FEEDBACK NO.

39

OVER SPEED PROTECTION – TESTING MECHANISM

A NEW VARIANT IN KWU DESIGN MACHINE (250 MW – DTPP)

1 The Need:

Turbo generators, like any other high speed, heavy duty & variable demands machines
are equipped with highly reliable governing and protection systems still, a risk of their
failure exists & this is overcome by incorporating a hydro-mechanical systems called
over speed protection system. This protection is one of the most vital protections
provided to safeguard the set form flying away & restricts the maximum speed of
machine. To ensure that this back-up protection is healthy and available all the time,
machines are also equipped with a testing mechanism for this protection system.

2 O. S. Pins:

O. S. Pins (2 nos, normally) are fitted in turbine rotor and consist of the eccentric bolts,
the adjusting screw, the spring and the screw plug.

The over speed trip mechanism is set by the adjusting screw. By appropriate adjustment
of the screw, the center of gravity of bolt is positioned eccentrically to the turbine shaft
so that below the tripping speed the bolt is held in the position as shown in attached
figure, by the spring against the centrifugal force. In this position the bolt bears against
the screw plug. If the turbine speed exceeds the overspend setting (normally 11 to 12%
above rated speed), the centrifugal force overcomes the force of the spring and forces
the bolt out of the turbine rotor. This activates the turbine trip mechanism.

3 The tripping mechanism:

The eccentric pins protrude out against the force of the spring under the effect of
centrifugal force during an overspend condition or when the test oil pressure is supplied.
The pins strike a pawl and thus open the Tripoli circuit so that the stop and control
valves immediately interrupt the admission of steam to the turbine.

3.1 Mechanism in LMW machines

LMW machines are equipped with O.S. protection with following salient features

Ø The O. S. bolts can be checked along with tripping mechanism for their healthiness
individually.

Ø Test oil for actuation of bolts is generated from control oil

Separate nozzle arrangements, independent of shafting system are utilized for oil injection.
(Thus, no central bore is required in MOP shaft)
 KWU machines of 210/500 MW have O. S. protection with following special features-

Ø On line testing facilities of protection system.

Ø The O.S. bolts cannot be checked independently. The test oil is generated &
pressure is built –up below both the bolts simultaneously. The tripping mechanism
operates with the actuation of bolt having less setting for its displacement due to
centrifugal forces. (However, other bolt may also trip if its setting is nearer to the
bolt having less set – values).

Ø The test oil is fed to the NDE side bearing chamber of MOP Test oil is transported
through a tube located in the hollow – central bore to MOP Shaft, via gear coupling
of MOP – emergency governor shaft O.S. bolt chambers.

Ø Only one test device is used to generate test oil, aux trip oil & aux start up oil.

Ø The test oil is generated from control oil/trip oil.

Ø During A.T.T. (Automatic Turbine Testing) the pilot valve whose down ward
movement causes generation of test oil is actuated by an electric motor & gear
mechanism.

1 Technological up gradation in O.S. testing mechanism (2 x 250 MW DTPP)

Ø The LMW technology has the provision of testing both the pins independently for
their healthiness.
 Ø The conventional KWU units do not have the provision of testing individual pins by
oil injection tests.

Ø In 210 / 500 MW KWU machines test oil passes through a tube installed in the
central bore of MOP shaft. Test oil is fed through MOP NDE bearing. In case bearing
develops defects leading to tube oil pressure building up in the tube, unit trips due to
actuation of O.S. protection mechanism.

Considering above aspects, 250 MW units of DTPP have been provided with improved
technology as discussed below.

4.1 There are two separate test devices for oil injection test. Test oil can be generated
individually for each bolt. Thus individual pin can be checked. Conventional
210/500 MW units of KWU design have been equipped with only one test device
having an A.C. motor driving a gear train to actuate the pilot for generation of test
oil. In the modified design, a solenoid valve is used for this purpose.

4.2 The test oil in modified design is fed to two separate lines. The injection nozzles
for individual pins are mounted vertically inside the front bearing pedestal just
below the emergency governor shaft in line with the pins.

A part of the test oil being injected by nozzle is transported via an opening below the
individual pin. This oil pressure together with the centrifugal force on pin due to rotor speed
causes the pin to pop – up & hit the tripping mechanism.
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