PT-210 : Woodward Governor Upgrade & Speed Fluctuations

Governor of PT-210 was upgraded during March/April’2011 T/A. During commissioning

checks it was found the Governor valve is having Jerky operation. The actuator was over
hauled and put back. Still there was jerky operation in initial 15 % of the valve opening.
Commissioning was completed and the log for Activities , Observations , Findings,
Conclusions during Commissioning , Running and Swapping are as below:-

Performance History of PT-210: The earlier history record and discussions with
operations personnel indicate erratic behavior of PT-210 during swapping and was
prone to speed fluctuations. Even before upgrade there was speed fluctuations of about
120 rpm from December-2010.

Governor Functions for Speed:

1) To maintain speed at IDLE speed.

2) To ramp-up / down during change over from C-206 to C-207 & vice versa.
3) To maintain speed at rated speed.

There are 2 sets of tuning parameters. The first set of tuning parameter known as OFF-
LINE tuning parameter is for IDLE speed & up-to Minimum Governor Speed. The 2 nd set
of tuning parameter known as ON-LINE tuning parameter is for rated speed.

Activities , Observations , Findings , Conclusion during commissioning , running and

swapping of PT-209 & PT-210.

Activity:

04.04.2011: PT-210 started. Speed variations up-to 180 rpm observed at IDLE speed.
PT-209 not running.

05.04.2011: PT-210 governor was tuned and made very slow. When in IDLE mode the
speed variations observed @ 25 rpm maximum. PT-209 in stop condition.

06.04.2011: PT-210 was put to RUN mode. In run mode with load and the speed
variations observed @ 30 rpm maximum. PT-210 continued in RUN mode. PT-209 in
stop condition.

08.04.2011: PT-209 was started and swapping was made. PT-209 came to RUN mode.
PT-210 could not come back to IDLE speed (it was above 1760 rpm) within the time
period as per logic and tripped. PT-209 continued in RUN mode. PT-210 was restarted
and put in IDLE mode. In IDLE mode the speed variations increased from 25 rpm to
about 44 rpm.
10.04.2011: Swapping was made from PT-209 to PT-210. PT-210 came to RUN mode but
PT-209 could not come back to IDLE speed (it was above 1760 rpm) within the time
period as per logic and tripped. PT-210 continued in RUN mode. PT-209 was started and
kept in IDLE mode. In IDLE mode PT-209 speed fluctuations were found to be about 20
rpm maximum.

Conclusion : With very conservative OFF line tuning parameters the compressor
swapping from IDLE to RUN mode is success while the compressor from RUN to IDLE
mode is failure. For smooth change over from RUN to IDLE mode require strong OFF
line tuning parameters.

Activity:

11.04.2011: OFF line tuning parameters were changed in PT-209 which was in IDLE
mode. Due to strong tuning parameters the speed variations increased from 20 rpm to
45 rpm. The same tuning parameters were set for PT-210. With new tuning parameters
in both PT-209 & PT-201 (Should be PT-210, I guess) swapping was done from PT-210 to
PT-209. PT-209 came to RUN mode & PT-210 came to IDLE mode. Swapping was
successful.

Finding: With strong OFF line tuning parameters PT-210 speed fluctuations increased
from 44 rpm to 240 rpm. This is due to the fact that for swapping high gain & reset
action is required. With high gain and reset action at IDLE speed the speed fluctuations
increases.

Factors which could cause the speed fluctuations (other than Governor / tuning
parameters) are as below:-

Speed sensing problem : Speed sensors were checked for reliable speed reading. Both
the speed probes read identical reading and also match with the hand held tachometer
readings. So the speed sensor problem is eliminated.

Governor valve actuator problem : The governor actuator was overhauled , calibrated
and the openings / closings were verified several times for repeatability. The actuator ,
valve positioner were found to be working ok. However the I/P convertor was replaced
with a new one to eliminate any possibility of I/P problem.

Steam quality & operating conditions : Operation department clarified that the steam
quality & operating conditions are within the specified limits. However it was found that
the operating pressure is about 1 kg/cm2 lower than the pressure in Dec-2010.
Governor valve problem : The stem of the governor valve was found to be slightly bent
which was causing the jerky operations in the initial 15% of valve opening. The valve
plug , stem & cage were replaced with new spares. After the new governor valve
components were replaced the turbine was started and the findings were as below:-

The turbine started rolling at governor valve opening of about 6-8%. The speed became
1300 rpm and kept increasing. So the valve opening was reduced gradually from 8% to
2.4% . At 2.4 % the speed fluctuations observed are 720 - 860 rpm. The valve opening
was increased to 3.6 % and the speed fluctuations are found to be in the range 1050 -
1270 rpm. Then again the valve opening was made 4.8 %. Again the valve opening was
made 3.6% , the variation in speed was found to be 886 - 1270 rpm.
When put in IDLE mode the speed fluctuations were in excess of 320 rpm and the
turbine used to trip when the speed increases beyond 1760 rpm. Further data collection
revealed that there is cyclic speed increase even at a fixed governor opening.

At fixed governor valve opening of 3.6% the speed (in rpm) increase / decrease was
recorded as :
1073>1134>1240>1203>1282>1238>1314>1276>1345>1303>1387>1345>1441>1490 …

When the governor valve opening was made 0% still there was speed of @ 600rpm.

Due to the above behavior the governor valve internals were again removed for
inspection. The internal inspection showed a small scratch on the seat. As no new spare
was available it was jointly decided to install the same internals. The actuator was
installed and calibration was done. The off line tuning parameters were changed (made
low) and the turbine was started. The following observations were made during start-
up.

The turbine started rolling at governor valve opening of about 10.8 %. The speed
became 1300 rpm and kept increasing. So the valve opening was reduced gradually from
10.8 % to 8.6% . At 8.6 % the speed came down to 850 rpm. The turbine was put on IDLE
mode and kept under observation.

For initial rolling of the compressor 10.8% governor valve opening is found to be a better
setting. With changed off line tuning parameter setting and better governing valve
opening range the speed variation was found to be about 180 rpm. But after 3 hrs this
variation increased to 220 rpm.

Hand Nozzle Valves : As per the OEM’s documents all nozzle valves are to be kept close
at IDLE speed as the power requirement is low i.e. only 35KW. But when one of the
nozzle valves was closed the speed variations increased and tripped the turbine. The
nozzle valve conditions to be checked during next opportunity.(Since this is a
recommendation it’s better to mentioned again at the end to emphasis on it)

Steam traps: The existing steam traps were checked and found not working. To be
replaced with new ones. .(Since this is a recommendation it’s better to mentioned again
at the end to emphasis on it)

Turbine Internals: The turbine internal clearances and arrangements could contribute
to speed fluctuations which is inherent to a particular unit.

Governor Replacement:

During the start ups it was noticed that the MPU # 1 fail alarm is appearing on the
Governor and does not reset during start up. Two times due to spikes in speed signal
there were disturbances and tripping. So the governor was replaced with a new one and
configured and again the turbine was started. There is speed variation of about 240 rpm
and the turbine is in IDLE mode since 11.05.2011.

Final conclusion and status: With the changed reduced Off Line tuning parameter the
speed variation remains @230-240 rpm at IDLE speed for PT-210. Swapping from PT-209
to PT-210 was tried on 25.05.2011 and it was successful. Reverse swapping from PT-
210 to PT-209 is to be tried at available opportunity and if the swapping is successful
then the speed variations at IDLE speed are inherent to the turbine and associated
components. The turbine internal inspection and suitable repairs are to be carried out at
appropriate time. Till such time the existing tuning parameters should not be changed.