Speedtronic Calibration MK-2

Gasco Asab Unit 24-K-401

Date 03/10/2001

Control specification used: 298A8726

Control adjustment spec used: 298A8728

Timers & Counters

Manual Initiated Starts:

Total Starts:
Emergency Stops:
Fired Starts: 297
Fast Load Starts:
Fired Time: 70228
Peak Fired Time:

Narrative

The following report is a summary of the controls and instrumentation works performed
during the Hi-tech upgrade and major inspection of unit 24-K-401.

i. MkII Speedtronic Control System

Prior to calibration a visual inspection of the Speedtronic panel was carried out. A light
deposit of dust was found on all surfaces. This was brushed off and the panel vacuumed
cleaned. No visible evidence of damage or excessive heating to any of the components or
wiring was observed.

A number of lamps on the annunciator display were replaced.

A calibration check was performed in accordance with the system adjustments and the
control specification. A record detailing the ‘as found’ and ‘adjusted’ set points is
attached within this report. A section summary is as follows:

Speed Control

Only minor adjustments were required for this section.

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Speed Relays

All speed relays were injected and found to be within specification, therefore no
adjustments were required.

Electronic Overspeed Protection

Both protection cards were injected and found to be within specification therefore no
remedial action was required.

LVDT Oscillators

Both protection cards were injected and the SOSG card for Channel A was found to be
out with specification no adjustment was possible therefore the card was replaced.
Channel B was found require only to minor adjustment.

Base Temperature Control

The temperature card amplifier STKJ was found to be out with specification. This is non
adjustable therefore the error has to be compensated for in the temperature control
calibration. These settings were also found to be out with specification and therefore
required minor adjustment.

Nozzle Temperature Control

The settings were found to be with in specification and therefore no adjustment was
required.

Overtemperature Protection

Both channel A and B amplifier outputs were found to be with in specification.

2nd Stage Nozzle

A new servo was installed by the client in accordance with his standard maintenance
practices. Minor adjustments were made to the nozzle stroke calibration.

Gas Fuel Control

The P2 Pressure control settings were found to require only minor adjustment. The servo
was replaced on the gas control valve as per the client’s standard maintenance procedures
and was cleaned on the SRV due to a new/refurbished servo not being available. Minor
adjustments were carried out to both valves during valve stroke calibration checks. Both
servo null bias voltages were found to be out with in specification.

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Start Up & Shutdown Control

Only minor adjustments were required. See running checks.

Vibration Protection

No adjustments were required to this section.

Bulk Power Supply

Minor adjustments were carried out.

ii. On Base

Gas Control Valves

The clearance between the valve stems and actuator spindle was recorded as follows:

Speed Ratio Valve 0.035 inches

Gas Control Valve 0.037 inches

Both the above readings are within specification.

Inlet Guide Vanes

The operation of the inlet guide vanes was checked prior to start up.

Flame Detectors

Both flame detectors were checked for correct operation prior to re-installation.

Ignition System

Both spark plugs were cleaned and their operation verified prior to re-installation.

Turbine Thermocouples

The client was responsible for the installation and removal of all wheelspace
thermocouples.

As part of the Hi-tech upgrade there was a requirement to install new exhaust
thermocouples and modify the radiation tubes to suit. The scope of work was poorly
defined and there was insufficient cable to wire back to the main junction box JB4. The
decision was made to utilize the existing junction boxes JB6 & 7 on the exhaust plenum.
In addition due to access restrictions the new junction boxes could not be mounted were
shown on the drawing supplied. Modification work was carried out to the exhaust plenum

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insulated doors to accommodate the new boxes. An as built drawing of the installation is
attached.

iii. Running Checks

The machine was initially run to approximately 5% NHP and shutdown to allow for
mechanical integrity checks. The run down time was recorded at 3 minutes 50 secs.
Another run to 20% NHP was carried out and the run down time recorded at 6 minutes 30
seconds.

The machine was fired and run up to minimum governor speed with no anomalies noted.
On loading the machine parameters were found to be within specification. A copy of the
operations data taken by Gasco is attached.

iv. Conclusions and Recommendations

The turbine Speedtronic control system was found to require only minor adjustments.
This is due to the panel being well maintained and the calibration checked at regular
intervals.

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Mk II Speedtronic Calibration Sheets

Power Supplies

Final Regulator
Supply Found Adjust to

P 5 Volt 5.32 5.30

P 28 Volt 28.00 28.00
P12 Volt 12.11 12.00
N 12 Volt -12.09 - 12.00

LP Speed Setpoint
Speed Counter Setpoint Setpoint Found Adjust to
rpm % Vdc None
3522 Empty 86 2.80 2.79
100 0.0 0.00
Max Full 105 -1.0 -1.00

LP Speed Control
Speed NHP % Vdc Found Adjust to
0 0 0 0 0
4670 100 10.0 9.92 10.0

LP Speed control and overspeed test found to operate as per design.

LVDT Oscillator
Oscillator # 1 Found Adjust to
Card replaced
7.0 Vrms 6.50 Vrms 7.0 Vrms
2920 Hz 2918 Hz 2920 Hz

LVDT Oscillator
Oscillator # 2 Found Adjust to

7.0 Vrms 6.94 Vrms 7.0 Vrms

3080 Hz 3079 Hz 3080 Hz

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 HP Speed Control
Speed NHP Speed Analog Found Adjust to
Rpm Vdc Vdc Vdc
Zero 0 0 0.0 0.0
Rated 5100 10.0 9.93 10.0

HP Speed Range SNCF

HP Speed Range SNCF

Speed Limit NHP Speed Analog Found Adjust to
rpm Vdc
Min 5049 9.90 9.18 5048
Max 5100 10.0 10.0 5100

Second Stage Nozzle Control

Position Angle NCE LVDT 1 LVDT 2 FB1 FB2
Degree Vdc Vrms Vrms

Open 15 10 3.10 3.15 5.68 5.67

Close -5 0 0.61 0.65 1.54 1.54

Servo Null Bias = +0.36

New Nozzle Fitted Servo Fitted

Stability Setting Gain = 37

Nozzle Position Check

NCE Angle Actual Angle
150 150 150
50 50 50
-50 -50 -50

Speed Pick-Up’s
Pick-up Pick-up Drop out Drop out
Relay Speed Found Adjust to Found Adjust to
14 HR Zero 5 16
14 HM Min Fire 1022 1022 65 65
14 HA Acc 2030 2030 1476 1476
14 HS Rated 4645 4645

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 Shutdown 4450 4450
14 LS Min Gov 3097 3097 2720 2720
14 MR IGV 5038 5038 4451 4451

Electronic Overspeed LP
LP Speed Found
Channel # 1 4785 rpm
Channel # 2 4785 rpm

Electronic Overspeed HP
HP Speed Found
Channel # 1 5620 rpm
Channel # 2 5618 rpm

Temperature Control

Temperature Recorder 26 TR
Injected Found Adjust to
0 oC 0 oC Recorder
100 oC 100 oC defective
200 oC 200 oC
300 oC 300 oC
400 oC 400 oC
500 oC 500oC
600 oC 600 oC

Pressure to Volts Transducer

Pressure PCDV Adjust to
Psig Found
0 0.00 Vdc 0.00 Vdc
87.5 2.50 Vdc 2.50 Vdc
175 5.00 Vdc 5.00 Vdc

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 Analoque STKJ (TX)
Temp C Input mV Amb. mV Spec Found Adjust to
Correction
371 15.18 14.012 3.50 3.57 Factory
510 21.07 19.90 4.75 4.82 Set
649 26.98 25.82 6.00 6.08

Base Load Control Settings

Temp C Amb. mV PCD Vdc PCDN Found Adjust to
Correction
538 21.098 0 - 2.02 0.00 534 538
529 20.71 2.22 0.60 524 529
443 17.054 4.29 6.84 438 443

Second Stage Nozzle Temp. Contorl

Temp mV input STKJ PCD PCDN Found Adjust to
538 22.25 5.00 0 0 538 None

Exhaust Temperature Protection

Analoque STKJ (OTA)

Temp C Input mV Amb. mV Spec Found Adjust to
Correction
371 15.18 14.10 3.50 3.509 Factory
510 21.07 20.00 4.75 4.75 Set
649 26.98 25.90 6.00 6.01

Alarm Setpoint (OTA)

Temp C Amb. mV PCD Vdc PCD psig Found Adjust to
Correction
549 21.567 0 - 2.02 70.7 OTA 551 OTA 549

Trip Setpoint (OTA)

Temp C Amb. mV PCD psig PCD Vdc Found Adjust to
Correction

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 560 22.04 70.7 0 – 2.02 560 560
552 21.695 77.6 2.22 552 552
465 17.988 150 4.29 465 465

Analoque STKJ (OTB)

Temp C mV Input Amb. mV Found Adjust to
Correction
371 15.18 14.10 3.49 Factory
510 21.07 20.00 4.73 Set
649 22.98 25.90 5.98

Alarm Setpoint

Alarm Setpoint (OTB)

Temp C Amb. mV PCD Vdc. PCD psig Found Adjust to
Correction
560 22.20 0 – 2.02 70.7 OTB 548 OTB 548

Trip Setpoint (OTB)

Temp C Amb. mV PCD psig PCD Vdc. Found Adjust to
Correction
560 23.20 70.7 0 – 2.02 561 560
552 22.84 77.6 2.22 558 550
465 19.14 150 4.29 464

Differential Alarm
Channel Deg. C Input mV Amb. mV Found Adjust to
Correction
Control 482 19.88 18.69 482 482
OTA 463 18.58 17.42 470 463
OTB 463 18.58 17.42 471 463

Start Up Temperature Suppression

Measured at 0.0729 volts per second

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 Vibration Protection
Alarm Alarm Trip Trip
Channel Not fitted Found Adjust to
1 Vdc 5.45 None
2 Vdc 5.45 None

Gas Fuel Control

Pressure to Volts Transducer 96 FG

Transducer Output
Point Pressure psig Found Adjust to
Zero 0 0.00 None
Mid 125 2.50
Max 250 5.00

Pressure Controller
NHP % Rpm PSRV out 96 FG Found Adjust to
20 1020 17 0.34 0.334 None
3060 100.5 2.02 2.01
100 5100 185 3.70 3.70

Gas Control Valve Stroke

Pos Feedback Feedback LVDT LVDT
VCE Volts 1 2 1 2
4 0.03 1.71 1.65 0.69 0.69
12 - 3.96 4.03 4.02 2.14 2.16
20 -7.87 6.25 6.37 3.45 3.55

New Servo Valve Fitted on GCV

Servo Null Bias = - 0.364

Speed Ratio Valve Stroke

VCE Volts TPC LVDT

2.50 - 1.98 0.651

10.50 -5.91 1.84
18.50 - 9.84 3.044

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Servo Null Bias = - 0.37
Servo removed and cleaned.

Start Up Control Card SSKC

VCE Vdc VCE Vdc
Condition Spec Found Adjust to
Fire 3.95 3.95 3.95
Warm up 3.55 3.55 3.55
Accel 5.00 5.00 5.01
Min 3.25 3.29 3.26
Max 9.75 9.65 9.65

Panel Meters

HP Speed
RPM NHP % Found Adjust to
None
0 0

100 100

LP Speed
RPM NLP % Found Adjust to
None
0 0

100 100

Digital Setpoint
DSP % Found Adjust to
80 80 None
100 100
105 105

Control Temperature
0
TX C Found Adjust to
0 -3 0 None

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 300 297 300
600 597 600

Nozzle Control
NCE 0 Found Adjust to
-5 -5 None
+ 15 + 15

VCE

VCE
Units Volts Found Adjust to

0.00 0.00 None

10.00 10.00
20.00 20.00

New Yokogawa Temperature Recorder fitted during this outage.

Timer Checks

Timer Sheet No. Card Location Found Set

4Y 04 E 1L3X 1 sec 1 sec

62 CDX 05 A 1L3X 2 sec 2 sec
Cooldown 05 D 1L3P 2 min 34 sec 2 min 34 sec
Reset timer 05 D 1L3P 1 sec 1 sec
88QE Off 05 D 1L4N 98 sec 98 sec
88QE On 05 D 1L3P 2 min 2 min
Ratchet Cycle 05 E 1L4N 2 min 58 sec 2 min 58 sec
Ratchet Reset 05 E 1L3K 1sec 1 sec
20 CS 05 E 1L3I 1 sec 1 sec
2 RT 05 E 1L2O 4 min58 sec 4 min 58 sec
IGV Position 06 B 1L3P 10 sec 10 sec
2 TV 07 A 1L3I 2 min 2 sec 2 min 2 sec
Firing Timer 07 A 1L3K 60 sec 60 sec
43/C 07 A 1L3X 1 sec 1 sec
Flicker 10 A 1L3K 1 sec 1 sec
Warm Up 10 A 1L3K 61 sec 61 sec
Incomplete Seq 12 A 1L3X 3 min 48 sec 3 min 48 sec

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 Clutch 18 C 1L4N 5 sec 5 sec
Loss of Flame 18 D 1L3I 2 sec 2 sec
CL 18 E 1L4N 5 sec 5 sec
Max Capability 31 B 1L3I 2 min 1 sec 2 min. 1 sec

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