Steam Turbine Stop Valve Testing

7/22/2019 Steam Turbine Stop Valve Testing

1/22

Steam Turbine Stop Valve testing.

We regularly test our Steam Turbine Emergency Stop valve to ensure it does not get stuck open. The

question was posed, what if the valve does stick open. How could you safely shut down the turbine? We are

developing a procedure for this and I am curious if anybody else already has an established procedure for

this problem. If so, please share it.

15 days ago

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UdhayakumarUnfollow Follow Udhayakumar

Udhayakumar Venkataraman As Governing vale can not be 100% shut valve, passing may over speed orshaft will not come to barring, churning may happen. How to bring down shaft speed down?? will add, all

our expert friends may address..if over speed sensor does not operate.. disaster in this ESV does not close but

the GV closed fully...

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MaheshUnfollow Follow Mahesh
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2/22

Mahesh Manoharan It is usually recommened to open the Generator breaker after experiencing reverse

power in case of tripping of the Turbine on any protections or manual shutdown of the Turbine. This isusually called programmed reverse power protection or sequential reverse power protection. Except for any

electrical protections the generator breaker will be opened after experiencing reverse power in case of any

tripping due to boiler or turbine protections ( except few turbine protections like Diff expansion). This is toensure that all the locked out steam got exhausted and the TG set is entering into motoring action. This will

avoid over speeding of the TG set due to passing of ESV and GV's.



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VictorUnfollow Follow Victor

Victor Buck Russel, can you give more info on all turbine steam valves on your unit (governor valves,

throttle valves, etc.)? Our Westinghouse unit has 2 throttle valves, 6 governor valves and 4 reheat valves (2stops and 2 intercepts). Although Udhayakumar states that a governor valve cannot be a fully shut

valve...that is not the case on our unit. At approximately 10% indicated governor valve position, all steam

flow through that valve has stopped. In our situation, if we had any one valve stick open, we would still beable to stop all steam flow and safely shut down the unit.

Your situation may be completely different and, without knowing your exact valve layout, it is hard to give a

good recommendation.



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AlanUnfollow Follow Alan

Alan Manza If the steam turbine emergency stop valve failed to close during unit tripping or normalshutdown, these are my recommendation: 1) Open the generator circuit breaker manually to isolate from the

grid and to protect it from reverse power, although reverse power protection is present. 2.) During opening of

the generator breaker, the steam turbine speed may increase and possibly reaches to its overspeed limit sincethe emergency stop valve is stucked open. The steam turbine may trip by activating the overspeed protection.

3) Then, try to open the vacuum breaker to aid slowing down of steam turbine.
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3/22



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josephUnfollow Follow joseph

joseph hanna I think we need more details about your system. In our plant: 1. sure there is a reverse power

protection to open the circuit breaker or even manually you can open the breaker but this wil not protect the

turbine, it will only protect the generator. 2. there are boiler main steam stop valves which isolate boiler

steam from going to turbine (sure you have to trip the boiler if you want to protect the turbine). Same storywe have with reheat inlet outlet from boiler.



0

NareshUnfollow Follow Naresh

Naresh Bansal Add another similar stop valve if it helps to care of the anxiety meanwhile I am waiting for

the procedure being worked out by your team.


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KONSTANTINOSUnfollow Follow KONSTANTINOS

KONSTANTINOS FARMAKIS 1)if the valve fail to close with the first trip signal it will never close by

the overspeed trip protection.
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4/22

2)the result of the opening of the breaker will be an overspeed without possibility of tripping because the

stacked valve. The damage will be very big3)dont break the vaccum with full steam flow through the steam turbine

what im thinking: 1)open the by passes .be carefull for the drum levels. we dont care about the hihi trip level,we already tripped , but for water to the steam turbine

2)open the steam line drains to redure the pressure and flow and to extract water from the steam lines.

3)if there is main isolation valve close it . the drum PSVs will open

4) open the breaker

5) less than 85% speed , with out steam flow break the vaccum.and good luck.



3

BobUnfollow Follow Bob

Bob Callery If the steam turbine ESV (emergency stops valves ) will not close, I recommend Not Openingthe Generator Breaker unless you want your steam turbine parts flying into the parking lot!

Trip the boiler and close the boiler steam stop valves. As the turbine speed decreases, the generator breaker

will open upon activation of the reverse current relay.

This condition ( failure of the ESV ) is one of the most dangerous conditions in a power plant and training

and procedures must be in place by the operating crews to understand how to deal with it.



9

josephUnfollow Follow joseph

joseph yarusinski Your primary steam inlet valves should always be installed in series...- Throttle Valve / Control Valvees

- Reheat Stop Valve / Interceptor Valves.

The valves should take hydraulic pressure to open, and spring pressure to close. The springs provide a fail-
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5/22

safe means of closing the valves on loss of hydraulic pressure or electric power.

Upon a turbine trip (due to low vacuum, low bearing oil pressure, loss of control oil pressure, complete loss

of load / overspeed trip) all valves should very quickly slam shut.

And all valves should seal off 100% of flow.

You must test the operation of the valves regularly. If you don't, mineral deposits from the steam may build

up along the valve stems and basically cement them in place. This will prevent the valves from closing in an

emergency.

Very simply, if the valves do not stop the steam flow very quickly in an emergency, the turbine will be

severely damaged. For instance, a steam turbine can accelerate to destructive overspeed in just a fewminutes, if the valves don't shut tight. You don't have time to take any other course of action --- except

maybe to trip the boiler as you are running out the control room door to safety.



0

Siraj AhmedUnfollow Follow Siraj Ahmed

Siraj Ahmed Khushk Agreed with the comment of Mr. Bob Callery. We may also close the main steam line

isolation valves of boiler.

Plus some frnds suggested here to open Gen. CB and let the turbine trip on overspeed but if t he turbine Stopvalve is stuck, it wont be fully closed and will allow the steam flow.

So i totally agree with Mr. Bob Callery



1

DaveUnfollow Follow Dave

Dave Muller Hi, not sure of your configuration, but we would also close the control vales at the same time,if these still pass then go further back and close the isolation valves.

Cheers.
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1

hannesUnfollow Follow hannes

hannes hedquist Only by means of control valve closing and boiler isolation valve too. Naturally trip the

machine and break vacuum plus bypass valve fully open.



2

vijayUnfollow Follow vijay

vijay patil when plant tripped and ESV remain open ..there is chance of overspeeding of turbine ..so

immediately close the MSV valve which is in series ofESV ..after that close speeder gear to zero ..then breakcondenser vaccuum immediately ..this result turbine coast down within 15 min & come on barring..but

sometimes MSV valves are also passing so close

boiler outlet steam valve


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0

LorneUnfollow Follow Lorne

Lorne Kause If your turbine stop valve sticks open immediate action must be taken to protect your turbine

from overspeed distruction as your main means of steam isolation has been lost and as noted governor valves
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7/22

should not be relied on for isolation as that is not their purpose. Immediate shutdown is required but under

"very" controlled conditions. I would suggest reducing boiler pressure to the lost allowable operatingpressure and bring the generation down to minimum (mtoring condition)--this will provide indication if the

governor valves are providing control at minmum steam flow. At this point it is suggested your turbine can

be tripped. If your unit is provided with boiler stop valves these should be closed as well.



0

Jean-PierreUnfollow Follow Jean-Pierre

Jean-Pierre Rickli Hi Russel

If the valve sticks open during the test, that means that some concerns may rise about a safe shut-down of the

ST in an emergency case.In most Arrangements, you have one ESV in serie with one or more control steam valves. That means that

you are still able to run down the ST in a controlled manner by reducing the load and closing the control

valves.Possibly, you will have also to reduce the boiler load.and thus the steam data. The ESV gives you

confidence, that the ST will be stopped despite any problems with the control valves. If the ESV is stucked,

you may be careful while loading down the ST in order to avoid the necessity of an emergency stop. Once

the ST is stopped, you can get the ESV problem fixed.

The test during Operation gives you the opportunity to have a scheduled shut-down for Fixing the ESV andnot be surprised by an emergency case.

Hope, it brings some help.



3

GidionUnfollow Follow Gidion

Gidion Mutanga This is a serious condition, if ESVs are stuck open, trip the boiler first and close boiler

steam stop valves to stop steam flow to the turbine and open drains, to drain away water. If the circuit
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8/22

breaker did not trip on protection as the turbine speed decreases, then open it manually. Time to act is very

limited here, it's why I believe tripping the boiler should be the first thing to do.



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FirozeUnfollow Follow Firoze

Firoze Kazi Open the turbine steam bypass valves to the condenser and shut the boiler steam valves.



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KalyanUnfollow Follow Kalyan

Kalyan Kumar Your plant configuration is required for suggesting a solution correctly. If there are multiple

boilers supplying steam to multiple STs through a main steam header, it may become practically impossibleto close the boiler main steam valves, if the availability of other STs should not be disturbed. In that case,consolidation of some of the above suggestions can be used to prepare a SOP.


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9/22

Joe Moroso I think reiterating Bob Callery's statement is warranted. The last thing you want to do is open

the breaker while still introducing any steam energy into the turbine. Once the energy is expended and youstart getting into a reverse current/motoring situation the generator protection system will open the breaker.



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ChuckUnfollow Follow Chuck

Chuck Holm Typically the governor valves will also close to prevent turbine overspeed. We typically test

the stop valve and the governor valves (and reheat/intercept if installed). I haven't worked on a turbine that

the governor valves cannot go fully closed.

The generator breaker should not be opened unless you see reverse power. If the stop valve and the governor

valves fail to close, keep the generator in service and use another means to isolate the steam. You're doingthe right thing by trying to come up with a plan before an event actually occurs.

I've actually never heard of all valves failing to close during an emergency when the valves are testedregularly - EXCEPT at a couple of facilities where the trip oil/hydraulic system was modified and when the a

trip was required - the oil did not dump off the valves. In these instances the valves test everytime until a real

emergency occurred.



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true 40 52 groupItem?seeM

RusselUnfollow Follow Russel

Russel Alexander Its good to see some of the same thoughts we had about this situation.

I will describe our turbine setup.

We have a steam turbine with a single Emergency Stop valve (ESV) and 4 governing valves. There is a Mainstop valve after the Superheater which is manually operated and a small solenoid operated vent valve

between the Main stop valve and the Turbine ESV.

The ESV is held open hydraulically and closes on loss of hydraulic pressure by a spring. All the safety

devices i.e. overspeed, emergency stop, trip a solenoid which drops the hydraulic pressure.
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10/22

So if the ESV does stick open there is no protection of the turbine.

So far we have come up with the following steps to safely shut down the turbine.1. Reduce the firing rate of the boiler

2. Start lowering the load of the turbine

3. Start closing the manual Main stop valve and do not stop until the valve is completely closed.4. The operator shall trip the boiler fire and will put the MW control at minimum so the governing valves

stay closed and do not try to open as the steam pressure drops and the turbine load goes down.

5. As the turbine load starts to drop, open the steam vent solenoid valve when load is at approx 2 MW's

6. As the unit is approaching 0 MW's open the vacuum breaker on the condenser.

7. Allow the load to continue to drop, so the unit goes into a reverse power condition and the breaker trips.8. At this point the Main stop valve should be closed, the governing valves should be at minimum, the steam

vent valve is venting any residual pressure in the steam line and the turbine should be spinning down.



0

ChuckUnfollow Follow Chuck

Chuck Holm Are you certain that the governor valves will stay open when hydraulic fluid is dumped from

the stop valve. And if the governor valves actually do stay in service when hydraulic pressure is dumped

from the ESV - should they stay open and was a modification made at some point that allowed this to occur.

I can't recall ever operating on a turbine that had separate hydraulic systems for the ESV and the governorvalves and I've worked on a lot. The ESV and governor valves should be supplied by the same hydraulic

system. I actually have a steam turbine design engineering manual for Russian made turbines and it alsoindicates that governor valves and stop valves being tied together in the trip circuit.

Just a thought!!



0

RanamunimUnfollow Follow Ranamunim
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Date post:	10-Feb-2018
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Steam Turbine Stop Valve Testing

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