __________________
Application:
Use: Continuous _______ Standby _________Autostart _________

I.3.2 Site Information

Actual Steam Conditions:
Inlet press. (P1) ______Inlet Temp. (T1) ______Exhaust press. (P2) _____
Yes No
Is the base provided level and adequate to support the turbine?  

Is piping deadweight supported by hangers or supports?  
Do inlet and exhaust flanges line up with piping flanges?  
Does the steam inlet pipe have a top take-off from the main  
header to minimize moisture induction?
Is there a piping run or dead leg beyond the take-off?  
Have expansion joints been used?  

Has the piping been blown out with steam (including exhaust  
for backpressure units)?
Has inlet and exhaust piping been drained at low points or  
trapped to avoid water legs?
Has a full-flow relief valve been installed in the exhaust system  
upstream of the first shut-off valve? Setting? ___________

I.3.3 Installation
Yes No
Is the turbine in good condition without signs of improper storage,  

mishandling or shipping damage?
Are foundation and base plate securing bolts adequate?  
Is the turbine properly secured to the base plate?  
Has the base plate been grouted?  
Was rust preventative removed from the shaft and other exposed  
surfaces?
If the turbine was prepared for long-term storage, was the inside of  
gland housings wiped clean and carbon ring sets installed?
If a sleeve bearing type turbine was prepared for long-term  
storage, was the bearing and shaft journal surface wiped clean?
Were bearing housings flushed and drained with a light oil prior to  
filling?
Are lubricating oil levels correct? Turbine  
Governor  
Lubricating Oil Used:
Turbine -- Brand _______________ Type __________
Governor -- Brand _______________ Type __________
Is the coupling properly lubricated and free to oscillate by  
hand?
Does the turbine rotate freely when turned by hand?  
Do the oil rings rotate with the shaft?  
Is the turbine rotation correct?  

Yes No
Do the throttle valve, overspeed trip valve and associated linkage  

move freely?
Does the Overspeed Trip lever reset easily and trip when operated  
by hand?
Does the emergency weight move freely in the governor cup  
assembly?
Has the lube system been site flushed?  

Are lube oil return lines pitched to the sump?  
Is there a Sentinel warning valve? Setting? _________  
Is the turbine adequately drained at all points?  
Are water-cooling lines to the bearing housings properly installed?  
Are there provisions for regulating cooling water flow?
 
Are steam leak-off connections piped correctly and unrestricted?  
(I.e., with no valves, manifolds, water legs or pipe size reduction).
Does the user understand the following:
Overspeed Trip System operation?  
Overspeed Trip Valve reset procedure?  
Overspeed Trip exercising requirement and procedure?
 

I.3.4 Start Up - Uncoupled

Drive shaft run out? ________ Driven equipment shaft run out? __________
Cold alignment method? (attach print out if available)
Rim & Face () Reverse Indicator ()

Laser () Other ()
RIM FAC E
Indicator mounted on _______________ coupling reading ________________

Turbine ___________________ inches low to driven equip.
Coupling Manufacturer _________________ Model ________
Yes No
Did governor operate properly?  
Is the running speed satisfactory?  
Trip speed checks #1 _______ #2 ________ #3 ________ RPM
Overspeed test witnessed by _______________________
Bearing oil temp (sump) Gov end _______ Drive end__________
Lube oil pressure to bearing ________ psig
Lube oil temp- Into Cooler ___________ Out ____________
Are protective devices operating properly?  

I.3.5 Start Up - Coupled

Actual Steam Conditions:
Inlet press. (P1) ______ Inlet Temp. (T1) ______Exhaust press. (P2) _____
Yes No
Does the turbine operate at rated speed?  
Speed variation? _____________ RPM  
Does auxiliary equipment operate properly?  
Is steam leakage within acceptable limits?  
Vibration: (in/sec) (mils) filtered unfiltered
(Indicate speed if mils are used __________ rpm)
Turbine (Vert/Horiz/Axial)
Gov Bearing ___/__/___
Coupling Bearing __/___/___
Driven equipment
Driven End Bearing ___/___/__
Non-Driven End Bearing ___/___/__
Are oil levels correct with no evidence of leakage?  

Oil temp at discharge? Gov. End _______ Drive End ________
Hot alignment method? (attach print out if available)
Rim & Face () Reverse Indicator ()

Laser () Other ()
RIM FAC E
Indicator mounted on _______________ coupling reading ________________

Turbine ___________________ inches low to driven equip.

Yes No
Were piping changes required to correct hot alignment readings?  

To turbine? Describe ___________________________________
To driven equipment? Describe __________________________  

Is turbine doweled to baseplate?  
Is driven equipment doweled?  
Was a copy of this report left with the customer?  
Comments:

I.4 Start-Up Procedure
WARNING
Turbine installation, operation, repair and service must be

performed by EXPERIENCED PERSONNEL ONLY. Read and
understand this instruction manual before installing, operating,
repairing or servicing turbines.
I.4.1 Restoration of Turbine from Shipping Condition

The turbine was completely assembled, adjusted for proper operation, and tested
immediately prior to shipment. A quick reference check list of tasks to complete prior
to placing the unit into operation is as follows: (Storage information is provided at the
end of this section.)
 Unpacking and inspection
 Cleaning of shipping preservatives
 Selecting and preparing foundation
 Bearing inspection and seal oil baffle outside diameters
 Aligning turbine and driven machine
 Connect steam and exhaust piping
 Connect water piping
 Preparation for initial starting and start-up
We recommend that Dresser-Rand Service Representatives oversee the installation and

initial start-up of this steam turbine unit.
Before starting a turbine for the first time, or one that has been in storage, it is
important to have the bearing cases, shaft packing areas, and the governor parts
clean. Solvent may be used for this purpose. (See Commercial Products for
Dresser-Rand Service List at the end of section
After factory testing, turbines are prepared for shipping and storage. The following
two sections describe activities to be performed prior to initial start-up.
I.4.1.1 Flushing/Filling of Bearing Housings

Before starting the turbine for the first time, open bearing case drains and allow
any residual oil to drain. Close the drains.
The oil recommended for permanent operation should now be added to the turbine
through the oil hole covers, until levels reach their respective permanent marks on

bearing housings. Add oil as necessary to constant level sight feed oilers mounted
at each bearing case. Note that a low oil level may result in improper lubrication
and a high oil level may cause leakage past the seals and/or overheating.
Refer to Section F, Lubrication System, for oil recommendations.
I.4.1.2 Shaft Packing

If the turbine was prepared for short-term storage, then no additional steps are
required.
For turbines in long-term storage, the upper half of the turbine case must be
removed to gain access to the shaft packing and turbine rotor. The garter springs
and stop washers should be wiped clean to remove the rust preventative. Matched
carbon ring sets (shipped with the turbine) should be installed. Labyrinth and
carbon ring seals, the inside of the turbine case and all internal components should
be cleaned of the water-soluble preservative.
I.4.2 Initial Start-Up Procedure

The following recommended start-up procedure applies to the basic turbine (ring-
oiled, TG governor, without reduction gear). For information on any optional
equipment, refer to the appropriate vendor instruction manual.
On ring-oiled units, the oil should be warmed up to a viscosity such that the oil rings will
turn and pick up oil; this may be done by circulating hot liquid through the water jackets,
or by means of electric heating elements in the oil compartments. On units equipped with a
flood lubricating system the oil should be warmed up to a viscosity such that the oil
pump will pick up its prime; this may be done by means of a steam heating coil or an electric
heating element. If electric heating elements are used, they should be limited to
approximately 250°F. temperature, to avoid carbonizing the oil. After the oil is warmed up,
circulate some of the warm oil by means of a hand, motor or steam driven pump.
It may not be necessary to pre-heat the oil unless the ambient temperature is well below 32°
F, depending on the relationship between temperature and oil viscosity. Experience will
determine the temperature at which it is necessary to preheat the oil.
After heating the oil or determining that it does not require heating, start the unit in
the usual manner, taking special care that all drain valves are left open long enough
to drain all condensed steam from the steam line and the turbine. Turn the unit over
slowly for a short time, making sure that the oil rings are turning and/or the oil
pump is delivering oil.
Before connecting steam piping to the turbine for the first time, all piping should
be thoroughly blown out with steam to ensure that solid particles such as welding

beads and rust are not carried along with the steam inlet into the turbine. Refer to
Section C, Installation. Thereafter, the following precautions must be taken:
a. Review warnings outlined in Section I.1. If this is the first time the turbine is
put in service, review the Installation Start-Up Checklist in Section I.3.
b. Check the driven machine and verify that it is ready to start.
c. Check oil levels in bearing housings and the governor.
d. Verify that the magnetic pick-up to signal gear clearance is correct (if
supplied).
e. Verify that all valves downstream of the exhaust-isolating valve are open.
f. On condensing units, admit sealing steam to carbon ring glands.
g. For turbines supplied with gland leak-off connections, open the leak-off
atmospheric valve. Refer to Section C.3.12 , Gland Seal Intermediate Leak-
Off Piping–High Back Pressure Exhaust
h. Open the exhaust-isolating valve.
i. Open all hand-valves.
j. Drain all condensate from low points in the inlet steam line, from the casing or
low points in the exhaust steam line, and from overspeed trip and throttle
valve bodies. Drain valves may be left open while the turbine is started, to
allow condensate to drain as the turbine warms up.
k. If a cooling water system is used, admit cooling water to bearing housing

water jackets. Flow should be adjusted to maintain bearing oil sump
temperature in the normal range, as shown in Table F-3, Recommended Oil
Sump and Bearing Temperatures. Refer to Section F, Lubrication System.
l. If a gland seal condenser is used, admit cooling water. If a steam ejector or

water eductor is used, admit the motive flow.
m. Start the lubrication system, if applicable.
n. Verify that the overspeed trip valve is latched open, by raising the manual
reset handle.

DANGER

o. Provide a means for measuring turbine speed, either with a tachometer or with
a stroboscope.
WARNING
Never operate the turbine with the governor or governor

system disabled.
p. Turn the governor-adjusting screw on the end of the governor fully

counterclockwise to the low speed position. Refer to Figure D-1, Woodward
Oil Relay Governor Features, for screw location.
q. Admit sufficient steam through the inlet-isolating valve to turn the turbine
over slowly (950 RPM minimum) and continue to operate at this speed until
the turbine is fully warmed. Close all drain valves when condensate no longer
drains. Some of the incoming steam will condense on the “cold” turbine walls.
CAUTIONS
DO NOT RUN turbines equipped with oil ring lubrication at

speeds LESS THAN 950 RPM. The OIL RINGS WILL NOT
OPERATE CORRECTLY at these speeds, causing BEARING
FAILURE due to lack of lubrication.
Do not operate the turbine above Maximum Continuous Speed

or below Minimum Allowable Speed as shown on the
nameplate, for sustained periods of time.
r. Listen for uneven running or vibration. Shut down and correct, if required.
Refer to Section I.5, Turbine Vibration Limits, when measuring shaft axial
displacement, shaft radial displacement, or bearing housing vibration.
s. Open isolating valve in the inlet steam line gradually, bringing turbine speed
up slowly until the governor takes control at the low speed setting. If the
governor has not assumed speed control by the time rated speed is reached,
shut down immediately and refer to Section K, Troubleshooting.

t. For turbines supplied with gland housing leak-off connections, open the leak-
off isolation valve and close the leak-off atmospheric valve. Refer to Section
C.3.12, Gland Seal Intermediate Leak-Off Piping–High Backpressure
Exhaust.
u. Once speed control has been established, open the throttle valve by adjusting
the speed setting screw on the governor clockwise to bring the turbine up to
the required operating speed of the driven equipment.
v. Monitor turbine operation until stable operation is attained.
I.5 Turbine Vibration Limits

I.5.1 Shaft Displacement Measured with Proximity Probes
Radial Displacement:
When the turbine has been provided with provisions for radial proximity probes,
the turbine shaft has been burnished and degaussed at the probe locations to limit
the electrical and mechanical runout of the shaft. API 611 specifies that when the
turbine is brand new and operated on the factory test stand that the vibration level
must be at or below the “shop limit + runout”. Actual coupled, loaded field
conditions tend to be higher.
Radial displacement in any plane during coupled, loaded, field conditions should
be at or below the alarm level as shown in the figure below. If the level of
vibration increases to greater than the trip level, the turbine should be stopped and
the cause of the vibration identified and corrected.

Wellsville SST Vibration Limits/Settings for API-

611 and Non-API Units
4.0
Unfiltered (mils peak to

3.5
Displacement, 3.0
Radial Shaft
2.5 Shop Limit

peak) 2.0 Alarm Setting
1.5 Trip Setting
1.0
0.5
0.0
1000 4000 7000
MCOS (RPM)
Figure I-1. Radial Shaft Displacement
Axial Displacement:
For turbines provided with standard ball thrust bearings, the shaft axial position is
typically not measured. Refer to tables B-1, Major Fits, Clearances, & Rotor
Balance Criteria - SST, and B-2, Major Fits, Clearances, & Rotor Balance
Criteria - for shaft endplay.
Turbines provided with tilting pad thrust bearings are designed to have some axial
clearance between the active and inactive thrust faces known as float. When these
turbines have been provided with provisions for axial position probes, the Alarm
and Trip set points are specified in Table I-1, Axial Shaft Displacement Tilting Pad
Thrust Bearings. If the level of displacement increases to greater than the trip
level, the turbine should be stopped and the cause of the displacement identified
and corrected.
Note: For API 612 turbines the shop limit is 1.0 instead of 2.0.

Turbine
Alarm Trip
Model
ALL SST
+/- 17 mils +/- 22 mils
MODELS
Table I-2. Axial Shaft Displacement Tilting Pad Thrust Bearings
I.5.2 Bearing Housing Vibration

When shaft proximity probes are not installed, the bearing housing vibration can be
used as an indirect measure of the shaft displacement.
API 611 and 612 specify that when the turbine is brand new and operated on the
factory test stand, the peak vibration measured on the bearing housing while it
operates at the maximum continuous speed shall not exceed 0.12 inches per second
[unfiltered] and 0.08 inches per second [filtered]. When measuring bearing
housing vibration, the alarm and trip set points are specified in the table below. If
the level of vibration increases to greater than the trip level, the turbine should be
stopped and the cause of the vibration identified and corrected.
Bearing Housing Vibration [inches per second, unfiltered]
Turbine Model Alarm Trip

ALL SST MODELS 0.24 0.36
Table I-3. Bearing Housing Vibration
I.6 Testing the Overspeed Trip Mechanism

Refer to Section E.6, Testing the Overspeed Trip Mechanism.
I.7 Governor Speed Adjustment

Standard SST turbines are supplied with WOODWARD TG-type hydraulic
governors. Operating speed of the turbine is adjusted using the TG governor speed
adjustment screw, located in the cover plate of the governor. Refer to Figure D-1,
Woodward Oil Relay Governor Features, for adjusting screw location. The speed
adjustment mechanism is provided with sufficient internal friction to eliminate the

need to externally lock the screw. A screwdriver, coin, or key may be used to
adjust speed, and only light torque is required to turn the adjusting screw.
Turning the adjustment screw clockwise increases the turbine speed setting.
Exercise care when increasing the speed setting, to ensure that driven machine
speed limits or trip speed are not inadvertently exceeded as a result of such
increases.
Turning the adjustment screw counterclockwise decreases the turbine speed

setting. Continuous governing below 1100 RPM for the low-speed governor,
below 2200 RPM for the medium-speed governor, or below 4000 RPM for the
high-speed governor is not recommended because governor oil pressure may not
be sufficient to actuate the governor valve.
Optional construction may include alternate governor configurations. Refer to the

certified drawings and appropriate vendor manual for complete description.
I.8 Governor Droop Adjustment

For WOODWARD TG-type hydraulic governors, droop is factory adjusted to
provide a no-load speed of approximately 106% to 110% of the full-load or normal
speed. If it becomes necessary to alter droop from this initial setting, follow
instructions in the Woodward governor manual.
Exercise caution whenever the governor is opened. The TG governor is a precise

hydraulic mechanism, and the entry of dirt or any other foreign material can cause
the governor to malfunction.
Optional construction may include alternate governor configurations. Refer to the

certified drawings and appropriate vendor instruction manual for complete
description.
WARNING

GOVERNORS should NOT be DISMANTLED OR REPAIRED

by INEXPERIENCED PERSONNEL. Governors contain
powerful springs that could cause PERSONAL INJURY and
have delicate components which, if damaged, could result in
GOVERNOR FAILURE.
WARNING
FIELD CONFIGURABLE GOVERNOR
Any change to control limits, such as (but not limited to) speed,
overspeed trip, control logic, other than “tuning” (see governor
manual) requires the prior written approval of Dresser-Rand
Company to assure the safe operating limits are not exceeded.
Failure to comply may result in damage to property, serious
injury or death to personnel. Refer to the instruction manual for
detailed instructions.
I.9 Hand-valve Adjustments

SST turbines can, as an option, be fitted with up to three hand-valves (350 frame
turbines: 1; 500 and 700LP frame turbines: 2; and 700, 700H, and 700 HLP frame
turbines: 3). These hand-valves provide the operator with the ability to increase or
decrease the number of nozzles admitting steam to the turbine wheel.
The turbine will operate most efficiently when the pressure in the steam chest is at
a maximum (approximately 90% of line pressure). The highest chest pressure
occurs when the fewest number of hand-valves are open, which will allow the
desired operating speed.
To adjust hand-valves for maximum efficiency, proceed as follows:
With all hand-valves open and the normal load applied, adjust the governor to the
required operating speed. Beginning with the hand-valve farthest from the inlet
flange close one hand-valve at a time until the turbine speed falls off sharply. Then
reopen the last hand-valve that was closed. The speed should return to the required
value. If both hand-valves are closed and no sharp drop in speed occurs, leave both
hand-valves closed.

Caution: When putting the unit into operation, do not close a hand-valve tightly
until the turbine is up to operating temperature and all parts are evenly heated. The
reason for this is that the material of the valve stem is subject to greater thermal
expansion than the turbine casing, and if the valve is closed tightly when cold, it
may lock the valve in the closed position making it difficult to open.
CAUTION
Do not leave any hand-valve partially open, as this may result

in steam cutting of the valve and seat. Hand-valves should be
completely open or completely closed. Turbine speed should
not be controlled by the hand-valves; this is the function of the
governor.
I.10 Shutdown
The following recommended shutdown procedure applies to the basic turbine
(ring-oiled, TG governor, without reduction gear). For information on any optional
equipment, refer to the appropriate vendor instruction manual.
After the unit is shut down in accordance with normal operating routine, special
care should be taken to be sure that all water is drained from the steam line, ex-
haust line, turbine casing, valves, oil cooler, etc. Pockets of water could cause
damage due to freezing, and could cause trouble during the next start-up.
Shutting down the turbine may be accomplished as follows:
a. Check shutdown instructions for the driven equipment.
b. Trip the overspeed trip lever manually.
b. Close the isolating valve in the inlet steam line.
WARNING
Do NOT USE the OVERSPEED TRIP VALVE as a permanent

SHUT-OFF VALVE.
d. For turbines supplied with intermediate gland housing leak-off connections,

open the leak-off atmospheric valve and close the leak-off isolation valve.
Refer to Section C.3.12, Gland Seal Intermediate Leak-Off Piping–High Back
Pressure Exhaust.

f. If cooling water is used, turn off cooling water to the bearing housings after
the turbine has cooled down, unless on standby or automatic start.
CAUTION
WATER-COOLING JACKETS must be DRAINED if there is a

possibility of FREEZING TEMPERATURES.
f. Close the exhaust-isolating valve.
g. For condensing units, turn off sealing steam to carbon rings.
h. If a gland seal condenser is used, turn-off cooling water. If a steam ejector or

water eductor is used, turn-off the motive flow.
i. Open all condensate drains.
j. If the turbine is on standby service, or is to be shut down for an extended time

period, it should be started up, or at least turned over one or two times by
hand, once or twice each month to distribute oil to bearings, preventing rust.
k. Turbines in standby service, where bearing housing cooling water continues to

be supplied, must be checked periodically to ensure that moisture is not
condensing in the lubricating oil. Refer to Section F, Lubrication System.
WARNING
After operating the turbine, allow sufficient time for the turbine
to cool down prior to performing an inspection, repair or
maintenance function.
I.11 Restart Procedure

Before restarting the turbine, refer to Section I.1, Warnings.
I.11.1 Non-Condensing Turbines

The following recommended procedure applies to the basic turbine (ring-oiled, TG

governor, without reduction gear). For information on any optional equipment,
refer to the appropriate vendor instruction manual.
a. Check all oil levels. Fill lubricators as necessary. Start lube oil system, if
applicable.
b. Place any controls, trip mechanisms, or other safety devices in their operating
positions.
c. Open all drain valves on steam lines, turbine casing, and steam chest, and fully
open hand-valves, if furnished.
d. Open the turbine exhaust-isolating valve.
e. If cooling water is used, introduce cooling water to bearing housing cooling

chambers to prevent overheating. Cooling water flow should be adjusted to
maintain bearing oil sump temperature in the normal range, as shown in Table
F-3, Recommended Oil Sump and Bearing Temperatures.
f. If a gland seal condenser is used, admit cooling water. If a steam ejector or

g. Open the steam inlet isolating valve and bring the turbine up to desired speed.
h. Make necessary governor adjustments to attain desired speed as load is

applied to the turbine.
i. Close all drain valves when drain lines show the system is free of condensate.
j. Close hand-valves, as appropriate, to attain maximum efficiency.
k. Check bearing temperatures and overall operation for any abnormal

conditions.
l. Monitor turbine operation until stable operation is attained.
I.11.2 Condensing Turbines

The following recommended procedure applies to the basic turbine (ring-oiled, TG

governor, without reduction gear). For information on any optional equipment,
refer to the appropriate vendor instruction manual.
a. Check all oil levels. Fill lubricators as necessary. Start lube oil system, if
applicable.
b. Place any controls, trip mechanisms, or other safety devices in their operating
positions.
c. Open all drain valves on steam lines, turbine casing, and steam chest, and fully
open hand-valves, if furnished.
d. Turn on sealing steam to carbon rings. Open supply valve until a wisp of steam
flowing out of the outboard leak off is observed.
e. If a gland seal condenser is used, admit cooling water. If a steam ejector or

f. Open the turbine exhaust-isolating valve.
g. If cooling water is used, introduce cooling water to bearing housing cooling

chambers to prevent overheating. Cooling water flow should be adjusted to
maintain bearing oil sump temperature in the normal range, as shown in Table
F-3, Recommended Oil Sump and Bearing Temperatures.
h. For turbines supplied with intermediate gland housing leak-off connections,

open the leak-off atmospheric valve. Refer to Section C.3.12, Gland Seal
Intermediate Leak-Off Piping–High Back Pressure Exhaust.
i. Open the steam inlet isolating valve and bring the turbine up to desired speed.
j. Make necessary governor adjustments to attain desired speed as load is

applied to the turbine.
k. Close all drain valves when drain lines show the system is free of condensate.
l. Close hand-valves, as appropriate, to attain maximum efficiency.
m. Check bearing temperatures and overall operation for any abnormal

conditions.

n. Monitor turbine operation until stable operation is attained.
I.12 Standby Operation

Turbines that are not running continuously are often in standby operation where
they must be ready to operate at any time with little or no advance notice. Turbines
in standby service must be capable of starting quickly and reliably in emergency
situations to prevent damage to large, costly systems, such as boilers or large
rotating machinery.
Turbines in standby operation present unique operational and maintenance

situations which must be understood and addressed. Listed below are the most
frequently encountered issues:
 Need to prevent collection of condensate in piping, valves or turbine casing.

Such condensate could slug or otherwise damage the turbine.
 Need to avoid thermal shock (casing and rotor stress) on rapid start-up.
 The need to start quickly with little or no intervention or effort by an operator.
 Avoidance of corrosion and fouling of control linkages, valves, glands,

packing, seals, etc., through lack of use.
 Degradation of lubricant by leakage, oxidation due to excessive heat, or

contamination from water, condensate, dirt or chemicals.
 Freezing of condensate or lack of lubrication due to extremely cold ambient

conditions.
Some methods and equipment employed to deal with the problems above are:
STEAM TRAPS - Steam traps are "smart valves" used in turbine drains and inlet
piping. Traps sense the presence of condensate and automatically open to allow it
to drain. When the condensate is drained the traps automatically close. Steam
traps are rated by pressure, temperature and flow. The amount of condensate
passed will vary, depending on the steam conditions and the steam piping design.
Steam traps should be valved to allow for maintenance and isolation. Manual
drains that bypass the trap are also recommended. When specifying steam traps
the highest pressure and temperature the trap might be exposed to should be taken
into account. This is often inlet pressure and temperature.

AUTO START VALVE - A valve in the inlet steam piping which can be
automatically and remotely opened to start the turbine. The auto start valve
actuation speed should be sufficiently slow to minimize thermal shock to the
turbine and to allow sufficient time for the turbine governor to establish speed
control.
BYPASS VALVE - A small valve typically used to pass a small amount of steam
around an auto start or isolating valve to provide warming and in some instances
slow roll of the rotor.
IDLING NOZZLE - A special nozzle, usually piped separately via a bypass

valve, that is optimally chosen to provide warming and slow roll of the rotor with
minimal steam consumption.
SLOW ROLL - The steam powered slow turning of a turbine rotor, usually
several hundred RPM. Slow rolling a turbine will maintain the bearings, seals and
carbon rings free and operable. It provides warming that will reduce thermal shock
on start up and prevents freezing of condensate. Slow rolling maintains lubricant
moisture free and flowing. Some types of driven equipment cannot be slow rolled.
When a turbine is slow rolled special considerations may be required for
lubrication depending on turbine design, lubrication design, speed, exhaust
temperature and ambient conditions. Consult factory if slow roll operation is under
consideration.
EXHAUST WARMING - A means of warming a turbine by closing the inlet

block or auto start valve and opening the exhaust isolating valve. This is only
effective when exhaust pressure is greater than atmospheric. Precautions are
necessary to prevent introduction of foreign material into the turbine via the
exhaust steam and excessive exhaust pressure that might exceed the turbine's rated
exhaust pressure. No slow roll occurs. Condensate must be drained or trapped
prior to auto starting.
When operating on standby, the following practices and precautions are necessary:
 The turbine should be started periodically to verify that it is in proper

operating condition. This must include test and exercise of the overspeed trip
system.
 Steam traps should be checked periodically to insure that they are operating.
 An idling nozzle provides more efficient operation than a simple bypass valve
for slow roll.

 To prevent excessive bearing temperatures, bearing housing cooling water

may be required during slow roll or exhaust warming operation.
 Excessive cooling water flow during standby operation could cause

condensation to contaminate lubrication oil. Maintain bearing oil sump
temperature in the normal range, as shown in Table F-3, Recommended Oil
Sump and Bearing Temperatures.
 Lubrication oil levels in the bearing housings and governor must be checked
periodically.
 When a standby turbine is started, cooling water must be turned on if required.
 Prior to start up, standby turbines must be drained of all condensate using
traps or manual valves.
 The exhaust isolating valve on a turbine with auto start must be open at all
times to prevent over pressurization of the exhaust casing on start up.
 When it is not possible to periodically operate or slow roll a standby turbine, it

should be periodically turned by hand.
 If a turbine in standby operation is exposed to freezing temperatures,

provisions must be made to prevent damage and clogging of drains with
frozen condensate.
I.13 Auto Start Operation

If a standby turbine must be started quickly and automatically or from a remote
location, then the turbine must be equipped with an auto start valve and trapped
drains. The exhaust-isolating valve must be kept open.
Refer to Section I.12, Standby Operation, for additional information and

considerations.
Refer to Section C.3.14, Suggested Piping Schematics for Standard SST Turbines,
for additional information and considerations.
I.14 Manual Start Operation

If a standby turbine is to be started manually the inlet isolating valve is normally
closed, drains do not require steam traps and the turbine is put into service by
manually opening these valves.

Refer to Section I.12, Standby Operation, for additional information and

considerations.
Refer to Section C.3.14, Suggested Piping Schematics for Standard SST Turbines,
for additional information and considerations.
I.15 Quick Start

In some applications, it is desirable to start up the turbine rapidly. Auxiliary oil
pumps and boiler feed pumps are often called upon to start quickly in emergency
situations. In such applications, condensate ingestion (slugging) and thermal shock
to the casing and rotor are concerns. Piping should be carefully designed and
trapped to prevent accumulation of condensate upstream on the inlet. Turbine
drains should be trapped as well. A small amount of inlet steam should be bled into
the inlet line to heat the turbine. Exercise care to ensure that the line, supplying this
warming steam, is not large enough to supply enough steam to drive the turbine.
Exhaust back pressure can be used for this purpose as well. Refer to Section I.12,
Standby Operation, and I.13, Auto Start Operation, and I.15.3, General, for
additional information.
I.15.1 Acceleration Rate
With steam turbine applications that are started with no load, the acceleration rate of a low
inertia rotating element can be so high that the control system response to close the
steam admission valve does not react prior to overspeed trip. This is particularly true
of the turbine generator sets, which may also require limited frequency variations in the
electrical system. In instances such as this, a ramp effect on governor valve closure may
be built into the control system.
I.15.2 Temperature Differential

On turbines with built-up rotors, the disc-to-shaft allowance tends to decrease to
unacceptable limits with a 200°F (93°C) temperature differential between the disc
and shaft. The probability of such a condition existing is greater at approximately five
minutes after start-up, rather than immediately at start-up. Loss of shrink fit can result in
axial or wobble movement of the disc on the shaft, possibly resulting in turbine
breakdown. The colder the unit at start-up, the greater the probability of the temperature
differential occurring. Since the utilization of forged discs in lieu of plate discs allows a
higher shrink fit, we normally recommend the customer consider using forged discs.
Operate in accordance with normal operating routine; except that in maintaining suitable
lubricating oil temperature and viscosity, it may be necessary to heat the oil instead of
cool the oil.

On some types of turbine governors, a change in the oil viscosity has some effect on the
speed of the units; therefore, when operating a unit under varying oil temperature
conditions, it may be necessary to make manual adjustments on the speed governor.
I.15.3 General
The subject of "quick," "fast" or "automatic" start is not something new in the steam turbine
industry, nor has Dresser-Rand decreased its engineering standards for design of steam
turbine shafts, bearings, or shrink fit of discs to shafts.
In general, reliability and durability are compromised by quick starting a turbine and will
result in a shortened overall turbine life. Frequent quick starts are particularly severe on
bearings and rotating elements. The more rapid the acceleration rate, the higher are the
transient loads and the more severe are the loading effects.
Dresser-Rand single stage turbines with standard construction are suitable for start-up in
five seconds provided the following conditions are met:
3. The inlet temperature of the steam shall not exceed 750°F (399°C).
4. The differential temperature between the inlet steam and exhaust steam shall not
exceed 350°F (177°C).
5. Back pressure shall be maintained on the casing during shutdown. (This in itself is not
a recommended operating condition due to possible wire cutting or carbon ring decay,
but will keep the casing warm.)
6. The operating speed of the turbine shall not exceed 6000 RPM.
In operating a turbine under the above conditions, the user must bear the responsibility
for bearing failure, loss of disc-to-shaft shrink fit, and carbon ring decay.
Dresser-Rand does not recommend quick starting turbines that are in locations
where the ambient temperature is less than 0F (-18C).
Units operating at very low ambient temperatures should be supplied with a

lubricating oil especially selected by a reputable oil company as being suitable for the
operating conditions. Special consideration should be given to insulating the entire

unit, including the lubricating oil lines and the oil tank (on units equipped with a flood
lubricating system), to avoid excessive heat losses and excessive condensation of steam.
I.16 Function Check of Sentinel Warning Valve

A sentinel warning valve (when provided) is mounted on the turbine casing to
warn of excessive exhaust pressure. It is not a pressure-relieving device. The
following test of this valve can be performed when the turbine is not running and
should be carried out at least yearly. The sentinel warning valve should be set to
operate just before the full-flow relief valve starts to open.
The sentinel warning valve can be tested as follows:
a. Close the inlet-isolating valve.
b. Open the exhaust-isolating valve.
c. Latch the overspeed trip mechanism.
d. Open exhaust casing drain valve two turns.
e. Slowly open inlet isolating valve until a little steam flow is visible from the
exhaust casing drain.
f. Close the exhaust drain valve.
f. Slowly close isolating valve in exhaust line and observe pressure on a pressure
gauge mounted to the turbine casing, or in the exhaust line before the isolating
valve. The sentinel-warning valve should open at the pressure value stamped
on it.
CAUTION
DO NOT allow EXHAUST PRESSURE to EXCEED the

stamped setting value by more than 10 PSIG (69 kPag).
h. Relieve pressure in casing by rapidly and fully opening isolating valve in

exhaust line.

i. Close the inlet-isolating valve.
j. Open all drains.
k. If sentinel warning valve does not function properly, replace it and repeat the
above test procedure.

Maintenance, Maint. Sched. and Inspect. Sched SST Turbine Instruction Manual

INTENTIONALLY

SST Turbine Instruction Manual Maintenance, Maint. Sched. and Inspect. Sched.
Section J
Maintenance, Maintenance Schedule and Inspection

Schedule
J.1 Introduction
The Dresser-Rand SST Turbine is a high-quality prime mover that has been
carefully assembled and thoroughly tested at the factory. As with any machinery,
the turbine requires periodic maintenance and service. This section discusses
periodic maintenance requirements and procedures. Please refer to Section L,
Disassembly and Parts Replacement, for major service and overhaul instructions.
DANGER
DO NOT attempt to SERVICE, REPAIR, OR ADJUST A

RUNNING TURBINE, unless explicitly recommended in this
manual.
WARNINGS
MAINTENANCE PERSONNEL should be THOROUGHLY

FAMILIAR with the TURBINE, its CONTROLS and
ACCESSORIES, before attempting any maintenance or
service. Thorough familiarity with this manual is recommended.
If INTERNAL COMPONENTS of the turbine require REPAIR or

replacement, CLOSE, SEAL AND TAG INLET AND EXHAUST
ISOLATING VALVES and open all turbine drain valves,
thereby isolating the unit and preventing ACCIDENTAL
INTRODUCTION OF STEAM into it. Ensure that driven
equipment cannot rotate turbine shaft or uncouple the turbine
from the driven equipment.

WARNINGS
When RESTARTING a turbine that was stopped for

maintenance or service, TESTING of the OVERSPEED TRIP
SYSTEM is MANDATORY prior to returning the unit to service.
to cool down prior to performing inspection, repair or
maintenance functions.
J.2 Maintenance and Inspection Schedule

Maintenance requirements and the corresponding schedule will vary with the
application and service conditions. The following maintenance and inspection
guidelines are recommended for turbines operated under normal conditions.
Frequency Maintenance or Inspection Procedure

Daily Check oil levels in bearing housings and governor. Add oil if
required.
Check for smoothness of operation, unusual noises, or other
changes in operating conditions.
Check overall appearance of turbine system for steam, oil, or
coolant leaks, and for external damage.
Check bearing oil temperatures and pressures; check coupling

temperature.
WARNING
DO NOT attempt TO MEASURE COUPLING
TEMPERATURE while the turbine is RUNNING.
Table J-1. Suggested Maintenance and Inspection Schedule

Frequency Maintenance or Inspection Procedure

Weekly Test the over-speed trip system. Refer to Section E, Overspeed
Trip System, for the test procedure. This exercise will not only
confirm operation of the trip system, but will prevent sticking of
the over-speed trip valve and linkage due to corrosion or steam
deposits.
Check operation of auxiliary oil pump (on turbines with this
equipment). See oil system schematic diagram in Appendix for
location of test valve.
Check operation of all low air/oil pressure shut down device(s).
Drain small quantity of oil from system and conduct an oil
analysis. Determine the need for an oil change. If system is
equipped with and oil filter element, change the element at the
time of the oil change.
Check throttle valve and linkage for freedom of movement.
Lubricate the governor lever connection.
Monthly Check bearing housings for sludge, sediment, or water
(condensate). Flush and refill, as required.
Check that oil rings rotate freely and smoothly.
Check throttle and overspeed trip linkage for looseness, wear,
and freedom of movement. Check governor drive coupling for
wear
Yearly Change oil in the Woodward TG governor.
Remove and clean the steam strainer. Replace every three years.
Inspect internal components of the throttle valve for wear.
Replace, if required. Replace valve stem seals.
Clean and inspect the over-speed trip valve. Replace worn parts.
Replace valve stem seals.
Thoroughly inspect the throttle linkage and overspeed trip
linkage for wear. Check governor drive coupling for wear.
Replace as required.
Table J-1. Suggested Maintenance and Inspection Schedule (Cont.)

Inspect, clean, and flush bearing housings, oil reservoirs, and

Yearly cooling water chambers.
Continued
Inspect carbon ring gland seals. Replace as required.
Check operation of the Sentinel warning valve.
Check alignment and foundation.
Remove top half of turbine casing and:
Clean scale and foreign material from wheels, buckets and
nozzles.
Check carbon rings for wear—remove, clean and reassemble
(refer to shaft packing section L.4.1 and L.4.2).
Check thrust bearing endplay.
Check calibration of all instrumentation.
Table J-1. Suggested Maintenance and Inspection Schedule (Cont.)
WARNING
Modification of, incorrect repair of, or use of non-DRESSER–

-Replacement Parts/Factory Service
J.3 Major Inspection

Dresser-Rand recommends that the turbine be periodically shut down and
subjected to a major teardown and inspection. The frequency of this inspection will
depend on turbine service conditions, its maintenance history, the convenience of
scheduling a shutdown, the user’s experience with this or similar machines, or the
customer’s insurance company’s requirements..
J.4 Inspection Checklist

The following list summarizes parts that should be inspected during a major
inspection.

Parts to be Area to Be
Inspect for Action Required
Inspected Examined
Cracks, poor rivet Consult manufacturer’s
Shrouds
heads representative or factory.
Turbine and sector File or grind smooth (Note:

blades removal of excessive material
Corrosion, cracks,
Blades will affect balance and blade
erosion
integrity. Consult manufacturer’s
rep. or factory if in doubt.)
Bearings Surfaces Wear, signs of Replace if defective. Check

foreign matter, condition of oil system.
scratches (pitting,
corrosion, galling,
excessive radial
play on ball
bearings) Drain oil & clean thoroughly.
Fouling, scale,
Bearing Housings Oil Reservoir Refill with new oil.
rust, and water
Bearing housing Labyrinth seal Wear, dents in

Clean thoroughly.
oil seals rings surface, scale, dirt
Replace if badly worn or broken.
Breakage, wear,
Carbon rings Clean. Carefully scrape high
high spots, dirt
spots.
Stainless steel
Glands high velocity Blistering, peeling Replace shaft.
oxy fuel
Labyrinth
Wear, dents in Clean thoroughly. Replace
steam seal
surface, scale, dirt labyrinths if wear excessive.
teeth
Table J-2. Inspection Checklist

Inspected Examined
Remove with solvent and/or
Stem Scale
crocus cloth.
Galling, wear Replace.
Replace valve or cage, as
Valve and cage Cutting, scaling
required.
Throttle valve Wear, excessive
Seal sleeves clearance, steam Replace.
leakage
Remove obstructions and dents.
Cracks, dents, or Replace if cracked or broken.
Steam strainer
obstructions Determine cause of damage and
correct.
Connecting rod
ends, linkage Wear, excessive Replace worn components. Clean
Governor linkage pins, bushings, clearance/play, with solvent and polish, if
Governor drive corrosion necessary.
coupling
Scale and boiler Remove with solvent and/or

Valve Spindle
compound, dirt crocus cloth.
Valve Spindle Wear, excessive
Overspeed trip Spindle clearance, steam Replace.
valve packing leakage
Wear, cutting,
Valve seat Replace.
cracks
Pilot valve Wear Replace.
Trip collar Binding, scale, Disassemble and clean; inspect
assembly corrosion, wear for wear; replace as an assembly.
Overspeed trip Linkage,

Foreign material, Clean and inspect. Replace worn
system connecting rod
wear, corrosion, and defective parts. Adjust and
ends, bushings,
freedom of confirm correct operation before
pins, reset
movement returning turbine to service.
handle
Table J-2. Inspection Checklist (Cont.)

Inspected Examined
Corrosion, Replace packing; remove foreign
Stem and
Hand Valves foreign material, material from stem; replace stem
packing
wear if pitted or worn.
Piping Fouling, scale, Clean thoroughly to remove.

reservoir rust, water, Filter oil to remove dirt. Drain
flaking paint oil; remove access covers to clean
out any accumulated scale and
refill with new oil.
Pressure lube
system (when used) Oil filter(s) Increased Replace filter element
pressure drop
Oil cooler(s) Fouling and Clean according to

corrosion on both manufacturer’s instructions
oil and water side
Table J-2. Inspection Checklist (Cont.)
Refer to the certified drawings and the appropriate vendor manual for inspection
and maintenance requirements for optional equipment.
J .4.1. Protective Devices and Steam Cleanliness
RAPID CLOSING OF VALVES SUPPLIED WITH THE TURBINE IS ESSENTIAL

TO PROTECT AGAINST OVERSPEED AND POSSIBLE OTHER MECHANICAL
PROBLEMS. Such valves (governor valves, trip valves, trip throttle valves, etc.) must
close in fractions of a second; and deposits on valves, seats, stems, etc cannot impede
their movement. Deposits can form rapidly - as a result of improper water treatment
and/or entrainment of impurities in the steam supply.
The design clearance at the end of the governor controlled steam valve(s) and trip or trip
and throttle valve stems are required to minimize steam leakage from the turbine.
The stem clearances used by Dresser-Rand are based on many years of practical
experience and will prevent binding under normal temperatures and steam cleanliness.
HOWEVER, THE DEGREE OF STEAM CLEANLINESS TOLERANCE ON

CONTROL VALVE AND TRIP VALVE COMPONENTS IS LIMITED AND

DEPOSITS MUST BE PREVENTED.
Steam cleanliness at the turbine flange is essential to reliable turbine operation.
Control of steam cleanliness is the responsibility of the turbine user and his system
operator. Cooperation with boiler manufacturers and water treatment specialists is
strongly recommended to maintain steam purity and cleanliness. Boiler operation must
prevent boiler compounds from being carried over to the steam turbine and causing
deposits on the valves.
DRESSER-RAND RECOMMENDS THAT THE TURBINE USER PERFORM
CAREFUL AND FREQUENT INSPECTION OF TRIP SYSTEM TO ASSURE NO
DEPOSIT BUILD-UP OCCURS that could cause the safety devices and valves to
become inoperative.
WE RECOMMEND THAT FREQUENT EXERCISING OF (I.E. LIMITED
MOVEMENT/PARTIAL STROKING) THE CONTROL COMPONENTS BE
PERFORMED, especially if boiler carryover deposits may have occurred.
Exercising of the governor controlled valves may be performed by either a small load
change (where practical) or steam inlet pressure change. This can be accomplished by
choking the trip or trip and throttle valve. At the same time, the trip or trip and throttle
valve is exercised.
CAUTION: If the KW load on a turbine-generator cannot be reduced in the normal
manner, it indicates the possibility of unacceptable deposits on the control valve
components. STUCK CONTROL VALVES ARE A DANGER SIGNAL THAT THE
TRIP VALVE MAY ALSO BE STUCK.
UNDER THESE CONDITIONS IT IS IMPERATIVE THAT THE GENERATOR LOAD
NOT BE REMOVED UNTIL THE TRIP VALVE IS CLOSED. If the trip valve cannot be
closed by normal means, then other valves in the steam system must be used to cut off the steam
supply to the turbine. THE UNIT CIRCUIT BREAKER SHOULD NEVER BE OPENED
WHILE LOAD IS ON THE UNIT AND TRIP AND THROTTLE / GOVERNOR
VALVES ARE INOPERABLE. FAILURE TO FOLLOW THESE PRECAUTIONS
COULD CAUSE A SEVERE OVERSPEED WITH EXTREME DANGER TO THE
TURBINE AND OPERATING PERSONNEL.
J.5 Factory Service

Dresser-Rand maintains repair and rebuild facilities worldwide. In addition,
factory-trained servicemen are available for start-up, field service, and
troubleshooting. Consult your Dresser-Rand manufacturer’s representative or the
factory for service needs. Refer to Section M, Replacement Parts/Factory Service.

J.6 Factory Replacement Parts
WARNING
Modification of, incorrect repair of, or use of non-DRESSER-

-Replacement Parts/Factory Service
Dresser-Rand recommends that only Dresser-Rand-supplied parts be used in

Dresser-Rand turbines. The use of Dresser-Rand parts ensures that replacement
components are manufactured from the highest quality materials, to exacting
tolerances and specifications, thereby assuring efficient, long-lasting, and
maintenance-free operation, under service conditions that the turbine was built for.
Dresser-Rand and selected Dresser-Rand manufacturer’s representatives maintain

a supply of the most frequently requested spare parts for immediate shipment
worldwide. Parts requested less frequently can be manufactured quickly on an
emergency basis when required.
Your Dresser-Rand manufacturer’s representative can supply you with an

interchangeability list and a suggested stocking list of recommended spare parts for
your turbine or turbines, allowing you to stock spare parts at your facility. Refer to
Section M, Replacement Parts/Factory Service.

Troubleshooting SST Turbine Instruction Manual

INTENTIONALLY

SST Turbine Instruction Manual Troubleshooting
Section K
Troubleshooting
K.1 Introduction
This section should be consulted when the turbine is not operating satisfactorily.
The table in Section K.2 lists the more common symptoms, probable causes, and
corrective actions in each case. If the problem cannot be completely remedied
using the table, refer all questions to your local Dresser-Rand manufacturer’s
representative, or to:
Dresser-Rand Company
Wellsville Operations, P.O. Box 592
Wellsville, NY 14895-0592
800-828-2818
585-596-3100
If corrective actions specified in items 5 through 8 of Section K.2 are attempted

and are not successful, and if the factory must be consulted, it is imperative to
provide exhaust pressure, speed, horsepower, and chest pressure. Chest pressure is
measured by installing a pressure gage in a hand-valve chamber drain hole and
reading the pressure with the hand-valve closed.
K.2 Troubleshooting
The following table lists common problems, possible causes, and the appropriate
corrective action of turbines that have operated successfully and develop problems
during the course of normal operation. Problems encountered during initial start-
up should be referred to the above contact information.

No. Symptom Probable Cause Corrective Action
1 Excessive Misalignment. Check the alignment when the turbine is hot.

vibration or Disconnect coupling between turbine and driven
noise machine; run the turbine alone. If the turbine
runs smoothly, there is either misalignment, a
worn coupling, or the driven equipment is at
fault. To check alignment, refer to Section C. If
the turbine drives a coupled gear, and the gears
run together at the top, allow for the pinion
running in the top of its bearing when under
load.
Worn bearings Replace bearings. Refer to Section L.
Worn coupling to driven Check condition of coupling. Replace if

machine. necessary.
Glands fitted too tightly. Tight carbon rings may cause vibration and
overheating. Refer to Shaft Packing Section for
proper clearance.
Loose wheels are extremely Rotor should be returned to the factory to be

unusual, but may be caused by a repaired.
runaway, excessive steam
temperature or shock loading.
Bent shaft May be caused by hot bearings (see “Bearing

Heating and Wear”), tight glands (see “glands
Fitted too Tightly”), or mechanical damage.
Check the shaft runout near the center, as well

as at the shaft extension. Replace the shaft if
runout is excessive. Refer to Section L.
Unbalanced coupling to driven Remove coupling halves and check for

machine unbalance.
Unbalanced wheel Check if turbine wheel has become unbalanced

due to fouling, over-speeding, or loss/damage to
shrouds or blades. Check if the turbine has been
standing idle for a long period without drainage
of the exhaust casing. Solid matter can build up
in the lower half of the wheel, causing
unbalance. The turbine wheel must be cleaned,
re-balanced or replaced. Refer to Section L.
Table K-1. Troubleshooting Guide

Piping strain Both the inlet and exhaust steam lines should be
properly supported to prevent strains from being
imposed on the turbine. Sufficient allowance
should be made for thermal expansion. Refer to
Section C.
Excessive end play Check the axial position of rotor. If the endplay
exceeds 0.020”, replace thrust bearing. Verify
that coupling is cleaned and installed properly
so that excessive thrust is not imposed on
turbine from driven equipment.
2 Bearing Improper lubrication Refer to Section F to verify that the proper

Failure lubricant is being used. Check oil periodically to
ensure that it is free of condensate and sediment.
Improper water cooling When water-cooling is required, the water flow

must be adjusted to maintain bearing oil sump
temperature in the normal range, as shown in
Table F-2.
Wear and/or scratches in sleeve Replace the sleeve bearings, drain oil reservoirs,
bearing clean bearing housings, and add new oil. Inspect
journal surfaces.
Rough or untrue thrust collars. Rough or untrue thrust collars on single-stage

(shoe-type bearing) machines may cause rapid wear on thrust
facings of the sleeve bearings. This could
eventually increase thrust clearance to a point
where the turbine wheels would rub on the
guide or reversing ring. Rough or untrue collars
should be replaced or repaired at the first
opportunity.
Misalignment Misalignment is one of the common causes of

bearing failure. Refer to remedies for
Misalignment under Vibration above.
Table K-1. Troubleshooting Guide (Cont.)

Bearing fit Ball bearings should fit on the turbine shaft with
a light press fit. Too tight a fit can cause
cramping; too loose a fit will allow the inner race
to turn on the shaft. Either condition results in
wear, vibration, overheating, and ultimate
bearing failure. Replace the shaft if worn below
recommended or specified size. Refer to Section
L.
Excessive thrust Verify that the coupling is clean and is installed

so that excessive thrust is not imposed on the
turbine from the driven equipment. If a fairly
high thrust is imposed on the turbine, consult the
factory to determine whether the thrust bearing is
suitable for the application.
Excessive belt pull On belt driven units, verify that belts are not too
tight and consult the factory to determine
whether the turbine bearing is suitable for the
application.
Unbalance Refer to Unbalanced Wheel under Vibration

above. Unbalance can cause excessive bearing
wear and early failure.
Excessive tension in The tension on the speed changer spring must be

spring type speed sufficient to hold the governor lever firmly
changer. against the governor spindle connection under all
conditions. Avoid any unnecessary loading on
this spring, as this would impose excessive load
on the thrust bearing.
Speed governor trying to Leaking or stuck valve should be corrected, as it

close a leaking or stuck constitutes a safety hazard, besides being
governor valve. detrimental to the thrust bearing. Excessive wear
is also imposed on the governor ball thrust
bearing.
Heavy slugs of water in This condition can be avoided through proper

the steam. boiler control. Damage to the thrust bearings
and wheels will result from water slugs.

Rust Rust may develop on bearing surfaces when the

turbine is improperly stored; refer to Section A
for details. Rust may also develop when the
turbine is out of service for long periods, without
receiving proper attention; refer to Section J.
3 Excessive steam Dirt under rings Steam leaking under carbon rings may carry
leakage past shaft seals scale or dirt, which can foul the rings. Remove
rings and clean, as per Section L. The rings
should be free to float axially, and the
downstream face of the ring must seat perfectly
against the smooth, true and clean surface of the
adjacent carbon ring spacer.
Shaft scored The shaft surface under carbon rings must be

smooth to prevent leakage. Factory-supplied
shafts are hard chrome plated. Polish minor shaft
imperfections or replace the shaft, per Section L.
Worn or broken carbon Replace with new carbon rings, as per Section L.
rings Although there are 3 segments per ring, the
entire ring must be replaced. Carbon rings
should have a slight clearance on the shaft when
cold, as carbon expands much less with heat than
steel.
Corroded, worn or dirty Steam will leak past the carbon ring partition
partition plate surfaces surface if dirt, corrosion or scoring prevents a
good seal. Polish sealing surfaces. Replace
partitions (when used) if badly worn or pitted.
Refer to Section L.
Labyrinth steam seal Refer to Sections L and Supplemental Data for

improperly installed proper installation procedure.
Worn or broken labyrinth Replace labyrinths. Refer to Sections L and

steam seal teeth Supplemental Data for proper installation
procedure.
Excessive exhaust Packing cases are designed for a pre-determined

pressure backpressure. Excessive backpressure causes
leakage, which is a common cause of water in
the lubricating oil.
Excessive joint sealing When replacing carbon rings, use joint

compound in gland compound sparingly. Excess compound may
housing foul carbon rings and gland housing sealing
surfaces.

Leak-off pipe plugged Verify that all steam and condensate can
discharge freely. Refer to Section C.3.10.
4 Oil leaks past laby seal High oil level Reduce the oil level to coincide with marks on
bearing housings. Refer to Section F.
Scratched or rough shaft Polish the shaft under the laby seal and install a
under laby seal new laby seal. Refer to Sections F and L.
Seal improperly installed Refer to Sections F and L for proper installation

procedure.
Shaft vibration Refer to all causes under Vibration above. Install

a new laby seal, if necessary, as per Sections F
and L.
5 Insufficient power Too many hand-valves Open additional hand-valves. Refer to Section I
(turbine does not run at closed for proper adjustment of hand-valves.
rated speed)
Oil relay governor set too Refer to Section D for speed adjustment and
low speed range limits.
Inlet steam pressure too Check the steam pressure at the turbine inlet and
low or exhaust pressure exhaust pressure close to the exhaust casing,
too high using accurate gauges. Refer to the turbine
nameplate for intended steam conditions. Low
inlet pressure may be the result of auxiliary
control equipment such as a pump governor
which is too small, improper piping size,
excessive piping length, etc.
Load higher than turbine Determine the actual load requirements of the
rating driven equipment. In some instances, modifying
a few components can increase available turbine
power. Consult the factory for this
determination.
Throttle valve not Close the main inlet valve and disconnect throttle
opening fully linkage. The valve lever should move freely
from fully open to fully closed. If not,
disassemble the throttle per Section L and free
up the assembly, as required.
Low governor oil level Refill—Refer to Section D.

Nozzles plugged Remove the cover and rotor and inspect nozzle
openings. Remove nozzle block to clean nozzles
as required.
Steam strainer Remove all foreign matter from steam strainer.

Refer to Section L.
6 Speed increases Throttle valve not closing Refer to governor valve not opening fully under
excessively as load is fully, governor responds Insufficient power above. Free the sticking valve
decreased slowly due to worn parts and inspect all pivot points in linkage for signs
or sticking. of sticking or binding or excessive wear.
Throttle valve and valve Remove governor valve, as per Section L. Check
seats cut or worn valve and seats for wear or steam cutting.
Replace if necessary.
7 Excessive speed Governor droop An increase in the internal droop setting will
variation adjustment reduce speed variation or hunting. Refer to
Droop Adjustment in the Woodward Governor
Manual.
Governor lubrication Low governor oil level, or dirty or foamy oil

may cause poor governor operation. Drain, flush,
and refill governor with the proper oil. Refer to
Section D.
Governor valve assembly Disassemble the governor valve per Section L.

friction Inspect for free and smooth movement of all
moving parts. If required, polish throttle valve,
governor valve and bushing assembly, and valve
stem with very fine Emery cloth. Inspect valve
stem for straightness and for build-up of foreign
material. Replace components as required.
Governor valve seal Check the valve stem for free and smooth motion
friction through the throttle bonnet assembly. If friction
or binding occurs, disassemble throttle bonnet
assembly and repair or replace seal components,
as necessary. Refer to Section L.
Rapidly changing load Rapidly changing load can sometimes cause

governor hunting. Consult the factory, providing
details of the application.

Governor knife edges These must be replaced if badly worn. There is

worn. no effective repair for these parts.
Lost motion so the This is usually the result of excessive wear at the
governor valve does not pivot points in the linkage. Bearing in the
always follow the motion linkage should be replaces, as well as the linkage
of the governor. pins.
Light load and high inlet In some cases, where the turbine provides a large
steam pressure amount of reserve power and the inlet steam
pressure is quite high, there is a tendency for
excessive speed variation. Try operating the
turbine with additional hand-valves closed. This
condition can sometimes be corrected by
replacing the governor valve and bushing
assembly. Consult the factory, providing details
of the application.
8 Sluggish governor Governor droop Reduce the droop setting. Refer to Droop
response. adjustment Adjustment in Woodward Governor Manual.
Turbine carrying very Open necessary hand-valves to increase

heavy load, little reserve horsepower.
power.
9 Slow start-up General Refer to all causes under Insufficient power

above.
High starting torque of Obtain the required starting torque from the
driven equipment driven equipment manufacturer and consult the
factory to determine whether the turbine is
overloaded in the application.
10 Governor not operating Governor valve travel Refer to Governor valve not opening fully under
restricted Insufficient power above.

No governor control on If the speed increases continuously on start up

start-up and the governor does not close the throttle
valve, the governor pump may be installed in the
wrong direction of rotation. Also verify that the
installed governor operates in the proposed speed
range. If pump rotation appears to be the
problem, remove the governor according to
Section L. Replace it with a governor of the
proper rotation. Refer to the Woodward
Governor Manual for instructions on changing
governor rotation or consult the factory.

11 Governor oil leakage General Isolate the source of leakage. If leakage is at the
cover plate gasket, drain plug or oil breather,
replace the gasket and/or tighten these
components to stop the leak. If leakage occurs at
terminal shaft seals or the drive shaft seal,
replace the governor per Section L.
Drive assembly vibration Vibration of the turbine shaft or governor drive

coupling may induce leakage at the governor
drive shaft seal. Refer to all causes under
Excessive vibration or noise above. Inspect and
tighten the coupling per Section L. Check for
misalignment or bent turbine or governor shaft.
12 Overspeed trip actuates Overspeed trip set too The over-speed trip should be set at
on load changes close to turbine operating approximately 16% OR 21% above the rated
speed speed, depending on the NEMA rating (D or A)
of the governor. Refer to Section E.
General Refer to all causes under Speed increases

excessively as load is decreased above.
Light load and high inlet Refer to Light load and high inlet steam pressure
steam pressure under Excessive speed variation above.
13 Overspeed trip actuates Excessive vibration Replace the trip lever and/or trip latch if latching
at normal operating surfaces are worn, after resolving cause of
speed excessive vibration.

Trip speed setting too If the turbine consistently trips at or close to the
low same speed, the trip setting may be set too low.
The setting should be approximately 16% OR
21% over rated speed, depending on the NEMA
rating (D or A) of the governor. Refer to Section
E for adjustment procedures.
14 Overspeed trip does not Trip speed setting too If the overspeed trip has not actuated when the
actuate at overspeed high turbine reaches 25% above rated speed, the trip
speed setting may be too high. The setting should
be approximately 16% OR 21% over rated
speed, depending on the NEMA rating (D or A)
of the governor. Refer to Section E for
adjustment procedures.

Overspeed cup Examine mechanism. Verify that it is clean and

mechanism in good working order, and that the trip weight
can be moved easily by a small screwdriver or
similar tool.
Improper adjustment or The trip valve must be tested frequently. To test

poor condition of the the valve, trip the over-speed mechanism by
tripping mechanism, hand. Make sure the trip valve closes promptly
springs or latches. and stops the turbine.
Excessive friction in trip These serious faults should be corrected by

valve spindle packing. cleaning, repairing or replacing parts so that this
Scaling, wear, or important safety device can operate effectively.
mechanical damages in
trip valve or its supports.
Governor does not trip at Gain access to and examine the overspeed
or near the proper speed. governor. Make sure it is clean, in good order,
and that the emergency weight can be easily and
freely moved in the governor cup by a small
screwdriver or similar tool. Adjust as described
in Section VI. Test the unit by actually over-
speeding. If it still does not trip at the proper
speed, adjust the setting of the emergency
governor as required. If low oil pressure trips,
solenoid trips, high back pressure trips, or similar
devices are provided, check them at the same
time.

Overspeed trip valve Overspeed trip valve may be frozen in place due
unable to close to steam deposits, corrosion, or other
contaminants. Disassemble and clean valve
assembly according to Section L.
A broken steam strainer, or other foreign objects,

may interfere with proper seating of the over-
speed trip valve. Disassemble and inspect
combination valve according to Section L.
15 Excessive steam Load greater than The operator, after acquainting himself with the
consumption. realized. correct hand valve use on the turbine, must make
sure the correct combinations of hand valves are
open for various loads.

Speed below normal. Check the steam pressure and backpressure. Make
sure the governor is fully opening the valve. Check
and see if the hand valves are in use as designed.
Too many hand valves This situation gives a turbine excessive capacity
open. which requires throttling by the governor valve to
maintain the proper speed. This is inefficient and
uses more steam than necessary. Close the hand
valves to eliminate throttling.
Steam pressure low, or These conditions must be corrected if the turbine is
exhaust pressure too to carry a full load. Better boiler control will
high. provide steam pressure correction. Horsepower
goes down as exhaust pressure goes up over
designed pressure.
Steam is wet, or the This condition not only causes loss of power, but
super- heat low. also is dangerous since it causes excessive erosion
on the nozzles and blades. Adjust steam conditions
as per manufacturer's recommendations.
Worn or damaged This adversely affects the efficiency of the turbine.
nozzles and blades. Nozzles and/or blades should be replaced or
repaired at the earliest opportunity.
Refer to the certified drawings and the appropriate vendor manual for
Troubleshooting Guidelines for optional equipment.


INTENTIONALLY

SST Turbine Instruction Manual Low Voltage Electrical Components
Section L
Disassembly and Parts Replacement
L.1 Warnings/Cautions
DANGERS
DO NOT attempt to ADJUST, REPAIR, DISASSEMBLE OR

MODIFY this turbine WHILE IT IS IN OPERATION, unless such
action is expressly described in this instruction manual.
NEVER DISCONNECT INLET OR EXHAUST FLANGES of the

turbine without first isolating the turbine from inlet and exhaust
systems by CLOSING AND TAGGING ISOLATING VALVES
and de-pressurizing the turbine casing and steam chest by
opening all drains. Open connections not protected by isolating
valves should be covered with blank flanges.
Do not remove any covers, guards, gland housings, drain

covers, etc. while the unit is operating.
WARNING
to cool down prior to performing inspection, repair or
maintenance functions.

Low Voltage Electrical Components SST Turbine Instruction Manual
CAUTION
Do not operate the turbine above Maximum Continuous Speed

or below the Minimum Allowable Speed as shown on the
nameplate, for sustained periods of time.
WARNINGS

RAND repair parts on this turbine could result in serious
compliance with European Directives. Refer to Section M –
Replacement Parts/Factory Service
NEVER REPLACE ANY ORIGINALLY SUPPLIED BOLT WITH

A SUBSTITUTE BOLT OF UNKNOWN or LESSER GRADE.
DO NOT MIX BOLTS during disassembly. Failure to use the
proper grade bolt could result in SERIOUS FAILURE of
pressure-containing components. Refer to Section B, Technical
Data.
MAINTENANCE PERSONNEL should be THOROUGHLY

FAMILIAR with the TURBINE AND ITS CONTROLS AND
ACCESSORIES, before attempting any maintenance or
service. A complete reading of this manual is recommended.

CAUTIONS
If the turbine is equipped with a throttle valve manufactured by

a party other than Dresser-Rand refer to Appendix B for
installation, operation, repair, and maintenance instructions.
If the turbine is equipped with a trip valve manufactured by a

party other than Dresser-Rand refer to Appendix B f this
manual for installation, operation, repair and maintenance
instructions.
WARNINGS
Dresser-Rand turbine components are manufactured from a

variety of materials, depending on steam pressure, steam
temperature, speed and horsepower. Before replacing any
components, be absolutely certain that the REPLACEMENT
PART was INTENDED for use in the TURBINE UNDER
REPAIR.
When RESTARTING a turbine after repair, maintenance or

rebuilding, always TREAT the turbine as if it were a NEW
TURBINE being started for the first time. Refer to Section I,
Start-Up and Operation.
CAUTION
CLEANLINESS is ESSENTIAL for long, trouble-free service

from BEARINGS and the GOVERNOR. Take care to ensure
that no foreign material enters bearing housings, the governor
or constant level oilers when performing maintenance, checking
oil, adding oil, or making adjustments.
L.2 General
This section describes disassembly and parts replacement for Dresser-Rand SST
turbines. Some parts of a SST turbine can be replaced in the field using instructions

presented in this section, if qualified personnel and facilities are available. If not, it
is recommended that a Dresser-Rand service representative be employed to make
the field repairs, or that the turbine be returned to the factory, where a complete
inspection can be made. If returned, the factory will prepare an estimate of the cost
of cleaning the turbine, replacing parts as required and restoring the turbine to
practically new condition. After factory repair, the turbine will be no-load tested
and preserved just as a new machine would be. A factory-rebuilt turbine receives a
new turbine warranty.
L.3 Turbine Case Upper Half Removal and Replacement

The upper half of the turbine case must be removed to gain access to the shaft
packing and turbine rotor. NOTE: Make sure that the steam inlet and the exhaust
line shut-off valves are shut before starting work.
In some applications, special bolting is supplied. Consult the factory before

replacing or torquing the bolts in the turbine.
WARNING
NEVER REPLACE THE ORIGINALLY SUPPLIED BOLT WITH

A SUBSTITUTE BOLT OF UNKNOWN or LESSER GRADE.
DO NOT MIX BOLTS during disassembly. Failure to use the
proper grade bolt could result in serious failure of pressure-
containing components.
If the applicable bolt torque is not specified in the Assembly/Disassembly section,

the following table may be used as a guideline.
The procedure for removing and replacing the case upper half is specified below.
L-1 Case Upper Half Removal

L-2 Flange Bolt Torque Sequence
L-3 Flange Bolt Torque Sequence, 700H Casing
L-9 Hand Valve Assembly
M-8 Case, Rotor and Mechanical Gland Seals
M-9 Case, Rotor and Carbon Ring Gland Seals
Turbine Cover Removal (Upper half of the exhaust casing)

a. Remove the bolts from the horizontal flange of the turbine.

b. Break horizontal joint (cover/case mating surfaces) by inserting jacking bolts

in holes provided at the four corners of the cover flange.
c. Using a hoist and center eyebolt at the top of the upper case half, lift turbine
cover slowly and carefully so as to avoid damaging the rotor inside. Refer to
Figure L-1 Case, Upper-Half, Removal.
Place turbine cover on a clean surface so as to prevent damage to its sealing

face.
Figure L-1. Case Upper-Half Removal
Turbine Cover Replacement (Upper half of the exhaust casing)
a. Inspect the interior of the turbine cover and exhaust casing. Remove any
foreign material.
b. Remove all old sealant from both surfaces of the horizontal joint. Do not file,
gouge or scratch these surfaces. If the surfaces are warped, steam-cut or
otherwise damaged, a leak-tight seal may not be possible.
c. Apply joint sealant after cleaning the split surface on case and cover. Apply a
light coat of Hylomar (recommended by Dresser-Rand) to sit for 15 minutes
before putting the cover on the case.

Exhaust End

Approximate
location if string or
tape is used
Steam End
Figure L-2. Flange Bolt Torque Sequence
TORQUE — STUDS AND STUD BOLTS
TORQUE VALUES BELOW ARE TO ATTAIN APPROXIMATELY 45,000 PSI STUD

STRESS
SIZE THREADS PER INCH TORQUE (FT.•LBS.)
0.500 13 53
0.625 11 106
0.750 10 188
0.875 9 303
1.000 8 455
Table L-1. Applied Bolt Torques for Case Flange Bolts
1. After the joint is properly prepared, the threads that protrude through the flange
should be lightly coated with a thread lube/anti-seize compound.
2. Tighten all nuts in the sequence shown to approximately 50 percent of the
specified torque for the first pass and to the full torque value for a second and
third pass.
3. Check and, if required, retighten after the turbine is at normal operating
temperature using the sequence shown.

d. Apply anti-galling thread lubricant to the threads of all bolts.
e. Lower turbine cover onto lower half of casing. Ensure the cover seats evenly.
f. Install and tighten the horizontal flange bolts in accordance with Figure L-2,
Flange Bolt Torque Sequence and Table L-1, Applied Bolt Torques for Case
Flange Bolts. Tighten all nuts uniformly to approximately 10% of the specified
torque; then using the illustration as a guide, tighten to full torque. Check and
re-tighten after turbine is at normal operating temperature, using the sequence
shown.
g. For the SST 700H casing, tighten all bolts in sequence indicated in Figure L-3
to level 1, and then repeat the sequence at level 2, and then at level 3 indicated
in table L-2.
Figure L-3. Flange Bolt Torque Sequence, Series 700H
BOLTS BOLTS
#1-#24 #25-#38
FIRST PASS 2601-FT-LBS 2001-FT-LBS
SECOND PASS 5251-FT-LBS 4001-FT-LBS
THIRD PASS 5251-FT-LBS 4001-FT-LBS
Table L-2. Applied Bolt Torques Case Flange Bolts

h. Complete installing flange bolts using the sequence in Figure L-3 and the
applied torques in Table L-2.
i. After the turbine is completely re-assembled and the coupling is made up, it
should be brought up to operating temperature and the bolts checked again.
There should be no slacking off of the bolts as a result of heating and cooling.
j. When removing or replacing the top half of the casing, great care must be
exercised to avoid damage.
L.4 Carbon Ring Removal and Replacement
L.4.1 Carbon Ring Removal

L-4 Carbon Ring Assembly, Non-Condensing Turbine

L-5 Carbon Ring Assembly, Condensing Turbine
Figure L-4 Carbon Ring Assembly, Non-Condensing Turbine
When removing the packing rings, be sure to keep each ring by itself. Note that the
ring segments are marked; these marks should be placed together when fitting or
replacing the rings in the turbine. When gland leakage indicates the necessity of
packing ring maintenance, it is recommended that new rings be installed.

New packing rings furnished by Dresser-Rand will be made with the correct
diametral clearance, based on the original contract steam conditions. A packing
ring diagram, EW-33275 located in Appendix A, shows the part number and
location of each ring in the turbine.
When it is necessary to refit old rings (due to emergency condition) remove a small
amount, approximately 0.001”/0.025 mm from the ends of each segment,
maintaining flat square ends. The diametral clearance between the carbon rings
and the shaft should be as specified in the Packing Ring Diagram.
When installing new rings, the shaft surface should be smooth and highly polished,
clean and free of dust, water or oil. The spacer rings should be clean and smooth
with a true surface. If the sealing surface of the spacer ring is warped, the carbon
ring cannot seal. Warped spacer rings should be replaces. To install new carbon
rings, see Figure L-6 for procedure.
Figure L-5 Carbon Ring Assembly, Condensing Turbine
a. If there is a leak-off connected to the cover disconnect this and remove the
pipe from the cover.

b. Remove turbine cover according to the procedure specified in Section L.3.1.
c. Disconnect the garter spring ends. Remove the garter springs and carbon ring
segments. Note that the anti-rotation pin in the packing case may interfere
with carbon ring segment removal. If so, simply rotate the segment in the
opposite direction, or rotate the partition plate.
d. Inspect and clean the spacer rings. If the spacer rings are damaged they should
be replaced. The shaft will have to be removed. Refer to Section L.9 Rotor
and Turbine Wheel Removal and Replacement.
e. Clean the stainless steel high velocity oxy fuel-coated surfaces of the shaft
with stainless steel high velocity oxy fuel spray. Inspect the stainless steel
plating. If plating is bubbled, split or peeling the shaft must be replaced.
L.4.2 Carbon Ring Replacement

a. Thread the garter springs into the slots between the spacer rings.
b. Install the carbon ring set one complete set at a time. Be certain to maintain
the correct relationship between carbon ring segments by matching dots
stamped on each segment. Dots should face toward the wheel. The anti-
rotation notch must engage the anti rotation pin.
c. Connect the garter springs to retain the carbon rings.
d. Replace the turbine cover per Section L.3.1.

Figure L-6. Typical Carbon Packing Installation
L.5 Casing Labyrinth Seal Removal and Replacement

No field repairs of labyrinth are recommended. Slight deposits of the labyrinth on
the turbine shaft is an acceptable condition.
When installing new labyrinth rings, polish the shaft clean to remove any deposits
which may have formed.
Make sure that the quadrants of each ring are matched and that the rings are
installed in their proper position as identified in the packing ring diagram, EW-
33275. On installation of each quadrant of a gland-packing ring, make sure a
compression ring is installed in each hole. (See Figure L-7)
All SST turbine designs require removal of the turbine cover to remove, inspect,
and replace labyrinth seals. Refer to the appropriate section below to service these
labyrinth seals.
L.5.1 Casing Labyrinth Seal Removal

Refer to the following figure:
L-7 Labyrinth Seal Assembly
a. Remove the turbine cover according to the procedure specified in Section

L.3.1. The labyrinth seal segment(s) in the cover will be removed during this
operation.
b. Remove leak-off piping before removal of seals.
c. Inspect labyrinth seal segments, locating springs, and the shaft for corrosion,
scoring, or other damage. Clean all components. Replace any part that is no
longer serviceable. Labyrinth seal segments must be replaced as a set. Severe
rubbing one side of all labyrinth teeth may indicate a worn or failed thrust
bearing. Refer to Section L.6.2, Thrust Bearing Removal and Replacement, if
the thrust bearing is suspect.
L.5.1 Casing Labyrinth Seal Replacement

a. Install labyrinth seal segments into the lower half casing by rotating them
between the shaft and casing. Install the locating springs in the depressions, in
the segment and compress the springs as the segment is rotated.

b. Install the labyrinth seal segments into the seal housing lower half with
springs. Note that the labyrinth seal segments are matched-marked. Insure
that they are installed with their match-marks next to each other.
c. Install the labyrinth seal segments and springs in the seal housing upper half.
d. Replace the turbine cover and gland-housing cap according to the procedure
specified in Section L.3.1.
L.6 Turbine Bearing Removal and Replacement

SST turbines can be supplied with two, split sleeve journal bearings and one ball
thrust bearing. Shaft journal and bearing dimensions are shown on the turbine data
sheets. When running clearance is excessive, the bearings should be replaced not
re-babbitted. Approximately 0.004”/0.101mm over the maximum clearance is
considered excessive. However, if conditions permit and the unit runs smoothly,
bearings may be kept in service when clearances exceed the recommended
maximum clearance. It is left up to the discretion of the operating engineer as to
when bearing replacement is necessary. The bearings are longitudinally split to
permit removal and installation without removing the shaft.
M-4 Bearing Housing Assembly, Exhaust End Simple Bearing Case

M-5 Bearing Housing Assembly, Exhaust End Hi Cap Bearing Case
M-6 Bearing Housing Assembly, Non-Drive End Simple Bearing Case
M-7 Bearing Housing Assembly, Non-Drive End Hi Cap Bearing Case
L.6.1 Sleeve - Type Journal Bearing Removal and Replacement

The journal bearing can be inspected and replaced without removing the turbine
upper case.
Sleeve Bearing Removal

a. Remove the bolts securing the governor mounting housing to the steam end
bearing cap.
b. Use a soft drift and hammer to loosen the upper half of the bearing housing.
Tap on the area where the upper half overlaps the lower half. Remove the
upper half.
c. Lift, raise, and slide oil rings over to allow removal of the upper bearing half.

d. Raise the shaft slightly (0.040 inch/1 mm) to expose the bearing split line and
remove the upper bearing half.
e. Rotate lower bearing half out of the bearing housing with the locating tab
exiting the housing upon initial rotation.
f. The shaft can then be rested on the labyrinth seal or optional Inpro/Seal after
the bearing is removed.
g. Inspect bearings for wear or scoring. Replace if necessary. Refer to Section

B.9 for recommended sealant.
h. Inspect shaft journals. If journals are worn or scored, the shaft must be
replaced. Slight scratches or nicks can be removed by stoning or with crocus
cloth.
Sleeve Bearing Replacement

a. Verify that the bearing journal is clean and undamaged. Coat the journal with
turbine oil.
b. Lift the shaft (0.040 inch/1 mm) to permit sufficient room to rotate the lower
bearing half into the housing.
c. Rotate lower bearing half into bearing housing with the locating tab correctly
aligned with the slot in the housing. Note that the bearing split line is below
the bearing housing split line. On installation, the bearing stops will act as
dowels and properly locate the bearings.
d. Lower the shaft onto the lower bearing half.
e. Snap the upper half of the bearing into the upper bearing housing half, aligning
the tab so that it fits into the milled slot. After installation, check clearance
using plasti-gage or lead wire.
f. Place the oil ring(s) into slot(s) on the upper bearing half and verify that they
are free to turn.
g. Drain and clean bearing housing reservoirs and refill to the proper level with
clean oil.
h. Apply a thin coating of sealant to the horizontal joint of the bearing housings.
Refer to Section B.9 for recommended sealant.
i. Replace the bearing cap carefully, so as not to crush the sleeve bearing tabs.

j. Insert and drive in the dowel/taper pin.
k. Install washer and nuts on studs. Torque the nuts first to 25 ft-lbs (34 N-m)
and then to 55-65 ft-lbs (75-88 N-m).
l. Install bolts and torque them to 55-65 ft-lbs (75-88 N-m).
m. Rotate shaft by hand and observe oil rings through inspection holes in the
bearing cap to verify that rings rotate freely.
n. Install bolts holding upper bearing housing half to governor mounting housing.
L.6.2 Thrust Bearing Removal and Replacement

The standard thrust bearing is a ball bearing located in the non-drive end bearing
housing. Tilting pad thrust bearings are supplied optionally on some turbines.
Refer to the appropriate vendor manual for details.
For turbines where the governor is coupled to the shaft, remove steam end bearing
case cap and then uncouple and remove the governor. For gear driven Woodward
governors disconnect the governor linkage without disturbing the length of the
connecting rod, then remove the bolts that fasten the governor to the housing and
lift off the governor.
The thrust bearing is properly positioned on the turbine shaft by shims at the
factory and should require no adjustment. These shims are used to adjust the
nozzle ring-to-wheel clearance. See figure L-8. Shims are also used to set the
running clearance (float) on a shoe or collar type thrust bearing. Recommended
running clearance for the thrust bearing is 0.010” to 0.020”.
Thrust Bearing Removal

a. Remove the turbine rotor according to the procedure specified in Section L.9.
b. Remove lock nut and lock-washer from the turbine shaft.
c. On turbines with ball bearing journal bearings, remove the oil ring and oil
ring sleeve.
d. Using a suitable puller, remove the thrust bearing from the shaft. Tag both
sets of upper and lower shims to facilitate re-assembly.
e. Using a suitable puller, remove the journal ball bearings from the
shaft.

CAUTION
When removing or replacing ball bearings mounted on a shaft,

NEVER PRESS OR APPLY FORCE to the OUTER RACE, as
this may damage the races or balls. NEVER HAMMER on
either the inner or outer races. Bearings should be pressed on
or off shafts with a steady force. Always inspect the shaft for
burrs or foreign material and remove them as necessary, prior
to removal or installation of bearings. If a BEARING BINDS
during installation or removal, DETERMINE THE CAUSE and
CORRECT it rather than apply more force. Installation should
be performed by heating bearings prior to assembly. Heat
bearings slowly and evenly to a temperature not exceeding
250F (120C). Special electrical heaters are available from
industrial suppliers for bearing heating. Alternatively, bearings
may be heated in an oil bath.
f. On turbines with sleeve journal bearings, take care not to lose the flat spring
located in the bottom of the bearing housing groove. This spring prevents
rotation of the outer race of the thrust bearing.
Thrust Bearing Replacement

a. Install thrust bearing on the shaft with the shield (if so equipped) facing out.
Make sure that the bearing is installed with the manufacturer’s marking, such as a
bearing number or “thrust here”, facing upstream (towards the steam end of the
shaft). Before installing the bearing case cap, check thrust bearing adjustments for
the proper thickness of shims: 0.050”, 1.27mm minimum with assembled shaft
moved fully towards steam end. Set the clearance by properly positioning the
thrust bearing. See Figure L-8 below:
Figure L-8 Nozzle Ring-To-Wheel Clearance

b. On turbines with ball bearing journal bearings, replace the oil ring sleeve and
the oil ring.
c. Replace lock-washer and lock nut.
d. Bend the lock tab(s) to lock the nut into position.
e. Replace the turbine rotor into the turbine casing according to the procedure
specified in Section L.9.
f. To replace a ball-type thrust bearing, see steam end bearing case assembly and
longitudinal section drawings in Appendix A and proceed as follows:
g. Remove governor.
h. Remove steam end bearing case cap.
i. Remove bearing case end cover.
j. Disassemble parts from steam end of turbine shaft as necessary to gain access
to the thrust bearing; then remove the bearing. Tag both sets of upper and
lower shims to facilitate reassembly.
k. Reassemble by reversing the removal procedure. Make sure that the bearing is
installed with the manufacturer’s marking, such as bearing number or “thrust
here”, facing upstream (towards the steam end of the shaft). Before installing
the bearing case cap, check the thrust bearing adjustments for the proper
thickness of shims.
L.6.3 Ball-Type Journal Bearing Removal and Replacement

Bearing removal and replacement on SST 500 and SST 700 turbines with ball
bearing journal bearings is accomplished using the same procedure as that specified
for the thrust bearing in section L.6.2, Thrust Bearing Removal and Replacement.
The only exception is that there is no lock washer or nut retaining the bearing on
the drive end of the shaft. Removal of the exhaust end bearing requires the
removal of the coupling and outboard bearing housing seal. Refer to Section L.5,
Casing Labyrinth Seal Removal and Replacement.
L.7 Bearing Housing Shaft Seal Removal and Replacement

Bearing housings are provided with either labyrinth-type oil seals or optional inpro
seals or magnetic seals. These seals prevent oil leakage from bearing housings and
also prevent penetration of steam, dust, and dirt into the housings.

Bearing housing shaft seals are mounted on the turbine shaft. There are two seals
on the drive end bearing housing and one on the non-drive end bearing housing.
Inpro seals & magnetic seals are optional, non-contacting bearing housing oil seals
that replace the three standard labyrinth-type bearing housing seals. The drive end
bearing housing has both an inboard and outboard seal. The non-drive end has only
an inboard seal.
Inpro or Magnetic Seal Removal (Steam End)

Refer to the following figure:
L-9 Bearing Housings With Optional Inpro/Seals
a. Remove the half-coupling from the shaft.
b. Remove the rotor from the turbine according to the procedure specified in
Section L.9.
c. On sleeve bearing turbines, remove the thrust bearing from the shaft according
to the procedure specified in Section L.6.2
d. Clean the turbine shaft outboard of the seal.
e. Slide the seal assembly off the turbine shaft.
Inpro or Magnetic Seal Replacement (Steam End)

a. Clean the shaft and remove any burrs that could damage the seal O-ring.
b. Lubricate the shaft and seal O-ring with turbine oil to facilitate seal insertion
on the shaft.
c. Slide the seal assembly onto the shaft, placing it at is approximate final
position.
d. On sleeve bearing turbines, replace the thrust bearing according to the

procedure specified in Section L.6.2
e. Replace the rotor according to the procedure specified in Section L.9, using
care to correctly position the seal when installing upper halves of the bearing
housings.

f. Replace half-coupling on the shaft.
Inpro or Magnetic Seal Removal (Exhaust End)

(Note: Rotor must be out of the turbine.)
a. Remove the half-coupling from the turbine shaft.
b. Remove journal bearing, oil slingers, and any other items located outboard of
the innermost seal.
c. Slide the seal out of the recess in the bearing housing and off the shaft.
Inpro or Magnetic Seal Replacement (Exhaust End)

a. Clean drive end of the shaft and remove any burrs that could damage the seal
O-ring.
b. Lubricate the shaft and seal O-ring with turbine oil to facilitate seal insertion
on the shaft.
c. Slide the seal onto the shaft, placing it into the recess in the lower bearing
housing half.
d. Replace the upper bearing housing half according to the procedure specified in
Section L.6.
e. Replace half-coupling on the shaft.
f. Reassemble rotor into the turbine along with the steam seals.

Figure L-9. Bearing Housings with Inpro/Seals
L.8 Bearing Housing Removal and Replacement

SST bearing housings are attached to the lower turbine casing with bolts. Two
dowel pins on each housing, maintain their position. Alignment of bearing
housings to the casing and to each other is essential for vibration-free operation and
long bearing life. Bearing housings are accurately aligned at the factory prior to
pinning. Should it be necessary to remove or replace a bearing housing, it is
essential that the alignment be checked and corrected, if necessary, prior to re-
installation of the rotor.
Bearing housing alignment is a precision process that requires skill, experience,

and precise measurement. If there is any question regarding the ability of site
personnel to properly align bearing housings, Dresser-Rand recommends that a
factory-trained serviceman be engaged to perform the service. Contact your
Dresser-Rand manufacturer’s representative or the Dresser-Rand factory to
schedule a service visit.
L.9 Turbine Rotor & Turbine Wheel Removal and Replacement


M-0 SST Turbine, General View

M-1 Trip Throttle Valve Assembly
M-2 Governor, Mounting Housing, and Trip Components
M-3 Gland Sealing Elements
M-4 Hi-Cap Bearing Case Assembly, Exhaust End
M-5 Bearing Housing Assembly, Exhaust End
M-6 Bearing Housing Assembly, Steam End
M-7 Bearing Housing Assembly, Steam End
M-8 Case, Rotor and Mechanical Gland Seals
M-9 Case, Rotor and Carbon Ring Gland Seals
L.9.1 Turbine Rotor Removal & Replacement

The governor, turbine cover, casing labyrinth seals (if so equipped), and carbon
rings must be removed or disassembled to remove the rotor.
Turbine Rotor Removal

a. For turbines where the governor is coupled to the shaft, remove the steam end
bearing case cap; then uncouple and remove the governor. (See longitudinal
section, Appendix A). For a gear driven Woodward governor, disconnect the
governor linkage without disturbing the length of connecting rod, remove bolts
that fasten the governor to the housing and lift off the governor.
b. Remove the over-speed trip collar according to the procedure specified in

Section L.14.
c. Remove upper halves of bearing housings according to the procedure specified

in Section L.6.1.
d. Remove the top half of the turbine case according to the procedure specified in
Section L.3.
e. Remove shaft packing according to Section L.5.
f. Remove cap from the exhaust end bearing case and steam end bearing case (if
not already removed in step 1.
g. Remove both main bearing top halves.

h. Arrange a suitable support for the rotor assembly. Verify that turbine wheel
blades and bearing journal surfaces on the shaft will not make contact with any
surrounding object. Verify that the assembly will not roll off the support.
i. Use slings and a crane or hoist to lift the rotor assembly just out of the lower
half of bearings; then remove lower half of bearings. Use extreme care when
lifting the assembly to avoid damaging the wheel, blades, shaft, or sector.
j. Place rotor assembly on the support.
Turbine Rotor Replacement

a. Verify that the interior of the turbine casing is clean and that all foreign objects
have been removed.
b. Clean or replace journal bearings (if so equipped) and lubricate journal area of
the shaft to prevent scratching or scoring.
c. If so equipped, place lower journal half into the bearing housing. Position oil
rings so that they fit into openings provided in the bearing housings.
d. Using slings and a crane or hoist, lower the rotor assembly into the casing. Use
care to avoid damage to the wheel, blades, shaft, or sector.
e. Check clearance between first wheel and nozzle ring. This clearance is
obtained by properly locating the thrust bearing. See figure L-8 and thrust
bearing adjustment procedure in section L.6.2.
f. Replace casing labyrinth seals (if so equipped) according to the procedure

specified in Section L.5.
g. Replace turbine cover and gland housing upper halves (if so equipped)
according to the procedure specified in Section L.3.1.
h. Replace the sleeve bearing upper halves (if so equipped) and bearing housing
upper halves according to the procedure specified in Section L.6.
i. Replace the governor mounting housing
j. Replace over-speed bolt trip collar according to the procedure specified in

Section L.14.
k. Replace governor drive coupling governor and associated linkage according to

the procedure specified in Section L.12.
L.9.2 Turbine Wheel Removal and Replacement

This operation is to be referred to Dresser-Rand service facilities.
CAUTION
DO NOT allow the heating FLAME TO IMPINGE on turbine

BLADES, as this could anneal and WEAKEN them.
WARNING
Exercise appropriate CAUTION in handling the HOT WHEEL

during disassembly and assembly.
CAUTION
Be certain to assemble the wheel and shaft with THE

SHORTER BLADES TOWARD the NON-DRIVE END OF THE
SHAFT. Otherwise, the rotor cannot be installed.
L.9.3 Turbine Rotor Balancing

Whenever a wheel or shaft is replaced, the wheel and shaft subassembly should be
dynamically balanced. This procedure must be performed by a Dresser-Rand
repair facility.
L.10 Nozzle Ring Removal and Replacement

Nozzle rings contain one or more nozzles which expand the inlet steam to a lower
pressure, creating the necessary kinetic energy (velocity) at the entrance of the first
wheel blading.
L.10.1 Nozzle Ring Removal

After the rotor and guide ring have been removed from the lower half turbine
casing—
a. Loosen and remove nozzle ring cap screws. This may, at times present
a problem. Broken screws will have to be extracted or drilled out.
Note: When nozzle ring is secured with inner and outer bolts, no caulking
strip is used.
b. The nozzle ring may now be lifted out of the casing. Mark the ring to
identify its location if reused (upper or lower half).
L.10.2 Nozzle Ring Replacement
Nozzle rings are caulked in at the outer periphery and bolted to the steam ring
nozzle bolting face of the main casing when a single row of bolting is used. When
a double row of bolting is used, there is not a caulking strip.
a. Identify the upper and lower half nozzle ring. If necessary check that the
valve port bridge walls match their seal surfaces using bluing or white lead.
b. Check that the clearance holes in the nozzle ring and tapped holes in the
steam ring face agree.
c. Thoroughly clean the sealing surface at the steam ring face. If the
surface is smooth, the most common sealing compounds are Turbo R or
Turbo 50. If the surface is rough, use Copaltite. If these compounds are
not available, use a key paste or a mixture of graphite and oil. If none of
these compounds is available, call Dresser-Rand Technical Support.
d. Bolt the nozzle ring half in place. The cap screws should be pulled tight
but not over-tightened. If Allen wrenches bend during tightening, the
screws are overstressed and their heads may snap off when the unit comes
up to temperature. Over-tightening of screws must be avoided. Prick-
punch head clearance holes at four positions so that cap screw heads (if
broken off) cannot come out into the steam path.
L.11 Hand-valve Removal and Replacement

Hand-valves are optional items. Depending on steam conditions, required power
and speed, and initial customer requirements, the turbine may incorporate no hand-
valves, one hand-valve, or two hand-valves.

The purpose of hand-valves is to isolate a nozzle or group of nozzles from inlet

steam, thereby allowing the turbine to operate at reduced power output without
excessive throttling. When operated at reduced power in this fashion, the turbine is
more efficient than it would be if all nozzles were active.
Hand-valves should be either fully open or fully closed, never in between.

Operating with a partially closed hand-valve is not only inefficient, but could result
in steam cutting of the seat resulting in excessive leakage. When putting the unit
into operation, do not close a hand-valve tightly until the turbine is up to operating
temperature and all parts are evenly heated. The reason for this is that the material
of the valve stem is subject to greater thermal expansion than the turbine casing,
and if the valve is closed tightly when cold, it may lock the valve in the closed
position making it difficult to open.
Refer to Figure L-10, Hand-valve Assembly.
L.11.1 Hand-valve Removal
WARNING
Close and tag inlet and exhaust isolating valves and open
drains to depressurize the turbine casing and steam chest
before maintaining hand-valves.
Note: Removal of the hand-valve is done from inside the turbine case.
a. Remove the turbine casing cover and bearing case covers, uncouple the turbine
rotor, and remove the carbon rings. See instructions in other sections of this
manual for these steps.
b. Remove the turbine rotor. Remove the nozzle ring.
c. Once the nozzle ring is removed you can see the hand-valve seat (761). Pull out
the hand-valve seat. The fit is on-line to 0.004” loose.
d. Remove the hand wheel (758). Remove the hand-valve bonnet (750).
e. Push the stem and disc assembly out towards the inside of the turbine. Remove
the old hand-valve packing (754). Note: Count the rings removed.
f. Clean the seat area, nozzle ring face, and all areas that might have sealant.
L.11.2 Hand-valve Replacement

a. Inspect the stem and disc assembly. Hand-valve collar (752) should be tight
and staked to the disc (751).
b. Insert the new stem and disc assembly into the turbine hand-valve location.

c. Make sure the seat (761) and the bore of the turbine case are clean. Insert the
seat into the hole where it was removed. If there is a slight interference, cool
down the seat in a freezer or with liquid Nitrogen.
d. Install the nozzle ring in accordance with instructions in other sections of this
manual.
e. Assemble new packing (754). Put in the same number of packing rings as
were removed.
f. Assemble bonnet (750) and hand wheel (758). Tighten the bonnet to compress
the packing until you feel a slight drag on the stem when you screw it in and
out.
L.11.3 Reassembly of the Turbine Rotor and Upper Half Casing

a. Clean all surface areas (turbine casing split-line, bearing case split-lines, etc).
b. Assemble the carbon rings, turbine cover, and bearing case covers per
instructions given in other sections of this manual.
L11.4 Handvalve Adjustment
a. One steam is admitted into the unit, re-tighten the hand-valve bonnet so there
is no steam leaking out of the steam area. This might have to be done again
when there is full pressure inside the casing to prevent leakage at the high
internal pressure.
b. The valve stem should be screwed fully closed or fully open. It should never
be partially open or closed.

Figure L-10. Hand Valve Assembly
L.12 Governor Removal and Replacement

M-2 Governor, Mounting Housing, and Bolt Trip Components

L-11 Direct Drive Governor Assembly
L-12 Gear Drive Governor Assembly
L.12.1 General
Field service on the oil relay governor is normally limited to yearly oil changes per
Section J, and droop setting adjustment, which is described in the governor manual
provided in Appendix B.

In the event that the governor exhibits operational problems, Dresser-Rand

recommends that the governor be removed as a unit and returned to the factory for
repair or overhaul, as required. In the meantime, a replacement oil relay governor
can be quickly and easily installed to keep the turbine in operation. The Dresser-
Rand factory maintains a stock of certain TG replacement governors for rapid field
delivery, and is equipped to perform comprehensive repair, overhaul, and testing of
oil relay governors.
For shipment, care should be exercised to support the governor by its mounting
flange and not by its shaft extension.
Some governors are direct-drive types coupled to the end of the turbine shaft by
couplings, as shown in Figure L-11. Others, due to speed requirements, are
connected by right-angle gear reduction units, as shown in Figure L-12.
L.12.2 Governor Removal (Direct Drive)

a. Drain oil from governor (300) at drain.
b. Disconnect connecting rod (1075) at governor lever (445) by removing

connecting rod end (1070). Do not disturb position of rod end (1070) bearing
on rod (to preserve open/close stroke adjustment).
c. Rotate turbine shaft (1), if necessary, to disengage coupling hub (303) by

loosening coupling setscrew.
d. Prop or support governor (300); then, unbolt governor from mounting housing
(201) and slide governor out of mounting housing. Be careful not to lose the
governor key.
e. Remove governor trip latch (446) (if same governor is not to be used as
temporary replacement) by loosening its setscrew.

Figure L-11. Direct Drive Governor Assembly
L.12.3 Governor Replacement (Direct Drive)

a. Install governor trip latch (446) and tighten lever set-screw securely.
b. Slip coupling spider between jaws of coupling (303) hub on turbine shaft
extension.
c. Install coupling hub (303) on governor shaft.
d. Slide governor (300) into place on mounting housing (201), verifying that
coupling (303) engages properly.
e. Install and tighten screws to secure governor to mounting housing (303). There
should be 1/16 inch (1.6 mm) play for the coupling spider between coupling
hubs. Coupling access is available through the open side of the mounting
housing. Tighten screw to secure coupling.
f. Reconnect connecting rod (1075).
g. Remove governor breather cap and fill governor with oil to proper level
indicated on sight glass.

h. Rotate turbine shaft (1) slowly by hand to ensure that governor and coupling
are free to turn when placed in operation.
L.12.4 Governor Removal (Gear Drive)

a. Drain oil from governor (300).
b. Disconnect connecting rod (1075) at governor lever (445) by removing

connecting rod bolt. Do not disturb position of rod end bearing on rod (to
preserve open/close stroke adjustment).
c. Remove cap screws securing governor (300) to gearbox (316) adapter; then,
lift governor vertically from adapter. The coupling (303) will remain on the
governor shaft at removal. Do not remove governor lever or coupling from
governor if same governor is to be installed again. If a new governor is to be
installed, transfer lever and coupling (with keys) to new governor. The lever
and coupling are secured to governor shafts by setscrews.
Note: The coupling, which joins the governor and gearbox shafts, is supplied with
the gearbox.
L.12.5 Governor Replacement (Gear Drive)

a. Verify that coupling and keys are installed on governor shaft, and that the
governor lever is mounted to its shaft at the side of the governor.
b. Lower governor (300) on gearbox (316) adapter with coupling key slots
positioned to allow mating of keys and key slots of shaft and coupling (303) as
governor and adapter flanges meet.
c. Rotate governor to align cap screw holes; then, install cap screws tightly.
L.12.6 Governor Drive Gearbox Removal

The governor (300) must be removed according to the procedure specified in
Section L.12.4, above, before the gear (310) and governor drive shaft (306) can be
removed.
a. Drain oil from steam end bearing case (200).
b. Remove pin (304) from coupling (303) to release coupling from governor
drive shaft (306).

Figure L-12. Gear Drive Governor Assembly

c. Remove lock-nut (313) and lock washer (312) retaining gear onto governor
drive shaft (306). Slide gear (310) up off of shaft (306), being careful not to
lose key (311).
d. Remove shim (308) being careful to document order of removal/replacement.
e. Remove snap ring (318) retaining bearing into housing (301). At this point the
governor drive shaft (306) can be extracted from the housing (301).
f. Prop or support governor drive shaft (306) in a vice being careful not to scar the
shaft surface and remove the snap ring (318) retaining the ball bearing (339).
At this point both ball bearings (339) and (305) can be pressed from the
governor drive shaft (306) for replacement.
The Dresser-Rand factory maintains a stock of replacement governor drive shaft

parts for rapid delivery to the user, and is equipped to perform complete repair and
overhaul service on gearboxes.
L.12.7 Governor Drive Gearbox Replacement

a. Install governor drive shaft (306) into housing (301) and install snap ring
(318). Replace shim (308), locate key (311) into slot on governor drive shaft
(306) and install gear (310), lock washer (312) and lock-nut (313) securing
gear onto governor drive shaft (306).
b. Install coupling (303) and pin (304) into and onto governor drive shaft (306).
c. Before installing the governor, check and record the backlash of the new gear.
In future inspections, use this dimension as a guide in determining the
necessity for replacement. If backlash is questionable use Dyken layout blue
or printers ink to check for proper mesh of gears. When a good mesh is
indicated, the gear may remain in service.
c. Mount governor (3004) onto housing (316), verifying that the splines on the
governor shaft slide into the coupling (303) easily. Install mounting bolts to
secure governor (300) onto housing (316).
d. Fill hydraulic governor with oil. Refer to Woodward Bulletin 25071 in

Appendix B.
e. Fill steam end bearing case (200) with recommended lubricant to required
level, as indicated by oil sight gage plug.
L.12.8 Governor Valve Travel and Linkage Adjustment

M-1 Trip Throttle Valve Assembly

L-11 Direct Drive Governor Assembly
L-12 Gear Drive Governor Assembly
L-13 Trip Valve Linkage
Adjustment of the linkage between the governor and throttle should be carried out
whenever linkage components, or the governor itself, are replaced. Rig the throttle
linkage as follows:
a. Check that the governor linkage is approximately at right angles to governor

connecting rod. (See upper view of figure L-13). Adjust the length of the
connection rod as necessary.
b. Back off the lock nuts on both sides of the governor lever block.
c. Pull the connecting rod out of the Woodward governor as far as it will go.
d. Push the connecting rod back toward the governor 3/16”/4.76mm. (To hold
this position while making the adjustment, place a block equal to the existing
clearance between the connecting rod end and the mating fitting on the
governor—see lower view in Figure L-18.
e. Push the valve stem in until the valve just seats.
f. Tighten the lock nuts on both sides of the governor lever block to secure
the ajdustment.
L.13 Trip and Throttle Valve Maintenance
CAUTION

If the turbine is equipped with a throttle or trip valve

manufactured by a party other than Dresser-Rand refer to the
accessory documentation section of this manual for installation,
operation, and repair and maintenance instructions.
M-1 Trip and Throttle Valve Assembly

L-13 Trip Valve Trip Linkage
L-14 Throttle Valve Trip Linkage
The design of the Dresser-Rand trip and throttle valve assembly permits routine
maintenance (disassembly and assembly) procedures while still mounted on the
turbine and without disconnecting the inlet piping. For major overhaul or
necessary machine work, remove the valve as indicated below.
WARNING
BEFORE SERVICING ANY COMPONENT of the combo valve,

verify that the ISOLATING VALVE in the INLET LINE is
CLOSED AND TAGGED. If the turbine is connected to the
exhaust steam header, CLOSE the ISOLATING VALVE in the
EXHAUST LINE AND TAG IT. OPEN ALL TURBINE DRAINS
to ensure venting of all pressure before disassembly begins.
CAUTION
In the following procedures, remove and replace all parts slowly

and carefully to avoid damage (digs, bends, scoring, chipping,
etc.) to conditioned surfaces. DO NOT use excessive force to
remove parts. Use backup bracing for unsupported parts when
taper pins or dowels are removed by hammer and drifts.
L.13.1 Valve Removal from Turbine

The steam strainer should be removed and cleaned at least once a year and
replaced every three years. Since it is necessary to remove the governor
valve before the strainer can be withdrawn, the governor valve and its seats
should be inspected and reground if necessary. To replace either the

governor valve or the steam strainer, proceed as follows: (See Figure L-

14).
a. Remove valve adjusting nut and washer.
Note: Do not disturb settings of lock nuts and connecting rod-ends (17 and 19) on
rod (18) unless parts need to be replaced. These are factory-set to provide
the required stroke for the rod.
b. Remove snap ring from the governor lever pin; then remove the pin and
carefully slide the governor lever off the governor valve stem.
c. Remove the nuts that secure the steam chest cover to the steam chest and
carefully remove the cover without contacting the valve stem.
d. Pull out the governor valve (see governor section, Appendix A).
e. Remove bolting at turbine flange; then, lift valve by slings and hoist to service
area for further disassembly.
f. Remove as an assembly together with the steam strainer.
g. Perform necessary maintenance and reassemble by reversing the removal

procedure.
h. After completing installation, set the following:
Overspeed Trip
Overspeed Trip Linkage
Governor Valve Travel

Finger 22 21 20 3 Valve Seat Bushing

Stem
Strainer
Figure L-13. Overspeed and Governor Valve Linkage
Legend 15. Lockscrew

1. Cap 8. Case – Steam End 16. Lever - Governor
2. Lever 9. Steam – Bellows 17. Pin
3. Lever – Trip 10. Bracket - Low Oil Trip 18. Rod End
4. Lever – Trip Connection 11. Low Oil Trip 19. Rod - Connecting
5. Rod – Trip Connection 12. Governor Cup 20. Shaft - Trip
6. Plate – Top 13. Adjusting Screw 21. Collar
7. Latch – Trip Assembly 14. Emergency Weight 22. Trip Finger & Lever

Figure L-14. Throttle Valve Linkage
Legend
1. Bushing – Valve Seat 8. Stem - Valve 14. Cover – Steam Chest
2. Bushing — Valve Stem 9. Pin 15. Lever - Governor
3. Valve 10. Bearing 16. Pin
4. Steam Chest 11. Bushing – Valve 17. Rod End
5. Gasket Stem-Outer 18. Rod- Connecting
6. Bracket – Governor Lever 12. Block - Pivot 19. Rod End
7. Bushing - Valve Stem - Inner13. Block – Sliding 20. Lever
L.13.2 Woodward TG Governor Valve Travel Setting

a. Remove pin that connects the governor lever to the connecting rod end.
(See Figure L-15.)
b. Push the governor lever in until valve just seats and hold this position.
c. Push connecting rod toward the valve closing direction (see arrow on
illustration) as far as it will go and hold this position.
d. Adjust the length of the connecting rod so that the hole for the pin in the
rod end is approximately 1/8”/3.75mm beyond the mating hole in the
governor rod.
e. Release the connecting rod and insert the connecting pin.
L.13.3 Woodward TG-13L Governor with Fisher Control

The Fisher pneumatic speed mechanism acts in conjunction with the Woodward
TG-13L governor to adjust the turbine speed to refined limits. If speed re-
adjustment is desired, re-locate the pin to another hole in the lever (see Governor
Speed Control Schematic, Appendix A).
The Fisher control can be used as a direct or reverse type control; either to increase governor
speed settings as control air pressure signal increases, or the reverse type to increase governor
speed as control air pressure signal
decreases.
Figure L-15. Governor Valve Travel Setting – Woodward TG Governor

L.13.4 Alternate Governor Valve Stem Connection

Some Dresser-Rand turbines may be equipped with an alternate method of securing
the governor valve stem to the rotating governor lever. This connection should be
installed so that the inner and outer washers are tight against the alignment pin.
The operator should be able to turn the washers by hand with no lost motion after
tightening the inner and outer jam nuts.
Figure L-16 Alternate Governor Valve Stem Connection

L.14 Emergency Valve Maintenance
WARNING
BEFORE SERVICING ANY COMPONENT of the Overspeed

Trip Mechanism, verify that the ISOLATING VALVE in the
INLET LINE is CLOSED AND TAGGED. If the turbine is
connected to the exhaust steam header, CLOSE the
ISOLATING VALVE in the EXHAUST LINE AND TAG IT.
OPEN ALL TURBINE DRAINS to ensure venting of all pressure
before disassembly begins.
The overspeed trip mechanism may be readily disassembled or assembled at a

workbench and then mounted to the turbine as a subassembly. Prerequisites for this
process are removal of the governor and coupling according to the procedure
specified in Section L.12, followed by removal of the overspeed trip collar (90)
from shaft (1), as described below.
It is important that the entire emergency trip system be properly adjusted and free
of binding or lost motion. The operation of the overspeed trip should be tested as
often as possible, especially at times that maintenance is performed and a
permanent record should be kept of these tests. The over-speed trip should
function to shut down the turbine within 2% of the speed specified on the turbine
data sheets. If the operational tests in Section I.6 indicate a requirement for
adjustment, proceed as follows:
L.14.1 Governor Cup Removal

L-13 Overspeed and Governor Valve Linkage

L-14 Throttle Valve Linkage
L-15 Governor Cup Assembly
a. Gain access to the overspeed governor cup.
For turbines with a Woodward gear driven governor – remove bearing

case end cover.
For turbines with a Woodward governor that is coupled to the shaft –

remove the steam end bearing case cap.

b. Manually rotate the turbine shaft (1) until the lock screw (P/N 15, Figure L-13
or P/N 92, Figure L-15) is accessible; then loosen the lock screw.
CAUTION
If the Overspeed Governor Cup Assembly is replaced, the rotor

may need to be re-balanced with the new assembly attached.
Figure L-17. Governor Cup Assembly
Legend:
90. Cup – Governor 94. Spring

91. Screw – Adjusting 95. Bushing - Weight
92. Set Screw 96. Ring – Retaining-Open type
93. Weight 97. Ring – Retaining-External type
b. Using a suitable spanner tool, turn the adjusting screw (91) clockwise to raise
the tripping speed or counterclockwise to lower, as necessary.
c. Tighten the lock screw (15 or 92) (setscrew) securely to lock the adjustment
position, then repeat the over-speed trip test (see warning below).

WARNING
The overspeed trip assembly should be locked in place before

starting the turbine. Four checks to make are as follows:
1. The overspeed governor cup must be tightly screwed into

the shaft.
2. If supplied, one of the tabs of the lock-washer is bent into

the miller slot of the overspeed cup. (The overspeed cup will
have two milled slots for the tabs of the lock-washer, but it will
only be possible to line up one of the tabs. This is due to the
fact that the tabs are not symmetrically located around the
outer diameter. There is no need for concern as long as one of
the tabs can be completely bent over into the slot.)
3. If the overspeed cup has drilled and tapped holes for half
dog point set screws, the shaft must be drilled at final assembly
with the overspeed cup in accordance with the table below to
ensure the tip of the dog point locks into the shaft. The set
screws must be tightened and staked into place.
4. The run-out of the cup must also be checked and adjusted

to within 0.002 inch (.05 mm) total indicated run-out.
L.14.2 Governor Cup Replacement

CAUTION
The adjusting screw/spring combination has been pre-set at the

factory for the trip speed originally set when the turbine was
shipped. Refer to Section L.14.7, Trip Linkage Adjustment, if
minor trip speed changes are to be made.
WARNING
Adjusting Screw (91), spring (94), and setscrew (92) are a

FACTORY-CONFIGURED SET, selected to obtain the proper
trip speed for a specific turbine. DO NOT MIX OR
INTERCHANGE THESE PARTS with similar parts from other
turbines or attempt to modify these components. Consult your
local Dresser-Rand manufacturer’s representative or the factory
if replacement parts are needed.
L.14.3 Trip Mechanism Disassembly
For 4” and 6” trip and throttle valve systems, the clearance between the overspeed trip
lever (Figure L-13) and the emergency weight (P/N 14) or (P/N 93 in Figure L-14) is
properly set at the factory for 0.060”/1.524mm plus or minus 0.010”/0.254mm. Gain
access to the over-speed governor cup as described in the preceding section L.14.1.
For 4” and 6” Venturi trip systems, the clearance between the over-speed trip lever
(figure L-13) and the emergency weight (P/N 14 or P/N 93) is properly set at the factory
for (0.090”/2.286mm plus or minus 0.010”/0.254mm. Gain access to the overspeed
governor cup as described in section L.14.1.
Rotate the turbine shaft (1) to position the overspeed weight adjacent to the overspeed
trip lever and measure the clearance. If adjustment is necessary, proceed as follows:
a. Loosen lock screw that secures the valve lever trip connection to the valve
spindle.
b. Slide valve lever connection along the valve spindle away from the steam
chest to increase the clearance, toward the steam chest to decrease the
clearance.
c. Tighten the lock screw to securely hold the valve lever connection.

L.14.4 Emergency Valve Travel

a. Unlatch valve lever (P/N 3, Figure L-13) to close emergency valve.
b. Manually pull out on the governor linkage to close the governor valve. On the
turbine, it may be necessary to remove the pin from the connecting rod. (See
lower view of Figure L-18)
c. With the governor valve fully closed, raise the valve lever until the emergency
valve will not open further (do not spring the valve lever).
d. Measure the clearance between the latch surface of the valve lever and the
latch surface of the trip lever. The clearance should be approximately ¼”/6.35
mm.
e. If adjustment is required, loosen the lock screw in the valve lever connection;
then reposition the valve lever connection and serrated valve spindle clockwise
or counter-clockwise as necessary to obtain the correct clearance.
NOTE: After making this adjustment, it will be necessary to re-check the

setting of the over-speed trip linkage.
L.14.5 Emergency Valve Removal and Replacement

a. Remove governor valve and steam strainer as described in section L.13.1.
b. Remove lock screw in the valve lever connection; then slide the valve lever
connection off the serrated valve spindle.
c. Remove access plug in the steam chest located above the valve spindle; then
remove the lock screw that secures the valve spindle to the valve link.
d. Remove access plug in the steam chest in line with the valve spindle and
withdraw the valve spindle.
e. Remove the valve link by sliding up and away from the valve stem.
d. Remove the valve portion of the assembly and inspect the valve seat.
NOTE: If the valve seat must be replaced, the steam chest must be removed from
the turbine.
e. Re-assemble and install the emergency valve by reversing the removal

procedure.

4 5
Figure L-18. Trip Valve Lever Orientation-Trip Valve Open and Closed
After completing installation, set the following:

Overspeed trip
Overspeed trip linkage
Governor valve travel
Emergency valve travel
L.14.6 Trip and Throttle Valve and Steam Strainer

The following are procedures for replacement of the steam strainer:
a. Close the main steam valve.
a. Disconnect the pressure and drain line connections at the oil cylinder flanges.
c. Disconnect the linkage from the governor lever.
d. Remove the bolts that fasten the trip throttle valve body to the valve body
cover.
e. Remove the bolts that fasten the valve body cover to the valve body; then lift
off the valve body cover.
f. Lift out the emergency valve guide.
g. Pull out the steam strainer.
h. Perform the necessary maintenance and re-assemble by reversing the removal

procedure.
i. For procedures on a vendor valve, see Appendix B.
NOTE: The 6” trip and throttle valve cover is equipped with a throttle screw that
regulates the amount of steam from the inlet side of the valve to the chamber
above the main disc. If chattering of the main disc is encountered when
opening the valve, it is necessary to increase the leakage to the chamber by
turning the throttle screw counter-clockwise. If, however, the hand-wheel
effort appears excessive, it can be reduced by turning the throttle screw
clockwise, thus decreasing the leakage to the chamber. A pipe tap is provided
in the cover to be used for a pressure gauge to check the pressure chamber
after the pilot valve has been opened. This leakage pressure should be
approximately 25% of the line operating pressure.

Section M
Replacement Parts/Factory Service
M.1 Factory Replacement Parts

Dresser-Rand Turbine recommends that only Dresser-Rand-supplied parts be used
in Dresser-Rand turbines. The use of Dresser-Rand parts ensures that replacement
components are manufactured from the highest quality materials, to exacting
tolerances and specifications, thereby assuring safe, efficient, long-lasting, and
maintenance-free operation under service conditions for which the turbine was
designed and built.
Dresser-Rand and selected Dresser-Rand manufacturer’s representatives maintain a

supply of the most frequently requested spare parts for immediate shipment
worldwide. Parts requested less frequently can be manufactured quickly on an
emergency basis when required.
Your Dresser-Rand manufacturer’s representative can supply you with a stocking

list of recommended spare parts for your turbine or turbines, allowing you to stock
spare parts at your facility. Refer to Section M.4, Recommended Spare Parts.
M.2 Turbine Identification

Dresser-Rand SST turbines are marked with a serial number, which appears on the
nameplate and is also, stamped on horizontal flange of the inlet casing. This serial
number is used by the factory to identify the turbine and should be used in all
inquiries and parts orders.
M.3 Parts Identification
When inquiring to determine parts availability, or when placing an order for spare
parts, the following minimum information is required:
Item Typical Example

Turbine serial number: XXXX
Part description: Shaft
Reference number: 21

Section Drawing LE-169235-N
If the turbine parts list is available, then the Dresser-Rand part number should also
be specified.
WARNING

RAND repair parts on this turbine could result in serious
– Replacement Parts/Factory Service.
M.4 Recommended Spare Parts

The recommended spare parts for a turbine owner is provided in the service
manual. The inventory recommendation for spare parts is based on Dresser-Rand’s
long experience with turbine applications.
M.5 Ordering Parts

Contact your local Dresser-Rand manufacturer’s representative to order parts. Your
representative will be pleased to provide any assistance you may require, as well as
to quote prices and delivery dates.
The following information is required when placing a parts order:
1. Your purchase order number.
2. Complete billing, shipping, and marking instructions.
3. Turbine serial number--from nameplate or horizontal flange of inlet casing.
4. Turbine frame size--from nameplate, i.e., 300, 500, 700, etc.
5. Quantity of each part or assembly.
6. Part or assembly reference number from drawing, illustration, or text.
7. Section drawing the reference number was taken from.
8. Description of part or assembly.

9. Dresser-Rand part number, if known (optional).
M.6 Service
Dresser-Rand Turbine maintains repair facilities on a worldwide basis to repair
equipment needs with OEM manufactured parts. When contacting Dresser-Rand,
please have your turbine serial number available.
Contact a service center nearest you by using the link below:

http://www.dresser-rand.com/contactUs.php
A Service Representative can also be dispatched to your site to assist you in start-
ups, general maintenance, and troubleshooting by using the same link (above).
Have your turbine serial number available along with a date for when services will
be required.
The Technical Support group at the factory can address your technical questions by
using the contact information below:
Dresser-Rand Wellsville Operations

37 Coats St.
Wellsville, NY 14895
USA Tel: (Int’l +1) 585-596-3100
Fax (Int’l +1) 585-593-5815
When contacting the representative or factory, please specify the turbine serial
number, frame size, nature of the problem or service requirement, and date that
service is required.
M.7 Revamps (Rerates)
It’s not uncommon for the requirements of the steam turbine to change due to a
process change, more product output, or just a need to reduce energy consumption.
Steam turbine can have a broad operating range. Powers and speeds can be
modified with simple internal hardware changes while still maintaining the same
steam turbine case and footprint.
If you would like to have Dresser-Rand review your equipment, please use the
contact information above the find the nearest service center or contact the factory
direct. Have your serial number available along with the new conditions you
would like to operate at.

WARNING
Materials used in turbine construction (cast iron, steel, stainless

steel, special alloys) vary with steam conditions, speed, and
power. These materials were selected according to the original
rating of the turbine. NEVER attempt to re-rate a turbine without
the assistance of a Dresser-Rand manufacturer’s
representative and/or the factory. Misapplication of materials
could result in serious equipment damage and/or personal
injury.
M.8 Upgrades
Many of older turbines can be modified or upgraded to improve performance and
reliability. Improved designs in seals, bearings, controls, and blading can all be
incorporated into the existing machine when required.
If you would like to have Dresser-Rand review your equipment, please use the
contact information above and find the nearest service center or contact the factory
direct. Have your serial number available.
M.9 Factory Start-Ups

Authorized Dresser-Rand service representatives are available for start-up service
and to train operating personnel in the operation and maintenance of Dresser-Rand
steam turbines. An experienced service representatives will review your installation
prior to start-up, following established Dresser-Rand procedures. Piping,
alignment, lubrication, overspeed trip, etc. will be carefully checked. Upon
commissioning the new installation, operating personnel will be trained.
Consult your Dresser-Rand manufacturer’s representative to schedule a start-up.
M.10 Parts Catalog
Refer to the applicable turbine cross sectional drawings included in the instruction
manual for a listing and location of the replacement part reference numbers used on
your turbine.

Section N Miscellaneous
N.1 Low Ambient Temperature Applications of Single

Stage ASTM A216-WCB Carbon Steel Pressure
Casing Steam Turbines
Dresser-Rand has been asked to provide a quotation for steam turbines that may be
installed into an area with an ambient temperature of –30°C (-20°C) or less.
The quoted D-R single stage turbine is offered with ASTM A216 Grade WCB
carbon steel pressure casing material that will meet the Charpy V-Notch Energy
requirements of ASME Pressure Vessel Code Section VIII, Division 1, UG-84 as
required by API 611 for ambient temperatures –30°C (-20°F) or higher. The
pressure vessel bolting is ASTM A193 Grade B7, and nuts are ASTM A194 Grade
2H or ASTM A563 Grade A, which also meet the requirements of the Pressure
Vessel Code and API 611for ambient temperatures of –30°C (-20°F) or higher. If
the offered turbine is installed into an area with ambient temperatures of lower than
–30°C (-20°F), the equipment user must take precautions to insure that the turbine
casing be kept warm and/or be warmed prior to equipment start-up to meet the
requirements of ASME Section VIII, Division 1, UG84, as appropriate.
When a steam turbine is in operation, the casing temperature s above the

brittle/ductile transition temperature of the casing material. Therefore, a low
ambient temperature is not a concern. However, to insure that the low ambient
temperature does not result in damage or failure of the turbine and its accessories, it
must be installed, started, operated, and shut down as described in the Low
Ambient Steam Turbine Application Guidelines outlined below. If compliance
with these guidelines and acceptance of the offered standard materials is not
possible, consult Dresser-Rand for further discussion or an alternate material
offering.
Prior to the purchase of the turbine, the final equipment user, driven equipment
vendor, and Dresser-Rand shall agree to the special precautions necessary with
regard to low ambient conditions that can occur during operation, maintenance,
transportation, erection, commissioning, and testing.
Dresser-Rand shall assume no liability of any nature for the offered turbine if not
transported, erected, installed, started, operated, maintained, and shut down as
described in compliance with the “Low Ambient Steam Turbine Application
Guidelines” outlined in this document.

Low Ambient Steam Turbine Application Guidelines

Note these requirements apply to both API and non-API applications.
General:
When a steam turbine is to be installed where the ambient temperature could be –

30°C (-20°F) or lower, the following issues require special attention to insure that
the low temperature does not result in damage or failure of the turbine and/or its
accessories.
See the turbine instruction manual for additional turbine installation and
operational details and the accessory instruction manuals for their cold start/low
ambient precautions and recommendations.
Transportation:
The turbine is suitable for transporting to site, unloading, and placing in storage, or
transporting to site, unloading, and placing on its foundations, or moving from on-
site unheated storage to its foundations, only when ambient temperature is at or
above –30°C (-20°F).
Installation:
The turbine and its auxiliaries can remain out of service with no external source of
heat when the ambient temperature is at or above –45°C (-49°F), provided the
turbine is not disturbed when its metal temperature is below –30°C (-20°F),
Turbine maintenance cannot occur unless the temperature of the turbine and all its
mechanical components is at or above –30°C(-20°F).
Turbine installation cannot proceed until the turbine and all its mechanical
components are t or above –30°C (-20°F). Alternatively, if the turbine components
are below –30°C (-20°F), the area musts be hooded and heated to raise the
component temperature above –30°C (-20°F).
Care must be taken to insure that the steam inlet and exhaust piping is properly
supported or equipped with flexible connections so they will not put excessive
force on the turbine when it is shut down. The turbine casing and inlet and exhaust
flange material are more prone to cracking when the ambient temperature is cold ad
their temperature is below the brittle/ductile transition temperature. This is of
increased concern if the piping is hot when the turbine is shut down and the inlet
and exhaust shut off valves are closed.

All turbine condensate drain connections and steam piping low points must be
properly drained to insure all condensate can be removed from the turbine and
steam system during shot-down. Similarly, cooling water lines to bearing housings
and water coolers, bearing housing water jackets, and oil coolers must be equipped
with drains to insure that water can be removed during shut-down.
Failure to remove all water from the turbine casing, piping, cooler,, bearing
housing, etc. when temperatures are below freezing could result in failure of the
piping and various other components.
If oil reservoirs, oil or water piping, bearing housings, and other components are
heat-traced, all local safety regulations and electrical codes must be adhered to.
Lubrication:
Dresser-Rand offers a variety of lubrication systems including oil ring lubrication,

oil ring lubrication with circulating oil cooling, circulating oil lubrication, mist oil
lubrication, and force feed lubrication.
When the ambient temperature is 15°C (60°F) or lower, it must be ensured that the
lubricating oil will circulate and that cooling water, if required, does not freeze
during operation or shut-down. Heat tracing or insulation of oil lines, bearing
housing, oil tanks, and water cooling lines may be required. Lubricant type and
required oil viscosities for turbine equipment packages are defined in the certified
drawings and data package and the applicable operation and maintenance manuals.
Viscosities for turbine lubrication are application specific, and the required
viscosity may range from ISO 32 (32cSt@40°C (100°F) 150 SUS @40°C (100°F)
up to ISO 100 (100 sSt @ 40°C (100°F) 550 SUS@40°C (100°F),
Use of the correct lubricants at the correct temperatures and viscosities is critical to
the trouble free operation of the turbine and its accessory equipment.
Accessories:
Some turbine accessories may require installation, heat tracing, special lubrication,
or adjustments for use in low ambient conditions. Others may require installation
into heated locations or preheating before use. The accessory instruction manuals
or accessory vendor must be consulted for additional guidance and precautions.
A partial list of typical turbine accessories might include governors, gauges, oil
pumps, control panels, instruments, reduction gears, lube oil systems, couplings,
steam piping, valves, solenoid valves, tachometers, ejectors, condensers, etc.
Turbine Start-Up:

Warming the Turbine Pressure Casing:
If metal temperature is at or below –30°C (-20°F), a warm-up of the complete

turbine must be performed prior to start-up, including the use of hooding and space
heating to elevate the metal temperature of all steam-contacted components to a
temperature of at least –30°C (-20°F) prior to the introduction of steam to the
turbine.
If metal temperature is above –30°C (-20°F), steam from the client’s exhaust steam
header piping may be used to preheat the cold back pressure turbine prior to start-
up. If exhaust steam is not available for this purpose, a small steam bypass line,
equipped with a valve, may be installed around the inlet block valve or start-stop
valve to allow preheating of the turbine casing with a small flow of inlet steam.
Allow the turbine casing to reach 15°C (60°F) or exhaust steam temperature before
proceeding further.
During warming, all turbine casing and associated steam piping drain valves must
be opened to allow liquid to drain from the turbine casing and its associated steam
piping. Take special care to insure all liquids are drained prior to closing the
valves for turbine start-up.
Prepare the Lubrication System for Start-Up
If the ambient temperature is less than 15°C (60°F), lubricating oil and, if supplied,
the lubrication system and oil piping must be warmed to 15,C (60°F) to insure that
the oil will flow to the bearings and back to the oil reservoir or oil tank.
For ring-oiled turbines, the oil temperature should be such that the oil rings will
turn and pick up the oil. This may require that a hot liquid be circulated through
the bearing housing “cooling” water jackets. “Cooling water,” if less than 15°C
(60°F), which may be required during normal turbine operation, should not be
applied to the bearing housing water jackets until the bearing housing temperature
exceeds 15°C (60°F), which may be required during normal turbine operation. For
turbines equipped with pressure lubricating or circulating oil systems, the lubricant
must be warmed to a viscosity such that the oil pump will prime and deliver
lubricant to the turbine bearings. His may be accomplished by use of a steam
heating coil or electric heating element. If electric heating elements are used, the
watt density should not exceed 23W/in² (3.5W/cm²), and a sheath temperature of
100°C (212°F) to avoid carbonizing the oil. After the lubricant is warmed, it must
be circulated throughout the entire lubrication system by means of a hand, motor,
or steam driven pump to warm all the associated lubrication system components
prior to turbine start-up.

After heating the lubricating oil or determining that it does not require heating, start
the turbine per the instruction manual. Turn the turbine over slowly for a short
time, insuring that the oil rings are turning and/or the lubrication system is
delivering lubricant to the turbine bearings.
Operation:
Operate in accordance with normal operating routine, except that to maintain

suitable lubricating oil temperature and viscosity, it may be necessary to heat the
oil instead of cool the oil, especially if there are long un-insulated or unheated oil
lines between the turbine and a remote lubrication system.
With some turbine speed governors, a change in the governor oil viscosity may
have an effect on the speed of the turbine. Therefore, when operating a turbine in
low ambient temperature, it may be necessary to make manual adjustments on the
speed governor.
Shut Down
After the unit is shut down in accordance with the instruction manual, special care
must be taken to insure that all water is drained from the steam lines, turbine
casing, bearing housing water jackets, valves, oil coolers, etc. Freezing water in
the turbine or its associated systems can cause major damage or problems during
the next turbine start-up. Any lubricant or accessory heating system should be
turned off to avoid overheating unless advised otherwise by the manufacturer’s
instruction manual.
If there is steam from other processes in the exhaust piping, leave the exhaust valve
open. If the turbine is to be shut down or a short period of time or is on standby,
thereby avoiding the need to preheat the pressure casing on restart. Case drain
valves should be left open.
When properly drained of water, the turbine and its auxiliaries can remain out of
service with no external source of heat when the ambient temperature is at or above
–45°C (-49°F) as long as the turbine is not disturbed when its metal temperature is
below –30°C (-20°F). Turbine maintenance cannot occur unless the turbine and all
is mechanical components are at or above –30°C (-20°F).

N.2 “Quick” Start,”Fast” Start, “Automatic” Start

Dresser-Rand Single Stage Steam Turbines
In the case of a “quick” start when the turbine is not thoroughly warmed nor
gradually brought up to the minimum governor speed, the principal areas of
concern are: (1) water slugging (2) bearing lubrication, (3) rotor acceleration rate,
and especially (4) sudden temperature differentials across the turbine.
1 Water Slugging
Since the velocity of a water particle passing through a turbine is low relative to the
steam and rotating blade velocity, such particles can cause extensive damage as
they impinge on the rotating blading. Furthermore, the downstream force
generated by such particles impinging on the rotor blading can be high enough to
cause thrust bearing failure. The warming of a steam turbine allows for
vaporization and removal of condensate in the steam inlet line ahead of the turbine
and in low points of the casing.
2 Lubrication
Without immediate and constant oil feed, the heat generated by the shaft in the
turbine bearings, unless properly dissipated, can cause bearing failure. Oil ring
lubricated bearings provide immediate lubrication as the shaft begins to turn, so
long as the proper oil level is maintained in the bearing housings. With pressure
lubricated bearings, the lubrication system must be arranged such that oil fills the
supply lines and feeds the bearings when the shaft begins to turn.
3 Acceleration Rate
With steam turbine applications that are started with no load, the acceleration rate
of a low inertia rotating element can be so high that the control system response to
close the steam admission valve does not react prior to overspeed trip. This
particularly true of the turbine generator sets which may also require limited
frequency variations in the electrical system. In instances such as this, a ramp
effect on governor valve closure may be built in the control system.
4 Temperature Differential
On turbines with built-up rotors, the disc-to-shaft allowance tends to decrease to

unacceptable limits with a 200°F (93°C) temperature differential between the disc
and shaft. The probability of such a condition existing is greater at approximately
five minutes after start-up, rather than immediately at start-up. Loss of shrink fit
can result in axial; or wobble movement of the disc on the shaft, possibly resulting
in turbine breakdown. The colder the unit at start-up, the greater the probability of
the temperature differential occurring. Since the utilization of forged discs in lieu

of plate discs allows a higher shrink fit, we normally recommend the customer
consider using forged discs.
5 General:
The subject of “quick,” “fast,” or “automatic” start is not something new in the
steam turbine industry. Nor has Dresser-Rand decreased its engineering standards
for design of steam turbine shafts, bearings, or shrink fit of discs to shafts.
In general, reliability and durability are compromised by quick starting of a turbine

and will result in shortened overall turbine life. Frequent quick starts are
particularly severe on bearings and rotating elements. The more rapid the
acceleration rate, the higher are the transient loadings and the more severe are the
loading effects.
Dresser-Rand single stage turbines with standard construction are suitable for start-
up in five seconds provided the following conditions are met:
3. The inlet temperature of the steam shall not exceed
750°F (399°C).
4. The differential temperature between inlet steam and
exhaust steam shall not exceed 350°F (177°C).
5. Back pressure shall be maintained on the casing during
shut-down. (This in itself is not a recommended
operating condition due to possible shaft wire cutting or
carbon ring seal decay, but will keep the casing warm).
6. The operating speed of the turbine shall not exceed 6000
RPM.
In operating a turbine under the above conditions, the user must bear the
responsibility for bearing failure, loss of disc-to-shaft fit, and carbon ring decay.

N.3 Dresser-Rand Standard Policy on Equipment Sound

Levels
It is Dresser-Rand’s intention to design and manufacture turbines with satisfactory
sound levels and work cooperatively with the user to make the overall installation
as quiet as possible. However, there are many environmental factors affecting
sound measurements which are beyond Dresser-Rand’s control. These might
include piping, room size, and other equipment or structures near the unit which
may tend to focus, reflect, or amplify sounds, as well as emit other sounds. In view
of this, Dresser-Rand is unable to guarantee noise levels other than to commit to a
willingness to assist the end user in corrective action (at end user’s cost) in cases
where a noise problem may be perceived to be present.
Expected sound levels for various types of Dresser-Rand-built equipment operating

at full load in a typical field installation are given below. Sound levels for the
turbine or gear alone isolated in a non-reflecting environment may be significantly
lower.
Octave Band Center Expected Sound Pressure Levels

Frequency (HZ.) (dB-Ref. 2 x 105 Nm²
Single Stage Multistage Reduction
Turbines Turbines gears
Acoustic Insulation  No Yes No Yes No Yes
63 97 96 105 104 103 102
125 92 91 97 96 99 98
250 90 88 91 89 93 91
500 89 86 90 87 91 88
1000 87 83 87 82 87 82
2000 85 82 87 82 87 82
4000 84 81 87 82 87 82
8000 84 81 87 82 87 82
Expected Over-All 88 85 90 85 90 85
(dBA)
The breakdown above gives maximum expected dB levels for each octave band
under typical operating conditions. Actual values for each octave band would
normally not equal all these maximum values. Hence, expected over-all sound
levels given above for each type of equipment are lower than the sum of the
individual (maximum) values.

Section O
LOW VOLTAGE ELECTRICAL COMPONENTS
O.1 LIST OF POSSIBLE INSTALLED ELECTRICAL

PARTS AND THEIR APPLICATIONS ON 350/500/700
SST TURBINES
There are numerous combinations of electrical devices installed in some

turbines. Below is a listing of the possible electrical components found on SST
turbines in various configurations.
Electronic Governor. Some of the electronic governors used on the SST

turbines are manufactured by Tri-Sen, Compressor Controls Corporation, and
Woodward. Magnetic speed sensors, in most cases a quantity of two, are
installed either external to the exhaust end bearing case or internally or
externally on the steam end bearing case. The sensors read a gear internally
mounted on the rotor shaft and are wired typically by the customer to the
electronic governor input location. The electronic governor serves the same
purpose as a mechanical governor (covered elsewhere in this manual) for
controlling turbine speed. The electronic governors provide an analog signal
output which can be utilized for remote customer DCS monitoring purposes.
Electronic governors also provide a means for relay control which can be
programmed to alarm and or trip other customer processes, as well as an option
for remote control via a switch panel either provided by the customer or
installed by Dresser-Rand. The electronic governors maintain turbine speed
through the use of an actuator. The actuator adjusts the governor valve in
response to the typical 4-20 mA signal received from the electronic governor.
A governor program is part of the documentation provided the customer

when an electronic governor is applied. Within the governor program are
the parameters, which are entered via keypad into the governor, when it is
programmed for operation.
Magnetic Speed Sensors. The electronic governors, tachometers, and
electronic over-speed protection require the use of speed probes to provide a
voltage-pulsed input for accurate turbine control. Each sensor is factory set to
the recommended adjustment gap between the probe tip and target.

Limit Switch. The trip and throttle valve may have a limit switch mounted on
the valve to indicate closed position of the valve. The contacts can be
configured as normally open or normally closed per customer requirement.
Solenoid operated emergency trip valve. The over-speed tripping of the
turbine can be accomplished by a mechanical method covered elsewhere in
this manual. Electronic options are available to trip the turbine in an over-
speed condition through a solenoid valve which dumps the air or control oil
from the trip valve operational configuration. D-R recommends that the
solenoid valve be wired through an interposing relay to safely sustain the
current required for the solenoid valve operation.
A customer controls interface is required if it is desired to have a customer trip
signal incorporated into the emergency tripping of the turbine. This set of controls
needs to be accomplished via a trip string of series interconnected contacts, any of
which would de-energize the trip solenoid valve, thereby tripping the unit.
Vibration Monitoring. The turbine shaft radial movements at both the steam
end, exhaust end, and axial thrust bearing displacement can be accomplished
by vibration probe and proximitor hardware. In addition to the radial and
axial probes is the inclusion of a keyphasor probe for the Bently Nevada
asset monitoring equipment, which is D-R’s standard vibration monitoring
recommended vendor. The vibration probes are sized and installed in the
bearing cases for optimum length to clear accessories mounted on or near the
bearing case. Proximitors are typically shipped installed into a junction box
or loose. In some cases provisions only are provided the customer and
installation holes in the bearing cases are plugged.
Bearing Temperature Monitoring. D-R offers RTD or thermocouple
electronic bearing temperature monitoring capabilities. The bearings can be
equipped with the customer-specified instruments embedded within the
bearings by D-R. The temperature instrument wires exit through the bearing
case through Minco trade name seals where terminal heads are then
installed, providing wire termination points. Single and dual element
temperature instrumentation is available. When provisions for future
temperature monitoring are requested by the customer, bearing cases have
installation holes machined and plugged so that bayonet style RTDs or
thermocouples could be installed at a later time.
Seismic Bearing Case Monitoring. Accelerometers are available for
installation on the bearing cases, an alternative to the more sophisticated
probe and proximitor type of shaft monitoring. They monitor the rotational
vibration levels being transmitted to the bearing case.
Electronic Speed Monitoring (tachometer). Electronic tachometers are available for
local and remote speed monitoring. Some tachometers have programmable relays for
optional alarm and trip interface with customer DCS or PLC equipment. Self-powered

tachometers are an available option. In most cases only one magnetic speed sensor is
required for use with the tachometer.
Electronic Overspeed Protection. Over-speed tripping of the turbine can be
accomplished by a mechanical method covered elsewhere in this manual. Electronic
options are available to trip the turbine in an overspeed condition through a solenoid
valve which dumps the air or control oil from the trip valve operational configuration.
D-R recommends that the solenoid valve be wired through an interposing relay to safely
sustain the current required for the solenoid valve operation. There are three magnetic
pickup speed probes supplying signals to the over-speed protection device.
Over-speed trip devices are composed of three separate modules which are in communication
with each other. If one magnetic pickup fails, the unit will continue to operate with the two
remaining speed input signals but will trip when one of the signals exceeds the over-speed trip
setting on one of the modules. Normal operation compares the three speed signals and takes
the two highest out of the three signals to trip the turbine, hence the name two out of three.
During the programming of the over-speed device it is of utmost importance that the exact
number of targets being read by the speed probes be correctly entered.
Electronic/pneumatic throttle valve actuator and controls. Any SST turbine with an
electronic governor requires an actuator to be attached to the inlet governor valve to receive the
signals from the governor for valve movement and positioning and, if desired, provide valve
position feedback for monitoring. The most common actuator used, the electro-pneumatic
actuator, has a current to pressure interface where the electronic governor, via analog signal, is
electrically connected to the actuator and accurately controls its force/movement on the throttle
valve.
Electronic pressure transmitters. There are some instances where a remote pressure
measurement is required, which can be provided with an electronic pressure transmitter. There
are several types of communication methods available by which the transmitter can interface
with the customer PLC or DCS.
Electronic temperature transmitters. There are some instances where a remote temperature
measurement is required, which can be provided with an electronic temperature transmitter.
There are several types of communication methods available by which the transmitter can
interface with the customer PLC or DCS.
O.2 Electrical Component Removal and Replacement
CAUTION

DO NOT perform work on any live electrical device or

component without a thorough lockout/tagout procedure in
place.
WARNING
Only professionally certified electricans are to be working on

the SST electrical components.
The upper half of the turbine exhaust and steam end bearing cases must be removed
to gain access to the shaft bearings and turbine rotor for RTD and thermocouple
access. See section L.3 for turbine case disassembly.
The procedure for removing and replacing the radial and journal bearings, which contain the
temperature monitoring hardware, is presented in section L.6.
Magnetic pickups are mounted on either the steam end or exhaust end bearing cases and can be
removed and replaced per field instruction procedures without the removal of the bearing cases.
Terminal heads can be removed from the pickup via the union and wiring removed from the
terminal blocks. In some instances the magnetic speed probes are installed inside the bearing
cases, in which case the bearing case must be disassembled to facilitate probe removal.
Limit switches indicating T&T valve position can be accessed from the outside of the valve and
removed by removal of the flexible conduit attached to the switch and removal of wiring from
the terminal blocks.
Vibration probes are mounted into the external cover of the bearing cases and can be removed
and replaced without turbine disassembly. Adjustment of the probes is accomplished with a
voltmeter set on DC voltage and turned until the voltage reads 9 volts DC whereby the locking
nut is secured in place.
The electro-pneumatic actuator is readily removable from the throttle valve body and removal
of flexible conduit and wiring disconnection from the terminal blocks.
The governor and over-speed protection equipment are shipped loose to be installed in the
customer control room, in most cases. For those cases where they are not shipped loose, both
devices are installed in a skid-edge enclosure with operators mounted on the external enclosure
door allowing for local governor operation when installed in a hazardous location. Wiring can
be removed from the terminal blocks allowing the components to be replaced.
In some cases, where there are RTDs and vibration probes as well as limit switch indicators of
the T&T valve position, there could be enclosures containing terminal blocks. These enclosures

could be installed on the turbine base on a junction box stand with conduit running from each
electrical device, mounted on the steam turbine, to the enclosure.
Accelerometers are installed externally on the bearing case caps and are readily accessible for
removal and probe cable disassembly and re-assembly.
Tachometers are shipped loose in most cases. They can be easily removed and replaced by
removal of the flex conduit at the union and disconnection of wiring from the terminal blocks.
Pressure and temperature transmitters are typically locally mounted by D-R and wired by the
customer. In cases where there is a skid-mounted enclosure, disconnection and reconnection
from terminal blocks and flex conduit with a union can remove the transmitter wiring.
O.3 Electrical Certification and Standards

The electrical components installed on all SST turbines are selected to satisfy the
specific electrical area classifications indicated/required by the customer. All
wiring is performed to meet current codes of the various countries where the SST
turbines will be operating: NEC (National Electric Code), IEC (International
Electric Code), ATEX Low Voltage criteria, ATEX Machinery Directive, CSA
(Canadian Electric Code), CCOE (Chief Controller of Explosives) in India,
GHOST in Russia among others. If required, the turbines will be wired to satisfy
intrinsically safe (IS) wiring methods as well as providing purged enclosures and
barriers.
Dresser-Rand wiring protection standard for electrical packaging is using conduit.

D-R can provide armored cable and tray for a cost adder.
O.4 Electrical Maintenance
O.4.1 Routine maintenance

It is the customer’s responsibility to carry out the routine maintenance per the
Dresser-Rand maintenance manual.
O.5 Electrical Packaging
O.5.1 How wiring is marked, protective conductor marking

Wiring is marked using electrical schematic drawing component tag numbers with
permanently embossed wire markers of heat shrinkable sleeve slip on type labels at
each end of the wire. If customer tag numbers are required, these labels are
installed on each conductor in addition to the Dresser-Rand label markers. The

terminal numbers to which the wires are terminated to are always provided on the
wire marker.
See Figure O-1 of a typical electrical schematic showing the wiring marker
information and termination methods. The wire markers are to be used from the
information in the bubbles (D-R standard tag number) as well as customer tag
numbers (located adjacent to D-R tag bubbles) if provided. Customer wiring is
shown as dotted lines.
Figure O-1 Typical Electrical Schematic Tag Numbers for Wire Marking
O.5.2 Control devices labeled

Control devices such as trip valve test pushbuttons and emergency stop buttons are
labeled with descriptive nameplates mounted on the housing of the operator
spelling out their specific function. If the customer has tag numbers, these are
included as a separate label or included in the wording of the label. See Figure O-2
for the detail of the tags indicated on the electrical schematic.

Figure O-2 Typical Tag Number Labels Attached to Junction Boxes
O.5.3 As built connection boxes and wiring routing

Enclosures are supplied either to be shipped loose or are installed on the turbine
which house the vibration proximitors and temperature monitoring devices with
customer wiring termination access. The Dresser-Rand standard is for 20% spare
terminal blocks to be provided. Weidmuller SAK-4EN terminal blocks are
Dresser-Rand standard.
No splices shall be permitted in any wire of cable and no more than two wires per
terminal shall be used.

All wiring shall be terminated in centrally located junction boxes. Wiring in the
boxes shall be run and laced together in an orderly fashion with all nylon tie wraps
from where it leaves the conduit bushing to where it connects in the terminal box.
Here is a list of electrical components which have resistance loads and therefore
power consumptive heat can be generated. Calculations are analyzed to insure that
enclosures are selected in a large enough size to dissipate excess heat generated
from housing electrical components.
COMPONENT WATTAGE
Peak 150 governor 38 Watts
Solenoid dump valves 36 Watts
Tachometer 15 Watts
Magnetic pickup 50 Watts
Electro-pneumatic actuator 5 Watts
TABLE O-1 WATTAGES OF ELECTRICAL COMPONENTS USED ON SST

From this table it is demonstrated that there are minimal thermal loads being added
to the overall thermal contribution from the electrical components used on SST
turbines.
O.5.4 Materials of conduit and how supported

Dresser-Rand’s standard for wiring protection is to use rigid galvanized steel
conduit supported with Unistrut installed on the baseplate, if provided. See figure
O-2 section O.5.9 for a graphic example of conduit routing on a baseplate.
All conduit runs are are to be a minimum of 10” distance from all steam lines and
steam casings, both horizontally and vertically.
Liquidtight (flex conduit) shall be used for connections to all equipment where
adjustments or vibration requires flexible connections. Maximum length of the
Liquidtight is 36”. Internal grounding wires are provided when applicable from the
device to the grounding bar installed inside the junction boxes.
O.5.5 Percentage fill of conduit

All wiring for the SST turbine does not exceed the minimum percentage fill limits
per the sizes of conduit applied.
O.5.6 Procedure to protect wiring when shipped loose

If electrical components are to be shipped loose, the wiring from the turbine to the
component will be coiled up with protective wrapping applied to the coils. The
wiring markers are installed on the wires for determination of connection to the
correct termination point per the electrical schematic and layout drawings
associated with the contract.

O.5.7 Terminal head drawing

Figure O-3 is of a standard supplied ¾” terminal head which typically are installed
on limit switches, solenoid valves, magnetic pickups and other electrical
components which do not have their own wiring termination protective hardware.
Figure O-3 Standard ¾” Terminal Head
O.5.8 Wiring into J-box

Junction boxes shall be arranged for side or bottom entry only. Top entry is not
allowed. Conduit unions shall be provided to facilitate replacement or removal of
instruments and junction boxes.
Seals are provided for wiring entrance into all enclosures if the hazardous area
classification requires them.
Hubs are installed into the bottom of the enclosure for Dresser-Rand electrical shop
wiring entrance. Customer connections are left for field installation unless
customer requests hub installation at the factory.
Vents and drains are provided in the top and bottom of the enclosures to allow
moisture from condensation to be drained. The drains and vents are specified in
accordance with the level of protection provided with the enclosure.

Dresser-Rand incorporates Crouse-Hinds and Hoffmann enclosures unless there are

customer requirements for other suppliers. At a minimum the enclosures are 304
Stainless Steel with NEMA 4X ingress protection ratings.
Here is a description of the ATEX-certified (NEXT) Crouse-Hinds enclosure gasketing:

Features include thirteen basic sizes in two standard depths to optimise the
accommodation of rail-mountable terminals or components.
 Fully removable lid, concealed hinges provide 180° opening

 Lid fixing, two or three stainless steel captive screws on one side
 Lip on upstand increases gasket contact area, ensuring high degree of ingress protection
 Internal / external earth stud
 40mm wide fixing lugs for assembly on standard frames
 Option of 0, 1, 2, 3 or 4 gland plates with earth stud
 One piece gasket on lid and gland plates
 Padlock hasp available as additional accessory
The retained stainless steel slotted hex bolt fastenings provide a rapid means of
achieving high integrity ingress protection (IP) of 66 for reliable & rapid
environmental protection. The high integrity “single piece” sealing gasket for
superior ingress protection (IP) of 66 and excellent recovery and re-sealing
properties for continuous environmental protection. An integral drainage channel
prevents liquids or other solids contaminates from running in or falling into the
enclosure when the door is opened, and to minimize gasket path contamination. An
integral external & internal feed through brass earth / ground stud assembly enables
rapid and reliable protective earth / ground connection mounted on the side of the
enclosure for ease of access.
Here is a description of a Hoffmann ATEX certified enclosure:
 Easy-to-use Type 316 stainless steel quarter-turn door latching

 3-mm double-bit insert for security
 Slot and through-hole side-mount hanging brackets
 Lift-off door hinges
 Fabricated from Type 316 stainless steel
 Type 316 stainless steel external fasteners
 Gray silicone high-temperature gasket on doors and gland plates
Internal/external brass earth/ground provision

FIGURE O-4 Enclosure Gasketing Details
O.5.9 Wiring routing drawing

In most cases the electrical wiring is in the customer’s scope from the magnetic
pickup termination head, the solenoid valve termination head, the limit switch
termination hardware, and the temperature monitoring device termination head. In
a few cases the turbine is sold with a baseplate and conduit runs from the
termination heads to the baseplate mounted junction boxes. Figure O-5 shows an
example of non-typical conduit routing into baseplate mounted enclosures.

Figure O-5 Example
of conduit routing, non-typical application
O.5.10 Details of neutral conductor

On the Dresser-Rand electrical schematic the conductor information is provided in
the notes section of the drawing.
O.5.11 Drawing stating markers for terminals and conductors

Dresser-Rand’s standard electrical schematic states the terminal type and
manufacture on the enclosure sheet of the schematic. Conductor data is located in
the notes section of the electrical schematic drawing, providing manufacture and
conductor part number data.
O.5.12 Drawing showing how cover plates are tied into bonding

On the Dresser-Rand electrical schematic/layout drawings the details of the

enclosure are provided with notes on gounding and bonding of components.
O.5.13 Drawing showing how protective bonding cross-sectional area of

circuit conductors.
Maximum impedance for protective bonding. Details of the circuit conductors are
provided in the notes section of the electrical schematics.
O.5.14 CE listed components are wired per manufacturer’s instructions.

Testing of component wiring per CENELEC EN60204-1 standards and data are
recorded on FAT form.
O.5.15 Prevention of touch voltage

Testing of touch voltage test limits per CENELEC EN60204-1 standards and data
O.5.16 Electrical shock hazard warning

There are electrical shock hazard warnings attached to the turbine per CENELEC EN60204-1
standards and the verification data is recorded on FAT form that all applicable drawings are
showing correct warning placement.
O.5.17 Peak starting currents and permitted voltage drops.

The electronic governors are capable of riding out minimal electrical supply
disturbances
O.5.18 Confirmation of use of SST electrical components:

A. Temperature
Electrical components provided by Dresser-Rand are selected for use within the
environmental parameters presented by the customer. The terminal blocks,
Weidmuller SAK-4EN, have a maximum temperature rating of 100C.
B. Altitude
environmental parameters presented by the customer. The terminal block
creepage and clearance values were calculated for 2000m above sea level.
C. Containment
environmental parameters presented by the customer.
D. Ionizing and non-ionizing radiation
E. Vibration

F. Shock
Electrical components provided by Dresser-Rand are selected for the use in
environmental conditions presented by the customer specifications.
G. Physical environment
environmental conditions presented by the customer specifications.
H. Operating conditions
operational conditions presented in the customer specifications.
I. Voltage ride-through
Electronic governors, electronic overspeed protection, solenoid valves, limit
switches and all other electrical equipment requiring external power will revert
to shelf state in the event of disconnection from the power supply. It is the
customer responsibility to provide backup power supply capabilities if it is
imperative that the turbine stay operational at all times. The Woodward Peak
150, the most common governor used on SST machines, has a ride-through
characteristic of 28 milliseconds for the 24 VDC power source range of 18-32
VDC. Ride-through is 50 milliseconds for a 120 VDC power source range of
90-150 VDC and 4 cycles ride-trhough for 100 VAC power source range of 88-
132 VAC with a frequency range of 47-63 Hz. Input voltage fluctuations within
the acceptable ranges listed above will not affect operation of the Peak 150
control.
J. Harmonics
The power quality of the electrical power supply is the responsibility of the
customer. It is the customer's responsibility to insure that the supplied electrical
power provided to the steam turbine is absent of power harmonics per the IEC
standards.
K. Ingress protection
The levels of ingress protection which are spelled out in the customer
specifications will be applied in the equipment installed on the turbine.
L. Gaskets on Enclosures
The enclosures specified by Dresser-Rand have the proper gasketing seals on the
enclosure doors to meet the customer specifications. See Figure O-4 above for
typical enclosure gasketing standards.
M. Tensile stress in cables
See Figure O-6 below for pull tension in Alpha Xtra Guard 5 cables or
equivalent typically used for wiring of RTDs and speed probes. The pull
tension of the 20 AWG is 298 N/mm2 and the pull tension of the 18 AWG wire
is 302 N/mm2 both well beyond the maximum requirements of 15 N/mm2 per
EN 60204-1:2006.

Figure O-6 Cable Pull Tension and Capacitance Properties

N. Types of insulation and documentation Figures O-6 and O-7
O. Heating effect on conductors
The wiring insulation provided by Dresser-Rand is certified to the highest
temperature rating available. In the notes section of the electrical schematics are
instructions to the electricians to place conduit runs at a minimum of 10” from
steam lines.
P. Drains
It is a Dresser-Rand standard to install vertical drains on all conduit low points.
Junction box vents and drains are installed as prudent engineering practice.
Q. Potential earth terminal leakage current
O.6 Electrical Testing

Which specific electrical testing is required for each turbine is delineated in the
Inspection and Test Plan (ITP) which is created for each turbine contract. In this
section is information pertaining to the possible tests which could be required.

O.6.1 Insulation test plan and certification

High potential (hipot) voltage testing with use of an insulation testing device
known as a MegOHM (meggar) resistance tester determines the condition of
insulation of the turbine wiring. Wires can be checked for good isolation between
the parts of a circuit, which helps to guarantee the safety and quality of electrical
circuits. Hipot tests are helpful in finding nicked or crushed insulation, stray wire
strands or braided shielding, conductive or corrosive contaminants around the
conductors, terminal spacing problems, and tolerance errors in IDC cables. All of
these conditions might cause a device to fail.
The Insulation Resistance test is typically done on every cable tested. It is usually
done at 300 to 500 Vdc with 100 to 500 Megahoms resistance. The test is a very
sensitive to contamination in the assembly process. Solder flux, oils, mold release
agents, and skin oil all can cause problems. This test excels at identifying insulation
that will conduct in the presence of moisture.
O.6.2 Functional preliminary testing

Each unit with an electronic governor is subjected to a Functional Acceptance Test
(FAT) . Items checked, signed and dated are:
b. Dimensions and correct construction of the panels are checked that they conform
to the drawings.
c. All components and instrumentation are checked for conformity.
d. Panel hardware is checked that it conforms to drawings.
e. All AC and DC power inputs are checked for shorts and isolation between
circuits and grounds
f. Panel is checked for internal grounding circuits.
g. Circuit breakers are closed and checked for governor and interface wiring.
h. All AC and DC power inputs to the panel are checked with proper voltage
supplies.
i. Electronic governor program is checked for accuracy.
j. All alarm inputs to panels are simulated for proper indication .
k. All trip modes in control system are simulated for proper indication on panel.
Trip signals are verified.
l. The balance of control loops are simulated, checking for correct operation,
indication, and outputs.
m. All circuits are checked for continuity.
O.6.3 Functional bonding test data

Testing of bonding per CENELEC EN60204-1 standards and data recorded on FAT
form.
O.6.4 High leakage current test limits and terminal leakage current

Testing of high leakage current test limits per CENELEC EN60204-1 standards
and data recorded on FAT form.
O.6.5 Analysis and test report documents showing barrier protection

Testing of barrier protection per CENELEC EN60204-1 standards and data
O.6.6 Documentation on insulation of Wire and Terminal Blocks

Testing of insulation current test limits per CENELEC EN60204-1 standards and
data recorded on FAT form.
Here are some of the details of the Alpha wire which is a standard Dresser-Rand
component. Bend radius is 10X cable diameter, pull tension is 56 pounds
maximum, voltage rating is 300 Volts RMS, capacitance is 26 picofarads per foot
at 1 kHz nominal, ground capacitance is 47 picofarads per foot at 1 kHz nominal.
Inductance is 0.16 micro henries per foot nominal, conductor DCR is 6.4 ohms per
1000 feet at 20 degrees C, nominal, OA shield DCR is 4.5 ohms per 1000 feet at
20 degrees C.
The maximum and minimum temperature rating range of the typically used Alpha
wire is from –80 to 200C. This wiring is used for the actuator, magnetic speed
probes and RTD temperature monitoring and very infrequently is located within
conduit runs which are near the bearing cases and actuator. The steam chest is
typically jacketed with a thermal insulation barrier for protection of surrounding
equipment and personnel. In most cases the customer is providing the wiring to the
actuator terminal head as well as the RTD and magnetic speed probe termination
heads installed on the bearing cases. The temperature levels are much lower than
the inlet temperatures in proximity to the bearing cases.
O.6.7 Documentation showing no residual voltage

Testing of residual voltage test limits per CENELEC EN60204-1 standards and
data recorded on FAT form.
O.6.8 Documentation showing size and location of terminal points, all wire
is copper, PE connections
Dresser-Rand standard electrical schematics show the size and location of terminal
points as well as wire type and manufacture and PE connections.
O.6.9 Test report on SST conductor clearances with each other.

Testing of conductor clearances per CENELEC EN60204-1 standards and data
recorded on FAT form. The values for the conductor clearances and creepage were
calculated from an Extract DIN VDE 0110-04.97. This standard is a technical
adaptation of IEC Report 664/664A. Installation Category II was used, which is

for equipment intended for use in installations or parts of installations in which no

overvoltages can occur.The clearance calculations were conducted per the
dimensions and characteristics of the Weidmuller SAK-4EN terminal blocks which
are standard offering of D-R. The clearance calculations indicate a maximum of
1.2 mm for these terminal blocks. The clearance between the terminals of the
SAK-4EN terminal blocks is 6.5 mm, more than 5 times the minimum clearance
allowed.
O.6.10 Test report on SST creepage of Conductors

Testing of creepage per CENELEC EN60204-1 standards and data recorded on
FAT form. The creepage calculations were checked per the Weidmuller SAK-4EN
terminal block dimensions. The distances between the conductors minimum
calculated value due to creepage is 1.5 mm which is 1/5 of the 6.5 mm terminal
block distances being used.
O.6.11 Test report on SST mechanical damage caused by short circuits.

Testing of short circuit test limits per CENELEC EN60204-1 standards and data
O.6.13 Analysis on SST enclosure gasketing construction.

Dresser-Rand incorporates Crouse-Hinds and Hoffmann enclosures unless there are
customer requirements for other suppliers. At a minimum the enclosures are 304
Stainless Steel with NEMA 4X ingress protection ratings.
O.7 Programming of Electrical Devices
O.7.1 Peak 150 programmer and program entry

In the Woodward Peak 150 Installation and Operation manual 85565 complete and
thorough instructions are provided for the programming of the Peak 150 governor.
Dresser-Rand provides a governor program which has the values that are punched
into the governor via the supplied hand held programmer.
O.7.2 Tachometer program entry
A. Tachtrol 30
For each turbine which has a AI-Tek tachometer, D-R provides programming
parameters on the associated electrical schematic drawing.
B. Moore
C. Red Lion
For each turbine which has a Red Lion speed meter, D-R provides
programming parameters on the associated electrical schematic drawing.

D. Beka
For each turbine which has a Beka tachometer, D-R provides programming
parameters on the associated electrical schematic drawing.
O.7.3 Valtek Calibration

The electro-pneumatic actuators are calibrated at the Dresser-Rand factory before the
no-load testing of each unit.
O.8 Customer Responsibilities
O.8.1 Power supply disconnect method

Typically the customer is responsible for the design and installation of power
supply disconnect hardware for the electronic governor, electronic over-speed
protection, solenoid valves and other power consuming components mounted on
the turbine. There must be an acceptable disconnect (isolation) at each single
incoming source when required (for example: for work on the machine, including
electrical equipment). When two or more supply disconnecting devices are
provided, protective interlocks for their correct operation shall also be provided in
order to prevent a hazardous situation, including damage to the machine or to the
work in progress.
The supply disconnecting device shall be one of the following types:
A. Switch-disconnector, with or without fuses, in accordance with IEC 60947-3,

utilization category AC-23B or DC-23B
B. Disconnector, with or without fuses, in accordance with IEC 60947-3, that has
an auxiliary contact that in all cases causes the switching devices to break the
load circuit before the opening of the main contacts of the disconnector.
C. A circuit breaker suitable for isolation in accordance with IEC 60947-2
D. Any other switching device in accordance with an IEC product standard for that
device and which meets the isolation requirements of IEC 60947-1 as well as a
utilization category defined in the product standard as appropriate for on-load
switching of motors or other inductive loads
E. A plug/socket combination for a flexible cable supply.
When the supply disconnecting device is one of the types listed in the above
sections A to D, it shall fulfill all of the following requirements:
a) Isolate the electrical equipment from the supply and have one OFF (isolated) and one
ON position marked with “O” and “I” (symbols IEC 604178-5008 (DB:2002-10) and
IEC 60417-5007 (DB:2002-10)).

b) Have a visible contact gap or a position indicator which cannot indicate OFF (isolated)
until all contacts are actually open and the requirements for the isolating function have
been satisfied.
c) Have an external operating means (for example—handle), (exception: power-operated

switchgear need not be operable from outside the enclosure where there are other means
to open it). Where the external operating means is not intended for emergency
operations, it is recommended that it be colored BLACK or GRAY.
d) To be provided with a means permitting it to be locked in the OFF (isolated) position

(for example by padlocks). When so locked, remote as well as local closing shall be
prevented.
e) Disconnect all live conductors of its power supply circuits. However, for TN supply
systems, the neutral conductor may or may not be disconnected except in countries
where disconnection of the neutral conductor (when used) is compulsory.
f) Have breaking capacity sufficient to interrupt the current of the largest motor when
stalled together with the sum of the normal running currents of all other motors and/or
loads. The calculated breaking capacity may be reduced by the use of a proven
diversity factor.
When the supply disconnecting device is a plug/socket combination, it shall fulfill

the following requirements:
Have the switching capability, or be interlocked with a switching device that has a
breaking capacity sufficient to interrupt the current of the largest motor when
stalled together with the sum of the normal running currents of all other motors
and/or loads. The calculated breaking capacity may be reduced by the use of a
proven diversity factor. When the interlocked switching device is electrically
operated (for example: a contactor) it shall have an appropriate utilization category.
Where the supply disconnecting device is a plug/socket combination, a switching

device with at appropriate utilization category shall be provided for switching the
machine on and off. This can be achieved by the use of the interlocked switching
device described above.
Operating Means—
The operating means (for example, a handle) of the supply disconnecting device
shall be easily accessible and located between 0.6 m (1.9 ft.) and 1.9 m (6.2 ft.)
above the servicing level. An upper limit of 1.7 (5.6 ft.) is recommended.

Excepted Circuits—
The following circuits need not be disconnected by the supply disconnecting
device:
a) Under-voltage protection circuits that are only provided for automatic tripping
in the event of supply failure.
b) Where such a circuit is not disconnected by the supply disconnecting device:
permanent wiring label(s) in accordance with 16.1 shall be appropriately placed in
proximity to the supply disconnecting device.
Local operation of the supply disconnecting device to effect emergency switching

off shall be readily accessible and should meet the color requirements.
O.8.2 Customer responsibility for emergency stop controls and devices,

location description of emergency devices
It is the customer’s responsibility to provide emergency stop controls and devices
and provide the location description and accessibility of these emergency devices.
Combined start and stop controls. Push-buttons and similar control devices that,
when operated, alternately initiate and stop motion shall only be provided for
functions which cannot result in a hazardous situation.
Use of more than one operator control station. Where a machine has more than one
operator control station, including one or more cable-less control stations, measures
shall be provided to ensure that only one of the control stations can be enabled at a
given time. An indication of which operator control station is in control of the
machine shall be provided at suitable locations as determined by the risk
assessment of the machine.
Devices for emergency stop shall be readily accessible by being located at each
operator control stations and at other locations where the initiation of an emergency
stop can be required.
There can be circumstances where confusion can occur between active and inactive
emergency stop devices caused by disabling the operator control station. In such
cases, means (for example: information for use) shall be provided to minimize
confusion.
Emergency switching off devices shall be located as necessary for the given
application. Normally, those devices will be located separate from operator control
stations. Where it is necessary to provide a control station with an emergency stop
device and an emergency switching off device, means shall be provided to avoid
confusion between these devices.

Color of actuators. Actuators of emergency switching off devices shall be colored

RED. If a background exists immediately around the actuator, the background
shall be colored YELLOW.
O.8.3 Customer responsibility for earth faults - required accidental start

protection
The customer is responsibility to provide earth fault interrupt equipment and
lockout process and procedure to prevent accidental startup.
Earth faults on any control circuit shall not cause unintentional starting, potentially
hazardous motions, or prevent stopping of the machine.
O.8.4 Customer responsibility for potentiometer rotation stop

The customer is responsible for providing rotation stops on any and all
potentiometer installations.
Devices having a rotational member, such as potentiometers and selector switches,

shall have the means of prevention of rotation of the stationary member. Friction
alone shall not be considered sufficient.
O.8.5 Customer responsibility for stopping by de-energizing

The customer is required to institute controls which will facilitate the turbine
stopping by de-energizing the controls.
O.8.6 Customer responsibility that control circuits are connected to bonding

circuit
The customer is responsible for ensuring the control circuits are connected to the
bonding circuit which is also within the customer’s responsibility.
Protection by automatic disconnection of supply: This measure consists of the

interruption of one or more of the line conductors by the automatic operation of a
protective device in case of a fault. This interruption shall occur within a
sufficiently short time to limit the duration of a touch voltage to a time within
which the touch voltage is not hazardous.
These measures necessitate the coordination between:
a) The type of supply and earthing system.

b) The impedance values of the different elements of the protective bonding
system
c) The characteristics of the protective devices that detect insulation fault(s).
Automatic disconnection of the supply of any circuit affected by an insulation
fault is intended to prevent a hazardous situation resulting from a touch voltage.

This protective measure comprises both protective bonding of exposed conductive

parts and either:
a) Over-current protective devices for the automatic disconnection of the supply

on detection of an insulation fault in TN systems, or
b) Residual current protective devices to initiate the automatic disconnection of
the supply on detection of an insulation fault from a live part to exposed
conductive parts or to earth in TT systems, or
c) Insulation monitoring or residual current protective devices to initiate automatic
disconnection of IT systems. Except where a protective device is provided to
interrupt the supply in the case of the first earth fault, an insulation monitoring
device shall be provided to indicate the occurrence of a first fault from a live
part to exposed conductive parts or to earth. This insulation monitoring device
shall initiate an audible and/or visual signal which shall continue as long as the
fault persists.
O.8.7 Customer responsibility that battery control station will not cause
hazardous condition
The customer has the responsibility to insure that the battery control station will not
cause any hazardous condition to exist in the SST operation.
Battery-powered operator control stations. A variation in the battery voltage shall

not cause a hazardous situation. If one or more potentially hazardous motions are
controlled using a battery-powered cable-less operator control station, a clear
warning shall be given to the operator when a variation in battery voltage exceeds
specified limits. Under those circumstances, the cableless operator control station
shall remain functional long enough for the operator to put the machine into a non-
O.8.8 Customer responsibility for operator control station stop over-ride

precedence
The customer is responsible for instituting the hardware/software to guarantee
operator control station stop over-ride precedence.
O.8.9 Customer responsibility for enabling control requirements

The customer is responsible for enabling control requirements.
Start functions. Start functions shall operate by energizing the relevant circuit.
Enabling control is a manually activated control function interlock that:
a) When activated allows machine operation to be initiated by a separate start

control

b) When de-activated---
---initiates a stop function and----prevents initiation of machine
operation.
Enabling control shall be so arranged as to minimize the possibility of defeating the

shut-down command, for example: by requiring the de-activation of the enabling
control device before machine operation may be re-initiated. It should not be
possible to defeat the enabling function by simple means.
O.8.10 Customer responsibility that ES (Emergency Stop) shuts off motive

force
The customer is responsible for proper design of the emergency stop controls
which will shut off any and all of the motive force to the turbine.
Emergency stop operations (emergency stop, emergency switching off). Once

active operation of emergency stop or emergency switching off of the actuator has
ceased following a command, the effect of this command shall be sustained until it
is reset. This reset shall be possible only by manual action at that location where
the command has been initiated. The reset of the command shall not restart the
machinery but only permit restarting.
O.8.11 Customer responsibility that resetting of ES requires manual

intervention
The customer has the responsibility to properly incorporate into the turbine controls
that the resetting of the emergency stop components requires manual intervention
for the reset of the turbine controls.
The emergency stop shall function either as a stop category 0 or as a stop category
1. The choice of the stop category of the emergency stop depends on the results of
a risk assessment of the machine.
In addition to the requirements for stop, the emergency stop function has the
following requirements:
a) It shall override all other functions and operations in all modes.

b) Power to machine actuators that can cause a hazardous situation(s) shall be
either removed immediately (stop category 0) or shall be controlled in such a
way to stop the hazardous motion as quickly as possible (stop category 1)
without creating other hazards.
c) Reset shall not initiate a start

O.8.12 Customer responsbility that any stop function over-rides any start
function
The customer has the responsibility to design and incorporate into the controls the
capability of any and all stop functions to over-ride any and all of the start function
controls.
Stop Function.
a) Stop category 1: A controlled stop with power available to the machine

actuators to achieve the stop and the removal of power when the stop is
achieved.
b) Stop category 2: A controlled stop with power left available to the machine
actuators.
Where more than one control station is provided, stop commands from any control
station shall be effective when required by the risk assessment of the machine.
O.8.13 Customer responsibility to provide over-current protection

It is the customer’s responsibility to properly design, install, and maintain over-
current protection equipment. The measures to be taken to protect the equipment
against the effects of over-current arising are from a short circuit, abnormal
temperature, loss of or reduction in the supply voltage, earth fault/residual current,
and over-voltage due to lighting and switching surges. General over-current
protection shall be provided where the current in a machine circuit can exceed
either the rating of any component of the current carrying capacity of the
conductors, whichever is the lesser value.
Supply conductors. Unless otherwise specified by the user, the supplier of the
electrical equipment is not responsible for providing the over current protective
device for the supply conductors to the electrical equipment Dresser-Rand states on
the P&I list the data necessary for selecting the over current protective device.
Power circuits. Devices for detection and interruption of over current shall be
applied to each live conductor.
The following conductors, as applicable, shall not be disconnected without

disconnecting all associated live conductors:
a) Neutral conductor of AC power circuits

b) The earthed conductor of DC power circuits
c) DC power conductors bonded to exposed conductive parts of mobile machines
Control circuits. Conductors of control circuits directly connected to the supply

voltage and of circuits supplying control circuit transformers shall be protected

against over-current. Conductors of control circuits supplied by a control circuit

transformer or DC supply shall be protected against over-current:
a) In control circuits connected to the protective bonding circuit, by inserting an

over-current protective device into the switched conductor.
b) In control circuits not connected to the protective bonding circuit.
c) Where the same cross sectional area conductors are used in all control circuits,
by inserting an over-current protective device into the switched conductor.
d) Where different cross-sectional areas conductors are used in different sub-
circuits, by inserting an over-current protective device into both switched and
common conductors of each sub-circuit.
Lighting circuits. All unearthed conductors of circuits supplying lighting shall be

protected against the effects of short circuits by the provision of over-current
devices separate from those protecting other circuits.
O.8.14 Customer responsibility that start functions shall operate by

energizing relevant circuit
The customer’s responsibility is to insure that the start functions shall operate by
energizing the specific circuit which starts the turbine.
In the case of machines requiring the use of more than one control station to initiate
a start, each of these control stations shall have a separate manually actuated start
control device. The conditions to initiate a start shall be:
a) All required conditions for machine operation shall be met.

b) All start control devices shall be in the released (off) position.
c) All start control devices shall be actuated concurrently.
O.8.15 Customer is responsible for DC power supplies

The customer is responsible for the proper sizing, installation and maintenance of
DC power supplies.
O.8.16 Customer is responsible for protective bonding circuit

The customer is responsible for the proper installation and maintenance of
protective bonding circuitry.
Dresser-Rand, when the contract requires it, provides bonding/grounding lugs on

the sole-plates, gauge-boards, and base-plates as shown in figures O-7 through O-9.

Figure O-7 Location of grounding lug (021) on turbine baseplate

Figure O-8 Grounding lug (008) on gaugeboard
Figure O-9 Grounding lug (007) on soleplate

Equi-potential bonding. Normally functional grounding is achieved by connection
to the protective bonding circuit. But where the level of electrical disturbances on
the protective bonding circuit is not sufficiently low for proper functioning of
electrical equipment, it may be necessary to connect the functional bonding circuit
to a separate functional earthing conductor.
Protective bonding circuit. The protective bonding circuit consists of PE

terminal(s). All parts of the protective bonding circuit shall be so designed that
they are capable of withstanding the highest thermal and mechanical stresses that
can be caused by the earth-fault currents that could flow in that part of the
protective bonding circuit. Where the conductance of structural parts of the
electrical equipment or of the machine is less than that of the smallest protective
conductor connected to the exposed conductive parts, a supplementary bonding
conductor shall be provided. This supplementary bonding conductor shall have a
cross-sectional area not less than half that of the corresponding protective
conductor.

If an IT distribution system is used, the machine structure shall be part of the

protective bonding cirduit and insulation monitoring shall be provided.
Protective conductors. Copper conductors are preferred. Where a conductor

material other than copper is used, its electrical resistance per unit length shall not
exceed that of allowable copper conductor and such conductors shall be not less
than 16 square mm in cross-sectional area.
The cross-sectional area of protective conductors. This requirement is met in most

cases where the relationship between the cross-sectional area of the phase
conductors associated with that part of the equipment and the cross-sectional area
of the associated protective conductor is in accordance with Table 1.
Continuity of the protective bonding circuit. All exposed conductive parts shall be
connected to the protective bonding circuit.
Exclusion of switching devices from the protective bonding circuit. The protective
bonding circuit shall not incorporate a switching device or an over-current
protective device (for example, switch or fuse). No means of interruption of the
protective grounding conductor shall be provided. Exception: Links for test or
measurement purposes that cannot be opened without the use of a tool and that are
located in an enclosed electrical operating area. Where the continuity of the
protective bonding circuit can be interrupted by means of removable current
collectors or plug/socket combinations, the protective bonding circuit shall be
interrupted by a first-make last-break contact.
Protective conductor connecting points. The protective conductor connecting

points shall have no other function and are not intended, for example, to attach or
connect appliances or parts. Each protective conductor connecting point shall be
marked or labeled as such using the symbol IEC 60417-5019 (DB:2002-10), or
with letters PE, the graphical symbol being preferred, or by use of the bi-color
combination GREEN-AND-YELLOW, or any combination of these.
Functional bonding. Protection against mal-operation as a result of insulation

failures can be achieved by connecting to a common conductor.
Measures to limit effects of high leakage current. The effects of high leakage
current can be restricted to the equipment having high leakage current by
connection of that equipment to a dedicated supply transformer having separate
windings. The protective bonding circuit shall be connected to exposed conductive
parts of the equipment and, in addition, to the secondary winding of the
transformer.

Control circuits supply. Where control circuits are supplied from an AC source, a
control transformer shall be used for supplying the control circuits. Such
transformer shall have separate windings.
Where DC control circuits derived from an AC supply are connected to the

protective bonding circuit, they shall be supplied from a separate winding of the
AC control circuit transformer or by another control circuit transformer.
O.8.17 Customer is responsible for over-voltage suppression (lightning

arrestors)
The customer is responsible for the proper installation and maintenance of over-
voltage surge protection (lightning arrestors).
Protection against over-voltages due to lightning and to switching surges.

Protective devices can be provided to protect against effects of over-voltages due to
lightning or to switching surges where provided:
a) Devices for the suppression of over-voltages due to lightning shall be

connected to the incoming terminals of the supply disconnecting device.
b) Devices for the suppression of over-voltages due to switching surges shall be
connected across the terminals of all equipment requiring such protection.
O.8.18 Customer is responsible for transformer over-current protection.

The customer is responsible for all transformer over-current protection devices to
be installed properly and maintained.
Transformers shall be protected against over-current in accordance with the

manufacturer instructions. Such protection shall also avoid nuisance tripping due
to transformer magnetizing inrush currents. The type and setting of the over-
current protective device should be in accordance with the recommendations of the
transformer supplier.
O.8.19 Customer is responsible for certifications

The customer is responsible for maintaining the certification documentation
required for customer ATEX/EU compliance.
O.8.20 Customer is responsible for accidental disabling of electricity to

SST turbine
The customer is responsible for proper design and installation of equipment to
prevent accidental power interruption to the SST turbine.
Protection against supply interruption or voltage reduction and subsequent

restoration. These conditions can cause a hazardous situation, damage to the

machine or to work in progress. Under-voltage protection shall be provided by, for

example, switching off the machine at a pre-determined voltage level. Upon
restoration of the voltage or upon switching on the incoming supply, automatic or
unexpected restarting of the machine shall be prevented where such a restart can
cause a hazardous situation.
O.8.21 Customer is responsible for prevention of unwanted startup

It is the customer’s responsibility to design, install, and incorporate lockout
hardware and procedures to prevent unwanted turbine startup.
Devices for switching off for the prevention of unexpected startup (for example:
where, during maintenance, a start-up of the machine or part of the machine can
create a hazard).
Such device shall be appropriate and convenient for the intended use, shall be
suitable placed, and readily identifiable as to their function and purpose (for
example: by a durable marking in accordance with 16.1 where necessary).
Means shall be provided to prevent inadvertent and/or mistaken closure of these

devices either at the controller or from other locations. Devices that do not fulfil
the isolation function (for example, a contactor switched off by a control circuit)
may only be provided where intended to be used for situations that include:
a) Inspections
b) Adjustment
O.8.22 Customer is responsible for locking of emergency off isolation

operators
It is the customer’s responsibility to incorporate locking out of emergency shut-
down isolator hardware.
Emergency switching off should be provided where there is the possibility of other
hazards or damage caused by electricity.
Emergency switching off is accomplished by switching off the relevant incoming

supply by electromechanical switching devices, effecting a stop category 0 of
machine actuators connected to this incoming supply. When a machine cannot
tolerate this stop category 0 stop, it may be necessary to provide other measures,
for example: protection against direct contact, so that emergency switching off is
not necessary.
O.8.23 It is the customer responsibility to ensure that there is not a

connection between the neutral conductor and the protective bonding
circuit

According to CENELEC EN60204-1 it is the customer responsibility to insure that

there is not a connection between the neutral conductor and the protective bonding
circuit.
There shall be no connection between the neutral conductor and the protective
bonding circuit inside the electrical equipment nor shall a combined PEN terminal
be provided. Exception: a connection may be made between neutral terminal and
the PE terminal at the point of the connection of the power supply to the machine
for TN-C systems.
O.8.24 It is the customer responsibility to guarantee that the electrical

components on the SST turbine are connected to a single incoming
power source.
A single point connection for the turbine power must be provided by the customer
that meets the parameters outlined in this chapter.
Incoming supply conductor terminations: It is recommended that, where

practicable, the electrical equipment of a machine is connected to a single incoming
supply. Where another supply is necessary for certain parts of the equipment (for
example, electronic equipment that operates at a different voltage), that supply
should be derived, as far as is practicable, from devices (for example, transformers,
converters) forming part of the electrical equipment of the machine.
O.8.25 Power supply testing is the responsibility of the customer.

The customer is responsible for the power supply testing per the requirements of
CENELEC EN60204-1.
The connection of the power supply and of the incoming external protective
conductor the the PE terminal of the machine, shall be verified by inspection. The
conditions for the protection by automatic disconnection of supply shall be verified
by both:
1) Verification of the fault loop impedance by
a) Calculation
b) Measurement
2) Confirmation that the setting and characteristics of the associated over-current

protective device are correct.
Functional tests. The function of electrical equipment shall be tested. The function
of circuit for electrical safety (for example: earth fault detection) shall be tested by
the manufacturer.

Re-testing. Where a portion of the machine and its associated equipment is

changed or modified, that portion shall be re-verified and re-tested as appropriate.
This re-testing is the responsibility of the customer.
O.8.26 Power quality customer requirements.

The customer is required by the IEC low voltage directive EN60204-1 to provide
power to the electrical load of supplied devices with harmonic distortion not
exceeding 10% of the total r.m.s. voltage between live conductors for the sum of
the 2nd through to the 5th harmonic. An additional 2% of the total r.m.s. voltage
between live conductors for the sum of the 6th through to the 30th harmonic is
permissible.
O.8.27 Customer responsibility for protection from electric shock.

The customer is responsible for the wiring and connection of electrical components
and equipment of electrical components which is in their scope (any wiring and
installation of equipment not installed and wired by Dresser-Rand) per the
component manufacturer instructions.
The electrical equipment shall provide protection of persons against electric shock
from:
a) Direct contact
b) Indirect contact
O.8.28 Customer responsible for abnormal temperature protection.

Resistance heating or other circuits that are capable of attaining or causing
abnormal temperatures (for example, due to short-time rating or loss of cooling
medium) and therefore can cause a hazardous situation shall be provided with
suitable detection to initiate an appropriate control response.
O.8.29 Customer responsible for motor over-speed protection.

The over-speed protection of auxiliary motors, such as lube oil pump motors,
which are in the customers’ scope of supply, are the responsibility of the customer
to provide over-speed protection controls.
O.8.30 Customer responsibility for operation and minimizing risks.

Where a machine has more than one control station, measures shall be provided to
ensure that the initiation of commands from different control stations do not lead to
a hazardous situation.
Control functions in the event of failure. Where failures or disturbances in the

electrical equipment can cause a hazardous situation or damage to the machine or
to the work in progress, appropriate measures shall be taken to minimize the
probability of the occurrence of such failures or disturbances. The required

measures and the extent to which they are implemented, either individually or in
combination, depend on the level of risk associated with the respective application.
The electrical control circuits shall have an appropriate level of safety performance
that has been determined from the risk assessment at the machine. The
requirements of IEC 60261 and/or 13849-1:1999, ISO 13849-2:2003 shall apply.
Measures to reduce those risks include but are not limited to:
a) Use of proven circuit techniques and components

b) Provision of partial or complete redundancy or diversity
c) Provision for functional tests
Measures to minimize risk in the event of failure – Use of proven circuit techniques
and components.
These measures include but are not limited to:

a) Bonding of control circuits to the protective bonding circuit for functional
purposes.
b) Connection of control devices 1
c) Stopping by de-energizing
d) Switching devices having direct opening action (see IEC 60947-5-1)
O.8.31 Physical separation or grouping (11.2.2) customer responsibility.

Control devices mounted in the same location and connected to the supply voltage,
or to both supply and control voltages, shall be grouped separately from those
connected only to the control voltages.
Terminals shall be separated into groups for:

a) Power circuits
b) Associated control circuits
c) Other control circuits, fed from external sources (for example: for interlocking)
The groups may be mounted adjacently, provided that each group can be readily
identified (for example: by markings, by the use of different sizes, by use of
barriers or by colors). When arranging the location of devices (including
interconnections), the clearances and creepage distances specified for them by the
supplier shall be maintained, taking into account the external influences or
conditions of the physical environment.
O.8.32 Customer responsibility for prevention of indirect contact

For each circuit or part of the electrical equipment, at least one of the measures
shall be applied:
a) Measure to prevent the occurrence of a touch voltage or

b) Automatic disconnection or the supply before the time of contact with a touch
voltage can become hazardous
Prevention of the occurrence of a touch voltage. Measures to prevent the

occurrence of a touch voltage include the following:
a) Provision of class II equipment by equipment insulation

b) Electrical separation
Protection by provision of class II equipment or by equivalent insulation. This

measure is intended to prevent the occurrence of touch voltage on the accessible
parts through a fault in the basic insulation. This protection is covered by one of
the following:
a) Class II electrical devices or apparatus (double insulation, reinforced insulation

or by equivalent insulation in accordance with IEC 61140)
b) Switch-gear and control-gear assemblies having total insulation in accordance
with IEC 60439-1
c) Supplementary or reinforced insulation in accordance with 413.2 of IEC 60364-
4-41
Protection by electrical separation of an individual circuit is intended to prevent a

touch voltage through contact with exposed conductive parts that can be energized
by a fault in the basic insulation of the live parts of that circuit. For this type of
protection, the requirements of 413.3.5 of IEC 60364-4-41 apply.

Section P
User Notes and Maintenance Records
Date Observation or Service Performed Comments By

Date Observation or Service Performed Comments By

This manual is provided for the assistance of personnel in operating and maintaining the equipment. It
does not vary or substitute for the express warranty of Dresser-Rand as set forth in the terms and
conditions of sale.
37 Coats St., Wellsville, NY 14895
800-828-2818 585-596-3100
Fax: 585-593-5815
TURBINE DATA SHEET
C-34347
Serial Number D6706

Turbine Frame 503E
Driven Machine Centrifugal Compressor
Number of Stages One Curtis
Turbine Rating 569 HP at 3600 RPM
Turbine Rotation (Viewed from Governor Clockwise
End)
Inlet Steam Conditions 200 PSIG at 388F
Exhaust Pressure 30 PSIG at 276F
Casing Material: Cast Steel
Shaft Packing: Carbon Rings

Steam End Five
Exhaust End Five
Speed Governor: Woodward Peak 150
5
Speeds Turbine Gear Signal
Maximum 3780 RPM
Normal 3600 RPM
Minimum 2520 RPM
1st Critical 10,000 RPM
NOTE: Magnetic Pickup Gear Has 30 Teeth
Turbine Weights: See Outline Drawing, 6079520 Figure A-3
1
TURBINE DATA SHEET
C-34347
Alarm and Trip Settings

ALARM TRIP
Emergency Overspeed Trip:
Mechanical --------- 4158 RPM
Electronic Governor --------- 4120 RPM
Solenoid Dump Valve --------- When de-
energized
Journal Bearing Information

Steam End Exhaust End
Shaft Diameter 3.000” + .000” 3.000” + .000”
- .001” - .001”
Bearing Bore 3.005” + .001” 3.005” + .001”
- .001” - .001”
Running Clearance .004" to .007" .004” to .007"
Cooling Water
Quantity of Fresh Water Required For:
Oil Cooler 2 GPM (7.6 LPM) at 90 F (32C) or less

for each bearing housing
Lubrication / Hydraulic System
Lube Oil Type ISO VG 68

Bearing Lubrication Ring Oiled with Trico Oilers
2
TURBINE DATA SHEET
C-34347
Governor Valve Size: 3 1/4 Inches
OPERATING CONDITIONS
R P M S T E A M CO NDI T I O NS STEAM HAND VALVES
INLET EXH RATE Position: Qty
HP PSIG °F PSIG LB/HP HR CLOSED
521 3600 200 388 30 46.6 1
569 3600 200 388 30 0
478 3600 200 388 30 1
386 3600 200 388 30 2
87 3600 200 388 30 2
Exhaust Relief Valve to start opening at 45 PSIG, to be fully open at 55 PSIG

and to pass 29,713 LBS/HR (SUPPLIED BY OTHERS)
Sentinel Warning Valve Set at 45 PSIG
3
TURBINE DATA SHEET
C-34347
WARNING:
THE TURBINE CASE IS NOT DESIGNED TO WITHSTAND FULL LINE
PRESSURE. OVERPRESSURE MAY RESULT IN DAMAGE TO THE
EQUIPMENT, PERSONAL INJURY OR DEATH. THE SENTINEL VALVE IS A
WARNING DEVICE ONLY; IT OFFERS NO PROTECTION AGAINST
OVERPRESSURE. FOR PROTECTION, INSTALL AN ATMOSPHERIC
RELIEF VALVE IN THE EXHAUST LINE BETWEEN THE TURBINE AND THE
FIRST VALVE. THE PIPING AND INSTRUMENTATION DIAGRAM
EQUIPMENT LIST GIVE THE PROPER SETTING FOR THE ATMOSPHERIC
RELIEF VALVE.
WARNING:
ALL GOVERNORS AND GOVERNOR DRIVES HAVE POTENTIAL TO FAIL.
SUCH FAILURE CAN CAUSE UNCONTROLLED HIGH SPEED (RUNAWAY)
OF THE PRIME MOVER. RUNAWAY CAN RESULT IN DAMAGE TO
EQUIPMENT, SERIOUS INJURY OR DEATH. FOR SAFETY, ALWAYS HAVE
A SEPARATE DEVICE TO TRIP THE PRIME MOVER UPON RUNAWAY
CONDITION.
CAUTION:
THE UPPER HALF OF THE TURBINE CASE FEATURES AN EYELET. THIS
EYELET IS NOT STRONG ENOUGH TO SUPPORT THE WEIGHT OF THE
WHOLE TURBINE; IT IS SUITABLE FOR LIFTING THE TOP MEMBER ONLY.
4
TURBINE DATA SHEET
C-34347
WARNING, VALTEK ACTUATOR:

EXTENSIVE DEPOSITS WILL OBSTRUCT THE MOTION OF A GOVERNOR
VALVE. WHEN OBSTRUCTED, ITS STEM CAN BE BENT BY A FORCEFUL
ACTUATOR. FOR THE PROTECTION OF EQUIPMENT, SUPPLY AIR TO THE
VALTEK ACTUATOR AT 60 PSIG MINIMUM, 70 PSIG MAXIMUM. REFER TO
THE PINSETTING DIAGRAM.
5
APPENDIX A
ENGINEERING DRAWINGS AND PARTS LISTS
C-34347
Figure No. Drawing No.
Recommended Spare Parts List A-1 C-34347

Packing Ring Diagram A-2 EW-33275
Outline Drawing / Piping Calculations A-3 6079520
Longitudinal Section A-4 192375
Governor Section A-5 213625
Rotor Clearance A-6 6002909
Assembly Steam End Bearing Case A-7 192055
Assembly Exhaust End Bearing Case A-8 192245
Trip Valve Assembly A-9 213649
Emergency Trip Parts A-10 169195
Hand Valve Assembly A-11 190958
Oil Level Indicators – Steam & Exhaust A-12 166403
Ends 166404
Governor Program A-13 6079793
Electrical Schematic A-14 6079521
Flange Movements Due to Thermal A-15 C-34347
Growth
Single Stage Turbine Installation and A-16 Dresser-Rand
Commissioning Checklist
STEAM TURBINE SPARES PARTS LIST
Dresser-Rand Date: 6/10/2011
37 Coats Street Quote No: CSS-514810
Wellsville, NY 14895 Unit: C34347
PH: 585-596-3100 / FX: 585-593-5815 Serial: D6706
Type: 503E
Customer: Ingersoll Rand
Used by: Campbell's Soup Please direct inquires and orders to:
Locations: Ohio
Prepared by: Lori Gavitt Jami Sherwood
Inside Sales Analyst Inside Sales Analyst
PH: (585) 596-3728 PH: (585) 596-3475
FX: (585) 593-5815 FX: (585) 593-5815
E-mail: LClineGavitt@Dresser-Rand.com E-mail: JSherwood@Dresser-Rand.com
UNITS OF MEASURE
QUANTITY PER UNIT
PART POSITION
SECTIONAL DRESSER-RAND START-UP 2-YR
DESCRIPTION OF PART (REFERENCE)
DRAWING PART NUMBER SPARES SPARES
NUMBER
LINE NO.
NUMBER
1 EA Exhaust End:
1 2 EA Exhaust End Bearing Insert 6016722 2358 W6007831-102 X X
1 3 EA Oil Ring 6016722 2366 W14-004 X X
2 4 EA Oil Baffle 6016722 2360 W146306-102 X X
5 EA Steam End:
1 6 EA Thrust Bearing 192055 69 W155854-022 X X
1 7 EA Steam End Bearing Insert 192055 214 W6007830-102 X X
1 8 EA Oil Ring 192055 218 W14-006 X X
1 9 EA Oil Baffle 169070 216 W146306-102 X X
10 EA Turbine Case & Parts
10 11 EA Carbon Ring 192375 140/190 W6026596-020 X X
10 12 EA Carbon Ring Spring 192375 141/191 W182885-001 X X
10 13 EA Stops (Rollpins) 192375 145/195 W130180-070 X X
1 14 EA Start up Spares Kit Box N/A N/A Pending X X
15 EA Turbine Rotor & Parts
1 16 EA Emergency Governor Cup/Parts 169195 90-97 W408972-003 X
17 EA Valve Body & Parts
1 18 EA Gasket 6" Flexitallic 213619 1023 W188521-001 X
1 19 EA Stem Bushing Lower 213619 1016 W146666-001 X
1 20 EA Stem Bushing Outer 213619 1015 W146665-001 X
1 21 EA Valve Link 213619 437 W192050-001 X
1 22 EA Valve Spindle 213619 441 W213976-001 X
8 23 EA Valve Stem Packing 213619 439 W72462-008 X
1 24 EA Spark Plug Gasket 213619 424 W174346-005 X
1 25 EA Gasket 8.78" OD x 6.10" ID N/A N/A W148353-001 X
1 26 EA Governor Valve and Stem 213619 1017/1018 W232360-703 X
1 27 EA Valve Bushing Assembly 213619 1019/1020 W232361-702 X
28 EA Steam End Bearing Case & Parts
1 29 EA Sylphon Bellow 173099 415 W20024-001 X
1 30 EA Spring 173099 416 W31087-001 X
1 31 EA Latch 173099 420 W149086-001 X
32 EA
33 EA
34 EA
35 EA
36 EA
37 EA
38 EA
39 EA
40 EA
Please contact factory prior to placing an order
"Preliminary" as of 6/10/2011. Part numbers are subject to change
DRESSER-RAND COMPANY
CONTRACT NO. C34347
S/N D6706
START-UP SPARES KIT
REF QTY P/N DESCRIPTION

1 W6066344-001 KIT BOX CASE CONTAINING:
001 10 W6026596-020 CARBON RINGS
002 1 W155854-022 THRUST BEARING (1 PIECE)
003 1 W6007830-102 STEAM END JOURNAL BEARING
004 10 W182885-001 CARBON RING SPRINGS
005 1 W14-004 EXHAUST END OIL RING
1 W14-006 STEAM END OIL RING
006 1 W6007831-102 EXHAUST END JOURNAL BEARING
007 N/A 2nd of 3 PIECE THRUST BEARING
008 3 W146306-102 OIL BAFFLES (2 E.E./1 S.E.)
009 10 W130180-070 CARBON RING STOPS (ROLLPINS)
010 N/A 3rd of 3 PIECE THRUST BEARING
STPrtsOrd (2).doc
D-R Steam Turbine

Parts Ordering Procedure
Ordering parts for your Dresser-Rand Steam Turbine is as simple as picking up
the telephone or sending us an e-mail along with with some vital information.
When placing an order we require all of the following information to efficiently

and accurately process your order:
• The unit serial number*
(26532 or D6157, for example)
• The unit frame size*
(705HT or 1QS4, for example)
• The unit or contract number*
(U-23924 or C-32666, for example)
• The section or assembly drawing number
(192375 or 6069054, for example)
• The catalog number from the section or assembly drawing
(1 or 2465, for example)
All of the above information can be found on the Specification Sheet within the
Instruction or IOM (Installation, Operation, and Maintenance) Manual supplied
with the steam turbine. Information marked with “*” can also be found on the
equipment nameplate.
• To phone in a parts order, call 1-800-828-2818 or 585-593-1234. When

calling, have the above information handy to relay to your D-R contact.
• To place an e-mail order, use the following e-mail address:

drwlsvparts@dresser-rand.com
Remember…be sure to include all the information required above to minimize

additional communication and processing time for your order.
Thank you for ordering your Steam Turbine parts from Dresser-Rand.
Rev. 00, 20JUN10 Page STPOP Copyright 2010 Dresser-Rand

Parts Express
Service for Steam Turbines
Dresser-Rand Parts Express is a parts fulfillment service for single-stage

For a complete listing of products and and multi-stage steam turbines manufactured in North America. It helps
services, visit us on the Internet at clients maintain reliability and efficiency throughout the life cycle of their
equipment.
or contact one of the following
Dresser-Rand locations:
D-R keeps more than 1,000 steam turbine parts in stock. Within the United
Dresser-Rand
States, orders for such products are ready to ship within 24 hours. Orders
Corporate Headquarters
received from outside the U.S. are ready to ship within 48 to 72 hours
West8 Tower Suite 1000 (proper paperwork and shipping information must be provided).
10205 Westheimer Road
Houston, TX 77042 USA
Tel: (Int'l+1) 713-354-6100 Examples of frequently shipped parts are trip Genuine OEM Parts
Fax: (Int'l+1) 713-354-6110 valve components, throttle valve and trip lever
email: info@dresser-rand.com assembly items, bearings, carbon rings, springs,
steam and oil seals, and other wear parts. Each
Regional Headquarters
order is shipped in its entirety, unless otherwise
The Americas specified in writing by the client. 100’s of parts from
Dresser-Rand our shelf to your
shop in 24 hours.
West8 Tower Suite 1000
10205 Westheimer Road Placing Orders
Houston, TX 77042 USA
Tel: (Int'l+1) 713-354-6100
There are no special procedures required to place or receive Parts Express
Fax: (Int'l+1) 713-354-6110 orders. All parts, whether or not they are shipped through the Parts Express
service, can be contained in the same order. If an order contains express
European Served Areas (ESA) and non-express items, it will be shipped complete at the earliest availability
Dresser-Rand S.A.
31, Boulevard Winston Churchill
of all parts, unless the shipment contains back-ordered items or partial
Cedex 7013 shipment is authorized in writing by the client. Parts orders can be placed
Le Havre 76080 France through your local D-R representative or directly from a D-R product center.
Tel: (Int'l+33) 2-35-25-5225
Fax: (Int'l+33) 2-35-25-5366/5367
All parts orders require a serial number to identify the equipment and to
Asia Pacific ensure shipment of the correct parts. Model identification and serial number
Dresser-Rand Asia Pacific Sdn Bhd can be found on the nameplate of your turbine. Use the contact list below
Unit 8-1, 8th Floor,
to order directly from a product center; this will expedite your request for a
Bangunan Malaysian Re
17 Lorong Dungun, Damansara Heights quote (RFQ).
50490 Kuala Lumpur, Malaysia
Tel: (Int'l+60) 3-2093-6633
Fax: (Int'l+60) 3-2093-2622 Steam Turbine Parts Contact List
©2008 Dresser-Rand. Printed in U.S.A.
Turbine Type Model US and Canada International
This document comprises a general overview of Telephone / Fax
the products described herein. It is solely for
informational purposes, does not represent a Single-stage TF, RL, RLH, RLV 1-888-268-8726 +1-508-595-1700
warranty or guarantee of the information con- / 508-595-1788
tained herein, and is not to be construed as
an offer to sell or a solicitation to buy. Contact Single-stage SST 300, SST 1-800-828-2818 +1-585-596-3100
Dresser-Rand for detailed design and engineering
500, SST 700 / 585-593-5815
information suitable to your specific applications.
Dresser-Rand reserves the right to modify its prod- Multi-stage R, K, U 1-888-614-9168 +1-319-753-5431
ucts and related product information at any time
without prior notice.
/ 319-752-1616
Multi-stage S, TS, T 1-800-828-2818 +1-585-596-3100
Form 2172
/ 585-593-5815
CARBON RINGS
Ring Clear Ring Drawing Shaft DIA Spring Stop

█ S E █ 1 .006" 6026596-020 3.5" 182885-001 130180-070
█ T N █ 2 .006" 6026596-020 3.5" 182885-001 130180-070
█ E D █ 3 .006" 6026596-020 3.5" 182885-001 130180-070
█ A █ 4 .006" 6026596-020 3.5" 182885-001 130180-070
█M █ 5 .006" 6026596-020 3.5" 182885-001 130180-070
E
X
█H █ 6 .006" 6026596-020 3.5" 182885-001 130180-070
█ A █ 7 .006" 6026596-020 3.5" 182885-001 130180-070
█U E █ 8 .006" 6026596-020 3.5" 182885-001 130180-070
█ S N █ 9 .006" 6026596-020 3.5" 182885-001 130180-070
█ T D █ 10 .006" 6026596-020 3.5" 182885-001 130180-070
Note: Drawing Numbers shown here correspond to the

numbers marked on the shipping containers. EW-33275
Location of Shaft Packing Carbon Rings for Single Stage
C-34347
DRESSER-RAND
WELLSVILLE OPERATIONS
PROGRAM – PEAK 150 GOVERNOR

For D-R Wellsville Unit: C-34347
User: Campbell’s Soup, Ohio

Purchaser: Ingersoll Rand
P.O.: M2018308-Rev. 2
 WARNING 
1. Refer to Woodward Peak 150 Manual for further detailed information.
2. FIELD CONFIGURABLE GOVERNOR: Any change to control limits, such as (but not limited to) speed, overspeed trip, control
logic, other than “Tuning”, requires the prior written approval of Dresser-Rand Company to assure safe operating limits are not
exceeded. Failure to comply may result in damage to property, serious injury or death to personnel.
ALTERATION BLOCK
C:\ENG\BOM\GOV\PROGRAMS\6079793-34347.doc
DRAWN BY: BKM C-34347 A-6079793

CHECKED BY: RP DATE: 12/16/10 PAGE 1 OF 4
DRESSER-RAND
WELLSVILLE, NY 14895
THIS PRINT IS CERTIFIED CORRECT FOR
INGERSOLL RAND
PURCHASE ORDER NO.: M2018308-REV. 2

BRANCH OFFICE NO.: RICK WHINERY
WORK ORDER NO.: C34347
Ron Perry
THE CONSTRUCTION SHOWN IS STANDARD FOR THIS

MACHINE. ANY DEVIATION FROM THIS STANDARD MAY
INVOLVE ADDITIONAL COST, A CORRESPONDING INCREASE
IN SELLING PRICE AND DELAY IN SHIPMENT. IF CHANGES
ARE NECESSARY, INDICATE THEM CAREFULLY IN DETAIL ON
THIS PRINT AND RETURN TO DRESSER-RAND. YOU WILL BE
ADVISED PROMPTLY AS TO THE ADDITIONAL PRICE.
MEANWHILE, THOSE DETAILS INVOLVED WILL BE HELD UP
UNTIL YOUR AUTHORIZATION TO PROCEED IS RECEIVED.
DRAWN BY: BKM C-34347 A-6079793

CONFIGURE MODE SERVICE MODE
SPEED CONFIGURATION ALARMS

Teeth Seen By MPU 30 MPU #1 Failed ? (status only)
Gear Ratio (1:xx) 1 MPU #2 Failed ? (status only)
MPU #1 Max Frequency (Hz) 2150 Remote Input Failed ? (status only)
MPU #2 Max Frequency (Hz) 2150 Comm Link Failure ? (status only)
Max Speed Level (Hz) 2150 Turbine Trip ? (status only)
Min Speed Level (Hz) 150 Use Trip As Common Alarm ? True
START MODE TRIPS

Manual Start ? True Last Trip Code (status only)
Automatic Start Mode ? False External Trip (status only)
Overspeed Trip (status only)
ACTUATOR CONFIGURATION Loss Of Both MPUs (status only)
Use 20-160ma Actuator ? False Front Panel Trip (status only)
Use 4-20ma Actuator ? (status only) Modbus Trip (status only)
Trip Codes
OPERATING MODE 1 = External Trip to Peak 150
Manual Control Only ? False 2 = Loss of both MPUs
Use Remote Speed Control ? True 3 = Overspeed Trip
Use High-Signal Select ? False 4 = Front Panel Trip
Use Modbus Analog Input ? False 5 = Modbus Trip
READOUTS SPEED DYNAMICS

Speed Readout: 4ma Value= 0 Low Speed Gain 5.0
Speed Readout: 20ma Value= 4300 Low Speed Reset 0.8
Readout #2 Option ? High Speed Switchpoint (rpm) 2520
1 = Actual Speed High Speed Gain 5.0
2 = Speed Setpoint High Speed Reset 0.8
3 = Actuator Output Hi Speed Dynamics Selected (status only)
4 = Remote Speed Setpoint
5 = Valve Ramp Value SPEED VALUES
6 = Not Used Actual Speed (status only)
Readout #2: 4ma Value= Local Speed Setpoint (status only)
Readout #2: 20ma Value= Actual Speed Setpoint (status only)
Remote Speed Setpoint (status only)
RELAYS Start Ramp Rate (rpm/sec) 50
Configurable Relay #3 Option ? n/a Setpoint Slow Rate (rpm/sec) 2
Configurable Relay #4 Option ? n/a Delay For Fast Rate (sec) 5
1 = Alarm Condition (normally energized) Setpoint Fast Rate (rpm/sec) 10
2 = Trip Output (same as trip relay output) Min Governor Speed (rpm) 2520
3 = Shutdown Condition (energizes on trip condition) Max Governor Speed (rpm) 3780
4 = Remote Speed Control Overspeed Level (rpm) 4120
5 = Speed Control External Overspeed Level (rpm) 4158
6 = Either/Any MPU Failed Overspeed Test Limit (rpm) 4208
7 = Overspeed Trip Droop (%) 0.0
8 = Overspeed Test Use Setpoint Set-back False
9 = Remote Signal OK
10 = Speed Switch or Handvalve #1 REMOTE SETTING (displayed only if configured)
11 = Speed Switch or Handvalve #2 Actual Remote Setpoint (rpm) (status only)
Use Speed Switch ? False Remote Setpoint Input (rpm) (status only)
Switch #2 Underspeed ? False Remote Not Match Rate (rpm/sec) 5
Use Hand Valve(s) ? False Remote Rate—Max (rpm/sec) 10
Trip Relay Energizes For Trip ? False Modbus Remote Used (status only)
Reset Clears Trip ? True
Configurable Contact #8 Is - False FAILED MPU OVERRIDE
Overspeed Test Enable ? Auto-Ovrd-Off Speed (Hz) 225
Use MPU Override Timer ? True
MODBUS COMM PORT CONFIGURATION (if modbus supplied) Max Starting Time (sec) 180
Use Modbus Port ? False Use Slow Rolldown Ovrd ? False
Hardware Configuration ? Auto-Ovrd-On Speed (Hz)
1 = RS 232 2 = RS 422 3 = RS 485 Auto-Ovrd-On Delay (sec)
Transmission Mode Configuration ? Override On Status (status only)
1 = ASCII 2 = RTU
Modbus Port Network Address Configuration?
DRAWN BY: BKM C-34347 A-6079793

SERVICE MODE (continued) SERVICE MODE (continued)
IDLE/MIN GOVERNOR RAMP (displayed only if autostart configured) I/O CHECK

Idle Speed MPU #1 (status only)
Use Idle/Min Gov Ramp ? MPU #2 (status only)
Minimum Governor Speed (rpm) Analog Input (status only)
Idle/Min Gov Rate (rpm/sec) DI #1 (Lower Speed) (status only)
Use Ramp To Idle Function ? DI #2 (Raise Speed) (status only)
Start = Ramp To Min Gov ? DI #3 (External Trip) (status only)
Ramping To Min (status only) DI #4 (Start) (status only)
Ramping To Idle (status only) DI #5 (Reset) (status only)
DI #6 (Idle/Min Gov) (status only)
CRITICAL SPEED BAND (displayed only if autostart is configured) DI #7 (Remote Speed Enable) (status only)
** Still has an effect even if autostart is disabled DI #8 (Ospd Test/Select Hi Dyn) (status only)
Use Critical Band ? False Trip P/B (OCP) (status only)
Critical Speed Min (rpm) Ospd Test P/B (OCP) (status only)
Critical Speed Max (rpm) Raise P/B (OCP) (status only)
Critical Speed Rate (rpm/sec) Lower P/B (OCP) (status only)
In Critical Speed Band (status only) Start P/B (OCP) (status only)
Reset P/B (OCP) (status only)
SPEED SWITCH/HAND VALVES(displayed only if configured) Tripped LED (status only)
Relay #1 On (rpm or %) MPU #1 OK LED (status only)
Relay #1 Off (rpm or %) MPU #2 OK LED (status only)
Relay #2 On (rpm or %) Ospd Enabled LED (status only)
Relay #2 Off (rpm or %) Rmt Spd LED (status only)
Underspeed Level (rpm) Trip Relay On (status only)
Alarm Relay On (status only)
VALVE OUTPUT Config Relay #1 On (status only)
Valve Position (%) (status only) Config Relay #2 On (status only)
Valve Offset Adjust 0.0
Valve Gain Adjust 1.0 -------------------------------------------------------------------------------------
Valve Ramp Position (%) (status only)
Manually Raise Ramp ? False NOTES:
Manually Lower Ramp ? False
Ramp Rate (%/sec) 10.0 1). Control mode set for local manual speed control.
Dither Adjust 0.0 2) See DR Electrical Schematic drawing 6079521.
Stroke Valve Output ? False
Stroke Position (%) 0.0
Min/Max Switch False
READOUT ADJUSTMENTS
Readout #1 (Speed Readout) Offset Adjust 0.0
Readout #1 (Speed Readout) Gain Adjust 1.0
Readout #2 (Config Readout) Offset Adjust 0.0
Readout #2 (Config Readout) Gain Adjust 1.0
Readiout #2 Value (status only)
MODBUS COMM PORT ADJUSTMENTS (if modbus supplied)

Modbus Port Hardware Configuration ?
1=RS 232 2=RS 422 3=RS 485
Modbus Port Baud Rate Configuration ?
1=1200 2=1800 3=2400 4=4800
5=9600 6=19.2k 7=38.4k
Modbus Port Stop Bit Configuration ?
1=1bits 2=1.5 bits 3=2 bits
Modbus Port Parity Configuration ?
1= Off 2=Odd 3=Even
Link Error (status only)
Exception Error (status only)
Error Number (status only)
Error Percent (status only)
DRAWN BY: BKM C-34347 A-6079793

DRESSER-RAND FLANGE MOVEMENTS DUE TO THERMAL GROWTH
SST LINE TURBINES
INLET 6" 600 # EXHAUST 8" 150 #
LOCATION U S T R Q P
DIRECTION FORWARD RIGHT DOWN FORWARD DOWN LEFT
INCHES 0.077 0.052 0.004 0.013 0.002 0.023
MOVEMENT
mm 1.968 1.316 0.096 0.325 0.042 0.582
CONTRACT: C-34347
FRAME: 503E
SHAFT END RISE: 0.007 " 0.185 mm

BASED ON AMBIENT TEMP: 80 F 27 C
INLET TEMP. (MAX): 388 F 198 C
EXHAUST TEMP. (MAX): 276 F 136 C
34347-FM
APPENDIX B
SPECIAL EQUIPMENT AND VENDOR DATA
C-34347
Figure No. Drawing No.
Electronic Speed Governor B-1 Woodward Peak 150

 Governor Bulletin 85565
Actuator B-2 Valtek, Mark 1 Size 25
Magnetic Pickup B-3 Electro, 3090A
Oiler Instructions B-4 Trico Oilers
Solenoid Valve B-5 ASCO, Model # EF8317G8
Limit Switch B-6 Micro, Model LZX-C4K
Product Manual 85565
(Revision D)
Original Instructions
Peak® 150 Digital Control

for Steam Turbines
9905-857/858/860/861/863/864/866/867
Installation and Operation Manual

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS  WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the publications page on the Woodward website:
www.woodward.com/searchpublications.aspx
The current revision of all publications is shown in file "current.pdf".
The latest version of most publications is available on the publications page. If your publication is
not there, please contact your customer service representative to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or battery-charging

device, make sure the charging device is turned off before disconnecting the battery
from the system.
To prevent damage to electronic components caused by improper handling, read

and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
© Woodward 1993
All Rights Reserved
Manual 85565 Peak 150
Contents
REGULATORY COMPLIANCE ........................................................................ V

ELECTROSTATIC DISCHARGE AWARENESS ................................................. VI
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
CHAPTER 2. INSTALLATION.......................................................................... 2
Packaging ...............................................................................................................2
Mounting .................................................................................................................2
Electrical Connections ............................................................................................2
CHAPTER 3. TURBINE OPERATION ............................................................... 6
Introduction .............................................................................................................6
START MODES ......................................................................................................6
OPERATING MODE...............................................................................................7
Communication .......................................................................................................8
CHAPTER 4. WIRING .................................................................................... 9
Inputs and Outputs .................................................................................................9
Jumpers and Test Points ......................................................................................14
CHAPTER 5. FUNCTIONAL DESCRIPTION .................................................... 16
Introduction ...........................................................................................................16
Magnetic Pickups .................................................................................................17
Analog Input .........................................................................................................17
Contact Inputs ......................................................................................................17
Actuator Driver ......................................................................................................18
Analog Outputs .....................................................................................................18
Relays ...................................................................................................................18
Speed Set Point....................................................................................................19
Remote Speed Set (Process Control) ..................................................................19
Idle/Min Start Ramp ..............................................................................................19
Critical Speed Band ..............................................................................................20
Valve Ramp Control .............................................................................................21
Speed Control .......................................................................................................21
Dual Dynamics .....................................................................................................22
Diagnostics ...........................................................................................................22
Shutdown and Alarm Summary ............................................................................22
Magnetic Pickup Failsafe......................................................................................23
Power Supplies .....................................................................................................23
Communications (Optional) ..................................................................................24
CHAPTER 6. OPERATING PROCEDURES ..................................................... 25
Front Panel Operation ..........................................................................................25
Prior To Turbine Start ...........................................................................................30
Turbine Start .........................................................................................................31
Idle/Minimum Ramp..............................................................................................31
Critical Speed Band ..............................................................................................32
Speed Reference Operating Modes .....................................................................32
Overspeed Test ....................................................................................................34
Shutdown and Alarm Function Summary .............................................................35
Stroking Actuator ..................................................................................................36
Dynamics Adjustments .........................................................................................37
Communications (Optional) ..................................................................................37
Woodward i
Peak 150 Manual 85565
Contents
CHAPTER 7. PROGRAMMING ......................................................................38

Introduction ...........................................................................................................38
Hand-Held Programmer .......................................................................................38
Configure Mode ....................................................................................................41
Service Mode ........................................................................................................42
Basic Program Architecture ..................................................................................43
Speed Relationships .............................................................................................45
Configuration Mode Programming........................................................................45
Service Mode Programming .................................................................................47
CHAPTER 8. CONFIGURATION MENUS.........................................................49
Introduction ...........................................................................................................49
Speed Configuration Menu ...................................................................................49
Start Mode Menu ..................................................................................................52
Actuator Configuration Menu ................................................................................52
Operating Mode Menu ..........................................................................................52
Readouts Menu ....................................................................................................53
Relays Menu .........................................................................................................54
Contact In #8 ........................................................................................................55
Port Configuration .................................................................................................55
Configure Mode Flow Diagram .............................................................................56
CHAPTER 9. SERVICE MENUS ....................................................................58
Introduction ...........................................................................................................58
Alarms Menu.........................................................................................................58
Trips Menu ............................................................................................................58
Speed Dynamics Menu ........................................................................................59
Adjusting Gain And Reset ....................................................................................59
Speed Values Menu .............................................................................................60
Remote Setting Menu ...........................................................................................61
Failed MPU Override Menu ..................................................................................62
Idle/Min Ramp Menu ............................................................................................63
Critical Speed Menu .............................................................................................63
Speed Switch / Hand Valve Menu ........................................................................64
Valve Menu ...........................................................................................................65
Readout Adjustments Menu .................................................................................66
Port Adjustments Menu ........................................................................................67
I/O Check ..............................................................................................................68
Service Mode Flow Diagram ................................................................................72
CHAPTER 10. FUNCTIONAL BLOCK DIAGRAM .............................................76
Explanation of Functional Block Diagram .............................................................76
CHAPTER 11. MODBUS COMMUNICATIONS .................................................87
Introduction ...........................................................................................................87
Modbus Wiring ......................................................................................................87
Basic Modbus Overview .......................................................................................91
Modes of Transmission ........................................................................................92
Modbus Addresses ...............................................................................................95
Additional Information ...........................................................................................96
ii Woodward
Contents
CHAPTER 12. TROUBLESHOOTING ............................................................. 97

General .................................................................................................................97
Diagnostics ...........................................................................................................97
Troubleshooting ....................................................................................................97
Troubleshooting Chart ..........................................................................................98
Debug Mode Tunables .......................................................................................103
Alarms / Shutdowns............................................................................................104
Wiring / Component Problems ...........................................................................104
Actuators / Control Adjustments .........................................................................105
Other Operating Problems..................................................................................105
CHAPTER 13. SERVICE OPTIONS ............................................................. 106
Product Service Options .....................................................................................106
Woodward Factory Servicing Options ................................................................107
Returning Equipment for Repair .........................................................................107
Replacement Parts .............................................................................................108
Engineering Services..........................................................................................108
How to Contact Woodward .................................................................................109
Technical Assistance ..........................................................................................109
APPENDIX. PROGRAM MODE WORKSHEETS ............................................. 110
Introduction .........................................................................................................110
Configure Mode Program ...................................................................................110
Service Mode Program .......................................................................................113
PEAK 150 CONTROL SPECIFICATIONS ..................................................... 120
Woodward iii
Illustrations and Tables
Figure 2-1. Peak 150 Control Outline Drawing...................................................... 4

Figure 2-2. Control Wiring Diagram ....................................................................... 5
Figure 4-1. Power Supply Input ............................................................................. 9
Figure 4-2. Relay Outputs ................................................................................... 10
Figure 4-3. Discrete Input Connections ............................................................... 11
Figure 4-4. Powering Discrete Inputs .................................................................. 11
Figure 4-5. Modbus Connections ........................................................................ 12
Figure 4-6. Connections for Analog Outputs ....................................................... 13
Figure 4-7. Connections for Speed Sensing ....................................................... 13
Figure 4-8. Connections for Analog Input ............................................................ 14
Figure 4-9. Jumper and Test Point Locations and Functions.............................. 15
Figure 5-1. System Overview .............................................................................. 16
Figure 6-1. Front Panel of Peak 150 Control....................................................... 26
Figure 7-1. Hand-held Programmer..................................................................... 40
Figure 7-2. Basic Program Architecture .............................................................. 44
Figure 7-3. Speed/Mode Relationships ............................................................... 45
Figure 8-1. Configure Mode Flow Diagram ......................................................... 56
Figure 9-1. Service Mode Flow Diagram ............................................................. 72
Figure 11-1. Modbus Communication Connections ............................................ 87
Figure 11-2. Typical RS-232 Communications.................................................... 88
Figure 11-3. Typical RS-422 communications .................................................... 89
Figure 11-4. Typical RS-485 Communications.................................................... 90
Figure 11-5. Basic Modbus Overview.................................................................. 91
Figure 11-6. Modbus Transmission Modes ......................................................... 92
Figure 11-7. Modbus Frame Definition ................................................................ 92
Figure 11-8. Modbus Function Codes ................................................................. 93
Figure 11-9. Modbus Messages .......................................................................... 93
iv Woodward
Regulatory Compliance
North American Compliance
UL: UL Listed for Class I, Division 2, Groups A, B, C, & D, T4 at
60 °C Ambient. For use in Canada and the United States.
UL File E156028
Special Conditions for Safe Use:

Input and output wiring must be in accordance with Class I, Division 2 wiring
methods and in accordance with the authority having jurisdiction.
All peripheral equipment must be suitable for the location in which used.
Woodward v
Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
vi Woodward
Chapter 1.
General Information
This manual describes the Woodward Peak® 150 digital control for steam
turbines and the hand-held programmer (9905-292) used to program it. The
following topics are covered in the chapter indicated:
 Installation & Hardware (Chapter 2)
 Overview of Turbine System Operation (Chapter 3)
 Peak 150 Inputs & Outputs (Chapter 4)
 Peak 150 Control Functions (Chapter 5)
 Explanation of Operating Procedures (Chapter 6)
 Overview of Hand Held Programmer and Menus (Chapter 7)
 Set up of Configuration menus (Chapter 8)
 Set up of Service menus (Chapter 9)
 Detailed Functional Block Diagram (Chapter 10)
 Modbus Communications (Chapter 11)
 Troubleshooting (Chapter 12)
 Service Options (Chapter 13)
 Program Worksheets (Appendix)
Parameter names are shown in all capital letters and match the syntax as seen
on the Hand Held Programmer or the plant wiring diagram.
The Peak 150 control is UL Listed for the US and Canada (cUL) for use in Class
I, Division 2, Groups A, B, C, and D or non-hazardous locations only.
EXPLOSION HAZARD—The Peak 150 control box should not be

opened when a hazardous atmosphere is present. Wiring
connections which could cause sparks are exposed inside the
cabinet.
Do NOT attempt to operate the turbine until the Peak 150 control has
been programmed. To do so could cause equipment damage.
The scope of this manual is to provide information on programming, operation

and troubleshooting of the Peak 150 control. This manual was written for the
program and specifications of the 5-digit display version of the Peak 150 control.
This manual can also be used for the 4-digit display version of the Peak 150
control. For the 4-digit version there may be slight differences in the program.
However, all aspects of the 4-digit version are covered by this manual.
Woodward 1
Chapter 2.
Installation
Packaging
Figure 2-1 is an outline drawing of the Peak® 150 control. All Peak 150 control
components are contained in a single, NEMA 4X enclosure. The enclosure can
be mounted indoors or out. Access to internal components is through a right-
hand-hinged door which is held closed by six captive screws. The approximate
size of the enclosure is 19 x 12 x 4 inches (approximately 483 x 305 x 102 mm).
The enclosure has two openings in the bottom for wiring access. One hole is
approximately 25 mm (1 inch) diameter, and the other is approximately 38 mm
(1.5 inch) diameter. These holes accept either English or metric standard conduit
hubs.
If it is necessary to meet NEMA 4X requirements, you must use the

appropriate conduit hubs and conduit when installing this control.
When using the stainless steel hubs to meet the NEMA 4X

requirements, ensure the ground post on the conduit hubs is
positioned down to allow the front door to fully and properly close.
All internal components are industrial grade. The components include the CPU
(central processing unit), its memory, the switching power supply, all relays, all
input/output circuitry, and all communications circuitry for the front door display,
touch keypad, remote RS-232, RS-422, and RS-485 Modbus® * communications.
* Modbus is a trademark of Schneider Automation Inc.
Mounting
The standard Peak 150 control enclosure must be vertically mounted on a wall or
19" (483 mm) rack, allowing sufficient room for lid opening and wiring access.
Two welded flanges, one on the right side and one on the left side, permit secure
mounting.
Electrical Connections
All electrical connections must be made through the two openings in the bottom
of the enclosure to the terminal blocks inside the enclosure. Route all low-current
lines through the large wiring port. Route all high-current lines through the small
wiring port.
Wiring for each MPU and for each actuator must be separately shielded. We also
recommend separate shielding for each mA input. Contact inputs may be
bundled together within a single multi-conductor cable with one overall shield.
Shields should be connected only at the Peak 150 control. Relay and power
supply wiring do not normally require shielding.
2 Woodward
Make sure that all inputs and outputs, including all shields, are NOT grounded
outside the Peak 150 control box. Terminal block 1 (ground) is the only
connection that should be wired to external ground.
See Figure 2-2 for the control wiring diagram and terminal block numbers.
EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,

Division or Zone applications.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I,
applications Division ou Zone.
All peripheral equipment must be suitable for the location in which

used.
Shielded Wiring
All shielded cable must be twisted-conductor pairs. Do not attempt to tin the
braided shield. All signal lines should be shielded to prevent picking up stray
signals from adjacent equipment. Connect the shields to the indicated shield
terminals. Wire exposed beyond the shield should be as short as possible, not
exceeding 50 mm (2 inches). The other end of the shields must be left open and
insulated from any other conductor. DO NOT run shielded signal wires along side
or in the same conduit with other wires carrying large currents. See Woodward
publication 50532, EMI Control for Electronic Governing Systems, for more
information.
Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below:
1. Strip outer insulation from BOTH ENDS, exposing the braided or spiral
wrapped shield. DO NOT CUT THE SHIELD.
2. Using a sharp, pointed tool, carefully spread the strands of the shield.
3. Pull inner conductor(s) out of the shield. If the shield is the braided type, twist
it to prevent fraying.
4. Remove 6 mm (1/4 inch) of insulation from the inner conductors.
Installations with severe electromagnetic interference (EMI) may require

additional shielding precautions. Contact Woodward for more information.
Woodward 3
Figure 2-1. Peak 150 Control Outline Drawing
4 Woodward
Figure 2-2. Control Wiring Diagram
Power Supply
Run the power leads directly from the power source to the control box. Use
3 mm ² (12 AWG) or larger wire for the power supply. Shield the power supply
wires and connect the shield to an external point. DO NOT POWER OTHER
DEVICES WITH LEADS COMMON TO THE CONTROL. Avoid long wire lengths.
This wiring must be fully enclosed in conduit to meet Class I, Division 2, Group D
requirements.
Input and output wiring must be in accordance with Class I, Division

2 wiring methods and in accordance with the authority having
jurisdiction.
Woodward 5
Chapter 3.
Turbine Operation
Introduction
Steam Turbine applications include mechanical drive systems such as: pumps,
fans, blowers, compressors, etc. The Peak® 150 is designed to operate those
Steam Turbines with a single-valve or a single-valve rack. The microprocessor-
based design of the Peak 150 provides the flexibility for configuring for any of the
above applications. This ability to configure the system in the field with a single
design reduces both cost and delivery time.
START MODES
Turbine start-up is accomplished by controlling the inlet steam with the turbine’s
Trip & Throttle valve and/or the Actuator/Valve. The sequence of operation for
these two devices determines the start mode which is either: MANUAL START
MODE and AUTO START MODE.
MANUAL START MODE

The MANUAL START MODE is when a turbine operator manually controls the
inlet steam by opening the TRIP & THROTTLE VALVE. The operator has control
of the turbine speed from zero RPM to the MIN GOVERNOR SPEED. While the
operator is starting the turbine, the Peak 150 ramps the speed set point to the
MIN GOVERNOR SPEED. It waits for the turbine speed to reach this point and
then it automatically takes control of the inlet steam.
The Peak 150 can be configured for MANUAL START by setting MANUAL
START MODE = TRUE. Setting MANUAL START MODE = TRUE will set the
AUTO START MODE = FALSE.
The Speed Relationship diagram (Figure 7-3) shows how the speed settings in
the Peak 150 relate to each other.
AUTO START MODE

AUTO START MODE is defined as controlling the inlet steam with the
ACTUATOR / VALVE via the Peak 150 during start up. In the AUTO START
MODE, the VALVE RAMP controls the speed from zero to either IDLE SPEED or
to the MIN GOVERNOR SPEED depending on how the control is configured.
(see Figure 7-3).
If IDLE SPEED is configured, the speed will control at IDLE until the IDLE / MIN
GOV input is closed. When closed, the speed will RAMP up to the MIN
GOVERNOR SPEED.
This mode of operation starts with the ACTUATOR/ VALVE RAMP closed and
the Trip and Throttle fully opened.
The Peak 150 can be configured for AUTO START by setting MANUAL START
MODE = FALSE. Setting MANUAL START MODE = FALSE will set the AUTO
START MODE = TRUE.
6 Woodward
Either start mode begins with the START command from the START button, the
START discrete input, or a Modbus START command. (All ALARMS and TRIPS
must be cleared and RESET for the Peak 150 to respond to the START
command).
OPERATING MODE
(Setting Turbine Speed)
The Peak 150 control has three operating modes for setting the turbine speed:
 MANUAL CONTROL mode
 REMOTE CONTROL mode
o Function of Analog Input
o Function of Modbus command
 COMBINATION mode
In all three modes, the set point for the turbine speed is the value of the ACTUAL
SPEED SETPT. The ACTUAL SPEED SETPT can be monitored in the SPEED
VALUES menu.
MANUAL CONTROL Mode

In the MANUAL CONTROL mode, the turbine operator adjusts the speed by
changing the value of the LOCAL SPEED SETPT. This set point is adjusted by:
 The RAISE / LOWER buttons on the front panel.
 The RAISE SPEED / LOWER SPEED discrete inputs.
 The Modbus RAISE SPEED / LOWER SPEED commands.
In the MANUAL CONTROL mode, the ACTUAL SPEED SETPT is equal to the
LOCAL SPEED SETPT. The LOCAL SPEED SETPT can be monitored in the
SPEED VALUES menu.
The MANUAL CONTROL mode is selected by configuring MANUAL CONTROL

ONLY = TRUE.
REMOTE CONTROL Mode

In the REMOTE CONTROL mode, the turbine speed is adjusted between the
MIN GOVERNOR SPEED and the MAX GOVERNOR SPEED with the REMOTE
SPEED SET input of 1–5 Vdc or 4–20 mA.
Terminology:
1. REMOTE SPEED SET INPUT: This is a 1–5 Vdc or a 4–20 mA input from
terminals 48 & 49. This signal can be the output from a Pressure
Transducer, a PLC or a Manual Control Station in the Turbine Control
Room.
2. REMOTE SPD SET: This is the value of the turbine’s REMOTE SPEED
SET INPUT converted to RPMs. The REMOTE SPD SET can be monitored
in the SPEED VALUES menu.
When the REMOTE CONTROL mode is configured and activated, the ACTUAL
SPEED SETPT is equal to the REMOTE SPD SET. In this mode the LOCAL
SPEED SETPT tracks the value of the REMOTE SPD SET. If the REMOTE
CONTROL mode is disabled, speed control reverts to the MANUAL CONTROL
mode at the last value of the LOCAL SPEED SETPT.
Woodward 7
The REMOTE CONTROL mode is selected by configuring MANUAL CONTROL
ONLY = FALSE, USE REMOTE SPD SET? = TRUE and USE HI-SIG-SELECT?
= FALSE.
The REMOTE CONTROL mode is active only when the turbine speed is at or
above MIN GOVERNOR SPEED, and there is either a REMOTE SPEED
ENABLE discrete input or a Modbus ENABLE REMOTE command.
MODBUS CONTROL Mode

The MODBUS CONTROL mode is a variation of the REMOTE CONTROL mode.
When the OPERATING MODE is configured USE MODBUS ANALOG INPUT =
TRUE, the REMOTE SPD SET uses the value of the Modbus analog write
REMOTE SETTING vs. the value of the Analog Input.
COMBINATION Mode
(High-Signal-Select)
When the OPERATING MODE is configured for USE HIGH-SIGNAL-SELECT,

the speed setting is a combination of the MANUAL CONTROL mode and the
REMOTE CONTROL mode. The values of the REMOTE SPD SET and the
LOCAL SPEED SETPT are adjusted independently. The ACTUAL SPEED
SETPT equals the set point, LOCAL or REMOTE, with the highest speed. If the
REMOTE CONTROL mode is disabled, control reverts to MANUAL CONTROL
mode with the speed set at the LOCAL SPEED SETPT.
Communication
Commands are communicated to the Peak 150 from four sources:
1. From the Front Control Panel
2. From a Hand-Held Programmer
3. From Inputs via the field wiring such as analog inputs and discrete inputs
4. From the Modbus serial port
8 Woodward
Chapter 4.
Wiring
Inputs and Outputs

All inputs and outputs to the Peak® 150 control are made through terminal blocks
inside the Peak 150 control enclosure. Wiring passes through two wiring ports on
the bottom of the control.
Inputs and outputs to the control are:

 Power Supply Input
 Analog Input
 Analog Outputs
 Discrete Inputs
 Discrete Outputs
 Speed Sensor (magnetic pickup) Inputs
 Modbus communications (optional)
 A service port for the hand-held programmer

connections which could cause sparks are available inside the
cabinet.
Power Supply
Figure 4-1 shows the power-supply connections. The following tables show the
Input voltages and frequencies for the different versions of the Peak 150 control.
Maximum power consumption is 38 W.
cUL Version NEMA 4 Part Number NEMA 4X Part Number

24 Vdc 9905-857 9905-863
24 Vdc w/Modbus 9905-860 9905-866
ac/dc 9905-858 9905-864
ac/dc/ w/Modbus 9905-861 9905-867
Figure 4-1. Power Supply Input
Woodward 9
Version Input Voltage Frequency
1 (24 Vdc) 18–32 Vdc NA
2 (ac/dc) 90–150 Vdc NA
88–132 Vac 47–63 Hz
No power switch is provided, the unit operates whenever power is applied. Input
over-or under-voltage shutdown is not provided; if the +5 Vdc supply in the unit
goes below 4.7 volts, the microprocessor will be reset.
Discrete Outputs
There are four hermetically-sealed relays. Two are dedicated, and two are user-
configurable:
 Output #1 = TRIP RELAY (programmed energize or de-energize
for trip)
 Output #2 = ALARM RELAY (de-energizes for alarm)
 Output #3 = CONFIG RELAY #1 (energizes for function)
 Output #4 = CONFIG RELAY #2 (energizes for function)
If required the configurable relays can be programmed as an additional Trip

(using Option 2) or Alarm (Option 1) function. See Functional Block Diagram
(Chapter 10) or Relays section of Configuration Menu (Chapter 8) for options.
Figure 4-2 shows the relay terminals.
Figure 4-2. Relay Outputs
Internal jumpers provide a choice of normally open or normally closed contacts

(see Figure 4-9 for jumper option chart).
Relay Contact Output Ratings

 2 A Resistive @ 28 Vdc
 0.3 A Resistive @ 115 Vac
An interposing relay is required if more current is needed.
10 Woodward
Discrete Inputs
There are eight discrete inputs (shown in Figure 4-3), powered either by an
internal 24 Vdc supply or by an external 5–28 Vdc supply:
 Input #1 = LOWER SPEED
 Input #2 = RAISE SPEED
 Input #3 = EXTERNAL TRIP
 Input #4 = START
 Input #5 = RESET
 Input #6 = IDLE / MIN GOV
 Input #7 = REMOTE SPEED ENABLE
 Input #8 = HI DYN SELECT or (OVERSPEED TEST)
A jumper or external shutdown switch must be installed across Input

#3.
As shown in Figure 4-4, internally powered contact inputs (dry contacts) use
Jumper 15 and +24 Vdc from analog Outputs Terminal 33 or 39). Externally
powered contact inputs use Jumper 16 and an external + 24 Vdc supply.
Figure 4-3. Discrete Input Connections
Figure 4-4. Powering Discrete Inputs
Woodward 11
Modbus Communications
Figure 4-5 shows the connections for Modbus communications. Refer to Chapter
11 for additional Modbus information.
If terminals 21–34 are not installed, your unit is not capable of Modbus
communications.
Figure 4-5. Modbus Connections
Analog Outputs
 Analog output #1 = Speed Readout

 Analog output #2 = User Configurable
 Actuator output = Signal to Actuator
Figure 4-6 shows the ANALOG OUTPUT connections. ANALOG OUTPUTs #1

and #2 are 4–20 mA or 0–1 mA, internal jumper selectable (see Figure 4-9 for
jumper option chart).
The ACTUATOR OUTPUT (current) can be programmed for 0–200 mA or 0–20

mA. The internal jumpers must be selected to connect the proper current to the
actuator driver (see Figure 4-9 for jumper option chart). The maximum load for
the 0–200 mA driver is 60 . The maximum load for the 0-20 mA driver is 450
ohms.
The fuel-valve actuator wires will carry a 0–200 mA or 4–20 mA signal and must
be fully enclosed in conduit to meet hazardous-environment requirements.
The SPEED READOUT output is included in the control to drive a tachometer

either near the turbine or in a control room. The maximum load for the readout
circuits is 600 Ω.
The control may be tailored to give accurate readings on the tachometer by

making adjustments on the set point programmer (see Configure Menus and
Service Menus Chapters).
See Readouts section of Configuration Menus for Configurable Readout options.
Figure 4-6 shows the connections for analog outputs.
12 Woodward
Figure 4-6. Connections for Analog Outputs
Speed Sensor Inputs

Figure 4-7 shows the connections for the two SPEED SENSOR INPUTS. The
minimum signal amplitude required for speed sensing is 1 Vrms. The minimum
detectable frequency is 200 Hz @ 1 Vrms. The maximum detectable frequency is
15 kHz.
 Input #1 = MAGNETIC PICKUP # 1

 Input #2 = MAGNETIC PICKUP # 2
Maximum control speed = 15 000 rpm.
The MPU cable must have two wires from the MPU plus a shield. The shield is
grounded at the control only: it must not be grounded at the MPU. The integrity of
the shield must be maintained between the MPU and the control. Polarity of the
signal wires from the MPU to the control is not important.
Figure 4-7. Connections for Speed Sensing
Analog Input
There is one analog input: the remote speed setting input. Figure 4-8 shows the
connections for the analog input.
There is a jumper option for the Analog Input for either 4–20 mA or 1–5 Vdc.
When 4–20 mA is selected, the ANALOG INPUT drives a 250  load (see Figure
4-9 for jumper option chart).
Woodward 13
Figure 4-8. Connections for Analog Input
Jumpers and Test Points

Figure 4-9 shows the location and functions of the Peak 150 control's jumpers
and test points.
14 Woodward
Figure 4-9. Jumper and Test Point Locations and Functions
Woodward 15
Chapter 5.
Functional Description
Introduction
A system overview in block form is shown in Figure 5-1. Chapter 10 contains the
detailed functional block diagram for the Peak® 150 control.
Figure 5-1. System Overview
16 Woodward
Magnetic Pickups
The Magnetic Pickups (MPUs) generate a speed signal that is used to provide
speed feedback to the Peak 150. The MPUs do this by generating voltage pulses
as the gear teeth pass through the MPU’s magnetic field. The Peak 150 counts
the number of pulses per second from the MPUs (frequency in HZ) and converts
this frequency to turbine RPM.
Two MPUs (MPU 1 and MPU 2) may be used to provide redundant speed inputs,
that is where one can fail and the remaining MPU keeps the turbine operating.
The Peak 150 determines which MPU is outputting the highest frequency and
uses that frequency as the speed feedback to control the turbine.
When only one MPU is used, the output should be connected in parallel to both
MPU inputs to prevent getting an alarm on the unused MPU input.
The Peak 150 converts the MPUs input frequency to RPMs by using the number
of teeth programmed in the SPEED CONFIGURATION menu for TEETH SEEN
BY MPU = xxxxx (Teeth) in the following formula:
RPM = (Hz x 60) / Teeth
When the speed of the main turbine shaft is different from the speed of the MPU
gear shaft, the value for MPU GEAR RATIO = x is programmed for the correct
ratio. The above equation will be multiplied by the RATIO so that the RPM seen
by the Peak 150 will be the turbine RPM and not the MPU gear shaft RPM.
RPM = ((Hz x 60) / Teeth) x Ratio
If the two MPUs are mounted on separate gears, each gear must have the same
number of teeth and rotate at the same RPM, so that both MPUs are sensing the
same speed.
When the MPU signal is below 1.0 VRMS the Peak 150 activates an ALARM of
FAILED MPU.
Analog Input
The ANALOG INPUT, REMOTE INPUT, is an isolated current-source which is
used for REMOTE SPEED CONTROL. When operating in the REMOTE
CONTROL MODE, this input controls the speed set point between the MIN GOV
SPEED and the MAX GOV SPEED.
Contact Inputs
The eight discrete inputs are:
 LOWER
 RAISE
 TRIP
 START
 RESET
 IDLE / MIN GOV
 REMOTE SPEED ENABLE
 SELECT HI DYN or OVERSPEED TEST
Woodward 17
These discrete inputs can be selected by connecting them to a 5–28 Vdc supply.
See Figure 4-4 for the power supply options.
For an EMERGENCY SHUTDOWN, power is removed from the TRIP input.

Therefore, before the turbine can be started, the external TRIP contact must be
closed with a switch, a relay contact or a jumper.
The IDLE / MIN GOV input is opened for IDLE speed and closed for MIN
GOVERNOR speed.
All other inputs close for the listed function.
Actuator Driver
The normal ACTUATOR OUTPUT currents are:
 20 to 160 mA for Woodward actuators
 4 to 20 mA for non-Woodward actuators
The ACTUATOR OUTPUT current is selected in the ACTUATOR

CONFIGURATION menu by setting USE 20–160 mA ACTUATOR = TRUE and
by installing the appropriate actuator drive current jumpers (see Figure 4-9). If
USE 20–160 mA ACTUATOR = FALSE then USE 4–20 mA ACTUATOR is
automatically set = TRUE (Status Indication Only).
Analog Outputs
There is a SPEED READOUT and a CONFIG READOUT available. These
readouts can be set for either 4–20 mA or 0–1 mA depending on the jumper
installed (see Jumper Option Chart figure 4-9). The configurable meter is
selected in the Configure Mode from the following five options:
 ACTUAL SPEED (RPM)
 ACTUAL SPEED SETPT (RPM)
 REMOTE SPEED SET INPUT (RPM)
 VALVE POSITION (Actuator Output) (0 to 100%)
 VALVE RAMP POS’N (0 to 100%)
Relays
The Peak 150 has 4 discrete outputs or relays. Two of the relay outputs are
dedicated:
 TRIP RELAY (Configurable to either energize or de-energize for trip)
 ALARM RELAY (Normally energized—de-energizes for alarm)
The other two relays are configurable from the following 11 options:
 Alarm
 Trip Output
 Shutdown
 Remote Control
 Speed Control
 Either MPU Failed
 Overspeed Trip
 Overspeed Test
 Remote Status
18 Woodward
 Spd Switch or Hand Valve #1
 Spd Switch or Hand Valve #2
Normally-open or normally-closed contact is selectable (see Figure 4-9).
Relay contacts are rated at:

 2.0 A of resistive load at 28 Vdc
 0.75 A of inductive load at 28 Vdc
 0.3 A of resistive load at 115 Vrms, 60–400 Hz
 (The relay contacts are not rated for 125 Vdc)
An interposing relay is required if more current is needed.
Speed Set Point

The SPEED SET POINT is the value (in RPMs) of the ACTUAL SPEED SETPT.
This is one of the inputs to the SPEED CONTROL. Depending on the Operating
Mode for setting the turbine speed, the ACTUAL SPEED SETPT is equal to the
LOCAL SPEED SETPT or the REMOTE SPEED SET point. (For additional
information about controlling the ACTUAL SPEED SETPT see the OPERATING
MODE section on page 8).
Remote Speed Set (Process Control)

In the REMOTE CONTROL mode the REMOTE SPEED SET input has control of
the ACTUAL SPEED SETPT and operates the turbine between the MIN GOV
SPEED and the MAX GOV SPEED when the REMOTE SPEED ENABLE is
closed. For additional information on this operation see REMOTE CONTROL on
page 8.
The REMOTE CONTROL mode can be used as a PROCESS CONTROL for

controlling processes such as pump discharge pressure, water drum level, etc.
The Process Control is external to the Peak 150 and its output is the input to the
REMOTE SETTING. The function of the Process Control is to compare a
Process Set Point to a Process Variable and generate a 4–20 mA or 1–5 Vdc
output used by the Peak 150.
Idle/Min Start Ramp

In the AUTO START MODE the Peak 150 can be programmed to use an IDLE
SPEED. During start up, the LOCAL SPEED SETPT ramps from zero RPM to
IDLE SPEED when the control is RESET and gets a START command. (If the
IDLE/MIN GOV input is jumped, the ramp will not stop at IDLE SPEED, but will
go to the MIN GOVERNOR SPEED).
When IDLE SPEED is used by programming USE IDLE / MIN GOV RAMP =
TRUE, closing the IDLE/MIN GOV input will automatically ramp the LOCAL
SPEED SETPT to MIN GOVERNOR SPEED. The RAMP to MIN GOVERNOR
SPEED can also be started by pushing the START button when the START =
RAMP TO MIN GOV is set to TRUE.
 When the IDLE / MIN GOV external contact is closed, the LOCAL SPEED
SETPT will increase to the MIN GOVERNOR SPEED at the IDLE/MIN GOV
RATE.
Woodward 19
 If the IDLE / MIN GOV external contact is opened before the speed reaches
MIN GOVERNOR SPEED, the ramp will stop at its current value. When
reclosed, the ramp will continue ramping to the MIN GOVERNOR SPEED.
 If there is a RAISE or LOWER command while in the IDLE / MIN GOV
START RAMP, the ramp will stop. Once stopped, the RAISE or LOWER
commands will increase or decrease the LOCAL SPEED SETPT. Also
reselecting the IDLE / MIN GOV input will restart the ramp.
When programmed for USE IDLE / MIN GOV RAMP = FALSE, the IDLE / MIN
GOV external contact will not ramp the SPEED SET POINT to RATED SPEED,
nor will the START button. When programmed for false, the RAISE and LOWER
buttons control the LOCAL SPEED SETPT. The RAISE button can drive the
SPEED SET POINT to the MAX GOV SPEED. The LOWER button can drive the
SPEED SET POINT to IDLE SPEED if the speed is below the MIN GOV SPEED
or it can only drive the SPEED SET POINT to the MIN GOV SPEED if the speed
is already above this set point.
Critical Speed Band

The CRITICAL SPEED BAND is used to prevent turbine operation at speeds
where there is excessive turbine vibration. The CRITICAL SPEED BAND function
does this by switching to a faster RAMP while the ACTUAL SPEED SETPT is in
the CRITICAL SPEED BAND. This function also prevents the ACTUAL SPEED
SETPT from being stopped while in the CRITICAL SPEED BAND.
The CRITICAL SPEED BAND menu is displayed only in the AUTO START
mode.
Even though the CRITICAL SPEED BAND menu is not displayed in

the MANUAL START MODE, the CRITICAL SPEED function will still
operate if enabled.
This function is enabled by programming USE CRITICAL BAND = TRUE. The

speed band is defined by the values assigned to CRITICAL SPEED MIN (RPM)
and the CRITICAL SPEED MAX (RPM). The CRITICAL BAND RATE = _____
(RPM / SEC) sets the rate used to pass through this speed range.
The default CRITICAL SPEED BAND is 1500 to 1800 RPM.
Normally the CRITICAL SPEED BAND will be between IDLE SPEED and MIN
GOV SPEED. As the ACTUAL SPEED SETPT cannot be stopped inside the
CRITICAL SPEED BAND it is NOT recommended to set this band between the
MIN GOV SPEED and the MAX GOV SPEED.
It is possible to change the direction of the speed ramp, (increase to decrease or

decrease to increase), by giving the control a LOWER, or RAISE command while
in the CRITICAL SPEED BAND. When a command is given for the opposite
direction, the ACTUAL SPEED SETPT will be driven to the appropriate
CRITICAL SPEED BAND limit, MIN or MAX and stop.
20 Woodward
Valve Ramp Control

Either the output of the VALVE RAMP or the SPEED CONTROL is used to open
and close the steam valve during turbine operation. These outputs are LOW
SIGNAL SELECTED by the LSS Bus so that the control function with the lowest
demand sets the position of the actuator.
The VALVE RAMP is opened via the START COMMAND during START UP to
run its output out of the way of the SPEED CONTROL (100%-Open). When the
control gets a TRIP command, the VALVE RAMP over rides the SPEED
CONTROL and closes the ACTUATOR (0%-Closed).
The SPEED CONTROL increases or decreases the steam demand signal during
normal turbine operation.
In the MANUAL START MODE the Trip & Throttle valve holds the steam valve
closed while the outputs of the VALVE RAMP and the SPEED CONTROL are
driven quickly to 100% and to the MIN GOVERNOR speed. Start is initiated
when the Peak 150 is RESET and receives a START command. Initial speed
control is via the Trip & Throttle valve with the operator in control of the turbine
speed.
Initially In the AUTO START MODE the VALVE RAMP and SPEED CONTROL
hold the ACTUATOR at the closed position. Before a START command is given
the Trip & Throttle valve is opened by the operator. When given a START
command the VALVE RAMP is opened slowly to apply steam to the turbine. At
the same time the LOCAL SPEED SETPT starts ramping from zero to IDLE
speed. When the turbine speed exceeds the LOCAL SPEED SETPT, the SPEED
CONTROL closes the actuator until it is controlling the turbine speed at the SET
POINT.
Speed Control
The SPEED CONTROL compares the turbine SPEED with the ACTUAL SPEED
SET POINT. When the two values are equal, the Actuator signal is a constant
value between 4 & 20 mA or between 0 & 200 mA. (The actuator output range is
selected in the ACTUATOR CONFIGURATION MENU).
The ACTUAL SPEED signal is the output of the MPU HSS (HIGH SIGNAL
SELECTOR). The ACTUAL SPEED SETPT is either the LOCAL SPEED SETPT
or the REMOTE SPEED SET depending on which CONTROL MODE has been
configured.
When needed, the speed control can be configured to use DROOP feedback.
Droop is defined as a decrease in speed set point proportional to an increase in
load. The DROOP Signal is a function of the VALVE POSITION (ACTUATOR)
signal. When DROOP is configured, the SPEED CONTROL compares the
ACTUAL SPEED SET POINT to the combination of the SPEED signal plus the
DROOP signal.
Woodward 21
Dual Dynamics
The SPEED DYNAMICS are used to match the control response time to the
natural response time of the turbine. When there is a change in speed (or load),
there will be an error between the inputs to the SPEED CONTROL. The PID
within the SPEED CONTROL responds to this error by driving the actuator signal
to the new required position. The P (Proportional) term determines how fast the
signal reaches the new position, while the I (Integral) term determines the
dampening when the new position is reached.
The Peak 150 has two sets of SPEED DYNAMICS for adjusting the turbine’s
response. They are LOW SPEED GAIN & RESET and HIGH SPEED GAIN &
RESET. These adjustments, found in the SPEED DYNAMICS MENU, can be
accessed in the SERVICE MODE menu with the turbine running. The transfer
between the dynamics is selected by the setting of the HIGH SPEED SWITCH
POINT or with the contact closure of the HI DYN SELECT input.
Diagnostics
When the control is powered up, the microprocessor begins executing the
software and illuminates the front panel CPU OK LED. The LED stays on as long
as the microprocessor is running. This LED is controlled in the hardware by a
watchdog timer circuit. When the microprocessor stops executing or when the
program is not running correctly, the watchdog timer will time out and the CPU
OK LED will turn off. When this happens, the I/O LOCKOUT will be activated,
and will turn off all DISCRETE and ANALOG OUTPUTS. To restart the control
the power must be cycled off and on.
When the control is powered on or when it is rebooting after being configured,

the software performs several hardware diagnostic tests. If an error is found
during this testing, it is annunciated through the tachometer display on the front
of the control. The tachometer will display the message "ERR" followed by an
error number. If any of these errors occur, the control must be returned to the
factory for repair. Refer to Chapter 12 for an explanation of the diagnostic tests
and their corresponding error numbers that are displayed if an error occurs.
 RAM Test Failure "Err0"

 Analog I/O Timer #1 Failure "Err1"
 Analog I/O Timer #2 Failure "Err2"
 I/O Lockout Failure "Err3"
 –12 V Power Supply Failure "Err4"
 +12 V Power Supply Failure "Err5"
 +12 V P Power Supply Failure "Err6"
 +4.5 V Power Supply Failure "Err7"
Shutdown and Alarm Summary

The following is a list of the various occurrences which generate either an
ALARM or SHUTDOWN condition. SHUTDOWN conditions are signaled by a
relay which is configured by the user to either ENERGIZE or DE-ENERGIZE for
shutdown. The front panel display will also indicate the cause of the trip. ALARM
conditions are signaled by a relay that de-energizes. Any common alarm or trip
condition can be identified using the hand-held programmer. In addition, the
cause of the last trip is held in a register and can be identified using the hand-
held programmer.
22 Woodward
Alarm conditions are:
 MPU #1 Failure
 MPU #2 Failure
 Remote Input Failure
 Shutdown (configurable)
 Communications Failure (if used)
Shutdown conditions are:

 Loss of both magnetic pickup signals
 Electrically-sensed overspeed trip
 Emergency Trip pushbutton is pushed
 Shutdown contact input initiated
 Trip initiated by Modbus device (if used)
Magnetic Pickup Failsafe

The Peak 150 has a MAGNETIC PICKUP FAILSAFE function that trips the
turbine when both MPU input signals are lost. During turbine start up, the
MAGNETIC PICKUP FAILSAFE function is automatically overridden.
The USE MPU OVERRIDE TIMER limits the time between the START
COMMAND and the minimum detected speed (approximately 200 RPM). The
turbine trips if the MAX STARTING TIME expires and the Peak 150 is not
sensing speed. The override is removed when the turbine speed exceeds the
AUTO-OVRD-OFF-SPEED. (This speed is programmed by the user and should
be above the minimum detected speed).
Slow Roll Down Failsafe Override

The USE SLOW ROLLDOWN OVRD function differentiates between the gradual
loss of the speed signal (or roll down when the Trip & Throttle Valve is closed
gradually) and a sudden loss of the speed signal.
When the speed gradually drops below the setting of The AUTO-OVRD-ON-
SPEED for the time set by the AUTO-OVRD-ON-DELAY, the MAGNETIC
PICKUP FAILSAFE override is switched on. This prevents a LOSS OF BOTH
MPUs trip, and drives the Peak 150 governor valve opens fully as turbine speed
decreases.
A sudden loss of the MPU inputs trips the turbine and closes the governor valve.
Power Supplies
The Peak 150 control is available with the following power supplies:
Version Input Frequency

1 (24 Vdc) 18–32 Vdc NA
2 (ac/dc) 90–150 Vdc NA
88–132 Vac 47–63 Hz
Power is supplied directly to the Peak 150 as no power switches are provided.
Woodward 23
The POWER SUPPLY INPUT is protected with two user-replaceable fuses that
are sized to eliminate nuisance trips. The following fuses are recommended:
Version 1 (24 Vdc) 3 A, 250 V, Slo-Blo, 3AG

Version 2 (ac/dc) 1 A, 250 V, Slo-Blo, 3AG
When replacement fuses are needed, the control should be tested and repaired.
If power is disconnected the control will continue to operate for at least the
following holdup times:
Version 1: 28 milliseconds from 24 Vdc

Version 2: 50 milliseconds from 120 Vdc
4 cycles from 100 Vac
Input voltage fluctuations within the acceptable range will not affect operation of
the Peak 150 control.
HIGH VOLTAGE—Before replacing fuses, remove all power from the

control; high voltage is present on the fuse clips and elsewhere in
the control. Contact with this voltage could cause personnel injury or
death.
Communications (Optional)
The Peak 150 control is capable of communicating to a plant computer using
Modbus protocol. All pertinent parameters are programmed to be transferred
through this link. The following link parameters are configurable: data bits, stop
bits, baud rate, and parity.
This option requires additional communication hardware not available unless

purchased. Be sure to specify the Modbus option if this is required.
See Chapter 11 for complete details.
24 Woodward
Chapter 6.
Operating Procedures
Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Do NOT attempt to operate the turbine until the Peak® 150 control has
been programmed. Refer to the program worksheets.
Front Panel Operation

Figure 6-1 shows the front panel of the Peak 150 control.
RPM Meter
The RPM METER (tachometer) displays the SPEED sensed by the Peak 150
control. The minimum speed will depend on when the MPU voltage level goes
above 1 Vrms, but can be no lower than 200 rpm.
When the Peak 150 control is tripped, the RPM display flashes a TRIP CODE.
The SPEED and TRIP CODE flash alternately. Once the trip is cleared with a
RESET command, the display will show only the SPEED. The last TRIP CODE
can be found in the Service Mode TRIPS menu using the hand-held programmer
(see Service Mode program chapter). The TRIP CODES are as follows:
Code Cause
1 External Trip (contact input opened)
2 Loss of Both MPU inputs
3 Overspeed Trip indication
4 Front Panel Trip indication
5 Modbus Trip indication
Woodward 25
Figure 6-1. Front Panel of Peak 150 Control
26 Woodward
LEDs
TRIPPED LED: The TRIPPED LED will be on as a result of pressing the EMER
TRIP button, opening the EXTERNAL TRIP input, or as a result of one of the
programmed TRIP conditions. In addition to illuminating the TRIPPED LED, the
TRIP relay will either energize or de-energize as programmed.
When programmed for RESET CLEARS TRIP, the TRIPPED LED and the TRIP
relay can be RESET even if a trip condition still exists. This restores the TRIP
RELAY to the RUN state which removes it from the turbine trip string. Resetting
the TRIP relay gives the operators the opportunity to prepare for a turbine re-
start.
When RESET CLEARS TRIP is active and after the control has been RESET, no
other trips can be activated / tested until the turbine has been started.
OVER SPEED TEST ENABLED LED: The OVER SPEED TEST ENABLED LED
indicates that the OVER SPEED TEST button on the front panel is pressed or,
contact input #8 is configured for OVER SPEED TEST ENABLE and is closed
(see OVERSPEED TEST section of OPERATING PROCEDURES chapter 6).
This LED is on while the OVERSPEED TEST is selected. It blinks at a slow rate
when the turbine's speed is above the control's trip point, and it blinks at a fast
rate when the turbine's speed is above the external trip device's trip point.
CPU OK LED: The CPU OK LED is always on when the control is operating
properly. During power-up this LED is out until all power-up diagnostics are
completed. If this LED is not on, the CPU is not running and this indicates a
hardware problem. If cycling the power does not reset the CPU OK LED, the
Peak 150 needs repaired.
MPU #1 OK and MPU #2 OK LEDs— MPU #1 OK and MPU #2 OK LEDs go out

if an MPU #1 or MPU #2 failed signal is detected. The LEDs are ON during start-
up and as long as the MPU output is within normal frequency range and voltage
levels. The LEDs will be ON during a turbine start, indicating the SPEED
FAILSAFE is overridden (see MAGNETIC PICKUP FAILSAFE OVERRIDE
section in OPERATING PROCEDURES chapter 6).
RMT SPD ENABLED LED—The RMT SPD ENABLED LED is on when the
REMOTE SPEED SET input is between 4 and 20 mA, the REMOTE SPEED
ENABLE input is closed and the turbine SPEED is equal to or greater than the
MIN GOVERNOR SPEED. When this LED is on, the REMOTE SPEED SET
input controls the ACTUAL SPEED SETPT / turbine speed. The following
conditions affect the operation of the REMOTE SPEED:
 The RMT SPD ENABLED LED blinks at a slow rate if remote control is
selected (USE REMOTE SPEED SETTING is configured and the REMOTE
SPEED ENABLE input is closed) but remote control is inhibited. Remote
control will be inhibited when the LOCAL SPEED SETPT is in control with
the turbine operating below the MIN GOV SPEED. Remote control will also
be inhibited when MANUAL CONTROL ONLY is selected.
Woodward 27
 The RMT SPD ENABLED LED blinks at a fast rate when the USE REMOTE
SPEED SETTING is configured but the REMOTE SPEED SET input has
failed. This input failure latches and requires a RESET after the input signal
has been restored. The REMOTE SPEED ENABLE contact enables the
REMOTE FUNCTION when closed and disables the REMOTE FUNCTION
when open. When open, the RMT SPD ENABLED LED is off, unless the
REMOTE SPEED SET input has failed. When the REMOTE SPEED SET
input fails (even if the REMOTE SPEED ENABLE contact is open), the RMT
SPD ENABLED LED will blink at a fast rate.
 Failure of the REMOTE SPEED SET input is when it drops below 2 mA (0.5
V) or goes above 22 mA (5.5 V). When the REMOTE SPEED SET input
fails, the ACTUAL SPEED SETPT remains at the last remote set point and
the RMT SPD ENABLED LED flashes at a fast rate. The ACTUAL SPEED
SETPT now follows the LOCAL SPEED SETPT and changes can be made
with the RAISE / LOWER buttons or the RAISE SPEED / LOWER SPEED
discrete inputs.
 If remote is not configured for use, this LED will not turn on.
RMT SPD ENABLED LED / COMBINATION MODE

When the combination mode is configured (see Configuration and Operating
chapters), the ACTUAL SPEED SETPT is equal to the higher value between the
LOCAL SPEED SETPT and the REMOTE SPD SET. The RMT SPD ENABLED
LED is ON when the REMOTE SPEED SET (point) is in control, is OFF when the
REMOTE SPEED ENABLE input is open, blinks slowly when LOCAL SPEED
SETPT is in control, and blinks fast when the REMOTE SPEED SET input signal
fails.
If the REMOTE SPEED SET input fails or is disabled by opening the REMOTE
SPEED ENABLE contact, the REMOTE SPEED SET (point) ramps to MIN GOV
SPEED at the SET POINT FAST RATE to allow the LOCAL SPEED SETPT to
be the highest setting. Once the input is restored and a RESET command is
issued, the ACTUAL REMOTE SPEED SET (point) will ramp towards the
REMOTE SPEED SET INPUT value.
Front Panel Buttons (FP/B)

ALARM RESET—The Peak 150 latches when it senses an ALARM or a TRIP
condition. After the ALARM or TRIP condition has been cleared, pressing the
ALARM RESET button will clear the latch function. Normal start sequence is to
push the ALARM RESET button then the START button.
Along with the ALARM RESET button, the Peak 150 can be reset externally with
the RESET discrete input, or with the Modbus RESET command.
START—Pressing the START button initiates the Turbine Start Sequence. The
START button is inactive until all ALARMS and TRIPS are cleared and RESET.
 In the MANUAL START MODE, pressing the START button opens the
VALVE RAMP and ACTUATOR while a turbine operator controls the turbine
speed with a trip & throttle valve. Governor speed control begins at the MIN
GOVERNOR SPEED.
 In the AUTO START MODE, the trip and throttle valve is opened before the
Peak 150 START button is pressed. When the START button is pressed,
the Peak 150 controls the speed with the VALVE RAMP and ACTUATOR.
Governor speed control begins at either IDLE SPEED or the MIN
GOVERNOR SPEED.
28 Woodward
 Either START MODE begins operating when the Peak 150 receives a
START command from the START button, the START discrete input, or a
Modbus START command.
If the external START input is closed, the RESET button will both RESET and
START the Peak 150.
 In the MANUAL START MODE the ACTUAL SPEED SETPT will RAMP to
the MIN GOVERNOR SPEED.
 In the AUTO START MODE the ACTUAL SPEED SETPT will RAMP to
IDLE speed. When the IDLE / MIN GOV input is closed, the ACTUAL
SPEED SETPT will ramp to MIN GOVERNOR SPEED.
If START = RAMP TO MIN GOV is configured as part of the AUTO START

MODE, pressing the START button after the turbine is running will ramp the
ACTUAL SPEED SETPT to MINIMUM GOVERNOR SPEED even if the turbine
speed has not reached IDLE SPEED.
EMER TRIP—Pressing the EMER TRIP button will trip the turbine. When
pressed it sets the ACTUAL SPEED SETPT to zero, drives the VALVE RAMP
(ACTUATOR) to zero (closed position) and changes the state of the TRIP
RELAY.
RAISE and LOWER— In the MANUAL MODE and the COMBINATION MODE,
these buttons will adjust the LOCAL SPEED SETPT. These buttons are disabled
in the REMOTE CONTROL MODE.
The LOCAL SPEED SETPT moves at the SETPT SLOW RATE until the DELAY
FOR FAST RATE time has expired. The ramp rate will then switch to the SETPT
FAST RATE.
Closing the RAISE or LOWER buttons while ramping from IDLE SPEED to MIN
GOVERNOR SPEED will halt the IDLE/ MIN GOVERNOR ramp as long as the
set point is not within a CRITICAL SPEED BAND. When the IDLE / MIN
GOVERNOR ramp is halted, the RAISE or LOWER buttons can be used to
manually adjust the ACTUAL SPEED SETPT. The ramp can be restarted by
selecting the START command.
OVERSPEED TEST—With the OVERSPEED TEST button closed, along with

the RAISE button, the governor speed can be increased above the MAX GOV
SPEED. This enables the testing of the overspeed trip devices, both the
OVERSPEED TRIP on the Peak 150 and any external overspeed trip devices.
Once the speed is above the OVERSPEED LEVEL, the ENABLED

(OVERSPEED TEST) LED blinks at the slow rate. If the OVERSPEED TEST
button is released above this point, the unit will trip. Code "3" will flash on the
display, and the TRIPS menu in the SERVICE header will indicate an
OVERSPEED TRIP has occurred.
If the speed reaches the EXTERNAL OSPD LEVEL the ENABLED

(OVERSPEED TEST) LED will blink at the fast rate. This is an indication that
turbine speed is near the trip speed of the external trip device.
If the OVERSPEED TEST button is opened below the OVERSPEED LEVEL, the
ACTUAL SPEED SETPT ramps back to MAX GOV SEED. If using
COMBINATION mode, the LOCAL SET POINT must be used to perform the test
as the speed cannot go above MAX GOV SPEED in the REMOTE mode.
Woodward 29
Relays
TRIP RELAY: The TRIP relay is activated as part of a turbine trip as a result of
pressing the EMER TRIP button, as a result of losing the EXTERNAL TRIP input
on terminal 14, or as a result of one of the internal trip conditions on the Peak 150.
The TRIP relay opens a set of contacts between terminals 4 &5 when tripped.
This set of contacts is used in many systems as part of a trip string where any of
the safety systems can open the string and trip the turbine. The string usually
consists of inputs from the lube oil system, the turbine vibration system, an over
speed trip device or one of the trips on the Peak 150.
 If one of the trip conditions de-activates the TRIP relay and opens the trip
string, the trip string removes the EXTERNAL TRIP input from terminal 14.
To overcome this trip loop, the Peak 150 can be configured so that RESET
CLEARS TRIP. When this is configured TRUE and the RESET is closed
momentarily, all trips are overridden and the TRIP relay resets. This
restores the speed control output in the trip string so the turbine operator
can RESET the turbine for the next start.
 When testing the TRIP function on the Peak 150, note that after a TRIP has
been RESET, all other TRIPs will be ignored until the turbine is started.
The TRIP relay defaults at DE-ENERGIZE to trip. However the TRIP relay can be
configured to ENERGIZE to trip by setting TRIP RELAY ENERGIZES FOR TRIP
to TRUE in the program. After configuring the TRIP relay, ensure that the correct
jumpers (Jumpers 2 & 17 OR Jumpers 1 & 18) are installed to provide closed
contacts and the proper LED display when the turbine is running. See Figure 4-9
for proper jumper selection and location.
ALARM RELAY: The ALARM relay de-energizes when an alarm condition is

detected. Even though the turbine continues to operate with an alarm condition,
the ALARM condition should be corrected before it develops into a trip condition.
CONFIG RELAY #1 & #2: The CONFIG relays can be configured for one of 11
functions. The CONFIG relays will be energized to indicate the function. The (+)
increases the configuration option number and the (–) decreases the
configuration option number. (For a list of the relay configuration options, see
Chapter 5 under the Relay heading).
Prior To Turbine Start

 Program the Peak 150 for the specific turbine application (see Appendix for
program worksheets).
 Stroke the actuator (linkage) to ensure that the turbine can be shut down
when calling for 0% actuator position and can reach full load when calling
for 100% actuator position (see Stroking Actuator).
 Be prepared to adjust the system dynamics when the Peak 150 takes
control of the speed (see Dynamics Adjustments).
When starting the turbine, monitor the speed readout to ensure you
have a good speed signal from the magnetic speed pickups,
especially on initial turbine start.
Refer to turbine manufacturer's operating procedures for complete

information on turbine start-up.
30 Woodward
Turbine Start
When starting the turbine, both the actuator and the Peak 150 have minimum
start up requirements:
 The Peak 150 needs a 1.0 Vrms MPU signal to sense speed.
 The Actuator, when driven directly from the turbine, requires enough speed
to develop the force required to operate the steam valves or servo valve.
The Peak 150 and actuator rely on an alternate means of opening the governor
valve or applying bypass steam to roll the turbine for start up. The minimum
speed at which the Peak 150 can control turbine speed depends on the minimum
speed required to meet these two conditions. (see the actuator specifications).
Idle/Minimum Ramp
If the Peak 150 control is programmed for a MANUAL START, this section can
be ignored. When MANUAL START is configured, speed control will begin at
MIN GOVERNOR SPEED which is much higher than IDLE speed. All speed
control, including avoiding the CRITICAL SPEED BAND, is the responsibility of
the operator until the turbine reaches MIN GOVERNOR SPEED.
If the control is programmed for AUTO START, the Peak 150 will begin
controlling the turbine speed at IDLE speed. The following apply to the AUTO
START mode.
The turbine can be accelerated either manually or automatically from IDLE to

MIN GOVERNOR SPEED.
 To operate the system manually, use the RAISE or LOWER buttons or
inputs. When a button is closed, the turbine speed will change. When the
button is opened, the turbine runs at the current speed.
 To operate the system automatically, use one of the following:
o Close the IDLE / MIN GOV input.
o Press the START button on the front panel, if START = RAMP TO MIN
GOV is set to TRUE.
 This ramp will accelerate the turbine at the IDLE / MIN GOV RATE.
If a CRITICAL SPEED BAND has been defined, the ramp rate of the speed
increase (or decrease) in this band will be the CRITICAL BAND RATE. When the
speed of the turbine is outside the CRITICAL SPEED BAND the ramp rate will
return to the IDLE / MIN GOV RATE.
The IDLE to MIN GOVERNOR SPEED ramp can be stopped at any point
between IDLE SPEED and MIN GOVERNOR SPEED, except within the
CRITICAL SPEED BAND:
 By pressing the RAISE or LOWER button on the front panel.
 By closing the external RAISE or LOWER contact.
 By opening the IDLE / MIN GOV input if one of the following scenarios has
been programmed:
o The USE RAMP TO IDLE function is set FALSE.
o The USE RAMP TO IDLE function is set TRUE and
START = RAMP TO MIN is set TRUE.
Woodward 31
If the speed is below the MIN GOVERNOR SPEED set point, the IDLE to MIN
GOVERNOR SPEED ramp can be changed with the RAISE / LOWER buttons, or
it can be restarted:
 By toggling the IDLE / MIN GOV input.
 By pressing the START button on the front panel if configured for START =
RAMP TO MIN GOV and the IDLE / MIN GOV input is open.
If the speed is below MIN GOVERNOR SPEED and the IDLE / MIN GOV input is
opened, the speed set point will move back to IDLE speed at the IDLE / MIN
GOV RATE if:
 USE RAMP TO IDLE is set TRUE.
 START = RAMP TO MIN GOV is set FALSE.
When the speed is at or above MIN GOVERNOR SPEED opening the IDLE /
MIN GOV input will not lower the turbine speed to IDLE speed.
The IDLE / MIN GOV input can be open or closed during turbine start-up.
 If the IDLE / MIN GOV input is open, when the trips are cleared, pressing
the START button will ramp the turbine speed to IDLE.
 If the IDLE / MIN GOV input is closed, when the trips are cleared, pressing
the START button will ramp the turbine speed to the MIN GOVERNOR
SPEED.
Critical Speed Band

The ACTUAL SPEED SETPT cannot be stopped within the CRITICAL SPEED
BAND. The ramp will continue at the CRITICAL BAND RATE until the actual
speed is outside the CRITICAL SPEED BAND then stop. Once outside the
CRITICAL SPEED BAND, the ACTUAL SPEED SETPT can be adjusted
manually with the RAISE / LOWER buttons or contact inputs and will change at
the Slow Rate defined under the SPEED VALUES service menu. The ACTUAL
SPEED SETPT can also be adjusted automatically by pressing the START
button (if configured) or by toggling the IDLE / MIN GOV input.
While operating in the CRITICAL SPEED BAND, if a LOWER command is issued

while the ACTUAL SPEED SETPT is increasing, the direction will reverse and
return to the CRITICAL SPEED MIN setting. If a RAISE command is issued while
the ACTUAL SPEED SETPT is decreasing, the direction will reverse and run the
speed to the CRITICAL SPEED MAX setting.
Speed Reference Operating Modes

Using the hand-held programmer, the user can choose one of three operating
modes to adjust the speed reference between the MIN and MAX GOV SPEED
set points. The span between MIN GOV SPEED and MAX GOV SPEED is the
normal operating speed range of the turbine. These limits are programmed by
the operator.
If the control has been configured for droop, the turbine speed will
always be less than the speed set point. The difference will depend
on the amount (%) of droop selected during programming.
32 Woodward
Manual Speed Set Mode

MANUAL SPEED SET mode is defined as:
 Changing the SPEED REFERENCE with the RAISE and LOWER buttons
on the FRONT PANEL.
 Changing the SPEED REFERENCE with the RAISE and LOWER discrete
inputs.
 Changing the SPEED REFERENCE with the RAISE SPEED and LOWER
SPEED Modbus commands.
The MANUAL SPEED SET mode is selected when MANUAL CONTROL ONLY
is configured in the OPERATING MODE menu.
The SPEED REFERENCE will change at the SET POINT SLOW RATE for the
DELAY FOR FAST RATE time. After the delay time, it will switch to the SET
POINT FAST RATE.
While in this mode, the REMOTE SPEED SET mode cannot be enabled.
Remote Speed Set Mode
The REMOTE SPEED SET mode is when an external 4–20 mA signal

sets the SPEED REFERENCE. (This 4–20 mA input, called the REMOTE
SPEED SET signal, normally comes from a PLC or manual turbine
control station). The REMOTE SPD SETPT is tracked by the ACTUAL
SPEED SETPT. The rate which the REMOTE SPEED SETPT can
change the ACTUAL SPEED SETPT is set by the REMOTE RATE---MAX
ramp.
The control speed defined by 4 mA and 20 mA is programmed in the

SPEED VALUES menu by the values assigned to the MIN GOV SPEED
and the MAX GOV SPEED respectively.
Before the REMOTE SPEED SET mode can be enabled, the following operating
conditions must be met:
 The turbine speed must be above the MIN GOV SPEED.
 The REMOTE SPEED ENABLE input must be closed.
 The REMOTE SPEED SET signal must be between 2 mA and 22 mA.
With the IDLE / MIN GOV input closed, and the turbine speed above MIN GOV
SPEED, when the REMOTE SPEED ENABLE input is closed, the ACTUAL
SPEED SETPT will ramp from the current speed to the REMOTE SPEED SET
input at the REMOTE-NOT-MATCHED RATE.
The RMT SPD ENABLED LED has the following flash codes:
 When the USE REMOTE SPEED SETTING is configured TRUE, the
REMOTE SPEED ENABLE contact is closed and the REMOTE SPEED
SETPT is below the ACTUAL SPEED SETPT the RMT SPD ENABLED LED
will flash at a rate of once per second.
 When the USE REMOTE SPEED SETTING is configured TRUE, the
REMOTE SPEED ENABLE contact is closed and the REMOTE SPEED
SETPT is equal to the ACTUAL SPEED SETPT, the RMT SPD ENABLED
LED will stay on (no longer flashing).
Woodward 33
 When USE REMOTE SPEED SETTING is configured and the REMOTE
SPEED SET input fails, the RMT SPD ENABLED LED will flash at a fast
rate. This will also trigger a general alarm. When the input is restored, the
control must be RESET to stop the LED from flashing. It is not necessary to
open and reclose the REMOTE SPEED ENABLE contact.
 When the control is configured for MANUAL SPEED SET mode, (USE
REMOTE SPEED SETTING is not configured), detection of an out-of-range
signal will have no effect on the control and the RMT SPD ENABLED LED
will not flash.
The Peak 150 will stay in the REMOTE SPEED SET mode unless one of the
following occurs:
 The REMOTE SPEED ENABLE input is opened.
 SPEED is reduced to below MIN GOV SPEED.
 A SHUTDOWN occurs.
 A REMOTE INPUT FAILURE occurs. The ACTUAL SPEED SETPT will be
the value of the REMOTE SPEED SETTING input at the time when a
REMOTE SPEED SET failure is detected.
Opening the REMOTE SPEED ENABLE contact will disable the REMOTE
SPEED SET mode, turn off the front panel RMT SPD ENABLED LED (unless out
of range), and revert speed control to the MANUAL SPEED SET mode.
Opening of the IDLE / MIN GOV, and the REMOTE SPEED ENABLE contacts,
will disable the REMOTE SPEED SET mode and ramp the SPEED
REFERENCE back to IDLE SPEED at the IDLE / MIN GOV RATE as long as
START = RAMP TO MIN GOV is false.
Combination Speed Set Mode

The COMBINATION SPEED SET mode uses the HIGH SIGNAL SELECT block
to choose the speed set mode with the highest speed demand from either the
REMOTE SPEED SET mode or the MANUAL SPEED SET mode. If the
REMOTE SPEED SET signal is disabled for any reason, operation defaults to
MANUAL MODE at the speed of the LOCAL SPEED SETPT.
If the IDLE / MIN GOV contact is opened, the REMOTE SPEED SET mode will
be disabled and the ACTUAL SPEED SETPT will ramp down to IDLE SPEED at
the IDLE / MIN GOV RATE.
Overspeed Test
While the OVERSPEED TEST button is pushed or the OVERSPEED TEST
contact is closed (if configured), the front panel OVERSPEED TEST ENABLED
LED will illuminate. This LED indicates that the ACTUAL SPEED SETPT can be
adjusted above the MAX GOV SPEED. The maximum speed that can be
reached during the OVERSPEED TEST is the value entered for the
OVERSPEED TEST LIMIT. The OVERSPEED LEVEL sets the electronic trip
speed of the control, and the EXTERNAL OSPD LEVEL sets the lower limit of
the external trip devices.
Closing the OVERSPEED TEST button disables the REMOTE SPEED SET
mode without changing the REMOTE SPEED SETPT. As long as the
OVERSPEED TEST button is closed, only the OCP RAISE and LOWER buttons
or the RAISE and LOWER contacts can be used to raise the ACTUAL SPEED
SETPT to the OVERSPEED TEST LIMIT at the SET POINT SLOW RATE.
34 Woodward
At any time during the test, when the OVERSPEED TEST button is released:
 If the speed is above the OVERSPEED LEVEL, the turbine will trip. If the
speed is manually lowered below the OVERSPEED LEVEL with the
LOWER button prior to opening the OVERSPEED TEST button the turbine
will not trip.
 If the speed is less than the OVERSPEED LEVEL, the control reverts to the
mode of operation that was programmed prior to the test.
o In the MANUAL SPEED SET mode the ACTUAL SPEED SETPT will
instantly ramp to the MAX GOV SPEED. The speed also returns to the
MAX GOV SPEED when the RAISE button is released.
o In the REMOTE SPEED SET mode, the speed will decrease to the
MAX GOV SPEED at the SET POINT SLOW RATE, than it will
decrease to the REMOTE SPEED SETPT at the REMOTE NOT
MATCHED RATE.
o In the COMBINATION SPEED SET mode, the speed will decrease to
the MAX GOV SPEED at the SET POINT SLOW RATE. Control stays
in LOCAL SPEED SETPT until the speed is manually decreased below
the REMOTE SPEED SETPT.
During the OVERSPEED TEST, at speeds greater than or equal to the

OVERSPEED LEVEL and less than the EXTERNAL OSPD LEVEL, the
OVERSPEED TEST button will flash at a rate of once per second. At speeds
equal to or greater than the EXTERNAL OSPD LEVEL, the OVERSPEED TEST
button will flash at a rate of twice per second.
Shutdown and Alarm Function Summary

The following indicates the various conditions which constitute either an alarm or
shutdown condition. A shutdown condition is signaled by the TRIP relay which
defaults as DE-ENERGIZE on trip. It can be configured to ENERGIZE on trip by
setting TRIP RELAY ENERGIZES FOR TRIP = TRUE. Alarm conditions are
signaled by the ALARM relay de-energizing.
Alarm conditions are:

 MPU #1 FAILED
 MPU #2 FAILED
 REMOTE INPUT FAILED
 COMM LINK FAILURE
 TURBINE TRIP (When configured USE TRIP AS ALARM = TRUE)
Shutdown conditions are:

 EXTERNAL TRIP (Contact input opened)
 LOSS OF BOTH MPU INPUTS
 OVERSPEED TRIP
 FRONT PANEL EMER TRIP
 MODBUS TRIP
The TRIP and ALARM functions latch. A RESET is required once the condition is
corrected to clear the latch. If the governor is TRIPPED, a RESET command will
clear the TRIP RELAY output and the front panel EMER TRIP LED if configured
for RESET CLEARS TRIP = TRUE. This does not clear the TRIP input on
terminal 14 which is part of the turbine trip string. When an operator resets this
string, the turbine is ready to start. (If an EXTERNAL TRIP still exists, the control
will not initiate a start).
A typical start requires a RESET command and a START command. If these two
separate commands are not desired, the START command can be closed with a
jumper and only a RESET command is required.
Woodward 35
Magnetic Pickup Failure Override

The MAGNETIC PICKUP signal failed shutdown is overridden during start up of
the turbine. The override is activated automatically during the start. It is removed
when the turbine speed is greater than the speed configured for the AUTO-
OVRD-OFF SPEED.
The MAGNETIC PICKUP signal failed shutdown can also be overridden during
start up for a set time in addition to using the AUTO-OVRD-OFF SPEED. This
function is enabled by configuring USE MPU OVERRIDE TIMER = TRUE, and by
setting the MAX STARTING TIME = _____ sec. When the speed is greater than
the AUTO-OVRD-OFF SPEED or the when the MAX STARTING TIME expires,
the override will be disabled.
When stopping the turbine, the MAGNETIC PICKUP signal failed shutdown will
be activated when the turbine speed is too low to produce an MPU signal greater
than 1 Vrms. BY configuring USE SLOW ROLLDOWN OVRD = TRUE the Peak
150 can differentiate between the sudden loss of the MPU signal and the loss of
the MPU signal due to the roll down during a normal stop. This function is
initiated when the turbine speed drops below the AUTO-OVRD-SPEED for the
AUTO-OVRD-ON DELAY time. The DELAY time differentiates between the
sudden loss of the MPU, which will trip the turbine, and the slow roll down.
On a normal stop, the trip and throttle valve would be closed gradually with the
Peak 150 control demanding the governing valve to be fully open as the turbine
speed decreases below the IDLE set point. With no fault conditions detected by
the Peak 150 control, the throttling valve needs only to be opened to affect a
start. If the governor initiated a shutdown, the RESET and START buttons must
be pushed before the turbine can be started.
Stroking Actuator
STEAM TO THE TURBINE MUST BE SHUT OFF BY OTHER MEANS

DURING THIS PROCESS. Overspeed sensing and trip detection are
disabled during this process. Overspeeding the turbine will cause
damage to the turbine and can cause personnel injury or death to
personnel.
The ACTUATOR OUTPUT can be stroked (or calibrated) from the SERVICE
MODE. Pressing the down arrow on the hand-held programmer when the display
shows WOODWARD GOVERNOR COMPANY will enter the SERVICE MODE.
Pressing the ESC key will return to the Woodward heading.
Press the left arrow until the VALVE header appears. Next, press the down arrow
to see VALVE menu options. Continue pressing the down arrow until STROKE
VLV OUTPUT? appears. Press the turtle or rabbit adjust-up arrow to change the
display to TRUE. The control must be tripped to perform this function.
Press the down arrow until the VALVE POSITION (%) is on the top line of the
display. Next, press the up-down arrow to change to the bottom display line. Go
to the VALVE header in the SERVICE MODE. Press the up arrow until MIN/MAX
SWITCH is displayed. Toggling this between TRUE and FALSE will change the
output current between minimum and maximum.
36 Woodward
Another option for stroking the actuator is the STROKE POSITION (%). This
allows the actuator to be set manually between 0% and 100% by using the rabbit
or turtle adjust up and down keys. The MIN/MAX SWITCH is a shortcut method
of accomplishing this.
When the VALVE POSITION (%) = 0%, the actuator should be closing the steam
valve. It is important that the actuator has sufficient over travel at the minimum
stop to ensure that the actuator can close the steam valve completely. When the
VALVE POSITION(%) = 100%, the actuator should be at maximum stop to
ensure the system can carry full load. The process of going between minimum
and maximum will have to be repeated several times before the initial start to
ensure the actuator and linkages are properly set up.
Be sure to set STROKE VLV OUTPUT to FALSE when done.
Dynamics Adjustments
DYNAMIC adjustments are made in the SERVICE MODE. Press the down arrow
on the hand-held programmer when it displays WOODWARD GOVERNOR
COMPANY to enter the SERVICE MODE. Press the ESC key to display the
WOODWARD message.
Press the right arrow until the SPEED DYNAMICS header appears. Next, press
the down arrow to see the dynamic menu options. The first two options are LOW
SPEED GAIN and LOW SPEED RESET and will be referred to as GAIN and
RESET, respectively.
The GAIN and RESET are used to match the response time of the Peak 150 to
the natural response time of the turbine. To obtain a faster transient response,
slowly increase the GAIN with the turtle-adjust-up key until the ACTUATOR
OUTPUT begins to oscillate. (The best way to verify this is by placing an analog
voltmeter across the ACTUATOR OUTPUT). When the GAIN is set, adjust the
RESET as necessary to stabilize the output. If stability cannot be obtained with
the RESET adjustment, reduce the GAIN setting.
A second set of dynamics is available, if necessary. This second set is selected

by closing the HI DYN SELECT input (if configured) or with a speed setting. The
dynamics switch point is the speed that is configured for the HI SPEED SWITCH
PT in the SPEED DYNAMICS menu. If only one set of dynamics is desired or the
contact input is used, set the HI SPEED SWITCH PT above the maximum speed
setting (i.e., above the OVERSPEED TEST LIMIT setting) to ensure the high
dynamics are never selected.
Communications (Optional)
The Peak 150 control is capable of communicating to a plant computer using
Modbus protocol. All pertinent parameters are programmed to be transferred
through this link. The following link parameters are configurable: data bits, stop
bits, baud rate, and parity.
This option requires additional communication hardware that is not available

unless purchased. The Modbus option must be specified when ordering the Peak
150.
See Chapter 11 for complete details.
Woodward 37
Chapter 7.
Programming
Introduction
The Peak® 150 control uses menu-driven software for ease of programming.
Programming is divided into two sections: CONFIGURE Mode (see Chapter 8),
and SERVICE Mode (see Chapter 9).
Before running the turbine the Peak 150 control must be programmed. The
program worksheets (see Appendix) must be filled out and these values entered
into the control. Different applications will have different programs because of
speed range, relay options, readout options, mode of operation, or other
programmable options.
Any parameters that do not require an input are listed as "STATUS

INDICATION ONLY" in the program worksheets. They are in the
program to provide information to the operator or programmer only.
All Programming is done with the hand-held programmer (CE version part
number 9907-205) (See Figure 7-1) through the service port on the front of the
Peak 150 control. It plugs into the 9-pin connector of the RS-485/422 port inside
the service port. The service port is normally sealed by a removable cover. When
not being used, the programmer should be disconnected from the control to
provide security against tampering.
EXPLOSION HAZARD—The programmer should not be connected or

disconnected while an explosive gas is present.
Hand-Held Programmer
Key Functions
A four-line digital display

that can show two
independent parameters at
DISPLAY the same time. The current
line is indicated by the @
sign.
These keys are used to

LEFT/RIGHT scroll through headers and
Arrows categories.
adjust the value of a
parameter either (Rabbit &
ADJust Arrows Turtle) up or down, at either
a fast 10% (rabbit) or slow
1% (turtle) rate.
38 Woodward
This key is used to enter a
– (minus) negative value.

adjust the value of a
parameter either up or down
at a very slow rate (Integer
ADJust Down/Up
values change by 1.0; Real
values change by 0.01). (+ is
up; – is down)
The Escape key, when

pressed once, will return to
the top of the category.
ESC When pressed twice, it will
exit the mode and save all
changed tunables.
The ID key identifies the

ID software used in your
system.
This key saves all changed
SAVE tunable values.
The BACKSPACE key

BKSP scrolls to the left.
The SPACE key scrolls to

SPACE the right.
To enter the exact value of a

tunable, press this key, then
enter the number, then press
ENTER. (must be within
=
10% of the value on the
screen, except when in the
configure mode.
This key enters the exact

value of a tunable (see =
ENTER
above).
This key selects the

Configure mode or enters a
 decimal point in a number.
Down arrow selects the

Service mode or scrolls
down through blocks. Up
Up/Down Arrows
arrow scrolls up through
blocks.
This key with a double-

ended arrows is used to
select screens; the selected
Up & Down Arrow
screen is identified by the @
sign.
These keys (0 and 1–9) are

used to enter the exact value
Number Keys
of a tunable (see = and
ENTER key descriptions).
Woodward 39
Figure 7-1. Hand-held Programmer
40 Woodward
Errors in configuration or programming of the Peak 150 control may

create dangerous overspeed conditions. The turbine must be
equipped with an overspeed device completely separate from the
Peak 150 control or actuators attached to the Peak 150 control. The
turbine must never be run when this device is not present and is not
operating correctly.
Configure Mode
The CONFIGURE mode has parameters that must be adjusted or changed with
the turbine shut down. When the CONFIGURE mode is entered, all control
outputs are disabled, the relays are de-energized, and the analog-output currents
go to minimum.
Configure Mode Menus

There are eight CONFIGURE MODE menus:
SPEED CONFIG This menu is used to set minimum and

maximum speed levels and to enter MPU
information.
START MODE This menu is used to select either MANUAL or

AUTO starting mode.
ACTUATOR CONFIG This menu is used to select either 20–160 mA or

4–20 mA actuator current range.
OPERATING MODE This menu is used to select the MANUAL,

REMOTE, HI SIG SELECT, or MODBUS
operating mode.
READOUTS This menu is used to scale the SPEED RO, to

select the configurable readout option, and to
scale the readout values.
RELAYS This menu is used to select the options of the

configurable relays and to configure the TRIP
relay to ENERGIZE or DE-ENERGIZE on trip.
CONTACT IN #8 This menu is used to set the operation of

CONTACT IN #8 as OVERSPEED TEST or HI
DYN SELECT.
PORT CONFIG This menu is used to set the parameters of the

port configuration for using MODBUS.
For details on these menus, refer to Chapter 8.
Woodward 41
Service Mode
Items in the SERVICE mode are parameters that can be adjusted at any time,
including while the turbine is running.
Service Mode Menus

There are 13 SERVICE mode menus, eight of which are always displayed. The
remaining five menus appear conditionally. The SERVICE mode menus are:
Always Displayed Menus
ALARMS This menu displays the status of the ALARMS

and is used to select when a TRIP is displayed
as an ALARM.
TRIPS This menu is used to display the code of the last

TRIP and to display the status of all the TRIPS.
SPEED DYNAMICS This menu is used to adjust speed dynamics for

turbine response and stability, to set the SPEED
where the control switches from LOW dynamics
to HI dynamics and displays which dynamics is
currently in use.
SPEED VALUES This menu displays turbine SPEED, and the

speed SET POINTS. It is also used to set the
RAMP rates, the MIN & MAX GOV SPEEDs, the
OVERSPEED set points and DROOP.
FAILED MPU OVRD This menu is used to set FAILED MPU OVRD
conditions and levels.
VALVE This menu displays the VALVE POSITION, and

the VALVE RAMP POS’N. It is used to set the
VLV OFFSET, the VALVE GAIN, the RAMP
RATE and the DITHER.
This menu is also used to stroke the actuator /

turbine valves by manually adjusting the VALVE
RAMP, or by opening and closing the
ACTUATOR / VALVEs.
READOUT ADJUST This menu is used to scale readout signals.
I/O CHECK This menu displays the status of most I/O points.
This menu is a tool for troubleshooting the
control.
42 Woodward
Conditionally Displayed Menus
The following menu displays if REMOTE is configured.

REMOTE SETTING This menu displays remote speed signal, the
remote set point, and sets the remote rates.
The following 2 menus display if Automatic Start is configured.

IDLE/MIN RAMP This menu is used to enable and set IDLE / MIN
RAMP and to set MIN GOVERNOR SPEED.
CRITICAL SPEED This menu is used to enable the CRITICAL

SPEED BAND, set the speed limits of the band
and the ramp rate through the band.
The following menu displays if speed switch or hand valve is configured.

SPD SW / HAND VLV This menu is used to set the speed or position
for picking up and dropping SPD SW or HAND
VLV relays.
The following menu displays if Use Modbus Port is configured.

PORT ADJUST This menu is used to set the Modbus port
communication parameters and displays error
information.
Refer to Chapter 9 for information on these Service mode menus.
Basic Program Architecture

Figure 7-2 shows the basic program architecture of the Peak 150 control.
Before the turbine can be run, the Peak 150 control must be
programmed for the specific turbine application. Programming is
divided into two sections: using the Configure mode and the Service
mode.
Refer to the Appendix for programming worksheets.
Woodward 43
Figure 7-2. Basic Program Architecture
44 Woodward
Speed Relationships
Figure 7-3 shows the relationships between the various set points, as well as the
mode (Service or Configuration) in which they are adjusted.
Figure 7-3. Speed/Mode Relationships
Configuration Mode Programming
To prevent damage to the turbine resulting from improper control

settings, make sure you save the set points before removing power
from the control. Failure to save the set points before removing
power from the control causes them to revert to the previously saved
settings. Dangerous conditions such as turbine overspeed may
result from operating the turbine with incorrect settings, possibly
resulting in equipment damage and injury or death of personnel.
The turbine must be shut down during configuration. Permitting the

turbine to run while the turbine is being configured can cause turbine
overspeed.
Using Configure Menus
 RIGHT and LEFT Arrows (top row of keys) moves between MENUS.
 DOWN ARROW (top row of keys) enters the list of items in each MENU.
 UP and DOWN arrows move through items in the MENU.
 ESC key moves back to the menu title.
Woodward 45
 ESC key again leaves the menu title and returns to the header. This records
in the permanent memory any changes made.
 Control will reboot as it leaves the Configuration mode.
Procedure For Configure Mode

1. Plug the programmer into the service port (on the front panel) and wait until
the self-test is complete (about 5 sec.). The back lighting will turn on and the
Woodward header will appear. If the Woodward header does not appear,
press the ESC key until it does.
2. Press "." to select the CONFIGURATION mode. Press the ENTER key
when the programmer displays “TO ENABLE CONFIGURE PRESS
*ENTER*, Press the ENTER key again when the programmer displays TO
SHUTDOWN I/O PRESS *ENTER*. When the DISCRETE OUTPUTS and
the ANALOG OUTPUTS are shutdown, the programmer will enter the first
Configuration Menu.
3. To scroll through the CONFIGURATION menus use the LEFT and RIGHT
arrows. When the desired menu is displayed, press the DOWN arrow to
enter the menu.
To scroll through the menu items use the UP and DOWN arrows.
To return to the menu header press the ESC button.
4. Two independent variables can be displayed on the programmer screen. An

"@"beside one of the variables indicates that this item can be adjusted. Use
the UP/DOWN arrow to toggle the "@" between the top to the bottom row.
5. To leave configuration press ESC until the Woodward header appears in the
window.
Making Changes In Configure Mode

To change TRUE / FALSE Values:
 Use the TURTLE UP or RABBIT UP arrows for TRUE.
 Use the TURTLE DOWN or RABBIT DOWN arrows for FALSE.
To adjust Numerical Values:

 Use the RABBIT UP and RABBIT DOWN arrows to change the existing
values by 10 percent in the direction indicated.
 Use the TURTLE UP and TURTLE DOWN arrows to change the existing
To Enter Numerical Values Directly:

(The number keys can be used to change the existing value. To make this type
of entry.)
 Press the = key.
 Enter the number (plus, minus, and decimal point keys work.)
 Press ENTER key to activate the number on the screen.
The change is not limited to 10% in the Configure mode, as it is in the

Service mode.
46 Woodward
The screen is limited to 20 characters. When the menu item is longer than
20 characters, scroll to the ends with the BKSP or SPACE keys.
To adjust Integer Values: The ADJ up (+) and the ADJ down (–) keys increment
integers up or down by 1.0.
Service Mode Programming

The Service mode can be used while the turbine is running.
Using Service Menus
 The LEFT and RIGHT ARROWS move from one MENU to the next.
 The DOWN ARROW opens the MENU.
 The UP and DOWN ARROWS scroll inside the MENU.
 Pressing the ESC key jumps to the MENU’s title.
 Pressing the ESC key a second time jumps from the MENU’s title to the
WOODWARD header. This also saves the changes in the permanent
memory. Another way to permanently store changes is to press the SAVE
key.
 The SERVICE MENUs can be changed with the turbine running. Changes
are immediately used by the Peak 150 to operate the turbine, but the
changes are not saved until the operator returns to the WOODWARD
header by pressing either ESC or SAVE key.
 A number of items in the service menus monitor information for the user.
These items are shaded, and cannot be changed. However, they will
change if the condition being monitored changes.
 On the programmer screen, tunable items are indicated by an asterisk (*)
following the number. Numbers which are for monitor only will not have an
asterisk (*) following the number.
Procedure for Service Mode

To enter the SERVICE MODE, press the DOWN ARROW when the
WOODWARD header is displayed. To display the WOODWARD header, press
the ESC key twice.
1. To enter a MENU press the DOWN ARROW.
2. To scroll between the menus, use the LEFT ARROW and RIGHT ARROW.
To return to a menu header, press ESC.
Values changed will become active immediately, but will not become part of
the permanent memory until the ESC button is pressed again and the
WOODWARD header reappears or the SAVE button is pressed. Either
method will save ALL changed parameters in permanent non-volatile
memory.
Two menu items can appear on the screen at the same time. Changes can be
made only to the item preceded by the @ sign. To make changes to the other
item, toggle the @ sign with the UP/DOWN key.
Woodward 47
Making Changes In Service Mode

To change TRUE / FALSE Values:
 Use the TURTLE UP or RABBIT UP arrows for TRUE.
 Use the TURTLE DOWN or RABBIT DOWN arrows for FALSE.
To adjust Numerical Values:

 Use the RABBIT UP and RABBIT DOWN arrows to change the existing
 Use the TURTLE UP and TURTLE DOWN arrows to change the existing
To Enter Numerical Values Directly:

The number keys can be used to change the existing value by as much as ±10%
of its current value. To make this type of entry:
 Press the = key.
 Enter the number (plus, minus, and decimal point keys work ).
 Press ENTER key to activate the number on the screen.
If the number you enter is more than 10% greater or less than the existing value,
the entry will be refused and an error message will appear on the screen. The
error message will remain on the screen for about 5 seconds, and the previous
value will be displayed.
The screen is limited to 20 characters. When the menu item is longer than 20
characters, scroll to the ends with the BKSP or SPACE keys.
TO adjust Integer Values: The ADJ up (+) and the ADJ down (–) keys
increment integers up or down by 1.0.
48 Woodward
Chapter 8.
Configuration Menus
Introduction
Before the turbine can be run, the Peak® 150 control must be programmed (see
Program Mode Worksheets in the Appendix). The configure mode parameters
can only be changed while the turbine is shut down.
Speed Configuration Menu

This menu is used to set the parameters for the MPU inputs and for scaling the
minimum and maximum signal of the MPUs.
To control the speed of a turbine, an MPU senses the speed in Hz (cycles per
second). In the Peak 150, the MPU speed signal is converted from Hz to RPM.
The values of the turbine’s operating speeds are set in RPM.
On many turbines (as in Case 1), the MPU gear is mounted on the main turbine
shaft so that the speed of the MPU gear is the same as the speed of the turbine.
On other turbines (as in Case 2), the MPU gear is mounted on an auxiliary shaft
so that the speed of MPU gear is different than the speed of the turbine. In Case
2, the RPM displayed and controlled by the Peak 150 is a function of the number
of teeth, the speed of the shaft and the ratio between the main turbine shaft and
the MPU gear shaft.
Before running the turbine, ensure that the correct RATIO between
the turbine speed and the MPU gear speed is entered correctly.
Failure to set the correct RATIO could result in personal injury, loss
of life, or property damage.
CASE1: Turbine speed and MPU gear speed are same:

Equation 1:
RPM T
MPU (Hz)
For example: with RPM = 3600 RPM

Teeth = 120:
MPU (Hz) = 7200 Hz
or
Equation 2:
MPU HZ
RPM
T
For example: With MPU (Hz) = 3600 Hz

Teeth = 60
RPM = 3600 RPM
Woodward 49
Case 2: Turbine speed and MPU gear speed are different:

The MPU gear ratio is the number of revolutions of the turbine divided by
the number of revolutions made by the magnetic pickup gear. For example,
if the turbine revolves twice for every revolution of the MPU gear, enter 2 for
the “MPU GEAR RATIO 1”. The following is the equation for calculating the
MPU Gear Ratio 1:
Equation 3:
T RPM
"MPU GEAR RATIO 1" X
MPU RPM
For example: With Turbine speed = 4500 RPM

MPU Gear = 3000 RPM
4500 RPM
"MPU GEAR RATIO 1" 1.5
3000 RPM
The equation for calculating turbine RPM is:
Equation 4:
MPU HZ
RPM * “MPU GEAR RATIO 1”
T
For example: With: MPU (Hz) = 3600 Hz

Teeth = 60.
MPU Gear Ratio 1 = 1.5.
RPM * 1.5 = 5400 RPM
The equation for calculating MPU HZ is:
Equation 5:
T RPM T
MPU (Hz)
MPU G R
For example: With Turbine RPM = 3600 RPM

Teeth = 72
MPU Gear Ratio 1 = 2
MPU (Hz) = 2160 Hz
(See Figure 7-3 for the relationships between the Speed Values and the mode in
which the values are set.)
The following parameters are set in the Speed Configuration Menu:
 TEETH SEEN BY MPU ______________

(Enter the number of gear teeth on the MAGNETIC PICKUP gear.)
(Tunable Range: 1 to 200.)
 MPU GEAR RATIO 1 ______________

(Enter the ratio between the speed of the turbine shaft and the MPU gear
shaft).
50 Woodward
The speed range of the Peak 150 needs to be scaled to optimize the
resolution of the speed sensing function. Use the following steps for
calculating the preferred values:
Determine the Overspeed Test Limit for the turbine in RPM.
Using Equation 5, convert the Overspeed Test Limit to Hz.
Set the MPU #1 – MAX HERTZ equal to 1.02 * (Hz value of the Overspeed
Test Limit).
With: Overspeed Test Limit = 4000 RPM

Teeth = 60
MPU Gear Ratio 1 = 1
T RPM T
MPU (Hz)
MPU G R
MPU (Hz) = 4000 Hz

MPU #1 - Max Hertz 1.02 Overspeed Test Limit Hz
= 1.02 * 4000 Hz = 4080 Hz
 MPU #1 – MAX HERTZ (HZ) ______________

(Enter the maximum speed/frequency in Hertz that will be seen by MPU #1.)
 MPU #2 – MAX HERTZ (HZ) ______________

(Enter the maximum speed/frequency in Hertz that will be seen by
MPU #2.)
(Same as MPU #1 – MAX HERTZ)
(Tunable Range: 0 to 15000).
 MAX SPEED LEVEL (HZ) ______________

(Enter the maximum speed/frequency in Hertz that will be seen by the
control).
(Same as MPU #1 – MAX HERTZ)
MPU #1—MAX Hz, MPU #2—MAX Hz, and Max Speed Level will
normally all three be the same value. This setting must be greater
than the Overspeed test Limit Speed (see Service Mode).
 MINIMUM SPD LVL (HZ) ______________

(Enter the minimum detectable speed/frequency in Hertz that will be seen by
the control. Below this speed, the MPU detects a failed signal and issues an
alarm. The MPU signal must be at least 1.0 Vrms at the MINIMUM SPD LVL.)
Do not set any set points greater than the value set for MPU #1—Max,
MPU #2—Max, and Max Speed Level. If the speed set point exceeds
the maximum frequency set by these set points, the turbine will
overspeed, resulting in possible equipment damage and personnel
injury or death.
Pressing the "ESC" (escape) key will return the display to the heading,
which would be Speed Configuration in this case. Using the right (or
left) arrow key at the header will advance the display to the next header.
Woodward 51
Start Mode Menu

This menu shows the starting modes.
 MANUAL START MODE? (TRUE/FALSE) ______________

(Set to TRUE to choose MANUAL START MODE
 AUTO START MODE? (status indication only)

(This indicates the status of the AUTO START MODE. This mode will be
TRUE when the MANUAL START MODE is set FALSE. No Configuration
required).
In Manual Start Mode, governor speed control starts at minimum

governor speed. In Auto Start Mode, speed control starts at idle
speed which is much lower than minimum governor speed (see Start
Modes in Operating Procedures chapter).
Actuator Configuration Menu

This menu shows the actuator configurations.
 USE 20–160 MA ACTUATOR? (TRUE/FALSE) ______________

(When this value is set TRUE, the 20–160 MA ACTUATOR DRIVER is
configured. Most Woodward actuators use 20–160 mA current. If not a
Woodward ACTUATOR, check with vendor for proper drive current.)
 USE 4–20 MA ACTUATOR? (status indication only)

(When TRUE, this status indicates the 4–20 mA driver is programmed. This
value will be TRUE when 20–160 mA is set to FALSE. No configuration
required.)
Check that the correct drive current jumpers are installed. For a
0–200 mA drive-current range, Jumpers 4 and 10 should be installed.
For a 0–20 mA drive-current range, Jumpers 3 and 9 should be
installed.
Operating Mode Menu

This menu shows the operating modes, MANUAL, REMOTE, HSS, and
MODBUS.
For a description of operating modes, see Chapter 3.
 MANUAL CONTROL ONLY? (TRUE/FALSE) ______________

(When set to TRUE, MANUAL MODE ONLY will be selected. All speed
control adjustments must be done with the RAISE and LOWER front panel
buttons or with the discrete inputs.)
52 Woodward
 USE REMOTE SPEED SET? (TRUE/FALSE) ______________
(This mode selects the REMOTE SPEED SET input, 4–20 mA or 1–5 V, for
setting the speed. This mode can be selected only when MANUAL
CONTROL ONLY = FALSE.)
Select the corresponding jumper for the input of 4–20 mA or 1–5 V.
 USE HI-SIG-SELECT? (TRUE/FALSE) ______________

(When set to TRUE, this mode High-Signal-Selects the greater speed
demand between the LOCAL SPEED SETPT and the REMOTE SPEED
SET. This mode can be selected only if MANUAL CONTROL ONLY =
FALSE and USE REMOTE SPD SET = TRUE)
 USE MODBUS ANALOG INPUT? (TRUE/FALSE) ______________

(When set to TRUE, this mode uses the REMOTE SPD SET mode where
the REMOTE SIGNAL comes from the MODBUS link rather than from the
analog 4–20 mA input. This mode can be selected only if MANUAL
CONTROL ONLY = FALSE and USE REMOTE SPD SET = TRUE. The
Peak 150 must be purchased with the Modbus option.)
Readouts Menu
This menu shows the READOUT options and VALUES at 4 mA and 20 mA.
 SPEED RO 4 MA VALUE (RPM) ______________

(This sets the RPM value for the readout at 4 mA.)
 SPEED RO 20 MA VALUE (RPM) ______________

(This sets the RPM value for readout at 20 mA.)
 READOUT #2 OPTION? (OPTION #) ______________

(The option number can be increased with the (+) key and decreased with
the (-) key.)
Readout #2 Options:
1. ACTUAL SPEED
2. ACTUAL SPEED SETPT
3. VALVE POSITION (Actuator Output)
4. REMOTE SPEED SET INPUT
5. VALVE RAMP POS’N
6. Not Used
Use the "+" and "–" keys to adjust the desired option number up or
down respectively.
 READOUT #2— 4 MA VALUE (RPM or %) ______________

(This sets the value for READOUT # 2 at 4 mA.)
 READOUT #2—20 MA VALUE (RPM or %) ______________

(This sets the value for READOUT #2 at 20 mA.)
Woodward 53
Relays Menu
This menu shows the relay options, use speed switch, hand valve, and trip relay.
 RELAY #3 OPTION? (OPTION #) ______________

(Select the relay function by entering the option number from the
configurable relay option list. The option number can be increased with the
(+) key and decreased with the (-) key.)
 RELAY #4 OPTION? (OPTION #) ______________

(Select the relay function by entering the option number from the
configurable relay option list. The option number can be increased with the
(+) key and decreased with the (-) key.)
Configurable Relay Options:

1. Alarm
2. Trip Output
3. Shutdown
4. Remote Control
5. Speed Control
6. Either MPU Failed
7. Overspeed Trip
8. Overspeed Test
9. Remote Signal OK
10. Speed Switch #1 or Hand Valve #1
11. Speed Switch #2 or Hand Valve #2
Use the "+" and "–" keys to adjust the desired option number up or
down respectively.
 USE SPEED SWITCHES? (TRUE/FALSE) ______________

(Set this value TRUE to use CONFIG RELAYs as SPEED SWITCHES. Set
the SWITCH point levels in the service mode.)
 SWITCH #2 UNDERSPD? (TRUE/FALSE) ______________

(Set this value TRUE to enable using CONFIG RELAY #2 as an under speed
indication.)
 USE HAND VALVE(S)? (TRUE/FALSE) ______________

(Set this value TRUE to use CONFIG RELAYs to control HAND VALVES.
Set the SWITCH levels in the service mode.)
A combination of both a hand valve and a speed switch is not

possible. If both "Use Hand Valve" and "Use Speed Switch" are set to
TRUE, hand valves will be selected (if Option 10 or 11 is selected
above in the relay options).
 TRIP RELAY ENERGIZES? (TRUE/FALSE) ______________

(If set TRUE the trip relay will energize on shutdown; if set FALSE, it will de-
energize.)
If the trip relay is programmed to energize for a shutdown, Jumper 2

and Jumper 17 must both be installed to properly display the unit's
"Tripped" status on the front-panel LED and to provide the proper
contacts between terminals 4 and 5. If the trip relay is programmed to
de-energize for a shutdown, Jumper 1 and Jumper 18 must both be
installed.
54 Woodward
 RESET CLRS TRIP RLY (TRUE/FALSE) ______________
(Setting RESET CLRS TRIP RLY = TRUE enables the resetting of the TRIP
relay with the RESET command even though the EXTERNAL TRIP input is
still in the TRIP state, open. If set FALSE all TRIP conditions including the
EXTERNAL TRIP INPUT must be cleared before a RESET command will
RESET the TRIP RELAY.)
Contact In #8
This menu is used to select the function of contact input #8.
 IN #8 IS OSPD TEST (TRUE/FALSE) ______________

(When TRUE is selected, the function of DI #8 is OVERSPEED TEST
ENABLE. If FALSE is selected, the function of DI #8 is HI DYN SELECT.)
Port Configuration
This menu is used to enable the Modbus option and set some communication
parameters.
 USE MODBUS PORT? (TRUE/FALSE) ______________

(If set TRUE the MODBUS PORT is enabled.)
 HARDWARE CONFIG (OPTION #) ______________

(This adjustment sets the hardware link used for the Modbus
Communication. The options in the following list correspond to the 3 types of
hardware configurations. The option number can be increased with the (+)
key and decreased with the (-) key.)
1 = RS-232 Communication
 TRANSMISSION MODE (OPTION #) ______________

(This value selects the protocol of the character transmission mode used by
Modbus.
(Enter the option number from the list below.)
Modbus Port Transmission Mode Configuration Options:

(The option number can be increased with the (+) key and decreased with
the (-) key.)
1 = ASCII
2 = RTU
 NETWORK ADDRESS ______________

(This value assigns a Network address to the Peak 150 in a multi drop
configuration.)
(Normally set to 01).
When configuration is complete, press the ESC key until the display
reads "Rebooting Control."
Woodward 55
Configure Mode Flow Diagram

Refer to Figure 8-1 for a flow diagram of the configure mode headers.
Figure 8-1. Configure Mode Flow Diagram

(2 pages)
56 Woodward
Woodward 57
Chapter 9.
Service Menus
Introduction
Before the turbine can be run the Peak® 150 control must be programmed (see
Program Mode Worksheets in the Appendix). The Peak 150 control uses easily
programmable menu driven software. Programming is divided into two sections:
SERVICE MODE and CONFIGURE MODE (see Chapter 7). The CONFIGURE
MODE parameters can only be changed while the turbine is shutdown. After the
initial programming is complete, the SERVICE MODE parameters can be viewed
and adjusted while the turbine is running.
Alarms Menu
The Alarms menu shows the alarms that have occurred.
 MPU #1 FAILED (status indication only)

(TRUE when MPU #1 input has failed).
 MPU #2 FAILED (status indication only)

(TRUE when MPU #2 input has failed).
 REMOTE INPUT FAILED (status indication only)

(TRUE when the REMOTE SPEED SET input has failed).
 COMM LINK FAILURE (status indication only)

(TRUE when the Modbus communication link has failed).
 TURBINE TRIP (status indication only)

(TRUE when the turbine has tripped).
 USE TRIP AS ALARM? (TRUE/FALSE) ______________

(When set to TRUE, a turbine TRIP indicates an ALARM in addition to
tripping the turbine).
Trips Menu
The Trips menu shows the trip conditions that have occurred.
 LAST TRIP CODE = (CODE#) (status indication only)

(Will display the TRIP CODE of the last trip from the list below. The TRIP
CODE also flashes on the front panel RPM display).
Code Cause
1 EXTERNAL TRIP
2 LOSS OF BOTH MPUs
3 OVERSPEED TRIP
4 FRONT PANEL TRIP
5 MODBUS TRIP
58 Woodward
 EXTERNAL TRIP (status indication only)
(TRUE when the EXTERNAL TRIP input is opened/tripped. (Input to
terminal 14 is open.)
 OVERSPEED TRIP (status indication only)

(TRUE when the turbine speed exceeds the OVERSPEED LEVEL set
point).
 LOSS OF BOTH MPUs (status indication only)

(TRUE when both MPU signals are lost).
 FRONT PANEL TRIP (status indication only)

(TRUE when the EMER TRIP button has been pushed).
 MODBUS TRIP (status indication only)

(TRUE when the MODBUS TRIP command is received).
Speed Dynamics Menu

This menu is used to set the dynamic values. These values can be adjusted with
the Hand Held Programmer while the turbine is running if preceded by an "*".
 LOW SPEED GAIN ______________

(This value is used to set the LOW SPEED (proportional) GAIN).
 LOW SPEED RESET ______________

(This value is used to set the LOW SPEED (integral gain) RESET).
 HI SPEED SWITCH PT (RPM) ______________

(The value entered for the HI SPEED SWITCH PT sets the speed where
control is switched from LOW SPEED DYNAMICS to HI SPEED
DYNAMICS).
 HI SPEED GAIN ______________

(This value is used to set the HIGH SPEED (proportional) GAIN).
 HI SPEED RESET ______________

(This value is used to set the HIGH SPEED (integral gain) RESET).
 HI SPEED SELECTED (status indication only)

(TRUE when the turbine speed exceeds the HI SPEED SWITCH PT and the
HI SPEED DYNAMICS are selected).
Adjusting Gain And Reset

See Dynamics Adjustments under Operating Procedures, Chapter 6.
Woodward 59
Speed Values Menu

This menu shows speeds, speed rates, overspeed levels, and droop. These
values can be seen without any other conditions occurring and can be adjusted if
preceded by an "*" on the hand-held programmer. See Figure 7-3 for the
relationships between all speed values and the mode in which the value is set.
 ACTUAL SPEED = (RPM) (status indication only)

(This displays the turbine speed.)
 LOCAL SPEED SETPT = (RPM) (status indication only)

(This displays the LOCAL SPEED SETPT. In the LOCAL mode this speed is
controlled by the RAISE/LOWER buttons or inputs. This is the speed set
point in the COMBINATION mode.)
 ACTUAL SPEED SETPT = (RPM) (status indication only)

(This displays the ACTUAL SPEED SETPT. This is a function of the LOCAL
SPEED SETPT or the REMOTE SPD SET depending on what OPERATING
mode is configured.)
Normally LOCAL and ACTUAL SPEED SETPTs will be the same. They
may be different in the REMOTE mode and in the HIGH-SIGNAL
SELECT mode.
 REMOTE SPD SET = (RPM) (status indication only)

(This displays the REMOTE SPEED SET.)
 START RAMP RATE (RPM/SEC) ______________

(This sets the rate of speed change from START to IDLE SPEED or to MIN
GOVERNOR SPEED depending on what START MODE is configured.)
(Tunable Range: 1-1000.)
 SETPT SLOW RATE (RPM/SEC) ______________

(This sets the initial rate of speed change when operating in the MANUAL
CONTROL mode and using the RAISE / LOWER commands.)
 DELAY FOR FAST RATE (SEC) ______________

(When operating in the MANUAL CONTROL mode and using the RAISE /
LOWER commands, this sets the delay time before switching from the
SLOW rate to the FAST rate.)
 SETPT FAST RATE (RPM/SEC) ______________

(This sets the rate of speed change when operating in the MANUAL
CONTROL mode and using the RAISE / LOWER commands after the
DELAY FOR FAST RATE has expired.)
 MIN GOV SPEED (RPM) ______________

(This sets the minimum speed of the turbines normal operating range. Once
the turbine speed is above the MIN GOV SPEED, the speed reference
cannot be adjusted below this point. This value also sets the minimum
setting (4 mA value) for the REMOTE SPEED SET input,)
60 Woodward
 MAX GOV SPEED (RPM) ______________
(This sets the maximum speed of the turbines normal operating range. This
value also sets the maximum setting (20 mA value) for the REMOTE
SPEED SET input, The only time the turbine can be operated above this
speed is during an OVERSPEED TRIP TEST.)
 OVERSPEED LEVEL (RPM) ______________

(This sets the TRIP point of the governor OVERSPEED switch. Unless the
OVERSPEED TEST button is held closed, the turbine will trip when it
reaches this speed.)
(This must NOT be the system’s primary OVERSPEED TRIP.)
 EXTERNAL OSPD LEVEL (RPM) ______________

(This sets the speed where external OVERSPEED trip devices are expected
to operate. When this speed point is reached, the function of this setting is
to flash the OVERSPEED TEST ENABLED LED on the front panel. This
value is typically set at the lower end of the external trip device's speed
range to let the operator know that the turbine should trip soon.)
 OVERSPEED TEST LIMIT (RPM) ______________

(This sets the maximum speed that the turbine can reach when performing
the OVERSPEED TRIP TEST. This limit is set above the OVERSPEED
LEVEL and the EXTERNAL OSPD LEVEL.)
 DROOP (%) *0.0 (%) ______________

(This sets the percent of speed droop. When set to 0.0, droop is disabled.)
 USE SET POINT SET-BACK (TRUE/FALSE) ______________

(When USE SET POINT SET-BACK = TRUE, opening the RAISE or
LOWER button will instantly reset the ACTUAL SPEED SETPT to the
ACTUAL SPEED.)
Remote Setting Menu

This menu shows the remote settings and appears only if REMOTE mode is
configured.
 ACTUAL REMOTE SETPT = (RPM) (status indication only)

(This is the value of the REMOTE SPEED set point.)
 REMOTE SET INPUT = (RPM) (status indication only)

(This is the value of the REMOTE SET INPUT.)
 RMT-NOT-MATCHED RATE (RPM/SEC) ______________

(This is the ramp rate used after REMOTE CONTROL is enabled while the
LOCAL SPEED SETPT matches the REMOTE SPEED SET.)
 REMOTE RATE—MAX (RPM/SEC) ______________

(This sets the rate that the ACTUAL SPEED SETPT can change as a
function of changes to the REMOTE SPEED SET input. This limits the rate
so that the Process Controller does not fight the SPEED CONTROL causing
oscillation.)
(Tunable Range: 0 to 100)
Woodward 61
 MODBUS REMOTE USED = (status indication only)
(When TRUE, the MODBUS communication link sets the REMOTE SPEED
SETPT.).
Failed MPU Override Menu

This menu shows the values for MPU overrides. These values can be seen
without any other conditions occurring and can be adjusted if preceded by an "*".
 AUTO-OVRD-OFF SPEED (Hz) ______________

(This is the speed where the FAILED MPU OVERRIDE is automatically
removed. This speed must be high enough so that the MPU signal is at least
1.0 Vrms.)
(If the speed drops below the MINIMUM SPD LVL (see CONFIGURE mode)
after the FAILED MPU OVERRIDE is removed, the turbine will trip on loss of
speed (Code 2). If only one MPU drops below the MINIMUM SPD LVL after
the FAILED MPU OVERRIDE is removed, that MPU OK LED will go out and
an alarm will be issued.)
 USE MPU OVRD TIMER? (TRUE/FALSE) ______________

(When USE MPU OVRD TIMER? = TRUE, there are two ways of removing
the FAILED MPU OVERRIDE. Normally the override is automatically
removed when the AUTO OVRD-OFF SPEED is reached. If this speed is
not reached and the TIMER expires the override will be removed. In this
scenario, the turbine will trip on MPUs failed to prevent a turbine
OVERSPEED.)
 MAX STARTING TIME= (SEC) ______________

(This sets the time that the MPU OVRD TIMER holds on the FAILED MPU
OVERRIDE while waiting for the turbine speed to reach the AUTO OVRD-
OFF SPEED. If the turbine has not reached the Minimum Speed level
before this time expires, the turbine will trip on MPUs failed to prevent
turbine OVERSPEED.)
 USE ROLLDOWN OVRD? (TRUE/FALSE) ______________

(When USE ROLLDOWN OVRD = TRUE, the MPU FAILED OVERRIDE is
turned on when the speed drops below the AUTO-OVRD-ON SPEED for the
AUTO-OVRD-DELAY time as it is being slowly reduced by closing the trip
and throttle or stop valve.. Using this option allows the operator to resume
operation at the last set point on the next startup rather than at minimum set
point.)
 AUTO-OVRD-ON SPEED (HZ) ______________

(This sets the speed for turning on the MPU FAILED OVERRIDE after the
AUTO_OVRD_ON DELAY time.)
 AUTO-OVRD-ON DELAY (SEC) ______________

(This sets the time delay for turning on the ROLLDOWN OVRD. If the
turbine speed drops below the MINIMUM SPD LVL before this time expires,
the unit will trip on LOSS OF MPUs and reset the speed set point to
minimum.)
62 Woodward
 OVRD ON STATUS (status indication only)
(This displays the status of the MPU OVERRIDE.)
Idle/Min Ramp Menu

This menu shows the IDLE SPEED and MIN GOVERNOR SPEED.
(This menu is displayed only if AUTOMATIC START mode is configured.)
 IDLE SPEED (RPM) ______________

(This sets the IDLE SPEED. This is the initial speed control point in the
AUTO START MODE and is normally used for turbine warm up.)
 USE IDLE/MIN RAMP? (TRUE/FALSE) ______________

(When USE IDLE / MIN RAMP = TRUE, closing the IDLE / MIN GOV
contact automatically ramps the turbine speed from the IDLE SPEED to the
MIN GOVERNOR SPEED).
 MIN GOVERNOR SPEED (RPM) ______________

(This sets the MIN GOVERNOR SPEED that is the target of the IDLE / MIN
RAMP. This is the speed where the turbine normally operates.)
 IDLE/MIN GOV RATE = (RPM/SEC) ______________

(This sets the rate the IDLE / MIN GOVERNOR ramp can change the speed
when ramping up to MIN GOVERNOR SPEED or down to IDLE SPEED.)
(Tunable rage: 0 to 1000).
 USE RAMP TO IDLE? (TRUE/FALSE) ______________

(When USE RAMP TO IDLE = TRUE, opening the IDLE / MIN GOV contact
will ramp the ACTUAL SPEED SETPT to IDLE speed. This function is
disabled if START = RAMP TO MIN is set to TRUE.)
 START = RAMP TO MIN (TRUE/FALSE) ______________

(When START = RAMP TO MIN is set TRUE, closing the front panel START
button will ramp the ACTUAL SPEED SETPT to the MIN GOVERNOR
SPEED in place of closing the IDLE / MIN GOV input. Closing the START
button after the unit is running will restart the ramp to MIN GOVERNOR
SPEED. When this function is used, the USE RAMP TO IDLE function is
disabled)
 RAMPING TO MIN (status indication only)

(This indicates the ramp is moving towards Minimum Governor.)
 RAMPING TO IDLE (status indication only)

(This indicates the ramp is moving towards Idle.)
Critical Speed Menu

This menu shows the critical speed band and rate—displayed only if Automatic
Start Mode is configured.
 USE CRITICAL BAND? (TRUE/FALSE) ______________

(When set to TRUE the CRITICAL SPEED BAND can be set up and used.
The CRITICAL SPEED BAND is used to prevent operation at turbine
speeds where there are high vibrations in the system.)
Woodward 63
 CRITICAL SPEED MIN (RPM) ______________
(This value sets the lower limit of the CRITICAL SPEED BAND.)
 CRITICAL SPEED MAX (RPM) ______________

(This value sets the upper limit of the CRITICAL SPEED BAND.)
 CRITICAL BAND RATE (RPM/SEC) ______________

(This value sets the rate that the speed reference changes while transiting
through the critical band.)
 IN CRITICAL BAND (status indication only)

(This indicates the speed is within the CRITICAL SPEED BAND.)
Speed Switch / Hand Valve Menu

This menu is displayed only if configured for SPD SW / HAND VLV.
 RLY #1 ON (RPM or %) ______________

(This is the SPEED or VALVE POSITION where CONFIG RELAY #1 is
energized. This function must be enabled In the Configuration mode by
setting USE SPEED SWITCH = TRUE or USE HAND VALVE = TRUE, and
also by setting RELAY #3 OPTION = 10.)
 RLY #1 OFF (RPM or %) ______________

(This is the SPEED or VALVE POSITION where CONFIG RELAY #1 de-
energizes.)
 RLY #2 ON (RPM or %) ______________

(This is the SPEED or VALVE POSITION where CONFIG RELAY #2 is
energized. This function must be enabled In the Configuration mode by
setting USE SPEED SWITCH = TRUE or USE HAND VALVE = TRUE, and
also by setting RELAY #4 OPTION = 11.)
 RLY #2 OFF (RPM or %) ______________

(This is the SPEED or VALVE POSITION where CONFIG RELAY #2 is de-
energized.)
A combination of both a hand valve and a speed switch is not

possible. If both "Use Hand Valve" and "Use Speed Switch" are set to
TRUE, hand valves will be selected (if Option 10 or 11 is selected in
the relay options—see Configuration).
 UNDERSPD LEVEL (RPM) ______________

(This is the SPEED setting where an under speed condition can be sensed
when the turbine speed is decreasing. This function is overridden during
start up until MIN GOVERNOR SPEED Is reached. CONFIG RELAY#2 is
configured for UNDERSPEED from the relay options list.)
64 Woodward
Valve Menu
This menu shows the valve position, offset, gain, stroke position, and valve ramp
position.
 VALVE POSITION (%) (status indication only)

(This is the displayed value of VALVE position. This is the signal to the
actuator demand or valve position.)
 VLV – OFFSET ADJUST _____*0.0_____

(This value sets the OFFSET ADJUSTMENT for the VALVE RAMP.)
(Tunable Range: -10000 to 10000).
 VLV -- GAIN ADJUST _____*1.0______

(This value sets the GAIN ADJUSTMENT for the valve RAMP.)
 VALVE RAMP POS'N = (status indication only)

(This is the displayed value of the RAMP POSITION. When the turbine is
tripped, this value will be 0.0%. As the turbine is starting, the VALVE RAMP
will open to 100%.
The VALVE RAMP is low-signal-selected with the speed control’s PID to
determine the demand position.
While running, the VALVE RAMP can be manually raised or lowered by
setting either MANUALLY RSE RAMP or MANUALLY LWR RAMP = TRUE.
When both are set to FALSE, the VALVE RAMP will stop.
During shutdown the VALVE RAMP lowers the actuator output to zero by
overriding the SPEED PID output.)
 MANUALLY RSE RAMP? ____*false_____

(When this is set to TRUE the VALVE RAMP will open. When set to FALSE
the VALVE RAMP will stop at the last position. By using the MANUALLY
RSE RAMP and the MANUALLY LWR RAMP the actuator can be used for
stroking the valves from limit to limit when the system is shut down.)
(This is used as a troubleshooting tool. No configuration is required. To
allow the actuator to have full travel during normal operation, make sure the
valve ramp is returned to 100% after troubleshooting.)
 MANUALLY LWR RAMP? ____*false_____

(When this is set to TRUE the VALVE RAMP will close. When set to FALSE
the VALVE RAMP will stop at the last position. This can be used for testing
the turbine by manually overriding the PID to electrically block the valve.
Also this can be used as a VALVE LIMITER to limit the maximum lift of the
valve.)
(This is used as a troubleshooting tool. No configuration is required. To
allow the actuator to have full travel during normal operation, make sure the
valve ramp is returned to 100% after troubleshooting.)
 RAMP RATE (%/SEC) ______________

(This value sets the rate at which the valve ramp will open during turbine
START UP. This is the same rate at which the valve ramp can be adjusted
with the MANUALLY RSE RAMP or MANUALLY LWR RAMP commands
above.)
 DITHER ADJUST ______________
Woodward 65
(DITHER is used to keep the VALVE OUTPUT active without affecting the
turbine speed. The DITHER ADJUST does this by adding a low magnitude,
high frequency movement to the ACTUATOR. DITHER is normally set to 0.0
when not needed or to a higher value for those systems that need it.)
The turbine must be shut down to perform the following functions.
 STROKE VALVE OUTPUT? (TRUE/FALSE) ______________

(Setting STROKE VLV OUTPUT = TRUE enables stroking the valves. When
STROKE VLV OUTPUT = TRUE, either the STROKE POSITION (%) or the
MIN / MAX SWITCH can be used for opening and closing the ACTUATOR /
VALVE.)
 STROKE POSITION (%) ______________

(Increasing on decreasing the % of the STROKE POSITION will move the
ACTUATOR / VALVE. It can be adjusted between 0% and 100% for stroking
the valve as long as the STROKE VLV OUTPUT is set TRUE and the MIN /
MAX SWITCH is set to false.)
 MIN / MAX SWITCH (TRUE/FALSE) ______________

(Setting the MIN / MAX SWITCH = TRUE will open the ACTUATOR /
VALVE. Setting it = FALSE will close the ACTUATOR / VALVE. By
switching between FALSE and TRUE, the actuator can be stroked between
0 and 100%. The STROKE VLV OUTPUT must be set TRUE.)
When the VALVE / ACTUATOR has been stroked, set the STROKE
VALVE OUTPUT? = FALSE.
Readout Adjustments Menu

This menu shows the adjustments for readouts #1 and #2.
 RO #1-OFFSET ADJUST: ______________

This value sets the RO#1 (SPEED READOUT) offset adjustment.
 RO #1-GAIN ADJUST: ______________

This value sets the RO#1 (SPEED READOUT) gain adjustment.
 RO #2-OFFSET ADJUST: ______________

This value sets the RO#2 (SPEED READOUT) offset adjustment.
 RO #2-GAIN ADJUST: ______________

This value sets the RO#2 (SPEED READOUT) gain adjustment.
The 4–20 mA readouts are factory calibrated. The adjustments are

provided as compensation for external meters, etc. If the 0–1 mA
readout option is required (see jumper option chart), the offset and
gains will have to be adjusted for full range output calibration.
66 Woodward
 RO #2 VALUE (status indication only)
(This is the value of the parameter configured as the output of readout #2.)
Port Adjustments Menu

This menu shows the adjustments for the MODBUS Communication Port and is
displayed only if "Use MODBUS Port" is configured (see Configuration).
 HARDWARE CONFIGURATION ______________

(This code # selects the hardware used for MODBUS Communications. The
option number can be increased with the (+) key and decreased with the (-)
key.)
Select the hardware configuration from the following list:
 BAUD RATE ______________

(This code # sets the BAUD RATE for the MODBUS communications. The
key.)
Select the BAUD RATE from the following list:
1 = 1200 Baud
2 = 1800 Baud
3 = 2400 Baud
4 = 4800 Baud
5 = 9600 Baud
6 = 19200 Baud
 STOP BITS ______________

(This code # selects the correct STOP BITS for the transmitted data. The
key.)
Select the STOP BITS from the following list:
1 = 1 STOP BIT
2 = 1.5 STOP BITS
3 = 2 STOP BITS
 PARITY ______________
(This code # sets the correct PARITY to be used during transmission The
key.)
Select the PARITY from the following list:
1 = Off
2 = Odd
3 = Even
 LINK ERROR (status indication only)

(When this indicates TRUE the MODBUS communication link has been
lost.)
 EXCEPTION ERROR (status indication only)

(When this indicates TRUE an exception error has been found in the
transmitted data.)
Woodward 67
 ERROR NUMBER (status indication only)
(This code indicates the cause of the exception error. See the following list
for the meaning of the error codes.)
1 = ILLEGAL FUNCTION (The message function is not an allowable

action.)
2 = ILLEGAL DATA ADDRESS (The message start address is not an
allowable address.)
9 = CHECKSUM ERROR (The received message had an incorrect
error check code.)
10 = GARBLED MESSAGE (The received message could not be
decoded.)
 ERROR PERCENT (%) (status indication only)

(This indicates the amount of time that an error has been detected in the
data being transmitted [displayed as a percent].)
I/O Check
This menu shows the status of the key input and output points of the control. This
menu can be used for troubleshooting of I/O hardware and wiring. It can also be
used to determine if an LED is bad.
 MPU #1 (RPM) (status indication only)

(This is the speed sensed by MPU #1.)
 MPU #2 (RPM) (status indication only)

(This is the speed sensed by MPU #2.)
 ANALOG INPUT (%) (status indication only)

(This is the REMOTE SPEED SET input. 0% = MIN GOV SPEED and 100%
= MAX GOV SPEED.)
The following I/Os are status indications only and will be TRUE
or FALSE.
 DI #1 (status indication only)

(When DI #1 is TRUE (Input Closed) the turbine operator is applying the
SPEED REFERENCE LOWER command.)

(When DI #2 is TRUE (Input Closed) the turbine operator is applying the
SPEED REFERENCE RAISE command.)

(When DI #3 is TRUE (Input Closed) there are no EXTERNAL TRIPS.
When DI #3 turns FALSE (Input Opens) one of the devices in the TRIP
STRING has opened the EXTERNAL TRIP contact to trip the turbine.)

(When DI #4 turns TRUE (Input Closes) the Peak 150 is receiving a START
command.)
68 Woodward
(When DI #5 turns TRUE (Input Closes) the Peak 150 is getting a RESET
command for clearing all ALARMS and TRIPS. This is a momentary contact
closure.)

(When DI #6 turns TRUE, closing the IDLE / MIN GOV contact, the Peak
150 will ramp from the IDLE SPEED to the MIN GOVERNOR SPEED.)

(When DI #7 is TRUE (Input Closed) the REMOTE SPEED ENABLE
function is selected to control the speed as a function of the REMOTE
SPEED SET input.)

(When DI #8 is TRUE (Input Closed) either the HI DYN SELECT or the
OSPD TEST function has been selected. The configuration is done in the
CONTACT IN #8 menu.)
 TRIP P/B (status indication only)

(When the front panel TRIP button is pressed, the TRIP P/B will indicate
TRUE. When the TRIP BUTTON is opened, the TRIP P/B will indicate
FALSE. However, the Peak 150 will latch in the TRIP state until the trip
condition is cleared and a RESET command is received. If the control is
configured for RESET CLEARS TRIP = TRUE, then the RESET command
will clear the latch even though the TRIP condition has not been cleared.)
 OSPD TEST P/B (status indication only)

(When the front panel OVER SPEED TEST button is pressed, the OSPD
TEST P/B will indicate TRUE. With the OVER SPEED TEST button closed,
the RAISE button will run the turbine speed higher than the MAX GOV
SPEED for testing OVER SPEED TRIP devices.)
 RAISE P/B (status indication only)

(When the front panel RAISE button is pressed, the RAISE P/B will indicate
TRUE. When closed, the RAISE button ramps up the SPEED REFERENCE
to increase the turbine speed. )
 LOWER P/B (status indication only)

(When the front panel LOWER button is pressed, the LOWER P/B will
indicate TRUE. When closed, the LOWER button ramps down the SPEED
REFERENCE to decrease the turbine speed.)
 START P/B (status indication only)

(When the front panel START button is pressed, the START P/B will
indicate TRUE. When closed momentarily, the START button initiates a
turbine start, either AUTO or MANUAL depending on the control
configuration.)
 RESET P/B (status indication only)

(When the front panel ALARM RESET button is pressed, the RESET P/B
will indicate TRUE. When closed momentarily, the RESET button clears the
latch circuits for all ALARMS and TRIPS.)
Woodward 69
 TRIPPED LED (status indication only)
(By default, the TRIP RELAY is configured to be energized to run, and
de-energized to trip. When the turbine is operating, the TRIP RELAY is
energized (terminals 4 & 5 closed), the TRIPPED LED in the I/O CHECK
service menu is TRUE, and the TRIPPED LED on the Front Panel is not
illuminated. When the turbine trips, the TRIP RELAY de-energizes
(terminals 4 & 5 open), the TRIPPED LED in the I/O CHECK service menu
is FALSE, and the TRIPPED LED on the Front Panel is illuminated.)
The TRIP RELAY can also be configured to energize to trip, and

de-energize to run. When the turbine is operating, the TRIP RELAY is
de-energized (terminals 4 & 5 closed), the TRIPPED LED in the I/O CHECK
service menu is FALSE, and the TRIPPED LED on the Front Panel is not
illuminated. When the turbine trips, the TRIP RELAY energizes (terminals
4 & 5 open), the TRIPPED LED on the I/O service menu is TRUE, and the
TRIPPED LED on the Front Panel is illuminated.)
If the trip relay is programmed to energize for a shutdown, Jumper 2

and Jumper 17 must both be installed to properly display the unit's
"Tripped" status on the front-panel LED and to provide the proper
contacts between terminals 4 and 5. If the trip relay is programmed to
de-energize for a shutdown, Jumper 1 and Jumper 18 must both be
installed.
 MPU #1 OK LED (status indication only)

(This indicates the status of MPU #1. When MPU #1 is sensing a speed
signal, the MPU #1 OK LED status is TRUE and the MPU #1 OK LED is
illuminated. When the speed signal is lost, the indication goes FALSE and
the LED is no longer illuminated.)
 MPU #2 OK LED (status indication only)

(This indicates the status of MPU #2. When MPU #2 is sensing a speed
signal, the MPU #2 OK LED status is TRUE and the MPU #2 OK LED is
illuminated. When the speed signal is lost, the indication goes FALSE and
the LED is no longer illuminated.)
 OSPD ENABLED LED (status indication only)

( The OSPD ENABLED LED = TRUE indicates that the front panel OVER
SPEED TEST button is being pressed or DI #8 is configured for
OVERSPEED TEST and is closed. The front panel ENABLED LED will also
be illuminated.)
 RMT SPD LED (status indication only)

(The RMT SPD LED = TRUE indicates that REMOTE SPEED CONTROL
has been configured and selected by closing the input to DI #7 (REMOTE
SPEED ENABLE). The front panel RMT SPD ENABLED LED will also be
illuminated.)
 TRIP RELAY ON (status indication only)

(The TRIP RELAY ON = TRUE when the TRIP RELAY is energized and the
contacts between terminal 4 & 5 are closed.)
(The default configuration for the TRIP relay is the TRIP RELAY
de-energizes for TRIP, which opens the contacts between 4 & 5. The TRIP
will also shut down the turbine and illuminate the front panel TRIPPED
LED.)
(The TRIP relay can also be configured for TRIP RELAY energized for
TRIP, so that terminal 4 & 5 close on trip. The TRIP will also shut down the
turbine and illuminate the front panel TRIPPED LED. In this configuration,
Jumper 1 must be removed and Jumper 2 installed.)
70 Woodward
 ALARM RELAY ON (status indication only)
(When the ALARM RELAY ON = TRUE there are no system ALARMS. This
also indicates that the ALARM RELAY is energized. When there is a system
ALARM, ALARM RELAY ON = FALSE and the ALARM RELAY is de-
energized. To RESET the ALARM RELAY, the fault must be cleared and the
ALARM RESET input or button must be closed momentarily.)
 CONF RLY #1 ON (status indication only)

(When CONF RLY #1 ON = TRUE, CONFIG RELAY #1 is energized. This
indicates that the status of the configuration option for RELAY #3 is TRUE.)
 CONF RLY #2 ON (status indication only)

(When CONF RLY #2 ON = TRUE, CONFIG RELAY #2 is energized. This
indicates that the status of the configuration option for RELAY #4 is TRUE.)
Woodward 71
Service Mode Flow Diagram

Refer to Figure 9-1 for a flow diagram of the service mode headers.
Figure 9-1. Service Mode Flow Diagram

(4 pages)
72 Woodward
Woodward 73
74 Woodward
Woodward 75
Chapter 10.
Functional Block Diagram
Explanation of Functional Block Diagram

The Functional Block Diagram explains how the Peak® 150 control operates in
logic diagram form. Sheet one of the block diagram covers general and specific
block diagram notes. Refer to this sheet for explanation of the information
contained on the additional sheets. Sheet two of the diagram shows an overview
of the system and identifies the following sheets on which detailed information
can be located.
The additional sheets show the simplified block diagram of the control. These
blocks represent the functional operational blocks of the control, the functions of
which are performed by the computer in the control. The general block diagram
notes cover the following topics:
 Signal flow
 Customer input/output (I/O)
 Interconnect code
 Operator control panels
 Switch contact inputs
 Function connectors
 Buses
 Function symbols
 Adjustable Parameter Codes
76 Woodward
Woodward 77
78 Woodward
Woodward 79
80 Woodward
Woodward 81
82 Woodward
Woodward 83
84 Woodward
Woodward 85
86 Woodward
Chapter 11.
Modbus Communications
Introduction
The Peak® 150 control with Modbus option can communicate to one device via
RS-232, RS-422 or RS-485 using an ASCII or RTU MODBUS transmission
protocol. The pertinent serial port communications parameters are all adjustable
in the service mode through the hand-held programmer of the Peak 150 control.
The loss of the communications link is annunciated as a common alarm
indication if the Modbus port is configured for use.
The transmission mode (ASCII or RTU), hardware configuration (RS-232,

RS-422, or RS-485), and network address (if multidropping) are all defined in the
Configure mode of the Peak 150 control (see Chapter 8). In addition, the baud
rate, stop bits, parity, and hardware configuration are all set up in the Service
mode (see Chapter 9).
All pertinent control parameters are programmed to be displayed on a CRT or

plant DCS computer. In addition, all relevant control functions (i.e., raise/lower or
enable) can be executed through this link. The functional block diagram (see
Chapter 10) shows all Modbus parameters and their address. See Figure 11-1
for an example showing the Modbus communications connections. The example
shows that Boolean write registers 1 and 2 are for raising and lowering the speed
set point, respectively. It also shows that analog read register 2 contains the
speed set point value.
Figure 11-1. Modbus Communication Connections
Modbus Wiring
The Peak 150 control with Modbus option can communicate to one device via
RS- 232, RS-422 or RS-485 using an ASCII or RTU MODBUS transmission
protocol. The communications port is brought out to terminal blocks for wiring.
Each communications mode is wired to different terminals. The following section
identifies the terminal landings required for each mode.
Woodward 87
RS-232 Wiring
An RS-232 link is limited to a distance of 15 m (50 feet). The Peak 150 control
utilizes terminal blocks 22, 25, 26, and 27 for RS-232 connections. Figure 11-2
shows typical RS-232 communications connection. The transmit data (TXD),
receive data (RXD), and signal ground (SIG GND) must be properly connected
as shown. In addition, the shield (SHLD) should be connected at one end only.
The data terminal ready (DTR) signal is a constant +12 Volt (+9 V typical) RS-
232 signal that is usually left unconnected but is available if required.
Figure 11-2. Typical RS-232 Communications
88 Woodward
RS-422 Wiring
An advantage of RS-422 is that it uses a differential voltage and can
accommodate much longer transmission distances. An RS-422 link can
communicate up to a distance of 1200 m (4000 feet). The Peak 150 control
utilizes terminal blocks 22, 23, 24, 28, 29, 30, 31, and 32 for RS-422
connections. Figure 11-3 shows a typical RS- 422 communications connection.
The transmit data (422T+ and 422T–), receive data (422R+ and 422R–), and
signal ground (SIG GND) must be properly connected as shown. In addition, the
shield (SHLD) should be connected at one end only. The last unit in the Modbus
network chain should have it's receiver terminated with a resistor. The Peak 150
control has termination resistors built-in and available at the terminal block
(TERM RES + and TERM RES –). The RS- 422 receiver should also be properly
terminated at the Modbus master. Use the alternate wiring if no signal ground is
available at the Modbus master.
Figure 11-3. Typical RS-422 communications
Woodward 89
RS-485 Wiring
RS-485 can also accommodate transmission distances up to 1200 m (4000 feet).
The Peak 150 control utilizes terminal blocks 22, 23, 24, 28, 29, and 32 for
RS-485 connections. Figure 11-4 shows a typical RS-485 communications
connection. The data lines (422R+/485+ and 422R–/485–), and signal ground
(SIG GND) must be properly connected as shown. In addition, the shield (SHLD)
should be connected at one end only. The last unit in the Modbus network chain
should have it's receiver terminated with a resistor. The Peak 150 control has
termination resistors built-in and available at the terminal block (TERM RES +
and TERM RES -). The RS-485 cable should also be properly terminated at the
Modbus master. Use the alternate wiring if no signal ground is available at the
Modbus master.
Figure 11-4. Typical RS-485 Communications
90 Woodward
Basic Modbus Overview

The Peak 150 control utilizes Modicon Inc.'s Modbus® protocol (see Figure
11-5 for Basic Modbus Overview). There are two transmission modes available
for use with the Modbus protocol, ASCII and RTU (see Figure 11-6). The Peak
150 control can only act as a slave unit, it responds only after being asked for a
set of parameters. Typically the Peak 150 control will communicate with a
Modbus Master device with a separate link to each device (i.e., point to point
wiring). However, if RS-422 or RS-485 is used, several Peak 150 controls can be
connected to one Master device on a single link (i.e., multidropping). The data is
passed between the Master and the Peak 150 control in the form of message
frames (see figure 11-7). The default slave address for the Peak 150 control is
01, however, this address is adjustable in the configure mode (see Port
Configuration in Chapter 8). On any single link, each slave address must be
unique.
Modbus Points Of Interest
 Master, Slave network protocol.

 One master and up to 32 slaves on a common line.
 Only the master initiates a transaction.
 A transaction comprises a single query and a single response.
 Data is passed between master and slave in the form of message frames.
 Use 9600 baud or slower when using multidropping.
Figure 11-5. Basic Modbus Overview
Woodward 91
Modes of Transmission
 ASCII and RTU are the two modes allowed.
 Mixing of modes is not allowed.
 ASCII mode requires twice as many characters as RTU mode to transmit
the same amount of data.
 RTU mode has more elaborate error checking.
Characteristics of ASCII and RTU modes.
Characteristic ASCII RTU

Coding System Hexadecimal 8 Bit Binary
Bits per Character 7 8
Parity Even, Odd, None Even, Odd, None
Stop Bits 1 or 2 1 or 2
Transmitted Data Per Character 4 bits 8 Bits
Error Checking LRC (Longitude Redundancy Check) CRC (Cyclical Redundancy Check)
Figure 11-6. Modbus Transmission Modes
Frame Definition
 Each slave must have a unique address.

 The function code tells the addressed slave what function to perform.
 The high order bit of the function code is used to indicate an exception
response.
 The data field contains information needed by the slave or collected by a
slave to perform a specific function.
 The error checking assures that the slave or master does not react to
messages that have changed during transmission.
ASCII and RTU frame definition.
Function ASCII RTU

Beginning of Frame : 3 Characters Dead Time
Slave Address 2 Characters, 8 Bits 1 Character, 8 Bits
Function code 2 Characters, 8 Bits 1 Character, 8 Bits
Data 4 Bits Data per Character 8 Bits Data per Character
Error Check Code 2 Characters, 8 Bits 2 Characters, 16 Bits
End of Frame CR LF 3 Characters Dead Time
Figure 11-7. Modbus Frame Definition
The data is passed between the Master and the Peak 150 control in the form of
message frames. The function code portion of the frame tells the addressed
slave what function to perform (see Figure 11-8).
92 Woodward
Function Code Definition

Code Description
1 Read Digital Outputs
2 Read Digital Inputs
3 Read Analog Outputs
4 Read Analog Inputs
5 Write Single Digital Output
6 Write Single Analog Output
7 Loopback Test - Returns the Query Message
8 Write Digital Outputs
9 Write analog Outputs
Figure 11-8. Modbus Function Codes
Figure 11-9 shows typical Modbus frames for the various function codes. If a
slave detects an error in a message, it will not act on or respond to that message.
For any requested data that is undefined, the slave will respond with a value of
zero. The slave will respond with an exception response if it detects illegal data in
a message. The following table lists the exception errors displayed by the Peak
150 control. If the Peak 150 control has an exception error, it will be annunciated
under the Port Adjustments heading in the Service mode (see Chapter 8).
Code Name Meaning

1 Illegal Function The message function is not an allowable action
2 Illegal Data Address The message start address is not an allowable address
9 Checksum Error The received message had an incorrect error check code
10 Garbled Message The received message could not be decoded
Figure 11-9. Modbus Messages
Woodward 93
Port Adjustments
Following is listed the parameters that can be set in the SERVICE Mode under
the PORT ADJUSTMENTS heading (see Chapter 9).
 Hardware Configuration: This adjustment sets the physical link to be used

by the Modbus Communication. Following is a list of the codes and the
corresponding hardware configuration associated with them.
 Baud Rate: This adjustment sets the baud rate or speed of communication.
The following list indicates the codes and the corresponding baud rates.
1 = 1200 Baud
2 = 1800 Baud
3 = 2400 Baud
4 = 4800 Baud
5 = 9600 Baud
6 = 19200 Baud
 Stop Bits: This adjustment sets the number of stop bits to be included in the
data being transmitted. The following list shows the code and the
corresponding number of stop bits to be used.
1 = 1 stop bits
2 = 1.5 stop bits
3 = 2 stop bits
 Parity: This adjustment selects the parity to be used during transmission.

The following list shows the code and the corresponding parity to be used.
1 = Off
2 = Odd
3 = Even
 Link Error: This will indicate TRUE if the Modbus communication link has
been lost.
 Exception Error: This will indicate TRUE if an exception error is found in the
transmitted data.
 Error Number: This indicates the cause of the exception error. The following
list shows the error codes and their meanings.
1 = Illegal Function: The message function is not an allowable action.
2 = Illegal Data Address: The message start address is not an allowable
address.
9 = Checksum Error: The received message had an incorrect error check
code.
10 = Garbled Message: The received message could not be decoded.
 Error Percent: This indicates the amount of time that an error has been
detected in the data being transmitted (displayed as a percent).
94 Woodward
Modbus Addresses
The Modbus communication port has address locations for the analog and
Boolean reads and writes. The Boolean reads and writes are also referred to as
input and holding coils. The analog reads are also referred to as input registers.
Following is a list of these register values along with a brief description of the
parameter.
Boolean Writes (holding coils)—Holding coils are logical signals that are both
readable from and writable to the Peak 150 control. The holding coils available
are listed below. A logical true denoted by the value 1 will cause the command
listed in the description to be executed. For example, if a 1 is written to address
0:0001, the manual speed set point will increase until a 0 is written to address
0:0001. The Peak 150 control supports function codes 1, 5, and 15. These
correspond to reading selected holding coils, writing to a single holding coil, and
writing to multiple holding coils, respectively.
Address Description
0:0001 Raise Speed
0:0002 Lower Speed
0:0003 Trip
0:0004 Reset
0:0005 Start
0:0006 Minimum Governor Select
0:0007 Idle Select
0:0008 Enable Remote
0:0009 Disable Remote
0:0010 Raise Valve Ramp
0:0011 Lower Valve Ramp
The functional block diagram (Chapter 10) shows all Modbus

communications inputs and outputs to the Peak 150 control's
software. It shows both the functional location of the parameter as
well as the Modbus address. This information is shown with the
symbol xx where xx is the Modbus address.
Boolean Reads (input coils)—Input coils are logical signals that are readable
from but not writable to the Peak 150 control. The input coils available are listed
below. The input coil will have the value 1 if the statement in the description
column is true and a 0 if false. The "1:" term in the address identifies an input
coil. The Peak 150 control supports MODBUS function code 2, which involves
reading selected input coils.
Woodward 95
Address Description
1:0001 Trip Status
1:0002 Alarm Status
1:0003 MPU #1 Failed
1:0004 MPU #2 Failed
1:0005 Remote Failed
1:0006 External Trip
1:0007 No Speed Trip
1:0008 Overspeed Trip
1:0009 Front Panel Trip
1:0010 Modbus Trip
1:0011 Remote Selected
1:0012 Remote Enabled
1:0013 HSS/LSS Remote Ctrl
1:0014 Ramping To Minimum Governor
1:0015 Ramping To Idle
1:0016 Overspeed Test Enabled
1:0017 Speed Control
1:0018 MPU Override On
Analog Reads (input registers)—Input registers are analog values that are
readable from but not writable to the Peak 150 control. The input registers
available are listed below. The value of the input registers are stored internal to
the control as floating point numbers representing engineering units (i.e., rpm).
The values that are transmitted are integer values ranging from -32767 to
+32767. The Peak 150 control supports MODBUS function code 4, which
involves reading selected input registers.
Address Description Units

3:0001 Actual Speed (RPM)
3:0002 Speed Set Point (RPM)
3:0003 Remote Set Point (RPM)
3:0004 Remote Input (RPM)
3:0005 Valve Ramp Position (0 to 100%)
3:0006 Speed Demand (0 to 100%)
3:0007 Valve Position Demanded (0 to 100%)
Analog Writes (holding registers)—Holding registers are analog values that are
readable from and writable to the Peak 150 control. The holding registers
available are listed below. The values transmitted are integer values ranging from
-32767 to + 32767. The Peak 150 control supports Modbus function codes 3, 6,
and 16. These correspond to read analog output, write single analog output, and
write analog outputs respectively.
Address Description Units

4:0001 Remote Setting (RPM)
Additional Information
Detailed information on the Modbus protocol is presented in "Reference Guide
PI-MBUS-300" published by AEC Corp./Modicon Inc., formerly Gould Inc. To
implement your own source code, you must register with Modicon. Registration
includes purchasing document PI-MBUS-300 and signing a non-disclosure
agreement. You can register to use Modbus at your nearest Modicon field office.
To find the office nearest you, contact Modicon Technical Support at
1-800-468- 5342.
96 Woodward
Chapter 12.
Troubleshooting
General
Most problems you will encounter are covered in the manual. Use the index to
locate the sections of the manual that may describe your problem. This
troubleshooting section contains a description of the diagnostic programs as well
as a few troubleshooting guidelines that our field service technicians and
engineers have suggested.
Diagnostics
When the control is powered on or when it is rebooting after being configured,
the software performs several hardware diagnostic tests. If an error is found, it is
annunciated through the tachometer display on the front panel. The tachometer
will display the string "Err" followed by an error number. If any of these diagnostic
errors occur the control must be returned to the factory for repair.
The following is a list of the diagnostic tests and the corresponding error numbers
that are displayed if an error occurs.
RAM Test Failure "Err0"
Analog I/O Timer #1 Failure "Err1"
Analog I/O Timer #2 Failure "Err2"
I/O Lockout Failure "Err3"
-12 V Power Supply Failure "Err4"
+12 V Power Supply Failure "Err5"
+12 VP Power Supply Failure "Err6"
+4.5 V Power Supply Failure "Err7"
Troubleshooting
When the control is powered on the microprocessor will begin executing the
software and will turn on the CPU OK LED on the front panel. This LED remains
on as long as the microprocessor is running. This LED is controlled in hardware
by a watchdog timer circuit and under normal operating conditions, should never
turn off. If for any reason, the microprocessor stops executing or if the program is
not running correctly, the watchdog timer will time out and the CPU OK LED will
turn off. If this happens the I/O Lockout will be activated, which will turn off all
discrete outputs and all analog outputs. The only way to restart the control is to
turn off the power and then turn the power back on.
The software in this control is user configurable. Before running the control, make
sure that the software is configured properly for your application. See Chapter 7,
Programming.
Woodward 97
Troubleshooting Chart
Symptom:
 CPU OK LED is off, EMER TRIP arrow light is off, and tachometer display is
blank.
Possible Causes:
 Ribbon cable from operator control panel module to the main control module
is unplugged.
 Power supply input wiring is incorrect.
 Power supply input voltage is not present.
 Power supply fuse is blown.
 +5 Volt power supply is bad.
Solutions:
 Check the possible causes listed above. The +5 V power supply voltage can
be measured at the test points shown in Figure 4-9. If the +5 V is incorrect,
replace the power supply module.
Symptom:
 CPU OK LED is off and EMER TRIP arrow light is on.
Possible Causes:
 Application PROMs are missing or installed incorrectly.
 +5 Volt power supply is bad.
 The microprocessor has stopped because of a hardware failure.
Solutions:
 Check the application PROMs (U11 and U12) for proper installation. They
are located underneath the power supply module.
 Measure the +5 V power supply at the terminals shown in Figure 4-9. If the
+5 V is out of tolerance replace the power supply module.
 Cycle the input power off for several seconds and then back on. If the CPU
OK LED does not come on after approximately ten seconds, the hardware
has failed and must be returned to the factory.
Symptom:
 Discrete outputs are not operating correctly.
Possible Causes:
 Incorrect wiring.
 The CPU OK LED is off activating the I/O Lock mechanism.
 The Normally Open/Normally Closed jumper options are not properly
selected.
 +21 Volt power supply is shorted or bad.
 The software is not configured properly.
Solutions:
 Remove the wiring and use an ohmmeter to check for proper contact
closure. If the meter indicates the output is working properly, then there is a
problem with the wiring.
 Check the CPU OK LED on the front door. If it is off, cycle the input power.
This will reset the I/O Lock mechanism.
 Check the jumper options in Figure 4-9 to make sure the correct jumpers
are in.
98 Woodward
 Check the +21 V power supply voltages at the test points shown in Figure
4-9. If the +21 V power supply is shorted, the voltage measured at the test
points will be low.
 Check the wiring at the (+) terminals of the analog outputs TB33, TB36, and
TB39. The +21 V power supply is connected to these terminals. Remove the
wiring from these terminals and check the +21 V power. If it is correct the
wiring is shorting it out. If it is still incorrect replace the power supply
module.
 Check the software to see what it is telling the outputs to do. To do this
enter the "Service" mode on the hand-held programmer. Find the I/O Check
category then check the fields listed below and see what its output is. "True"
should energize the associated relay and "False" will de-energize it.
Trip Relay ON RELAY OUTPUT #1
Alarm Relay ON RELAY OUTPUT #2
Conf Rly #1 ON RELAY OUTPUT #3
Conf Rly #2 ON RELAY OUTPUT #4
Symptom:
 Discrete inputs are not operating correctly.
Possible Causes:
 The external/internal power supply jumper options are not properly selected.
 The internal +21 Volt power supply is shorted or bad.
 The external power supply is bad or is wired incorrectly.
Solutions:
 Make sure that the wiring is correct. Refer to Figures 4-3 and 4-4 to see how
the contacts and power supplies should be wired.
 Check that the correct jumper option is being used for the external/ internal
power supply as shown in Figure 4-4.
 If the internal +21 V power supply is used, check the voltage at the test
points shown in Figure 4-9. If the +21 V power supply is shorted, the voltage
measured at the test points will be low. Check the wiring at the (+) terminals
of the analog outputs, TB33, TB36, and TB39. The +21 V power supply is
connected to these terminals. Remove the wiring from these terminals and
check the +21 V power. If it is correct, the wiring is shorting it out. If it is still
incorrect, replace the power supply module.
 If an external power supply is used, check it to make sure the voltage is
correct. Refer to Figures 4-3 and 4-4 to see how the contacts and power
supplies should be wired.
 Check the software to see what it senses at the inputs. To do this, enter the
"Service" mode on the hand-held programmer. Find the I/O Check category
then check the fields listed below and see what its input is. As a contact is
closed, the associated variable should be "True" and when it is opened it
should be "False". If this is not the case, make sure that the wiring is correct
and that the correct jumper option is being used for the External/Internal
power supply as shown in Figure 4-4.
DI #1 INPUT #1
DI #2 INPUT #2
DI #3 INPUT #3
DI #4 INPUT #4
DI #5 INPUT #5
DI #6 INPUT #6
DI #7 INPUT #7
DI #8 INPUT #8
Woodward 99
Symptom:
 Analog outputs are not operating correctly.
Possible Causes:
 The CPU OK LED is off, activating the I/O Lock mechanism.
 The 4–20 mA/0–1 mA jumper options are not properly selected.
 +5 V power supply is bad.
Solutions:
 Make sure that the wiring is correct. Refer to Figure 4-6 to see how the
analog outputs should be wired.
points will be low. Check the wiring at the (+) terminals of the analog
outputs, TB33, TB36, and TB39. The +21 V power supply is connected to
these terminals. Remove the wiring from these terminals and check the +21
V power. If it is correct, the wiring is shorting it out. If it is still incorrect,
 Check the front door CPU OK LED. If off, cycle the input power. This will
reset the I/O Lock mechanism.
 Check the jumper options (see Figure 4-9) to make sure the correct jumpers
are in.
 Check the +5 V power supply voltage at the test points shown in Figure
4- 9). If it is incorrect the unit must be sent back to the factory for repair.
 Check what the software is telling the outputs to do. To do this, enter the
"Service" mode on the hand-held programmer. Find the category and the
fields listed below and observe its output. The output value will be in
engineering units. How this value relates to current depends on how the
control was configured.
Speed Values Actual Speed Output #1
Readout Adjustments RO#2 Value Output #2
Symptom:
 Actuator output is not operating correctly.
Possible Causes:
 The CPU OK LED is off, activating the I/O Lock.
 The 0–200 mA/0–20 mA jumper option is not properly selected.
 +5 V power supply is bad.
Solutions:
 Make sure that the wiring is correct. Refer to Figure 4-6 to see how the
actuator output should be wired.
points will be low. Check the wiring at the (+) terminals of the analog
outputs, TB33, TB36, and TB39. The +21 V power supply is connected to
these terminals. Remove the wiring from these terminals and check the +21
V power. If it is correct the wiring is shorting it out. If it is still incorrect
100 Woodward
 Check the CPU OK LED on the front door. If it is off, cycle the input power.
This will reset the I/O Lock mechanism.
 Check the jumper options (Shown in Figure 4-9) to make sure the correct
jumpers are in.
 Check the +5 V power supply voltage at the test points shown in Figure 4- 9.
If it is incorrect, the unit must be sent back to the factory for repair.
 Check the software to see what it is telling the output to do. To do this, enter
the "Service" mode on the hand-held programmer. Find the category and
field listed below and see what its output is. The output value will be in
actuator position (0% - 100%). How this value relates to current depends on
how the control was configured.
Valve Valve Position (%)Actuator Output
Symptom:
 Speed sensor inputs are not operating correctly.
Possible Causes:
 The magnetic pickup is not functioning properly.
 +12 V or -12 V power supply is bad.
 +4.5 V Ref, +4.5 V, +5 V, or -5 V power supply is bad.
Solutions:
 Make sure that the wiring is correct. Refer to Figure 10 to see how the
speed sensor inputs should be wired.
 Check the magnetic pickup. It must provide at least a 200 Hz, 1 Vrms signal.
 Check the +12 V and -12 V power supply voltages at the test points shown
in Figure 4-9. If either is incorrect, replace the power supply module.
 Check the +4.5 V REF, +4.5 V, +5 V and -5 V power supply voltages at the
test points shown in Figure 4-9. If any of them are incorrect, the unit must be
sent back to the factory for repair.
 Check the software to see what it senses at the inputs. To do this, enter the
and the field listed below and see what its input is. The input value will be in
Hz.
MPU #1 SPEED SENSOR INPUT #1
MPU #2 SPEED SENSOR INPUT #2
Symptom:
 Analog input is not operating correctly.
Possible Causes:
 The 4–20 mA/1–5 V jumper option is not properly selected.
 +12 V or -12 V power supply is bad.
 +4.5 V REF, +5 V, or -5 V power supply is bad.
Solutions:
 Make sure that the wiring is correct. Refer to Figure 11 to see how the
analog inputs should be wired.
 Check the jumper options (See Figure 4-9) to make sure the correct jumper
is in.
 Check the +12 V and -12 V power supply voltages at the test points shown
in Figure 4-9. If either is incorrect replace the power supply module.
Woodward 101
 Check the +4.5 V REF, +5 V and -5 V power supply voltages at the test
points shown in Figure 4-9. If any of them are incorrect, the unit must be
sent back to the factory for repair.
 Check the software to see what it senses at the input. To do this, enter the
and the field listed below and observe its input. The input value will be
0–100, 0 represents 4 mA and 100 represents 20 mA.
Analog Input Analog Input #1 Remote Speed Input
Symptom:
 Operator Control Panel not operating correctly.
Possible Causes:
 Ribbon cable from operator control panel module to the main control module
is unplugged.
Solutions:
 Check the ribbon cable to make sure it is properly connected. If the ribbon
cable is properly connected and there still seems to be a problem, check the
hardware with the hand-held programmer. To check the operator control
panel switches, enter the "Service" mode on the hand-held programmer.
Find the I/O Check category and the field listed below and see what its input
is. The input value should be "True" when the associated switch is pressed,
and should be "False" when the switch is released.
INPUT I/O MENU
EMER TRIP Trip FP/B
OVERSPEED TEST Ospd Test FP/B
RAISE Raise FP/B
LOWER Lower FP/B
START Start FP/B
ALARM RESET Reset FP/B
 To check the operator control panel LEDs enter the "Service" mode on the
hand-held terminal. Find the I/O Check category and field listed below and
see what its output is. The LED should be on when the associated output
value is "True" and off when the output value is "False". The only exception
to this is if the TRIPPED LED jumper option is set for trip relay de-energized
for shutdown. (See Figure 4-9). If this is the case then the TRIPPED LED
will be on when the output is "False" and off when the output is "True".
LED I/O MENU
TRIPPED Tripped LED
MPU #1 OK MPU #1 OK LED
MPU #2 OK MPU #2 OK LED
OVERSPEED TEST ENABLED Ospd Enabled LED
RMT SPD ENABLED Rmt Spd LED
The CPU OK LED should always be on. If it is not, see the "CPU OK
LED is off": Symptom above.
Symptom:
 The TRIPPED LED is on for normal operation and off when the turbine is
tripped or is always off.
Cause:
 The trip relay energized/de-energized for shutdown jumper is in the wrong
position or is not installed.
Solution:
 Install the jumper according to Figure 4-9.
102 Woodward
Symptom:
 The hand-held programmer is not working.
Cause:
 +12 VP power supply is bad.
Solution:
 Check the +12 VP power supply at the test points shown in Figure 4-9. If
incorrect, replace the power supply module. If correct, the hand-held
terminal should beep and go through a self-test when plugged in.
Debug Mode Tunables

There are 15 tunables (16 for the 4-digit model) available in the debug mode that
may be used for troubleshooting. These tunables are not intended for general
use. They have been factory calibrated and should only be adjusted if necessary.
The block and field names are listed and a brief description of that tunable's
function follows. The "black square" key is used to enter the debug mode.
COMM.CRT.RST Clears Modbus exception errors generated

by the Peak 150 control. (Range = True to
False, Default = False)
COMM.CRT.INIT_MOD Re-initializes the Peak 150 control Modbus
outputs to their default values. (Range =
True to False, Default = False)
COMM.CRT.TIME_OUT The dead time allowed on the Modbus
comm link before a link error is generated.
(Range = 0.00 to 100.00, Default = 3.000)
IO.INPUT1.OFFSET Offset adjustment for the remote speed
analog input calibration. An input of 4 mA is
equal to 0%. (Range = -20.00 to 20.00,
Default = 0.000)
IO.INPUT1.GAIN Gain adjustment for the remote speed
analog input calibration. An input of 20 mA is
equal to 100%. (Range = 0.00 to 2.00,
Default = 1.000)
OSPD.HOLD_TRIP.DLY_TIME Trip code sampling hold delay time. Do not
adjust. (Range = 0.00 to 1.00, Default =
0.100)
OSPD.SPD_LAG.LAG_TAU Front panel display speed filter. (Range =
0.00 to 10.00, Default = 1.000)
OSPD.XXDISPLAY.NC Front panel display update time. Do not
adjust below 0.250. (Range = 0.01 to 2.00,
Default = 1.000)
REMOTE.RMT_IN.LAG_TAU Noise filter for the remote speed analog
input. (Range = 0.00 to 10.00, Default =
0.000)
SHUTDOWN.TRIP_OUT.CTRL This tunable is in debug mode for the 4-digit
version only. The 5-digit version has this
function in the configure mode. See the
Configure mode, Relays heading, Reset
Clears Trip Relay field for a description of
this function. (Default = True for the 4-digit
version)
SPD_CTRL.DROOP_LAG.LAG_TAU Speed Droop delay. Typically set to 10/I
when droop is used. (Range = 0.00 to 10.00,
Default = 0.200)
Woodward 103
SPD_CTRL.I_SCALED.IN_1 Normalizing value for the Integral constant.
Factory set, do not adjust. (Range = 0.01 to
100.00, Default = 0.100)
SPD_CTRL.P_SCALED.IN_1 Normalizing value for the Proportional
constant. Factory set, do not adjust. (Range
= 1.00 to 100.00, Default = 100.000)
SPD_CTRL.SPD_PID.S_D_R The PID speed derivative ratio. This affects
the derivative portion of the speed PID.
Typically set to 100 for mechanical drive
applications. (Range = 0.01 to 100.00,
Default = 100.000)
SPD_CTRL.VLV_RAMP.P_SP_2 The maximum valve position limit in %.
(Range = 0.00 to 100.00, Default = 100.000)
SPD_REF.SETBACK.DLY_TIME The set point setback pulse time. Factory
set, do not adjust. (Range = 0.00 to 1.00,
Default = 0.100)
Alarms / Shutdowns
If the control shuts down due to a CPU fault or watchdog timer failure, indicated
by the CPU OK LED being off, you must turn off control power then turn the
power back on. Until you do, you cannot step through any functions in the hand-
held programmer.
After any shutdown, the Shutdown relay contacts should be reset to ensure
proper start-up.
Wiring / Component Problems

Most Peak 150 control problems are caused by wiring problems. Carefully and
thoroughly check all wiring connections at both ends. Be very careful when
installing wires into the Peak 150 control terminal blocks. Check all shields for
proper grounding at the control end only.
You can measure all inputs and outputs directly at the terminal strips. The hand-
held display will show what the Peak 150 control measures. This comparison will
tell you if the Peak 150 control is interpreting the input signal correctly.
EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,

Division or Zone applications.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I,
applications Division ou Zone.
104 Woodward
Actuators / Control Adjustments

If the actuator output is unsteady or hunts, try blocking the steam valve by
closing the valve ramp. If you block the steam valve in this manner and the
actuator output is steady but the turbine still hunts, then the problem is outside
the governor. If an actuator hunts, it may need dither (especially TM type).
If the Peak 150 control is not able to fully close or open the actuator, check to
make sure that the actuator is calibrated correctly. If the Peak 150 control is not
able to control speed above or below a certain speed, the steam valve may not
be adjusted correctly. An indication of this is if the control is calling for minimum
actuator but the speed is still climbing or staying the same, or if the control is
calling for maximum actuator but the speed will not increase. Shut down the
control and verify that the actuator is closed. If it is, then partially open the T&T
valve and verify that the turbine does not turn.
If the T&T valve allows the turbine to turn, then the steam valve is not seated.
Other Operating Problems

If actual speed is less than the speed called for by the speed reference, check for
speed droop. Droop causes the actual speed to be less than the speed
reference.
If the Remote Speed input values are reading incorrectly, check that the input
wire shielding is properly grounded at the Peak 150 control end only.
Woodward 105
Chapter 13.
Service Options
Product Service Options

Do not attempt to service internal electronic components nor attempt to
remove any of the circuit boards. If the control requires repair, contact
Woodward or your nearest Woodward authorized service facility.
The field-configured portion of the program will be zeroed out after
factory repair. To prevent damage to your equipment, you must
reconfigure the Program Mode before the unit is put back into service.
If you are experiencing problems with the installation, or unsatisfactory

performance of a Woodward product, the following options are available:
 Consult the troubleshooting guide in the manual.
 Contact the manufacturer or packager of your system.
 Contact the Woodward Full Service Distributor serving your area.
 Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In many cases, your
problem can be resolved over the phone. If not, you can select which course
of action to pursue based on the available services listed in this chapter.
OEM and Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on Woodward's
behalf. Service (not new unit sales) is an AISF's primary mission.
 A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
 A Recognized Turbine Retrofitter (RTR) is an independent company that
does both steam and gas turbine control retrofits and upgrades globally, and
can provide the full line of Woodward systems and components for the
retrofits and overhauls, long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available by searching on

"25225" or "worldwide directory" at:
www.woodward.com/searchpublications.aspx
106 Woodward
Woodward Factory Servicing Options

The following factory options for servicing Woodward products are available
through your local Full-Service Distributor or the OEM or Packager of the
equipment system, based on the standard Woodward Product and Service
Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture
Replacement/Exchange: Replacement/Exchange is a premium program

designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime. This is a flat-rate program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned within 60 days, a credit for the core charge will be issued.
Flat Rate Repair: Flat Rate Repair is available for the majority of standard
products in the field. This program offers you repair service for your products with
the advantage of knowing in advance what the cost will be. All repair work carries
the standard Woodward service warranty (Woodward Product and Service
Warranty 5-01-1205) on replaced parts and labor.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option with the exception that the unit will be returned to you in “like-
new” condition and carry with it the full standard Woodward product warranty
(Woodward Product and Service Warranty 5-01-1205). This option is applicable
to mechanical products only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
 return authorization number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.
Woodward 107
Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.
To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.
Engineering Services
Woodward offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Woodward website.
 Technical Support
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending
upon the product and application. This service can assist you with technical
questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business
hours by phoning Woodward and stating the urgency of your problem.
Product Training is available as standard classes at many of our worldwide

locations. We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product

and location, from many of our worldwide locations or from one of our Full-
Service Distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface.
For information on these services, please contact us via telephone, email us, or
use our website: www.woodward.com.
108 Woodward
How to Contact Woodward

For assistance, call one of the following Woodward facilities to obtain the address
and phone number of the facility nearest your location where you will be able to
get information and service.
Electrical Power Systems Engine Systems Turbine Systems

Facility---------------- Phone Number Facility---------------- Phone Number Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany--------- +49 (0) 21 52 14 51 Germany---------- +49 (711) 78954-0 India --------------- +91 (129) 4097100
India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191
Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191 Korea -------------- +82 (51) 636-7080
Korea -------------- +82 (51) 636-7080 Korea -------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111
Poland--------------- +48 12 295 13 00 The Netherlands - +31 (23) 5661111 Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811 United States ---- +1 (970) 482-5811 United States ---- +1 (970) 482-5811
You can also contact the Woodward Customer Service Department or consult our
worldwide directory (search on "25225" or "worldwide directory" at:
www.woodward.com/searchpublications.aspx) for the name of your nearest
Woodward distributor or service facility.
Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
Your Name
Site Location
Phone Number
Fax Number
Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
Woodward 109
Appendix.
Program Mode Worksheets
Introduction
The program mode worksheets provide a quick reference for programming the
Peak® 150 control. You may copy or print the worksheets for your use.
The Peak 150 requires a hand-held programmer to set the following menus. (See
Chapter 7, Programming for information on the use of this unit.)

connections which could cause sparks are exposed inside the
cabinet.
Errors in configuration or programming of the Peak 150 control may

create dangerous overspeed conditions. The turbine must be
equipped with an overspeed device completely separate from the
Peak 150 control or actuators attached to the Peak 150 control. The
turbine must never be run when this device is not present or not
operating correctly.
To prevent damage to the turbine resulting from improper control

settings, make sure you save the set points before removing power.
Failure to save the set points before removing power causes them to
revert to the previously saved settings. Dangerous conditions such
as turbine overspeed may result from operating the turbine with
incorrect settings, possibly resulting in equipment damage and
injury or death of personnel.
Do NOT attempt to operate the turbine until the Peak 150 control has
been programmed. To do so could cause equipment damage; the
turbine will start, come up to idle speed, trip and shutdown.
Governor Serial Number __________________________________
Application _____________________________________
Configure Mode Program

(The turbine must be shut down to enter this mode.)
Enter the configure mode by pressing the "." key when the screen displays the
"Woodward Governor Company" message. The "Woodward Governor Company"
heading can be displayed by pressing the "ESC" (escape) key.
110 Woodward
Speed Config
TEETH SEEN BY MPU ______________
MPU GEAR RATIO 1 ______________
MPU #1 – MAX HERTZ (Hz) ______________
MPU #2 – MAX HERTZ (Hz) ______________
MAX SPD LEVEL (Hz) ______________
MINIMUM SPD LVL (HZ) ______________
Start Mode
MANUAL START MODE? (TRUE/FALSE) ______________
AUTO START MODE (status indication only)
Actuator Config
USE 20–160 MA ACTUATOR? (TRUE/FALSE) ______________
USE 4–20 MA ACTUATOR (status indication only)
Operating Mode
MANUAL CONTROL ONLY? (TRUE/FALSE) ______________
USE REMOTE SPD SET? (TRUE/FALSE) ______________
USE HI-SIG-SELECT? (TRUE/FALSE) ______________
USE MODBUS ANLG IN? (TRUE/FALSE) ______________
Readouts
SPEED RO 4 MA VALUE (RPM) ______________
SPEED RO 20 MA Value (RPM) ______________
READOUT #2 OPTION? (OPTION #) ______________

Readout #2 Options:
1. ACTUAL SPEED
2. ACTUAL SPEED SETPT
3. VALVE POSITION (Actuator Output)
4. REMOTE SPEED SET INPUT
5. VALVE RAMP POS’N
6. Not Used
READOUT #2— 4 MA VALUE (RPM or %) ______________
READOUT #2—20 MA VALUE (RPM or %) ______________

Woodward 111
Relays
RELAY #3 OPTION? (OPTION #) ______________
RELAY #4 OPTION? (OPTION #) ______________
Configurable Relay Options:

1. Alarm (normally energized)
2. Trip Output (same as trip relay output)
3. Shutdown (energizes on trip condition)
4. Remote Control
5. Speed Control
6. Either MPU Failed
7. Overspeed Trip
8. Overspeed Test
9. Remote Status
10. Spd Switch or Hand Valve #1
11. Spd Switch or Hand Valve #2
USE SPEED SWITCHES? (TRUE/FALSE) ______________
SWITCH #2 UNDERSPD? (TRUE/FALSE) ______________
USE HAND VALVE(S)? (TRUE/FALSE) ______________
TRIP RELAY ENERGIZES? (TRUE/FALSE) ______________
RESET CLRS TRIP RLY? (TRUE/FALSE) ______________
Contact In #8
IN #8 = OSPD TEST? (TRUE/FALSE) ______________
Port Config
USE MODBUS PORT? (TRUE/FALSE) ______________
HARDWARE CONFIG? (OPTION #) ______________
MODBUS PORT HARDWARE Configuration Options:

1 = RS-232
2 = RS-422
3 = RS-485
TRANSMISSION MODE? (OPTION #) ______________
MODBUS PORT TRANSMISSION MODE Configuration Options:

1 = ASCII
2 = RTU
NETWORK ADDRESS? ______________
112 Woodward
Service Mode Program

Enter the service mode by pressing the down arrow key when the screen
displays the "Woodward Governor Company" message.
Alarms
MPU #1 FAILED (status indication only)
MPU #2 FAILED (status indication only)
REMOTE INPUT FAILED (status indication only)
COMM LINK FAILURE (status indication only)
TURBINE TRIP (status indication only)
USE TRIP AS ALARM? (TRUE/FALSE) ______________
Trips
LAST TRIP CODE = (status indication only)
1) EXTERNAL TRIP
2) LOSS OF BOTH MPUs inputs
3) OVERSPEED TRIP
4) FRONT PANEL TRIP
5) MODBUS TRIP
EXTERNAL TRIP (status indication only)
OVERSPEED TRIP (status indication only)
LOSS OF BOTH MPUs (status indication only)
FRONT PANEL TRIP (status indication only)
MODBUS TRIP (status indication only)
Speed Dynamics
LOW SPEED GAIN _____*0.8______
LOW SPEED RESET _____*5.0______
HI SPEED SWITCH PT (RPM) ______________
HI SPEED GAIN _____*0.8______
HI SPEED RESET _____*5.0______
HI SPEED SELECTED (status indication only)
Woodward 113
Speed Values
ACTUAL SPEED (RPM) (status indication only)
LOCAL SPEED SETPT (RPM) (status indication only)
ACTUAL SPEED SETPT (RPM) (status indication only)
REMOTE SPD SET (RPM) (status indication only)
START RAMP RATE (RPM/SEC) ______________
SETPT SLOW RATE RPM/SEC) ______________
DELAY FOR FAST RATE (SEC) ______________
SETPT FAST RATE (RPM/SEC) ______________
MIN GOV SPEED (RPM) ______________
MAX GOV SPEED (RPM) ______________
OVERSPEED LEVEL (RPM) ______________
EXTERNAL OSPD LEVEL (RPM) ______________
OVERSPEED TEST LIMIT (RPM) ______________
DROOP (%) _____*0.0______
USE SET POINT SET-BACK (TRUE/FALSE) ______________
Remote Setting
(This menu is displayed when REMOTE CONTROL is configured.)
ACTUAL REMOTE SETPT (status indication only)
REMOTE SET INPUT (status indication only)
RMT-NOT-MATCHED RATE (RPM/SEC) ______________
REMOTE RATE—MAX (RPM/SEC) ______________
MODBUS REMOTE USED (status indication only)
Failed MPU Ovrd

AUTO-OVRD-OFF SPEED (HZ) ______________
USE MPU OVRD TIMER? (TRUE/FALSE) ______________
MAX STARTING TIME = (SEC) ______________
USE ROLLDOWN OVRD? (TRUE/FALSE) ______________
AUTO-OVRD-ON SPEED (HZ) ______________
114 Woodward
AUTO-OVRD-ON DELAY (SEC) ______________
OVRD ON STATUS (status indication only)
Idle/Min Ramp
(This menu is displayed only if configured for Auto Start.)
IDLE SPEED = (RPM) ______________
USE IDLE / MIN RAMP? (TRUE/FALSE) ______________
MIN GOVERNOR SPEED (RPM) ______________
IDLE/MIN GOV RATE = (RPM/SEC) ______________
USE RAMP TO IDLE? (TRUE/FALSE) ______________
START = RAMP TO MIN (TRUE/FALSE) ______________
RAMPING TO MIN (status indication only)
RAMPING TO IDLE (status indication only)
Critical Speed Band

(This menu is displayed only if configured for AUTO START.)
USE CRITICAL BAND? (TRUE/FALSE) ______________
CRITICAL SPEED MIN (RPM) ______________
CRITICAL SPEED MAX (RPM) ______________
CRITICAL BAND RATE (RPM/SEC) ______________
IN CRITICAL BAND (status indication only)
SPD SW/Hand VLV

(This menu is displayed only if configured for SPD SW / HAND VLV.)
RLY #1 ON (RPM or %) ______________
RLY #1 OFF (RPM or %) ______________
RLY #2 ON (RPM or %) ______________
RLY #2 OFF (RPM or %) ______________
UNDERSPEED LEVEL (RPM) ______________
Woodward 115
Valve Output
VALVE POSITION (% TRAVEL) (status indication only)
VLV – OFFSET ADJUST _____*0.0______
VALVE - GAIN ADJUST _____*1.0______
VALVE RAMP POS’N (% TRAVEL) (status indication only)
MANUALLY RSE RAMP? (TRUE/FALSE) ____*false_____
MANUALLY LWR RAMP? (TRUE/FALSE) ____*false_____
RAMP RATE (%/SEC) ______________
DITHER ADJUST _____*0.0______
STROKE VLV OUTPUT? (TRUE/FALSE) _____*false_____
STROKE POSITION (% TRAVEL) _____*0.0______
MIN / MAX SWITCH (TRUE/FALSE) _____*false_____
Readout Adjust
RO #1 -- OFFSET ADJUST (SPEED READOUT) _____*0.0______
RO #1 – GAIN ADJUST (SPEED READOUT) _____*1.0______
RO #2 – OFFSET ADJUST (CONFIG READOUT) _____*0.0______
RO #2 -- GAIN ADJUST (CONFIG READOUT) _____*1.0______
RO #2 VALUE (status indication only)
Port Adjust
HARDWARE CONFIG (OPTION #) _______________
Modbus Port Hardware Configuration Options:

1 = RS-232
2 = RS-422
3 = RS-485
BAUD RATE (OPTION #) _____________
Modbus Port Baud Rate Configuration Options:

1 = 1200 Baud
2 = 1800 Baud
3 = 2400 Baud
4 = 4800 Baud
5 = 9600 Baud
6 = 19200 Baud
116 Woodward
STOP BITS (OPTION #) ______________
Modbus Port Stop Bit Configuration Options:

1 = 1 Stop Bit
2 = 1.5 Stop Bits
3 = 2 Stop Bits
PARITY (OPTION #) ______________
Modbus Port Parity Configuration Options:

1 = Off Parity
2 = Odd Parity
3 = Even Parity
LINK ERROR (status indication only)
EXCEPTION ERROR (status indication only)
ERROR NUMBER (status indication only)
ERROR PERCENT (status indication only)
I/O Check
(Status Indications Only)
MPU #1 (RPM)
MPU #2 (RPM)
ANALOG INPUT (%)
DI #1 (LOWER SPEED) (TRUE/FALSE)
DI #2 (RAISE SPEED) (TRUE/FALSE)
DI #3 (EXTERNAL TRIP) (TRUE/FALSE)
DI #4 (START) (TRUE/FALSE)
DI #5 (RESET) (TRUE/FALSE)
DI #6 (IDLE / MIN GOV) (TRUE/FALSE)
DI #7 (REMOTE SPEED ENABLE) (TRUE/FALSE)
DI #8 (OSPD TEST/HI DYN SELECT) (TRUE/FALSE)
TRIP P/B (OCP EMER TRIP) (TRUE/FALSE)
OSPD TEST P/B (OCP OVER SPEED TEST) (TRUE/FALSE)
RAISE P/B (OCP RAISE [Speed]) (TRUE/FALSE)
LOWER P/B (OCP LOWER [Speed]) (TRUE/FALSE)
START P/B (OCP START) (TRUE/FALSE)
Woodward 117
RESET P/B (OCP ALARM RESET) (TRUE/FALSE)
TRIPPED LED (TRUE/FALSE)
MPU #1 OK LED (TRUE/FALSE)
MPU #2 OK LED (TRUE/FALSE)
OSPD ENABLED LED (TRUE/FALSE)
RMT SPD LED (TRUE/FALSE)
TRIP RELAY ON (TRUE/FALSE)
ALARM RELAY ON (TRUE/FALSE)
CONF RLY #1 ON (TRUE/FALSE)
CONF RLY #2 ON (TRUE/FALSE)
118 Woodward
Woodward 119
Peak 150 Control Specifications
Inputs
Magnetic Pickup Inputs (2) Two identical inputs, high-signal-selected
Minimum input voltage 1 Vrms, minimum frequency
200 Hz, maximum frequency 15 kHz
Analog Input (1) Remote Speed Setting signal
(4–20 mA or 1–5 Vdc, internal jumper selectable)
Discrete Inputs (8) Remote (isolated, 5–28 Vdc)
Options Raise speed
Lower speed
Emergency stop
Alarm reset
Remote speed set enable
Start
Idle/minimum governor
Select high dynamics or overspeed test
Outputs
Analog Outputs (2) Actual speed output (scalable, 4–20/0–1 mA)
Configurable readout (scalable, 4–20/0–1 mA)
Options Actual speed
Speed setpoint
Actuator output
Remote speed setpoint
Valve ramp value
Actuator Output (1) 4–20 or 0–200 mA (internal jumper selectable)
Relay Outputs (4) Internal jumpers provide choice of normally-open or normally-closed
contacts
Contact ratings are 2 A resistive @ 28 Vdc
0.3 A resistive @ 115 Vac
Shutdown (de-energizes or energizes for shutdown)
Alarm (de-energizes for alarm)
Configurable Relay #1
Configurable Relay #2
Options Alarm
Trip output
Shutdown
Remote control
Speed control
MPU failure
Overspeed trip
Overspeed test
Remote signal OK
Speed switch #1
Speed switch #2
Hand valve #1
Hand valve #2
Operator Control Panel
Keypad Switches (6)
Options Raise speed
Lower speed
Emergency trip
Start
Overspeed test
Alarm reset
LED Indicators (6) Remote speed setting signal status
Shutdown status
MPU #1 status
MPU #2 status
CPU status
Overspeed test status
Digital Display Five-digit LED speed display
Power
Input Models are available with these input power requirements:
24 Vdc
90–150 Vdc or 88–132 Vac, 47–63 Hz
Maximum power consumption,
all models: 38 W
Environmental Specifications
Operating Ambient Temperature –25 to +65 °C (–13 to +149 °F)
Storage Ambient Temperature –40 to +85 °C (–40 to +185 °F)
Humidity Designed to meet US MIL-STD-810D, Method 507.2, Procedure II, induced,
non-hazardous, cycle 5 (fifteen 24-hour cycles, varying 19–75% humidity,
over 33–63 °C)
Vibration US MIL-STD-167, Type 1
Shock US MIL-STD-810C, Method 516.2, Procedure 1
Dimensions
Width 483 mm (19 inches)
Height 310 mm (12.2 inches)
Depth 105 mm (4.1 inches)
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please reference publication 85565D.
PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058
Email and Website—www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
2011/4/Colorado

Manual Steam Turbine PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Steam Turbine PDF

Uploaded by

Copyright:

Available Formats

INSTRUCTION MANUAL

TURBINE SERIAL NUMBER D6706

March 2011 INSTRUCTION MANUAL 107

Revision A SST Turbine Instruction

How to Use This Manual

This instruction manual contains installation, operation, and maintenance

A complete reading of this manual by personnel in contact with

The Instruction Manual consists of 15 sections, as listed in the table of contents.

This is a general instruction manual, describing a standard ring oiled or pressure

For turbines supplied with options such as forced or circulating lubrication

March 2011 Revision A 1

Throughout this manual, it is assumed that the motive flow applied at

Should further information be desired, or should particular problems arise, the

All inquiries regarding installation, operation, maintenance, spare parts, or service

Refer to Section M, Replacement Parts/Factory Service, for information on how to

2 Revision A SST Turbine Instruction

If there is a CE mark on this turbine nameplate it indicates

ATEX Certified turbines will have a mark –c C X on the turbine

Refer to the Machinery Directive – List of Residual Risks and

Additional cautions and warnings are located throughout this

SST Turbine Instruction Manual Revision A 3

How to Use This Manual............................................................................................................... 1

Safety Precautions ........................................................................................................................ 17

Section A Introduction and General Description.......................................................................... 25

A.1 Turbine Description ................................................................................................ 25

Section B Technical Data............................................................................................................. 45

4 Revision A SST Turbine Instruction

B.6 Major Fits, Clearances, and Rotor Balance Criteria.................................................49

C.1 General .....................................................................................................................63

SST Turbine Instruction Manual Revision A 5

C.10 Hot Alignment Check ............................................................................................... 94

Section D Speed Control System ................................................................................................ 96

Section E Overspeed Trip System............................................................................................... 105

E.1 General..................................................................................................................... 105

Section F Lubrication System ...................................................................................................... 120

F.1 General..................................................................................................................... 121

6 Revision A SST Turbine Instruction

F.6 Pressure Lubrication System....................................................................................125

Section G Optional Gland Condensers, Eductors and Ejectors ..................................................135

Section H Optional Instruments and Controls ..............................................................................137

H.1 Sentinel Warning Valve ............................................................................................137

Section I Start-Up and Operation .................................................................................................139

SST Turbine Instruction Manual Revision A 7

I.5.2 Bearing Housing Vibration ....................................................................................... 158

Section J Maintenance, Maintenance Schedule and Inspection Schedule ................................. 172

J.1 Introduction............................................................................................................... 173

Section K Troubleshooting........................................................................................................... 185

K.1 Introduction............................................................................................................... 183

Section L Disassembly and Parts Replacement.......................................................................... 195

L.1 Warnings/Cautions................................................................................................... 195

L.2 General..................................................................................................................... 197

8 Revision A SST Turbine Instruction

L.4 Carbon Ring Removal and Replacement.................................................................203

SST Turbine Instruction Manual Revision A 9

L.14.1 Governor Cup Removal ........................................................................................... 235

Section M Replacement Parts/Factory Service ........................................................................... 242

M.1 Factory Replacement Parts...................................................................................... 242

Section N Miscellaneous.............................................................................................................. 249

N.1 Low Ambient Temperature Applications .................................................................. 249

Section O Low Voltage Electrical Components ........................................................................... 257

O.1 Electrical Parts and Applications.............................................................................. 257

Section P User Notes and Maintenance Records .................................................................... 292

10 Revision A SST Turbine Instruction