AUTOMATIC TURBINE TESTING SYSTEM

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AUTOMATIC TURBINE TESTING SYSTEM

INTRODUCTION

Under the present crunch of power crisis, the economy dictates long intervals between
turbine overhauls and less frequent shutdowns. This warrants testing of equipments
and protection devices at regular intervals, during normal operation.

The steam stop valves and control valves along with all the protective devices on the
turbine must be always maintained in serviceable condition for the safety and
reliability.

The stop and control valves can be tested manually from the location but this test
does not cover all components involved in a tripping. Also manual testing always
poses a risk of mal operation on the part of the operator, which might result in loss of
generation or damage to machine components.

These disadvantages are fully avoided with the conduct of automatic turbine test
facility. A fully automatic sequence for testing all the safety devices has been
incorporated which ensures that the testing does not cause any unintentional
shutdown and also provides full protection to turbine during testing. An automatic
turbine tester for safety devices of steam turbine should fulfill all above-mentioned
requirements and has been provided.

SALIENT FEATURES

The Automatic Turbine Tester is distinguishable by following features:

• Individual testing of each protective device and stop/control valve.

• Automatic functional pre-testing, upon selection of a test, of the substitute

devices that protect turbine during that test.

• Testing of the protective devices during normal turbine operation can only be
performed if the pretest has run without fault and protection of the turbine
during testing is assured.

• Monitoring of all programme steps for execution within a predefined time.

• Interruption if the running time of any programme step is exceeded or if trip is

initiated.

• Automatic reset of test programme after a fault.

• Protection of turbine during testing provided by special test protective devices.

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Automatic Turbine Testing extends into trip oil piping net work where total reduction
of trip oil pressure due to actuation of any protective device, is the criteria for the
satisfactory functioning of devices.

During testing general alarm of the case of tripping are also initiated so that this part
of alarm annunciation system also gets tested. Also, during testing, two electrically
formed values of 3300 rpm take over protection of turbine against over speed.

OPERATING INSTRUCTIONS

LAMP TEST: Before switching on the ATT, a lamp test should be performed to verify
that all lamps are operational.

SELECTION: Any of the subgroups may be switched on by simultaneous depressing

of the pushbutton “SGC ON/OFF” and “RELEASE” .As a result, the lamp
“AUTOMATIC ON” on the control coordinator tile will light up.

The subgroup remains ON until switched off when the program has been completed.
The individual subgroups are mutually interlocked, so that only one subgroup can be
in operation at a given time.

After the subgroup has been switched on, the protective device to be tested is selected
by depressing the selection push button for the individual device. The lamp
“SELECTION RELEASED” .The individual selections are mutually interlocked also so
that only one selection and subtest can be executed at a given time.

CANCEl: The selection can be cancelled by depressing the pushbutton “Automatic ON

/OFF pushbutton only. This pushbutton is used to terminate the test program at any
time and to initiate the reset program. The reset program has the priority over the test
program.

INDIVIDUAL TESTS: After a device is selected, the subgroup is started up by a

simultaneous depressing of the pushbuttons “RELEASE” and “TEST PROGRAM ON”.
If the initial conditions of the test are fulfilled, the lamp “TEST PROGRAM ON” will
light up. Otherwise the subtest will be blocked and the missing initial conditions be
indicated in code form on the criteria display.

The momentary status of the automatic test program will be indicated by means of
several open text displays.

The individual tests can be carried out only after completion of pretest & after the
hydraulic test circuit has been established. Successful completion of each test is
annunciated by the limit switches on the main trip valves , trip device tested ,pressure
switch in the auxiliary trip oil circuit between changeover & main trip valve.

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The function of the pretest is to detect any faults in the protection circuits to be used
during testing and if any are detected to inhibit testing of the protective device as this
would leave the turbine without protection.

INTERRUPTION IN AUTOMATIC TURBINE TESTING

Interruption due to running time exceeded:

• The reset program is automatically initiated if the running time for any step in
the test program is exceeded. If any running time is exceeded during the reset
program, the program is halted. In either case, the alarms fail signal and time
overrun are generated. If the fault in the ATT alarm is displayed, the fault lies in
the ATT itself.

Interruption due to turbine trip:

• If the electrical trip is initiated during testing, all solenoid valves are de-
energised and positioner is returned to its extreme position and the program is
cancelled. All equipment associated with the Automatic Turbine Tester is
automatically returned to its normal position.

SUB GROUPS OF ATT SYSTEM

The testing system of ATT is sub-divided in two functional sub-groups.

ATT

PROTECTIVE DEVICES STOP/CONTROL VALVES

Each sub-group contains the device & all associated transmission elements for
initiation of a trip.

AUTOMATIC TESTING FOR PROTECTIVE DEVICES

SCOPE OF TESTING

The automatic turbine tester (ATT) subgroup for the protective devices is divided into
the following five individual testing system:

PRELIMINARY TEST

1. Remote trip solenoid MAX52 AA001

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 2. Remote trip soleonid MAX52 AA002

3. Overspeed trips MAY10 AA001/MAY 10 AA002

4. Low vacuum trip MAG01 AA011

5. Thrust bearing trip MAY10 AA011

One or more systems can be selected for testing at the control panel and the selection
stored. The start of the test program automatically causes a pretest to be carried out
on the protective channels, which are to be effective during actual testing, and then
establishes the hydraulic test circuit. Once the first selected test has been completed
and the protective device has latched in again, the hydraulic circuit is restored to its
normal operational configuration. Further selected tests must be started individually
by pressing the Test pushbutton to start the test program.

GENERAL

During normal operation, the protective devices act via main trip valves MAX51 AA005
and MAX51 AA006 on the stop and control valves and extraction swing check valves.
The remote trip solenoids MAX52 AA001 and MAX52 AA002, overspeed trips MAY10
AA001 MAY10 AA002, low vacuum trip MAG01 AA011 and thrust bearing trip MAY10
AA011 actuate main trip valves MAX51 AA005 and MAX51 AA006 by opening the
auxiliary trip medium circuit. For the duration of testing of the protective devices, a
hydraulic test circuit is established. In order to keep the trip medium circuit effective,
it is isolated from main trip valves MAX51 AA005 and MAX51 AA006 by means of
changeover valve MAX51 AA211 and supplied with control medum via solenoid valves
MAX51 AA201 and MAX51 AA202 (control medium supply during testing).

TRIP INITIATION DURING TESTING

To provide normal protection for the turbine during testing any trip initiation signals
from the protective devices will de-energize the solenoid valves for control medium
supply during testing and at the same time initiate the reset program. This also
applies to all normal electrical remote trips such as generator protection, etc. For the
duration of testing, two electrical speed signals are formed to provide protection
against turbine overspeed. The electrical tripping action can also be initiated via the
associated limit switch if the thrust bering trip is genuinely actuated during testing,
except during testing of the thrust bearing trip itself.

During all electrical testing of the protective devics, actual trip is prevented however,
all annunciations are activated as for actual trip. The appropriate section of the alarm
annunciation system is thus also tested.

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FEATURES OF THE AUTOMATIC TURBINE TESTER

1. The automatic turbine tester is distinguished by the following features:

2. Individual testing of each protection device.

3. Automatic functional pretesting, upon selection of a test, the substitute devices

that protect the turbine during that test. Testing of the protective devices
during normal turbine operation can only be performed if the pretest has run
without fault and the protection of the turbine during testing is assured.

4. Monitoring of all program steps for execution within certain time.

5. Interruption of the running time of any program step is exceeded or if trip is

initiated.

6. Automatic reset of the testing program after fault.

7. Protection of the turbine during testing provided by special test protective

devices.

TEST PROCEDURE

The test begins with the selection of the Protective devices subgroup. This is
performed by pressing the subgroup ON/OFF pushbutton. The subgroup remains in
the ON position until switched off when the program has been completed. While the
protective devices subgroup program is running, the other subgroups are blocked.

The ON/OFF pushbutton is also used to acknowledge alarms.

SELECTION

After the subgroup has been switched on, the protective device to be tested is selected
by pressing the selection pushbutton for the individual device.

A separate selection pushbutton is provided to each protective decive. Only one

selection may be made at a time. Selection of a further test is possible only once all
other programs have ended.

TEST PUSHBUTTON

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The automatic test program is started by pressing the Test Pushbutton.

CANCEL PUSHBOTTON

This pushbotton can be used to terminate the test program running at any time and to
initiate the reset program. The reset program has priority over the test program.

LAMP TEST PUSHBOTTON

All the signal lamps on the control panel can be tested by pressing the Lamp Test
pushbotton.

INDIVIDUAL TESTS

The individual test can be performed only after completion of the pretest and after the
hydraulic test circuit has been established. Successful completion of each individual
test is annunciated by the limit switches on main trip valves MAX51 AA005 and
MAX51 AA006, pressure switch MAX52 CP211 in the auxiliary trip medium circuit
and pressure switch MAX51 CP209 in the trip medium circuit between changeover
valve MAX51 AA20. The associated limit switch also annunciates when a protective
device (except for the remote trip solenoids) has been activated. On completion of each
individual test, all activated protective devices are returned to their normal operating
position by reset solenoid valves MAX48 AA201 and MAX48 AA202 and the hydraulic
circuit is de-activated.

Wherever several of the same type of protective devices are provided, only one will be
described in the following as the test procedure is the same for all.

PRELIMINARY TEST

Pressing the Test pushbotton automatically initiates a test of the protective circuits to
be usd during testing, and, if any are detected, to inhibit testing of the protective
device, as this would leave the turbine without protection.

TEST SEQUENCE

In the course of the preliminary test, solenoid valves MAX51 AA201 and MAX51
AA202 (control medium supply during testing) are automatically tested before the
hydraulic test circuit is established. These valves (MAX51 AA201 and MAX51 AA202

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are first energized, resulting in a build-up of control medium upstream of changeover
valve MAX51 AA211. By initiation of the Schmitt triggers (in the speed measuring
unit), solenoid valve MAX51 AA211 is drained. Successful completion of testing is
annunciated by pressure switch MAX51 CP207 between solenoid valve MAX51 AA201
and changeover valve MAX51 AA211. Subsequently, solenoid valve MAX51 AA202 is
de-energized via the second channel of its Schmitt triggers thereby depressurising the
control medium still present between solenoid valves MAX51 AA201 and MAX 51
AA202. This process is monitored by a pressure switch MAX51 CP205. On successful
completion of the preliminary test, the hydraulic test circuit is automatically
established, which permits realistic testing of the protective devices without initiating
turbine trip.

Solenoid valves MAX51 AA201 and MAX51 AA202 (control medium supply during
testing) are again energized, whereupon control medium is supplied to changeover
valve MAX51 AA211. Then solenoid valve MAX61 AA201 is energized effecting
changeover from trip medium to control medium. The control medium in this line
drains off, and the pressure difference drives changeover valve MAX51 AA211 into its
test position (upper end position), thereby actuating limit switch MAX51 CG211C
which annunciates this status.

DE-ACTIVATING THE HYDRAULIC TEST CIRCUIT

The test circuit is de-activated in the reverse order on completion of the selected test
and after automatic latching-in of the protective device concerned in its normal
operating position.

HYDRAULIC TEST SIGNAL TRANSMITTERS

The function of the hydraulic test signal transmitters is to activate the protective
devices (with the exception of the remote trip solenoids).

Each protective device has an associated test signal transmitter. For testing the
overspeed trip device, the associated test signal transmitter builds up a test pressure
relatively slowly and press it to the overspeed trips' for testing the low vacuum trip an
air pressure signal is introduced to the device via an orifice; and for testing the thrust
bearing trip, a control medium signal is passed to the test piston.

The test signals to remote trip solenoids MAX52 AA001 turbine tester goes by itself
and not by a test signal transmitter.

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 1. Compression Spring
2. Coil
3. Valve Disc

FOR THRUST BEARING TRIP

I: Test Medium To Releasing Device
II: Drain Medium
III: Control Medium

FOR LOW VACUUM TRIP

I: Vacuum To Low Vacuum Trip
II: Vacuum From Condenser
III: Air At Atmospheric Pressure

HYDRAULIC TEST SIGNAL TRANSMITTER

MAIN TRIP VALVES

MAX51 AA005 and MAX51 AA006

Only one of the two main trip valves is described in the following, as they are
constructionally and functionally identical.

FUNCTION

The function of the main trip valve is to amplify and store the hydraulic or mechanical
(manually initiated local) trip signal. It must respond in the course of every successful
protective device test.

OPERATION

Each main trip valve is kept in its operating position by auxiliary trip medium
pressure. If a protective device is actuated, the auxiliary trip medium circuit is de-
pressurized and the main trip valve is activated. This connects the trip medium and
auxiliary trip medium circuits to drain and shuts off the control medium supply to the

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turbine valves. At the same time, limit switches 1 are actuated. Auxiliary start-up
medium pressure forces piston 3 into its normal operating position. Control medium

1: LIMIT SWITCH

2: SPRING

3: PISTON

4: BODY

I: TRIP MEDIUM

II: AUX. TRIP

MEDIUM

III: DRAIN MEDIUM

IV: CONTROL

MEDIUM

V: AUX. START-UP

MEDIUM

MAIN TRIP VALVE

IV is then free to pass through to build up the pressure in the trip medium and the
auxiliary trip medium circuits. Pressure switches MAX48 CP201 and MAX48 CP202
monitor the auxiliary start-up medium circuit to ensure that the pressure collapses
when the main trip valves latch-in nominal position.

REMOTE TRIP SOLENOIDS

MAX52 AA001 and MAX52 AA002

The twin electrical remote trip feature consists of the two solenoid valves MAX52
AA001 and MAX52 AA002. One trip channel is described here, as the test procedure is
the same for both.

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FUNCTION

The function of the remote trip solenoids is to depressurize the trip medium circuit in
the shortest possible time, thereby bringing main trip valves MAX51 AA005 and
MAX51 AA006 into their trip positions, in the event of a malfunction requiring
electrical trip initiation.

REMOTE TRIP SOLENOID

1. COMPRESSION SPRING

2. MAGNET SYSTEM

3. BODY

4. VENT HOLE

I: AUXILIARY TRIP FLUID

II: DRAIN MEDIUM

During normal operation the remote trip solenoid blocks the passage of auxiliary trip
medium to the drain. For testing, the solenoid valve is switched over by the automatic
turbine tester so that the auxiliary trip medium circuit is connected to drain. Trip
initiation is monitored downstream of the main trip valves by pressure switch MAX51
CP209 and MAX52 CP211 in the auxiliary trip medium circuit. In addition, the limit
switch of each main trip valve must annunciate successful completion of the test.

LATCHING-IN

On successful completion of testing, solenoid valves MAX52 AA001 and MAX52 AA002
are de-energized. The reset program is then started.

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OVER SPEED TRIPS

MAY10 AA01/MAY10 AA002

FUNCTION

The two overspeed trips are provided to protect the turbine against overspeeding in the
event of load coincident with failure of the speed governor. As they are particularly
important to the protection of the turbine, they can also be locally tested by hand
during turbine operation at rated speed with the aid of overspeed trip test device
(hydraulic test signal transmitter) MAX62 AA001.

OVER SPEED TRIP DEVICE

1. TURBINE SHAFT I: TEST OIL

2. ECCENTRIC SHAFT FLY BOLT II: AUXILIARY START-UP MEDIUM
3. COMPRESSION SPRING
III: AUXILIARY TRIP MEDIUM
4. PAWL
IV: DRAIN MEDIUM
5. PISTON
6. LIMIT SWITCH

OPERATION

When the preset overspeed is reached, the eccentric flybolt 2 each overspeed trip
activates piston 5 and limit switch annunciator 6 via pawl 4. This connects the
auxiliary trip medium circuit to drain thereby de-pressurising it. The loss of auxiliary
trip medium pressure causes the main trip valve to drop, which in turn causes the trip
medium pressure to collapse. To activate the overspeed trip at rated speed, as the test
routine performed by the automatic turbine tester requires, a specific force, equivalent

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to the increase in centrifugal force between rated speed and present trip overspeed, is
needed. For testing, this force is exterted by the test oil pressure, acting on the head of
bolt 2. On the bais of the existing defined geometry, the test oil pressure is a
reproduceible measure for the trip speed, and can therefore be used to check whether
the overspeed trip responds at the desired setting.

OVER SPEED TRIP DEVICE HTT

1. LIMIT SWITCH (NORMAL

POSITION
2. LIMIT SWITCH (TEST
POSITION)
3. VALVE FOR TEST OIL
4. ACTUATOR

I: CONTROL MEDIUM
II: TEST OIL
III: AUXILIARY TRIP MEDIUM
IV: AUXILIARY START-UP
MEDIUM
V: CONTROL OIL
VI: DRAIN OIL

TEST SEQUENCE

The test oil pressure is produced using the hydraulic test signal transmitter which is
also used for manual testing First the command is given to the actuator motor to go
into the trip position (down). After a cetain idling time, the test oil pressure builds up
to act on the two overspeed trip bolts 2.

If the two bolts are functioning correctly, they will fly outwards into the trip position
when the defined pressure is reached, thereby activating the main trip valve via pawl
4, slide valve 5 and the auxiliary trip medium circuit. The two overspeed trips are
monitored for actuation at the given test oil pressure by observing the two pressure
switches MAX62 CP211 and MAX62 CP212 in the test oil line, and the annunciation
from limit switch 6. Pressure switches MAX62 CP211 and MAX62 CP212 are preset to
respond at a certain level (approx. 0.15 atm) below and above the test oil reference
pressure respectively. This test reference oil pressure is determined empirically during

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commissioning and entered in the operating log. Limit siwtch 6 must respond within
the pressure range between the settings of pressure switches MAX62 CP211 and
MAX62 CP212. A slow build-up of pressure is required for this operation, which is why
a relatively long monitoring period, equivalent to the running time of the actuator, has
to be selected. Premature response of the overspeed trips is annunciated.

LATCHING-IN

Once the trip has been initiated, the actuator of the hydraulic test signal transmitter is
driven back until the integral limit switch annunciates that normal position has been
reached. In addition, monitoring must be continued until the test oil pressure at
pressure switch MAX62 CP213 is less than 0.1 atm.

This double check-back of the hydraulic test signal transmitter having returned to
normal position ensures that, after completion of testing, the overspeed at which the
turbine will trip is not reduced due to test oil pressure remaining effective and that the
overspeed trip will not be set off prematurely in the event of load reduction. While test
oil pressure is being dispersed, the two overspeed bolts spring back into their normal
positions at a pressure well above 0.5 atm.

Subsequently by, piston 5 is brought back into its nominal position by pressure of
auxiliary start-up medium II and latched in with pawl 4. At the same time, piston 5
shuts off drain channel IV, so auxiliary trip medium III can build up pressure. Once
this has been done, the auxiliary start-up medium can be depressurized.

LOW VACUUM TRIP MAG01 AA011

FUNCTION

The function of the low vacuum trip is to operate the main trip valve during normal
operation, if the vacuum in 4, the turbine condenser is too weak for condensation to
be properly effected.

OPERATION

In each trip device, compression spring 3, set to a specific tension, pushes downwards
against diaphragm 4, the top side of which is subject to the vacuum. If the vacuum is
too weak to counteract the spring tension, the spring moves valve 6 downwards. The
pressure beneath valve 7 is thereby dispersed and the auxiliary trip medium circuit is
connected to drain. The resultant depressurization of the auxiliary trip medium circuit
actuates main trip valves MAX51 AA005 and MAX51 AA006, thereby closing all
turbine valves.

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 LOW VACUUM TRIP DEVICE

1. ADJUSTING
PISTON
2. STEM
(ADJUSTABLE)
3. COMPRESSION
SPRING
4. DIAPHRAGM
5. LIMIT SWITCH
6. VALVE
7. VALVE

I. PRIMARY OIL
II. VACUUM
III. ATMOSPHERIC
PRESSURE
IV. AUXILIARY
TRIP MEDIUM
V. DRAIN MEDIUM
VI. CONTROL
MEDIUM

TEST SEQUENCE

First, test signaller (solenoid valve) MAG01 AA201, fitted in the vacuum carrying signal
line, is energized. This blocks off the vacuum line and simultaneously connects the
space above diaphragm 4 to the atmosphere, so that air is free to flow in via an orifice
(connection II) to weaken the vacuum. Compression spring 3 presses down valve 6 to
connect the auxiliary trip medium circuit to drain via valve 7 when the preset limit is
reached

The low vacuum trip is monitored for operation within the specified vacuum range by
observing pressure switches MAG01 CP202 and MAG01 CP201.

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LATCHING-IN

When test signal transmitter MAG01 AA201 has been de-energized and the connection
between low vacuum trip and the condenser re-established, vacuum builds up again
above diaphragm 4. Valve 6 moves into its upper end position, thereby opening the
passage for the control medium to flow to valve 7. When valve 7 is in its upper end
position, the auxiliary trip medium circuit is closed again. Restoration of normal
operating configuration is annunciated by the limit switch of the low vacuum trip and
by pressure switch MAG01 CP201.

THRUST BEARING TRIP MAY10 AA011

FUNCTION

The function of the thrust bearing trip is to monitor the shaft position in the bearing
pedestal and, if a fault occurs, to depressurize the auxiliary trip medium and thus the
trip medium circuit in the shortest possible time, thereby tripping the turbine.

OPERATION

The two rows of tripping cams 2 which are arranged on opposite sides of turbine shaft
1 have a specific clearance, equivalent to the permissible shaft displacement, relative
to pawl 3 of the thrust bearing trip. If the axial displacement of the shaft exceeds the
permissible limit, the cams engage pawl 3, which releases piston 6 to de-pressurize
the auxiliary trip medium circuit and at the same time to actuate limit switch 8.

TEST SEQUENCE

To test the thrust bearing trip, the associated hydraulic test signal transmitter MAX61
AA202 is energized. Test medium IV is then free to pass to test piston 4, which then
deflects pawl 3 against the force of spring 5. The combined force of the auxiliary trip
medium and of compression spring 7 drives piston 6 into its trip position. The
pressure of test medium IV is monitored by pressure switch MAX61 CP211.

LATCHING-IN

After the pressure of test medium IV has dropped again, the thrust bearing trip is
returned to its normal operating position by applying the pressure of start-up auxiliary
medium II to valve piston 6, thus moving the piston against the force of compression
spring 7. Thereby pawl 3 latches in and holds valve piston blocks off drain III. Once
this has been done, the auxiliary start-up medium is depressurized again.

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 THRUST BEARING TRIP DEVICE

1. SHAFT I: AUXILIARY TRIP MEDIUM

2. TRIPPING CAM II: AUXILIARY START-UP MEDIUM
3. PAWL III: DRAIN MEDIUM
4. TEST PISTON IV: TEST MEDIUM
5. TENSION SPRING
6. VALVE PISTON
7. COMPRESSION SPRING
8. LIMIT SWITCH

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RESET SOLENOIDS

MAX48 AA201 AND MAX48 AA 202

FUNCTION

The function of the reset solenoids is to restore the tripped protective devices to their
normal operating positions during the ATT reset program.

RESET SOLENOID

1. COMPRESSION SPRING
2. COIL
3. VALVE DISC

I: AUXILIARY START-UP MEDIUM

II: AUXILIARY START-UP MEDIUM
TO PROTECTIVE DEVICES
III: CONTROL MEDIUM

OPERATION

The reset solenoids are two 3-way solenoid valves (2 ports open at any time), fitted in
the auxiliary start-up medium line. Both solenoid valves are energized in the course of
the reset program conducted after each subtest, so that auxiliary start-up medium
line II is supplied with control medium III. The control medium pressure forces all
protective devices back into their normal operating positions, and the trip medium and
auxiliary trip medium pressure can build up again.

When the protective devices have latched in again, reset solenoid MAX48 AA201 is de-
energized first to shut off the control medium supply through this valve. Dispersion of
the auxiliary start-up medium pressure is monitored by pressure switch MAX48
CP201.

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The second reset solenoid MAX48 AA202 is then de-energized to disperse the pressure
between the two solenoid valves. This is monitored by pressure switch MAX48 CP202.
The use of two reset solenoids ensures that main trip valves MAX 51 AA005 and MAX
51 AA006 will always be sure to be actuated if either one of the two reset solenoids is
deenergized.

ATOMATIC TURBINE TESTER FOR STOP AND CONTROL VALVES

GENERAL

The stop valves and the control valves of the turbine are the final control elements
governed by the protective the final control elements governed by the protective
devices and it is therefore equally important that these, as well as the protective
devices, should function reliably. The testing of these valves in conjunction with
testing of the protective devices, ensures that all elements which must respond on
turbine trip are tested for their ability to function reliably.

Each stop valve is tested together with its associated control valve. The automatic
turbine tester is designed so that only one valve assembly may be selected and tested
at any time.

TEST REQUIREMENTS

To avoid turbine output changes and initial pressure variations due to the closing of
the tested control valve during testing, the electro-hydraulic turbine controller must be
in operation prior to testing. For the same reason, the closing time of the control
valves is relatively long. To enable initial pressure to be maintained constant, testing is
only permissible when the turbine output is below a certain value.

SPECIAL CONDITIONS DURING TESTING

During testing one of the control valves MAA10 to 40 AA002 or MAB10 to 40 AA002 is
closed completely by means of a motor-operated positioner - AA002M acting on relay
piston KA06 parallel to pilot valve KA05. This results in a closing movement
simulating that which occurs when the associated secondary pressure drops.

This constant slow closing movement is also necessary in order to enable the
associated controller to keep the output or initial pressure constant. Thus the
conditions for actuation of the valve are the same during testing as during normal
actuation by the controller.

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The stop valves, which are held in the open position by trip medium pressure during
normal operation, are subjected to exactly the same hydraulic conditions during
testing as would be the case in the event of actual turbine trip, as the action of the
protective devices is simulated by solenoid valve MAX61 AA211 to 214 or MAX61
AA221 to 224, respectively. The steam side conditions during testing are somewhat
more severe than during actual trip, as the pressure downstream of the stop valve
connot drop off during closure because the control valve is closed. This means that the
steam pressure acting against the spring closure force (steam lift) is greater than is the
event of normal trip.

The automatic turbine tester intervenes in the medium circuits normally used to
control the valves and uses only trip medium both for operation of test valves MAX47
AA011 to 014 and MAX47 AA021 to 024 and for resetting and opening of the stop
valves. Thus closure of the valves cannot be impeded in the event of a trip during
testing, regardless of the stage which the test has reached. This also applies to the
control valves, as the ATT does not interrupt the secondary medium circuit and the
secondary medium can thus be depressurized in the normal manner in the even of a
trip.

FEATURES OF THE AUTOMATIC TURBINE TESTER

• The automatic tester is distinguished by the following features:

• Individual testing of each valve assembly

• Monitoring of all program steps for execution within a certain time.

• Automatic reset of the testing program after a fault.

Protection of the turbine during testing provided by special test protective devices.

TEST SELECTION UNITS

There are 4 combined main stop and control valves and 4 combined reheat stop and
control valves, each of which is tested as a separate unit and has a separate selection
push button in the ATT control panel. They are:

• Selection 1: Main stop and control valve,

• Selection 2: Main stop and control valve,
• Selection 3: Main stop and control valve,
• Selection 4: Main stop and control valve,
• Selection 5: Reheat stop and control valve,
• Selection 6: Reheat stop and control valve,

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 • Selection 7: Reheat stop and control valve,
• Selection 8: Reheat stop and control valve,

TEST PROCEDURE:

START OF TESTING

The test begins with the selection of the valve test subgroup. This is performed by
pressing the subgroup ON/OFF pushbutton. The subgroup remains in the ON postion
until switched off when the program has been completed. While the valve test
subgroup program is running, the other subgroups are blocked.

The On/Off pushbutton is also used to acknowledge alarms.

SELECTION

If the test requirements have been fulfilled and the balve test subgroup switched on,
the valve assembly (e.g. main stop and control valve, to be tested is selected by
pressing the selection pushbutton for the individual valve assembly. A separate
selection pushbutton is provided for each valve assembly. Only one selection may be
made at a time. Selection of further test is possible only once all other programs have
ended.

TEST PUSHBUTTON

The automatic program is started by pressing the Test pushbutton of the valve test
program tile.

CANCEL PUSHBUTTON

All the signal lamps on the control panel can be tested by pressing the Lamp Test
pushbutton.

CLOSURE OF CONTROL VALVE

If all the test requirements have been fulfilled and the selection and Test pushbottons
pressed, control valve MAA10 to 40 AA002 or MAB10 to 40 AA002 of the valve
assembly selected is closed by means of its associated valve test positioner (test motor,
-AA002M). Operation of positioner -AA002M is continued until limit switches CG002C
on the control valve and -AA002 MS72 and -AA002 MS73 on the actuator are actuated
to annunciate, with a slight delay to achieve a ceratin overtravel, that the control valve
being tested is in closed position.

KORBA SIMULATOR 21
KORBA SIMULATOR
22
ATT OF STOP VALVE AND CONTROL VALVE
During this time, the controllers compensate for the effects of closure of the valve
being tested on the initial pressure or turbine output by opening the other control
valves.

The running time for closure of the control valve is monitored. If the control valve is
functioning properly, it will close within the pre-set running time.

CLOSURE OF STOP VALVE

If the control valve has closed properly, solenoid valve MAX61 AA211 to 214 or
MAX221 to 224 is energized. This allows trip medium to flow to the space below
changeover slide valve MAX61 AA011 to 014 or MAX61 AA021 to 024, which moves
into its upper end position and connects the space below piston disc KA02 with the
drain. The pressure in this space drops rapidly and is monitored by the pressure
switch MAX51 CP223 CP223, 228, 233, 238 or MAX51 CP248, 253, 258, respectively.
When the pressure at this pressure switch has dropped slightly below the break-away
pressure of piston disc KA02, monitoring of the stop valve closure time starts. Limit
switch - CG001E annunciated entry of the valve into its closed position, thus making
it possible to monitor the valve closing action for completion within the maximum
running time.

OPENING OF STOP VALVE

Next, solenoid valve MAX47 AA211 to 214 or MAX47 AA221 to 224 is energized (test
position) and trip medium is admitted to the control surface of the piston in test valve
MAX47 AA011 to 014 or MAX47 AA021 to 024. The piston moves into its lower end
position against the spring force, thus permitting trip medium to flow to the space
above piston KA01 of the stop valve. This piston is forced downwards by the pressure
of the medium, thereby tensioning the spring between piston KA01 is relatively low,
being equal to the spring force acting against it. The spontaneous pressure rise when
piston KA01 has made contact with piston disc KA02, and thus on completion of the
spring tensioning action, is detected by pressure switch MAX51 CP222, 227, 232, 237
or MAX51 CP242, 247, 252, 257. If all conditions are fulfilled within this relatively
long monitoring period, solenoid valve MAX61 AA211 to 214 or MAX61 AA221 to 224
is de-energized (operating position), so that trip medium is once again able to flow to
test valve MAX47 AA011 to 014 or MAX47 AA021 to 024 and the drain is blocked off
again. The build-up of trip medium pressure monitored by pressure switch MAX51
CP221, 226, 231, 236 or MAX51 CP241, 246, 251, 256.

When the pressure is sufficiently high, the stop valve is opened by de-energizing
solenoid valve MAX47 AA211 to 214 or MAX47 AA221 to 224 (operating position). Test
valve MAX47 AA011 to 014 and MAX47 AA021 to 024 switches over, admitting trip

KORBA SIMULATOR 23
medium to the underside of piston disc KA02 and, after a certain amount of further
travel, slowly connects the space above piston KA01 with the drain. The resultsant
pressure difference causes the tensioned piston relay to open the stop valve. As soon
as open position is reached, the full trip medium pressure builds up. This is
monitored by pressure switch MAX51 CP223, 228, 233, 238 or MAX51 CP243, 248,
253, 258 and by limit switch - CG001D. Testing of the stop valve is now completed.

RE-OPENING OF CONTROL VALVE

If the conditions are fulfilled within the specified monitoring period, the control valve is
re-opened. The motor of positioner--AA002M is operated in the opening direction.
Positioner -AA002M moves the control valve into its original position in the reverse
sequence to the closing action. Again the initial pressure and output are kept constant
by the appropriate controller. Operation of positioner -AA002M is continued until,
after a certain amount of overtravel, it has positively ceased to influence the controller.
This position is detected by limit switch -AA002 MS61 or -AA002 MS62. If the control
valve is functioning properly, it will open within the pre-set running time.

CANCELLATION OF SELECTION

On conclusion of testing of each valve assembly, the selection is automatically canelled

and the program shut down.

INTERRUPTION DUE TO RUNNING TIME EXCEEDED

The reset program is automatically initiated if the running time for any step is the test
program is exceeded. If any running time is exceeded during the reset program, the
program is halted. In either case, the alarms Fail signal and Time Overrun are
generated. If the Fault in ATT alarm is displayed, the fault lies in the automatic tester
itself.

INTERRUPTION DUE TO TURBINE TRIP

If electrical turbine trip is initiated during testing, all solonoid valves are de-energized
and positioner -AA002M is returned to its extreme position and the program cancelled.
All equipment associated with the automatic turbine tester is automatically returned
to its normal position.

KORBA SIMULATOR 24