BANTEN1×670MW POWER PLANT PROJECT

Turbine Over Speed Test Procedures

January 29, 2024

 Content

1. Purpose.........................................................................................................................2

2. Objective......................................................................................................................2

3. References....................................................................................................................2

4. Acceptance Criteria......................................................................................................2

5. Pretest requirements and special requirements for safety............................................2

6. Test Procedure..............................................................................................................3
 STG Over-speed Test
1. Purpose

This procedure defines the activities required for the successful demonstration that the steam
turbine has a fail safe electrical and mechanical over speed trip device, as required by normal
requirement after overhaul, and the electric over speed tripped value is consistent with setting
point 110% rated speed(3300rpm) (normally set) and the mechanical over speed tripped value
is nearly 112% rated speed(3360rpm).

Notes: For BANTEN1×670MW unit, in order to quickly connect the unit to the grid with load,
only one TSI electrical overspeed test will be conducted after this major overhaul. And the
target TSI overspeed setting will be 3050 rpm, this target speed is intended to verify the
overspeed loops are fully functional.

2. Objective

The test shall demonstrate that the steam turbine has a primary and backup over-speed trip
system. These systems shall be demonstrated with the turbine at a no-load condition.

3. References
System description and operating instruction supplied by steam turbine company (SDOI)

4. Acceptance Criteria

The test shall be considered satisfactory if, it can be demonstrated by actual test, that the
primary and backup over-speed trip system for the STG is fully functional. And the real action
is reach to the requirements as following:
 The electric over speed tripped value is consistent with setting point (temporary
setting for TSI is 3050rpm, DEH setting is still at 3300rpm)

5. Pretest requirements and special requirements for safety

To ensure the safety of unit startup and overspeed test, the following precautions need to be
taken
(1) At all times during the test, the Facility shall be operated base manufacture’s
requirements
(2) governor valve stroke test need to be down before steam turbine start up and
overspeed test.
(3) Steam turbine DC emergency lube oil pump need to test to demonstrate that the pump
can operation fully functional
 start the pump by emergency button at DCS control table
 start the pump at site control cabinet
  interlock test
 low lube oil pressure test by open the solenoid valve to trigger the lube oil pressure
switch.
(4) Steam turbine lifting oil pump need to test to demonstrate that the pump can operation
fully functional
 interlock test to demonstrate the pump can be started automatically during the steam
turbine coasting down process.
 interlock test to demonstrate the standby pump can be started when the header pressure is
lower or operation pump tripped.
(5) Parameters need to be monitoring kept in normal scope during steam start up and test
process which including:
 steam turbine-generator bearing temperature
 steam turbine thrust bearing temperature
 lube oil pressure
 steam turbine axial displacement
 total expansion of steam turbine-generator
 steam turbine differential expansion between rotor and cylinder
 shaft vibration and pedestal vibration
(6) Steam turbine water detector monitoring
In order to prevent water from entering the steam turbine during startup, the following
precautions need to be taken
 all the drain valves of main steam pipeline, reheat steam pipeline and steam extraction
pipeline need to be opened before start up
 confirm that the bottom and upper temperature differential is less than 42 ℃ for extraction
steam pipeline
 Confirm that steam turbine inner cylinder drains valves and out cylinder drain valves are
opened during steam turbine start up and test process.
(7) steam turbine HP-IP cylinder metal differential temperature between the upper and
bottom part should be always kept in normal scope which normally not bigger than 42℃
and it will be better control it at the scope of less than 30℃
(8) Due to the start up and overspeed process, steam turbine is operation with no load. So
only little steam enters into the steam turbine. In order to prevent the high exhaust
temperature of the high-pressure turbine blades and the low exhaust temperature of the
last stage blades of the low-pressure rotor caused by air blowing, it is necessary to ensure
that the high-pressure exhaust ventilation valve is in the open position before starting the
turbine, and at the same time, the low-pressure cylinder water spray cooling is in service.

6. Test Procedure
The steam turbine over-speed test is standard mandatory safety test that each and every steam
turbine manufacturer performs soon after the steam turbine is capable of spinning. The test
will be considered successful only after it is demonstrated that the steam turbine trips, and
returns to safe operating condition below the steam turbine manufacturer’s over-speed limits
specified in the steam turbine manufacturer’s over-speed test procedures.

6.1 Governor operation test

Time Measurement of Hydraulic Driven Valves
Test date Test time

Design travel Measured travel AST action to

Name of valve
(mm) (mm) Valve full closed time(s)
Main stop valve 1
(MSV 1)
Main stop valve 2
(MSV2)
Governing valve 1
(GV1)
Governing valve 2
(GV2)
Governing valve 3
(GV3)
Governing valve 4
(GV4)
Reheat stop valve 1
(RSV 1)
Reheat stop valve 2
(RSV 2)
Intercept control
valve 1
(IV1)
Intercept control
valve 2
(IV2)
Intercept control
valve 3
(IV3)
Intercept control
valve 4
(IV4)
6.2 Governor operation test
Calibration test of steam turbine control valve and governing valve
Test date Test time

Command of the valve

100
Name of the valve 0% 10% 20% 30% 40% 50% 60% 70% 80% 90%
%

Feedback of the valve

Main control valve 1

(MSV 1)
Main control valve 2
(MSV2)
Governing valve 1
(GV1)
Governing valve 2
(GV2)
Governing valve 3
(GV3)
Governing valve 4
(GV4)
Intercept control
valve 1
(IV1)
Intercept control
valve 2
(IV2)
Intercept control
valve 3
(IV3)
Intercept control
valve 4
(IV4)

6.3 Electric over speed

(1) Make sure that the turbine speed is keep in 3000rpm for steady

(2) Open RCM control panel and push electric over speed button and the
background color will be change to red which show that the over speed test control logic is in
service.
(3) Set target speed at 3060rpm, and set the speed increasing rate to 100rpm/min
(4) Start test
(5) When speed reach to 3050rpm and the AST solenoid valve action and turbine tripped.

6.2 Electric over speed record sheet

Record sheet for electric over speed

Test time:

Test date:

Turbine speed rate Real speed Target speed Trip speed

Item
(rpm/min) (rpm) (rpm) (rpm)
1 3050(TSI)
2
Over speed test curves(sample):

Speed(rpm)

Trip
3050RPM

3000RPM

start

Time