TMR Over Speed Protection System Gulf Refinery
GCS was contracted to provide new control system and overspeed protection on all refinery API612 (Steam Turbines Special-Purpose Application) classified rotating equipment. The new system needed to be SIL3 compliant and 2oo3 voted, so the mechanical overspeed trip device could be eliminated.
- Petrochemical Refinery
- TurboDyne Turbine Compressor
- Woodward Peak 150 Digital Governor - Speed Control
- Woodward ProTech TPS Electronic 2oo3 voted Over Speed protection
- Woodward QuickTrip 2oo3 voted trip valve
GCS was contracted to provide new control system and overspeed protection on all refinery API612
(Steam Turbines Special-Purpose Application) classified rotating equipment. The new system needed to be
SIL3 compliant and 2oo3 voted, so the mechanical overspeed trip device could be eliminated.
The existing trip system used parallel pneumatic dump valves that had become unreliable and were NOT capable of online testing or online repair. Also, the Woodward Peak 150 governor was over 10 years old and the refinery wanted to replace with another Peak 150 due to the familiarity of the control to operations and the reliability displayed by the control.
New System Overview
GCS built an integrated control enclosure housing the Woodward Peak 150 and Woodward ProTech TPS, and utilized the Woodward QuickTrip as the trip system oil dump valve. Having GCS integrating the Woodward products as an engineering project ensured the installation, done by the customers 3rd party contractor, went smoothly which streamlined the commissioning process. This benefited the customer since typically the process charge compressors are the last equipment to start and by not experiencing delays in the commissioning of the new control system the plant could get back on line minimizing any delay.
As part of the engineering project, GCS conducted a full system FAT, including fabrication of an identical trip header to the existing turbine trip header in GCS shop. This allowed GCS and the customer to be able to test the entire system closed loop, quantify trip times, ensure trip header orifices were sized properly, and allowed refinery personnel to test all the features of the system prior to installation in the field.
The FAT included a data acquisition element (Woodward 2300) to record oil pressure and Protech / Quicktrip cycle times in 5ms resolution.
Industrial Standards Compliance: API 670, API 612, SIL
A major benefit of using the Woodward TPS / QuickTrip combination is off the shelf SIL3 compliance. The products along with GCS established tested / commissioning procedures ensure the safety system design, testing, and commissioning is documented following the relevant industry standards.
The added benefit of the ProTech TPS is the ability to use the hardware as the integrated Emergency Shut Down system as well as the primary Overspeed protection. What this means for the end user is all machinery protection trips are processed in the ProTech TPS. This minimizes trip times and provides the end-users with first out time stamped trip recordings. The flexibility of the ProTech TPS and its 30 available analog or discrete inputs allows multiple levels of redundancy both increasing the availability and reliability of the system.
API 670: ESD Intigrated Architecture
Woodward Peak 150 Operator & Speed Digital Control The Woodward Peak 150 digital control is designed to control a steam turbine driving a mechanical load. It provides tight control of speed (NEMA D) and includes an
input for a 4 20 mA remote speed control signal, which can be used for a process-generated input to control the speed setting.
Woodward ProTech TPS
Safety System with Integrated Overspeed Protection The Woodward ProTech-TPS is a safety programmable logic controller with integrated overspeed protection designed to safely shut down plant process equipment when sensing a safety event.
The QuickTrip trip block assembly is designed for use in steam, gas, and hydro turbine shutdown systems for quick and reliable dumping of the turbines trip oil header. This trip block assemblys 2-out-of-3 voting design provides users with a very high level of system reliability as well as compliance with industry standard API- 670.
Wooward SIL3 MPU
These speed sensors are designed for use in SIL-3, SIL-2, or SIL-1 (safety integrity level) rated turbine or engine safety systems. When applied with a SIL rated logic solver and final element, users can easily create an overspeed safety instrumented function (SIF) which meets the required safety integrity level for the specific application. As these variable reluctance (VR) speed sensors do not utilize active components, they have a very low failure rate, making them ideal for use in safety systems requiring long system life and low probability of failure on demand (PFD) values.
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