turbine overspeed trip protection -...

Charles R. (Charlie) Rutan is SeniorEngineering Advisor (Engineering Fellow),a position that is a shared resource withLyondell/Equistar, in Alvin, Texas. Hisexpertise is in the field of rotating equip-ment, hot tapping/plugging, and specialproblems. Mr. Rutan previously worked forthe chemical companies of Monsanto,Conoco, DuPont, Cain, and Occidental. Hehas two patents and consults worldwide onturbomachinery, hot tapping, and plugging

problems.Mr. Rutan received his B.S. degree (Mechanical Engineering,

1973) from Texas Tech University. He has published and/orpresented articles in Hydrocarbon Processing, ASME, AIChE,Pumping Systems, Vibration Institute, Houston Business RoundTable, Texas A&M’s Turbomachinery and International Pump User’sSymposia, Southern Power Machinery and Gas CompressionConference, and Predictive Maintenance Technology Conference.Mr. Rutan is a member of AIChE Process Gas Users Committee,Texas Tech Academy of Engineers, Hydraulic Institute/ANSI PumpStandards Review Committee, and is on the Advisory Committee ofthe Turbomachinery Symposium.

ABSTRACTThis paper discusses the design, history, current standards and

designs, and the relation between turbine overspeed and the timeconstant of rotors. Overspeeding of turbine rotors as it pertains totime lag of the overspeed devices and the amount of energy storedbetween the trip valve and the exhaust of the turbine is addressed.Also discussed are redundant “fail safe” designs that will givemaximum protection and reliability.

INTRODUCTIONIf the overspeed trip protection of a steam turbine fails to

function at the design set speed, turbine buckets or a section of awheel can break free of the rotor and, in a worst case scenario,penetrate the turbine casing. This can cause major damage to theturbine-driven equipment with a possibility of injuries and/or fatal-ities to individuals in the immediate area. There is also a very highprobability that an oil fire will occur.

STANDARDSSpecial-Purpose Steam Turbines for Petrochemical, Chemical,

and Gas Industry Services, API Standard 612 (1995), FourthEdition, June 1995, paragraph 2.6.1.2 states:

“Rotors shall be capable of safe operation at momentaryspeeds up to 127% of the rated operating speed at normaloperating temperature.”

Paragraph 4.3.3.2.3 states:“Overspeed trip devices shall be checked and adjusteduntil values within 1% of the nominal trip setting are

attained. Mechanical overspeed devices, when supplied,shall attain three consecutive nontrending trip values thatmeet this criterion.”

General-Purpose Steam Turbines for Refinery Service, APIStandard 611 (1988, Reaffirmed 1991), Third Edition, paragraph2.6.1.1, states:

“Rotors shall be capable of operating without damage atmomentary speeds up to 110% of trip speed. Thisstandard defines in paragraph 1.4.25 Trip speed (in rev-olutions per minute) is the speed at which theindependent emergency overspeed device operates toshut down the turbine. The trip speed setting will varywith the class of governor see (3.4.2.7), Parameter Tripspeed Class per NEMA SM 23 A is 115% of rated speedand for SM 23 B is 110% of rated speed.”

At the maximum of 127 percent of rated speed, all the rotorstresses will be approximately 56 percent above the normalstresses with a corresponding reduction in the safety factors. APIStandard 670 (2000) also addresses overspeed trip requirements.

International Standard (ISO/DIS) 10437 (1993) for petroleum andnatural gas industries—special-purpose steam turbines is slightlydifferent from the API Standard 612 (1995) referenced above.Paragraph 12.3.1.1 of 12.3 overspeed shutdown systems states:

“A dedicated overspeed shutdown system shall beprovided capable of independently shutting down theturbine. This system shall not be dependent on thegoverning system or any other system. The system shallprevent the turbine rotor speed from exceeding 127% of therated speed on an instantaneous, complete loss of coupledinertia and load while opening at the rated condition. In theevent of loss of load without loss of coupled inertia thesystems shall prevent the speed from exceeding 120% ofthe rated speed unless otherwise specified by the drivenequipment vendor. The turbine vendor shall have unitresponsibility for the overspeed shutdown system.”

Additionally, paragraph 12.3.1.2 states:“The overspeed system shall include but not limited tothe following:a) electronic overspeed detection system (speed sensorsand logic devices), API 670;b) electro-hydraulic solenoid valves;c) emergency trip valve(s)/combined trip throttlevalve(s).”

OVERSPEEDIf you have a car with a tachometer, you know what the red line

value is. Every piece of rotating equipment has a red line value.The red line value is the maximum rpm (revolutions per minute)that the engine, turbine, or compressor should not be operatedabove. If the piece of rotating equipment is run above this limit,damage to the internal components will occur.

An overspeed trip shuts off the steam flow to the turbine, whichcauses the turbine rotor to decelerate.

109

TURBINE OVERSPEED TRIP PROTECTION

byCharles R. Rutan

Senior Engineering AdvisorLyondell/Equistar Chemicals, LP

Alvin, Texas

ELECTRONIC TRIP SYSTEMAPI recommends two speed sensors where:

• “A” or “B” trip signal is seen, then the turbine trips.

• “A” or “B” loss of signal or power, an alarm is given but theturbine remains running.

• “A” and “B” loss of signal or power, the turbine trips.Figure 1 is the simplest system that can be used for a “special

purpose steam turbine.” This system is adequate if the loss of theturbine and the equipment driven by the turbine does not result ina significant upset and/or pose a safety hazard and/or damage theenvironment. If a turbine is determined to be in a critical service, afault tolerant overspeed trip system should be utilized. In this casea minimum of three speed sensors is required where:

• Any combination of two trip signals will result in a turbine trip,i.e., “A” and “B,” “B” and “C,” or “A” and “C.”

• The loss of power signal or power of any one of the speedsensors will result in an alarm.

• The loss of power or signal of any two of the speed sensors willresult in a turbine trip.(Note: This is for a de-energized to trip configuration as preferredby API.)

Figure 1. Overspeed Shutdown System.

Figure 2 is an example of the minimum electronic governorsystem for a general-purpose steam turbine.

Figure 2. Example of Minimum Electronic Governor System forGeneral-Purpose Steam Turbine.

Since the speed sensors are critical to the operation of theturbine, at least one spare speed sensor is normally installed. If anelectronic fault tolerant governor is used, then three additionalspeed sensors and one spare are installed. A separate speed sensoris installed for the vibration monitoring system. All the speedsensors are reading one multitooth “speed pickup wheel” that isbeing held in position by a nonferrous mounting bracket (Figures3 and 4). In addition to the speed sensors, two radial vibrationprobes, two thrust (axial position probes), thrust bearing tempera-ture indicators, and radial bearing temperature indicators arenormally installed. As is readily apparent to the most casualobserver, the thrust end of the turbine is now taking on the appear-ance of the Starship Enterprise.

Figure 3. Speed Pickup and Sensor Mounting Bracket.

Figure 4. Top Half of Bracket with Sensors Installed.

MECHANICAL TRIP SYSTEMInside a mechanical overspeed trip mechanism there are four

basic components. The internal components consist of two bushings,a plunger, and a spring as shown in Figures 5, 6, 7, 8, and 9.

One of the bushings is screwed completely into the overspeedtrip body at a set depth. This controls the position when the turbineis not rotating. Then a bushing is installed over the plunger andspring, and then tightened down. The spring pushes against theplunger “stopper disk” and the adjustable bushing where theplunger extrudes from the body (Figure 5). Now the spring is incompression holding the plunger inside the mechanism body. Theoverspeed trip is then attached, typically bolted, to the outboardend of the rotor.

As the speed of the rotor increases, centrifugal force pulls theplunger to the outside, against the spring. As the rotor speedincreases, the force from the plunger increases on the spring. Once

PROCEEDINGS OF THE THIRTY-SECOND TURBOMACHINERY SYMPOSIUM • 2003110

Figure 5. Mechanical Overspeed Trip Mechanism (Side View).

Figure 6. Mechanical Overspeed Mechanism Installed in TurbineRotor.

Figure 7. Mechanical Overspeed Mechanism.

Figure 8. Mechanical Overspeed Mechanism Disassembled.

Figure 9. Mechanical Overspeed Trip Mechanism (End View).

the centrifugal force increases from the speed, rpm, the plungerovercomes the spring force causing the plunger to protrudeoutward.

A stationary lever, set with a relatively tight clearance, is posi-tioned such that when the plunger moves out, the lever is struck.The lever is integral with the emergency mechanical trip device.When the mechanical trip is actuated, the hydraulic oil is dumpedto the drain, which results in the immediate closing of the valverack and trip valve.

The overspeed trip device is critical to the safety of the turbine.Without the overspeed protection, the turbine would run to destruc-tion when the load (compressor, pump, or generator) was lost.

How fast the turbine accelerates determines how fast theoverspeed trip system must respond (refer to Figure 10). If theturbine valves change their position instantaneously, this measure-ment of time is now as the time constant, TC. The speed is a firstorder function of torque, and then the mathematical equation is:

(1)

where:n = Per unit change, speedε = 2.71828t = Time, secondsTC = Time constant, secondsFrom Equation (1), when t = TC, then n = 1 2 1/ε or n = 0.63.

Figure 10. Overspeed Trip System.

TURBINE OVERSPEED TRIP PROTECTION 111

n t TC= − −ε /

Then, the rotor time constant gives the length of time that ittakes the rotor to reach 63 percent of its total speed change due toan instantaneous change in the turbine valve position.

The rate of change at the instant the inlet valve’s positionchanges are found by differentiating Equation (1) and setting thetime to zero. The result is:

(2)

From Equation (2), dn = 1.0 when dt = TC, which leads to asecond definition of the rotor time constant. The rotor timeconstant gives the length of time it would take the rotor to reach100 percent of its total speed change due to an instantaneouschange in turbine valve position if it continued to change speed atits initial rate.

Making the instantaneous valve opening correspond to the fullload change can make the above definition clearer. Thus, the defi-nition is changed to: the rotor time constant gives the length oftime it would take the rotor to reach twice the speed due to a 100percent instantaneous drop in turbine load, provided the rotorcontinued to change speed at its initial rate.

This definition is used to generally determine what wouldhappen in a very short period of time between the loss of the loadand the activation of the emergency trip device. It is assumed thatthe steam flow has not been changed and that all relationships arelinear. Then for an instantaneous change in load and for very smallvalues of time:

(3)

where:t = Time, secondsn = Speed change in time “t,” percentTC = Rotor time constant, secondsL = Instantaneous load change, percent

From Equation (3) it is seen that the rotor TC/10 seconds tochange speed 10 percent if there is an instantaneous 100 percentchange in the load. This is a significant speed change in a shortperiod of time. Thus, extremely fast speed controls and emergencyoverspeed tripping systems are required to limit the speed rise to areasonable value when an instantaneous loss of load occurs.

ROTOR TIME CONSTANTSThe fundamental measure of rotor response is the rotor time

constant. From the equation for horsepower, the rotor time constantcan be calculated by substituting the speed and time for accelera-tion. The rotor time constant is:

(4)

where:TC = Rotor time constant, secondsN = Rated speed, rpmWR2 = Rotor inertia, lbs-ft2HP = Rated horsepower

The only factor in Equation (4) that depends on the rotor designof the turbine is the rotor inertia. It, the rotor inertia, cannot be cal-culated until the design of the turbine is complete. For mechanicaldrive turbines the rotor inertia varies considerably, but typicallyhas an inverse relationship with the speed. The turbine rotor timeconstant, TC, normally lies within a range of two seconds to eightseconds. There are rotors with a rotor response as quick as 0.5seconds and some as long as 10 seconds.

The speed of the steam inlet valve(s), trip valve(s), solenoidvalve(s), electronic and/or hydraulic controls or relays, and the rateof change of the load are measured relative to the rotor responsetime. The understanding of the total system response is critical.Any change that requires more than 1/10 of the rotor response timeconstant should be considered too slow. It is apparent that theslower the rotor response time and the load change coupled with afast steam control(s) system is very desirable.

LOSS OF LOADLoss of the load, prior to this, has been considered instanta-

neous. This means that the loss of the load took zero time. Themaximum speed change of the turbine rotor is the result of aninstantaneous loss of load. Thus, what is the difference between theturbine rotor speed response to an instantaneous loss of load asopposed to a sudden loss of load?

In 0.05 seconds or less, a couple of cycles, a turbine driving anelectrical generator can lose full load. This is the type of situationwhere the loss of load must be considered instantaneous. The pro-tection system(s) should then be designed accordingly. Oneadvantage to this situation is that the loss of load can occur withoutthe failure of the coupling(s) between the turbine and the generatorand, in some installations, the gearbox. In this situation the timeconstant would include the turbine rotor and the generator rotor,WR2. The increase in the overall system rotor time constant willreduce the probability of an overspeed.

Mechanical drive steam turbines, turbines that drive compres-sor(s), pumps, fans, blowers, etc., are entirely different. There arefour ways a sudden loss of load can occur.

• A throttling of the suction, but in this case there would only bea partial load reduction. Surging a compressor or breaking suctionof a pump may still require as much as 30 percent of the full load.The time required to throttle the inlet would require a minimum ofone second to two seconds. This would only be a problem withvery slow 10 second turbines.

• A coupling failure, which is rare in this day and age. There are nodata on the time; however, in analysis of a few coupling failures, thecomplete failure would take one second to two seconds.

• A loss of load due to a process upset takes seconds to be accom-plished. In most cases of a process upset, the loss of load is onlypartial. This again gives the system time to respond.

• A catastrophic failure of the discharge piping in close proximityof the driven equipment.

It is apparent, from the discussion above, that a required re-sponse time of the overspeed trip protection system of one secondis sufficient as a result of a 100 percent sudden loss of load. Again,the response time constant must include the WR2 for all the rotorsof that drive train.

TIME LAG AND STORED ENERGYDuring an overspeed situation, there are two reasons the speed

of the rotor will increase above the 110 percent of maximum con-tinuous speed or high-speed stop. The first is the time lag in themechanism that closes the steam inlet valves and/or the stop valve.And the second is the steam energy stored in the turbine, nozzlebox, valve chest, and piping located between the stop valve and thesteam chest of the turbine.

By equating the stored energy of the steam to the change in thekinetic energy of the turbine rotor, the change in the rotor speedcan be determined mathematically. Equation (5) shows themaximum speed the turbine rotor can reach above the trip speeddue to the stored energy. Equation (5) is based on the assumptionthat the turbine has an efficiency of 60 percent at the design ratedload and steam conditions as the stored energy is used.

(5)


dndt TC

=

( )

( )

∆

∆

n L t T

or

t n L T

C

C

=

=

( ) ( )T N WR HPC = 2 2

( ) ( )( ) ( )N N BTU WR Nf t t2 2 2= +

where:Nf = Maximum speedNt = Trip speed, rpmBTU = Total stored energyWR2 = Rotor inertia, lbs-ft

The amount of stored energy in the steam chest, nozzle box, andthe turbine case downstream of the nozzle box is extremelydifficult to quantify. In an effort to make things a bit easier,Equation (5) can be reduced to address the stored energy in thepiping between the trip throttle valve and the steam chest. Thus,the feet of inlet piping (P) between the trip throttle valve and steamchest required to reach an overspeed can be calculated.

(6)

where:P = Length of inlet piping between trip throttle valve and turbine

steam chest, feetTC = Turbine rotor time constant, secondsV = Steam velocity in inlet piping, ft/sec

With a steam inlet velocity of 150 ft/sec and a 1/2 second timeconstant, the length of pipe required to overspeed the turbine froma trip speed of 110 percent of the rated speed to a maximum speedof 115 percent of the rated speed would be 7.125 feet of equivalentpipe.

If the actual overspeed trip of the rotor exceeds the API marginof error, then action should be taken to address the time lag and/orthe stored energy. The time lag due to slow response of the systemcan be remedied by the replacement of slow valves with fastervalves and/or increasing the hydraulic pressure in the control oilsystem. True stored energy can be addressed by lowering the tripspeed set point of the overspeed protection mechanical or electri-cal. This, however, can present a problem. If the true trip speed isabove the desired trip speed due to very rapid acceleration of theturbine rotor but the actual trip speed is within the design parame-ters at a slow acceleration from the governor high speed stop, thenearly trips may be experienced. Although the machine is ade-quately protected, the early trip may become a problem to thereliability of the process. This situation can be seen if the WR2 ofthe equipment train is very low. An example of this would bewhere a turbine is driving a single compressor, the turbine has 15percent excess power, and the molecular weight of the gas beingcompressed is low. A simple electronic system is shown in Figure11, and a dual electronic system is shown in Figure 12.

Figure 11. Simple Electronic System.

Figure 12. Dual Electronic System.

TESTINGA steam turbine solo is the testing of the turbine with the turbine

uncoupled from the machine train. The soloing of the turbine isrequired to:

• Determine the actual critical speed

• Define minimum governor set point (low speed stop)

• Determine maximum governor set point (high speed stop)

• Test the emergency trip systemsIncluded in the testing of the emergency test systems is the

testing of the overspeed trip set point(s). As long as the governorfunctions properly, the operation of running up to the overspeedset point(s) is a conscious decision of the individuals involved inthe testing. The highest exposure to a potentially dangeroussituation for the individuals and equipment involved is at thispoint in time.

Every company that the author has been associated with,directly or as a nonpaid consultant, has had a written overspeed triptest procedure for turbines. In most cases, the procedure isfollowed to the letter when testing the large and/or critical turbines.Typically these procedures define responsibilities, frequency,exceptions, maintenance activities, safety requirements, and proce-dures. In the past few years, in addition to the written procedure, agraphical outline of the procedure for each individual steamturbine was developed and provided to all the individuals involvedin the overspeed trip testing (Figure 13). This has minimized anyconfusion or misunderstanding.

During the research for this paper, it was found that the run to anoverspeed failure of a large/critical steam turbine was rare. It isbelieved that this is a result of the amount of attention to thedetailed procedures is at its highest. These situations are typicallyon new installations or after an overhaul where sensitivity is at itshighest. With the use of electronic overspeed trip protection andthe upfront testing of the emergency trip system, the overspeedtesting as it relates to speed should be a nonevent. Problems withhigh vibration due to rotor bows and rubs, unbalance, damagedbearings, and improperly installed bearings, etc., are outside thescope of this paper.

The preliminary steps to validate the safety protection systemsfunction prior to the physical testing of the turbine overspeed are:


P T VC=

Figure 13. Graphical Outline of a Steam Turbine.

• Signal generator is used to test the overspeed set points, if anelectronic governor is used and/or an independent electronicoverspeed protection system is used.

• Oil trips.

• Emergency trips, mechanical, electronic, and manual, on theturbine platform and in the control room.

• When possible the mechanical overspeed plunger assemblyshould be removed from the turbine rotor and tested in a spin pit ifthe mechanical trip is to provide primary or secondary overspeedprotection.

After all the initial checks are made, the turbine rotor can bebrought up to a slow roll state, typically between 100 rpm and 1000rpm. The slow roll speed varies based on the design of the turbine.Once the turbine is up to the temperature desired, the oil tripsshould be tested again in addition to all the emergency trips beforeramping up the turbine speed. Functionality of the trip devicesshould also be checked at this time.

The next step is to validate or set the minimum governor speedand the maximum (high speed stop) governor speed. This step canbe quite difficult when the governor is a mechanical/hydraulicsystem.

It is now time to test the overspeed trip protection system inearnest. The electronic protection systems are the easiest tovalidate. The set points should have already been verified. Thus,the testing is, or is hoped to be, a formality.

The hybrid overspeed trip system consisting of mechanical/elec-tronic devices is the next easiest. The electronic overspeed trip setpoint must be set below the mechanical overspeed trip assembly. Ifthe electronic overspeed trip point is set above the mechanical setpoint, then the only way to test the set point is with a signalgenerator, because it should be impossible to run past the mechan-ical set point. This is true if the mechanical set point is set properlyand the assembly functions as designed.

The mechanical overspeed trip assembly is not very high tech.These systems use a bushing, adjustment nut, plunger, andspring arrangement. As the spring is compressed, the force toovercome the spring force is increased as the force to overcomethe spring force is reduced. The weight of the plunger, springforce, speed, and the distance from the plunger to the trip leverdefines the trip speed. Since the desired trip speed, the weight ofthe plunger, and the distance the plunger must travel to strike thetrip lever are fixed, the only adjustment that can be made is thespring force. Adding or removing shims, or repositioning thespring compression adjustment nut, changes the trip speed. Theonly way to change the trip speed is to shutdown the turbine tomake the mechanical adjustments. Multiple runups are notunusual. This is time consuming and introduces a potential forhuman or mechanical error. The author has experienced many

problems over the years with the setting of mechanicalgovernors, to list a few:

• Trip plunger improperly machined, a phonograph finish on thebore of the plunger guide bushing

• The end of the plunger was flared out preventing the trip plungerfrom moving. This was the result of a millwright physicallypushing on the end of the plunger with a center punch of drift.

• The plunger and guide bushing had a buildup of varnish.

• The installed spring was too strong.

• The installed spring was too weak from either an old spring thathad lost some of its force or a spring with too low a springconstant.

• The millwright turned the adjustment nut in the wrong direction.If everything is perfect, then a mechanical/hydraulic system will

protect the turbine from self-destruction when an instantaneous ora sudden loss of load is experienced.

A comparison of a mechanical overspeed trip system versus anelectronic trip system is shown in Table 1.

Table 1. Comparison of Mechanical Overspeed Trip System VersusElectronic Overspeed Trip System.

INCIDENTSIncident 1

A 22 Megawatt, 3600 rpm unit oversped to at least 5400 rpm asa result of the disk and bolt, from an upstream extraction nonreturnvalve, became loose and moved into a position that resulted in thenonreturn valve sticking open (Figures 14, 15, and 16).

Figure 14. Generator.


Figure 15. LP Turbine End to Generator.

Figure 16. Turbine Rotor (Incident 1).

Incident 2An incident showing a turbine driving a generator with an

instantaneous loss of load is shown in Figures 17, 18, 19, and 20.

Figure 17. Turbine Rotor (Incident 2).

Incident 3On 02/24/01, a condensing steam turbine driving a blower in a

steel plant went past the overspeed set point. One individual waskilled and another individual was injured. The turbine developedabout 8500 hp and was designed to run at 4100 rpm with theoverspeed trip set at 4500 rpm. The first overspeed trip test was suc-cessful. On the retest, the highest logged speed was 4988 rpm, buteyewitness accounts say the reed tachometer showed 5300 rpm.

Incident 4A catastrophic failure of a 300 hp, 3600 rpm, boiler feed water

pump drive turbine occurred on 05/30/00. The turbine disin-tegrated due to overspeed following a coupling failure and a

Figure 18. Turbine Generator Bay (A, Incident 2).

Figure 19. Turbine Generator Bay (B, Incident 2).

Figure 20. Turbine Generator Bay (C, Incident 2).

governor oil pump shaft failure. The overspeed trip valve closed,but not fast enough to prevent a very severe overspeed. No one wasinjured during this event.

Incident 5On 01/01/98, a condensing steam turbine driving a water pump

in the United Kingdom failed during an overspeed trip test. Theturbine was rated for 600 hp at 4643 rpm, with a steam inletpressure of 40 psig. Two reed tachometers were used to measurethe turbine speed, and the first trip test was successfully completedat 5400 rpm. On the second test, the operator reported the reedtachometer reading was 4900 rpm and heard the trip mechanismstart to “clatter” as the turbine disintegrated. The operator at thetrip throttle valve died on the way to the hospital from the injuriessustained; two other employees received severe injuries requiringmultiple surgeries. Debris from the turbine was scattered over awide radius, and adjacent equipment was damaged. Calculationsshow that the blades should not have been overstressed and thrownbelow 8000 rpm. The incident investigation concluded that theremay have been a misinterpretation of the turbine speed on the reedtachometer, the overspeed trip mechanism malfunctioned, andexcessive steam flow was available for the test.


Incident 6An operator, about 15 years ago, was putting a steam turbine

driven refrigeration compressor online, and he was reading thespeed with a reed tachometer setting on the auxiliary oil pumpturbine, which was normally off. The lube oil pump was runningbecause the shaft driven governor oil pump had failed. The lube oilturbine ran at 3600 rpm and the main turbine was designed to runat 3800 rpm. The operator kept giving the main turbine more steambecause he believed the turbine would not speed up past 3600 rpm.Calculations showed that the compressor impellers actually flewapart at 5400 rpm. Pieces of the compressor were thrown through-out the building barely missing the operator. The overspeed tripvalve should have prevented the turbine from overspeeding, butthe valve was stuck open from steam deposits.

INSURANCE DATABASEA commercial insurance company (Clark, 2002) has been main-

taining a database concerning overspeed failures. The databasecaptures, when possible, the:

• Year of the incident

• Size of the turbine

• Driven object

• Why the governor failed to control the speed

• Why the overspeed trip failed

• Other factors/informationThis is an excellent database; however, it is not totally accurate.

The database input information is based on information suppliedby companies that are insured by this company and individualinput. If the overspeed incident does not result in major damageand/or personnel injuries, the incident may not be reported. (Referto APPENDIX A for a sample incident table.)

CONCLUSIONA safe, reliable, fast-acting overspeed trip protection system is

required. The system will be tested initially while the turbine isdown and then again, at speed, with the turbine uncoupled from itsload. When the solo testing is performed, the level of risk to thepersonnel and equipment is at its greatest. The designer must takeinto consideration the instantaneous loss of load while the turbineis in operation. However, the entire protection system—electrical,mechanical, and hydraulic components—must perform flawlessly.Human errors can and must be minimized through training andpractice, but they can never be eliminated. Every turbine must betreated as the most critical and dangerous piece of equipment in theplant.


APPENDIX ATable A-1. Steam Turbine Overspeed Incidents—Contributing Factors (05/02/97)—#1 through #20.


INCIDENTNUMBER

YEAR SIZE DRIVENOBJECT

WHY GOVERNOR FAILED TOCONTROL SPEED

WHY OVERSPEED TRIPFAILED

OTHER FACTORS / INFORMATION

1 >5000 hp T/T Valve Stuck Occurred during normal operation; exactdetails not known.

2 <5000 hp T/T Valve Stuck Occurred during normal operation; exactdetails not known.

3 <5000 hp T/T Valve Not Operational Occurred during uncoupled overspeed triptest. One fatality. Turbine destroyed.

4 1987 >5000 hp Cent.Compressor

Retrofitted electronic governorimproperly configured. System inmanual; system ignoredoverspeed signal.

T/T Valve assembled improperlycausing it to not close fast enoughto prevent overspeed. Valve wasclosed after accident; probablyclosed due to severe vibrationduring accident.

Coupling installed incorrectly duringturnaround. During process upset,coupling spun on shaft which unloadedturbine. Turbine oversped to completedestruction; case could not be repaired.

5 1995 >5000 hp Cent.Compressor

T/T Valve stuck; improperlyadjusted

Coupling broke causing turbine to unload.Coupling improperly installed. Rotorcould not be repaired; case was repaired.

6 1987 >5000 hp Generator Probably stuck due to steamdeposits.

Probably stuck due to steamdeposits.

Details not available, but steam qualitywas a primary factor. Turbine andgenerator oversped to completedestruction.

7 1987 >5000 hp Details not available.8 1986 >5000 hp Compressor Valve stuck due to boiler

carryover deposits.Valve stuck due to boiler carryoverdeposits.

Extreme boiler carryover.

9 1960s <5000 hp Recip. Cmpr. Direct mechanical type governor;reason governor did not controlspeed not known.

Either stuck open due to steamdeposits or failed to close fastenough. Butterfly type valve.

Gearbox between turbine and compressorfailed which unloaded turbine. Turbinecentrifugally exploded; totally destroyedwith damage to surrounding building andobjects.

10 1976 <5000 hp Fan Governor was oil pressure toclose type. Lost oil, so governorwent wide open.

Stuck due to steam deposits. Nipple on gearbox oil drain line brokedue to fatigue. Without oil, gearboxfailed which unloaded turbine. Gearboxoil also supplied governor system.Turbine centrifugally exploded; largesections of case thrown some distance.Total loss.

11 1995 <5000 hp Fan Governor out of service duringuncoupled trip test.

Probably, trip setpoint set too high. Turbine oversped during uncoupledoverspeed trip test.

12 1988 <5000 hp Fan Probably steam quality and maintenancerelated.

13 1970sor1980s

<5000 hp BFW Pump Pump was in service - may have rotatedbackwards after turbine tripped due tostuck check valve. Turbine disintegrated.

14 1980s >5000 hp Cent.Compressor

Unknown Valve stuck, probably steamdeposits.

Oversped during uncoupled trip test.Stopped turbine by manually trippinggovernor valve; should have closedautomatically, but did not.

15 1985 <5000 hp Cent. Pump Steam was off to turbine; turbinedriven by pump.

Steam was off to turbine, turbinewas driven by pump.

Due to pump check valve sticking open,turbine oversped in reverse rotation.Turbine damaged, but all componentsstayed in the case.

16 1985 <5000 hp Cent. Pump Steam was off to turbine, drivenby pump.

Steam was off to turbine, turbinewas driven by pump.

Due to check valve sticking open, turbineoversped in reverse rotation. Sameturbine as above. This time, turbinecentrifugally exploded; turbine destroyed.

17 1996 >5000 hp Generator Design of governor system wassuch that governor did not closewhen overspeed trip signal wasreceived or when emergency stopbutton was actuated. Duringincident, governor sensed fallingspeed and opened governor valve100%

Trip valve hung open; probablysteam deposits. Prior to theaccident, the governor valve hadbeen sticking due to steam deposits,and a spare valve was scheduled tobe installed during next outage.

Operator was shutting down turbinegenerator. He decreased load ongenerator, then hit emergency trip buttonwhich disconnected load. Trip valve didnot close. Governor valve was wideopen. Turbine oversped. Excitercentrifugally exploded.

18 >5000 hp Cent. Cmpr. Hydraulic relay in speed sensing /trip system stuck preventingclosing of trip valve.

19 >5000 hp Cent. Cmpr. Hydraulic relay in speed sensing /trip system stuck preventingclosing of trip valve.

Same plant as above accident; stuck relaywas not diagnosed in first incident, so itcaused another accident.

20 >5000 hp Insulation sagged enough to interfere withthe movement of the weighted arm on anextraction line check valve. When turbinetripped and check valve did not close,turbine oversped by backflowingextraction steam.

Table A-2. Steam Turbine Overspeed Incidents—Contributing Factors (05/02/97)—#21 through #34.


INCIDENTNUMBER

YEAR SIZE DRIVENOBJECT

WHY GOVERNOR FAILED TOCONTROL SPEED

WHY OVERSPEED TRIPFAILED

OTHER FACTORS / INFORMATION

21 <5000 hp Governor out of service duringuncoupled trip test.

OEM trip throttle valve linkagewas so "flimsy" it could berelatively easily distorted enoughthat valve would not trip. Afteraccident, replaced T/T valve onfive machines with similar linkage.

Turbine oversped to destruction.

23 1950 to1996

Turbine oversped during uncoupled orlow load test of the overspeed trip system.All of the following are from Ed Nelson’spaper.

24 >5000 hp Generator Governor and/or extraction valvestuck due to poor steam quality.

Trip valve stem stuck due to poorsteam quality. During accidentinvestigation, trip valve stem couldnot be moved with a 25 ton jackplus oil and sledge hammer.

Also human error. Operator could notdecrease generator load below 10% due tosticking governor valve, but hedisconnected the load anyway. Shouldhave shutdown machine by closing steamblock valve.

25 >5000 hp Generator Extraction check valve failed to closebecause a sprinkler pipe had beeninstalled that interfered with the checkvalve counterweight arm. Unit trippedduring thunderstorm; then oversped withextraction steam. Generator exploded; oilfire ensued.

26 >5000 hp Generator Stuck open; reason unknown. Stuck open; reason unknown. Face of coupling flange not machinedtrue; bending moment caused solidcoupling to break. Turbine oversped.Because of extreme destruction, cause ofvalves sticking open could not bedetermined.

27 >5000 hp Cent. Cmpr. Found closed after wreck. Stuck open; probably poor steamquality.

Coupling bolts failed sequentially due tomisalignment. Increasing vibrationignored by operators. Coupling finallythrown completely. Turbine partsdemolished exhaust casing.

28 >5000 hp Cent. Cmpr. Coupling hub installed with insufficientshrink fit; also sharp corners on bore.Fretting/rubbing caused hub to dig intoshaft. Shaft failed by fatigue. Unloadedturbine oversped.

29 <5000 hp Cent. Pump Direct mechanical type governorfailed to respond fast enoughwhen trip valve was suddenlyopened.

After turbine repeatedly tripped onoverspeed, operators securedoverspeed trip in open positionwith bailing wire.

Turbine was tripping on overspeedbecause of restricted pump suction.When overspeed trip was defeated withbailing wire, turbine centrifugallyexploded. Case was destroyed. Onefatality and one serious injury.

30 >5000 hp Generator During startup, first valve in racksystem "popped" open. Linkagesystem included a spring whichlet valve open more than a morerigid system would allow.Turbine oversped before governorcould gain control.

Unknown Generator centrifugally exploded duringoverspeed. Design of control systemrequired that turbine be started up ongovernor valve rather than with a blockvalve. Due to large pressure differential,it is common for first rack valve to "pop"open.

31 >5000 hp Cent. Cmpr. Shaft broke causing loss ofgovernor/speed input.

Shaft broke causing loss of speedindication.

When shaft broke, governor sensed lowspeed and went wide open. Turbineoversped, but components stayed in case.Speed limited by compressor load.Design errors included wrong shaftmaterial and wrong bearing type.

32 >5000 hp Paper millline shaft

Valve stuck open; probably due tosteam deposits.

Trip valve stem was bent. Also,switch in trip circuit was wired"normally open" instead of"normally closed" per OEM’sdrawing error.

Operators had been able to start turbinefor years in spite of incorrectly wiredswitch. However, when governor valvestuck open, turbine oversped when tripvalve was reset during startup. Lineshafts tore loose from bearings anddestroyed a large area.

33 >5000 hp Out of service for uncoupled test. Trip inoperative; was being set atmanufacturer’s test stand.

Speed was monitored with strobe light.Operator did not notice shaft wasspinning at twice the strobe flashingspeed. One fatality. Turbine destroyed.

34 1997 <5000 hp Cent. Pump Mechanical overspeed trip systemhad been improperly assembled /adjusted during last overhaul. Tripbolt functioned, but rest of systemnot actuated.

Coupling failed which initiated turbineoverspeed. Reason for coupling failurenot known.



35 1990s >5000 hp Cent. Pump Pump lost suction which unloadedturbine. Turbine oversped to destruction;not repairable. Another source said thiswas a fatality accident.

36 <5000 hp During uncoupled test, small turbineoversped.

37 1990s During uncoupled test, turbine overspedto destruction. One fatality.

38 1984 <5000 hp Cent. Pump Governor valve gagged partlyopen so machine could be slowrolled in normal service.

Combined governor/trip valve(butterfly type).

Turbine oversped during uncoupledoverspeed trip test. Vibrating reedtachometer apparently was misreadduring test. Turbine and gear completelydestroyed.

39 1985 <5000 hp Cent. Pump Governor system response wastoo slow to control speed whenpump lost suction.

Combined governor/trip valve(butterfly type).

Pump lost suction which unloadedturbine. Turbine oversped to destruction.

40 1988 <5000 hp Cent.Compr.

Governor valve stuck due tosteam deposits.

Trip valve stuck due to steamdeposits.

Compressor surged heavily causing lossof load. Turbine overspeed with damage.Cast aluminum impellers in compressoralso destroyed.

41 1993 <5000 hp Cent. Pump Unknown - possibly response tooslow.

Trip valve stuck due to steamdeposits.

Coupling gear teeth failed which causedloss of turbine load. Turbine oversped.

42 1984 <5000 hp Cent. Cmpr. In manual control for uncoupledoverspeed trip test.

Electrical/electronic overspeed tripsystem failed due to a broken part.Mechanical overspeed trip systemfailed also; a critical adjustmentwas in specifications, but justbarely.

During uncoupled test, turbine overspedto 120% of maximum design speed.Machine was not damaged.

43 1997 >5000 hp Generator 11 MW unit was known to have oversped- top rpm est. 5100 while design was3600. Damage discovered during 5 yearscheduled overhaul. Retaining rings andsome turbine components damaged.

44 1995 >5000 hp Generator Too slow Too slow A gear (which gear unknown, probably inmechanical governor drive) of the wrongmaterial failed. Turbine oversped beforetrip system actuated. Generator damagedbeyond repair and replaced with a usedunit.

45 <5000 hp Pump Coupling Failure46 1994 <5000 hp Cent. Pump Boiler feedwater pump cavitated due to

process upset. Overspeed trip andgovernor did not work properly; reasonunknown. No testing program forgovernor or overspeed trip prior toincident. Governor centrifugallyexploded, but no injuries.

47 1995 <5000 hp Cent. Pump Steam turbine driving cooling tower waterpump oversped to destruction.

48 1979 >5000 hp Axial flowcompressor

Steam turbine and axial flow compressoroversped to destruction. Details notknown why governor and overspeed tripfailed. Unit down months. Couplingfailed catastrophically, but no injuries.Parts of case of compressor and steamturbine salvaged.

49 1997 <5000 hp Cent. Pump Governor was noted to alwaysoperate wide open followingturbine rerate, but no correctiveaction was taken.

Pump cavitated, turbine oversped.Retainer that holds trip bolt in shaftfailed ejecting trip bolt from shaft.Trip was then no longer operative.

Flyball type governor came apart duringoverspeed event but parts stayed insidethe machine. Trip lever would not reset,so operator held it up manually. A"brace" was installed to hold up theturbine trip lever. Turbine overspedagain, and operator noticed that the scattershield on the end of the turbine wasbeginning to dent, so he shutdownturbine.

50 1995 <5000 hp Cent. Pump Pump in Sulfuric Alky unit was operateddry/cavitating. Turbine oversped todestruction.

51 1989 <5000 hp Cent. Pump Cooling tower water pump turbineoversped after coupling failed.

52 2001 Turbine overspeed trip was being tested.Had worked successfully twice. On thirdtry, turbine overspeed. Speed was beingcontrolled by control valve rather thanblock valve. One fatality and one injury.

53 2001 >5000 hp Generator R. West reported. No details.

REFERENCESAPI Standard 611, 1988, Reaffirmed 1991, “General-Purpose

Steam Turbines for Refinery Service,” Third Edition,American Petroleum Institute, Washington, D.C.

API Standard 612, 1995, “Special-Purpose Steam Turbines forPetroleum, Chemical, and Gas Industry Services,” FourthEdition, American Petroleum Institute, Washington, D.C.

API Standard 670, 2000, “Vibration, Axial-Position, and Bearing-Temperature Monitoring Systems,” Fourth Edition, AmericanPetroleum Institute, Washington, D.C.

Clark, E. E., 2002, “Steam Turbine Overspeed Incidents,” TheHartford Steam Boiler Inspection and Insurance Company.

ISO 10437, 1993, “Petroleum and Natural Gas Industries—Special-Purpose Steam Turbines for Refinery Service,”International Organization for Standardization, Geneva,Switzerland, Paragraph 12.3.1.1.

BIBLIOGRAPHYWeaver, F. L., 1976, “Reliable Overspeed Protection for Industrial

Drive Turbines,” Proceeding of the Fifth TurbomachinerySymposium, Turbomachinery Laboratory, Texas A&MUniversity, College Station, Texas, pp. 71-78.



54 2001 >5000 hp Generator Due to upset in mill, other generatorswere shutdown resulting in subjectgenerator operation at maximum load.For some reason, load was lost. Brokebearing pedestals, threw pieces throughroom and into side of pressure vessel.Solid coupling bolts sheared. At least oneinjury; no fatalities. Turbine had beenretrofitted with electronic governor, butthis was not used for overspeedprotection.

55 ? >5000 hp Generator In past, turbine generator oversped to thepoint retaining hardware failed in thegenerator.

56 ? >5000 hp Governor In past, turbine generator oversped to thepoint retaining hardware failed in thegenerator.

57 1999 ? <5000 hp Generator Turbine oversped during overspeedtrip testing. Operator accidentallyopened steam valve too much whileturbine was disconnected fromgenerator.

turbine overspeed trip protection -...

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