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Retrofit Example of Elliott and Terry Turbines
Index :
Index :............................................................................................................................ 1
Scope of Order ............................................................................................................ 2
Speed measurement kits .......................................................................................... 3
Gear wheel .................................................................................................................. 3
Speed pick-ups. .......................................................................................................... 6
Elliott Mounting ............................................................................................................ 6
Terry Mounting............................................................................................................. 7
Actuator......................................................................................................................... 8
Solenoid valve ........................................................................................................... 11
Mechanical change write-up .................................................................................. 11
Speed pick-up installation....................................................................................... 12
Speed gear installation ............................................................................................ 15
Actuator installation .................................................................................................. 15
Control system .......................................................................................................... 18
Control system .......................................................................................................... 19
Vantage®GP .............................................................................................................. 19
Series 3++ Controllers ............................................................................................... 19
Overspeed Prevention System (OSP) ................................................................. 20
Guardian® ................................................................................................................. 20
Page 2
Scope of Order
The Scope contains a mechanical retrofit package for six steam turbines of two types (Terry and
Elliott).
There are two Terry Turbines and four Elliott turbines.
The engineering scope contains the following items:
1) Design speed measurement kits for two types of steam turbines (Elliott and Terry).
2) Create machine part drawings for speed kits.
3) Create installation/instructions for speed kits for two types of steam turbines (Elliott and
Terry).
4) Specify the magnetic pick-up.
5) Visit at the machining shop for Factory Acceptance Test.
Page 3
Speed measurement kits
Gear wheel
The speed measurement is essential for an accurate control of the speed and indirect the
process. During the site survey it became clear that the position of the worm gear is a good
place to install a new speed measurement gear.
Existing New Existing New
Machine Terry Terry Elliott Elliott
Outer Worm gear 95 mm 96 mm 46.8 mm 96 mm
Inner Worm gear 41.2 mm 41.2 mm 22.2 mm 22,2 mm
Number of teeth 30 30
freq @ rated 2410 Hz 2410 Hz
Note 1: Outer diameter is = Module * (z + 2)
Both gears contain 30 teeth. This has to be configured in the controller.
Page 4
Elliot Gear wheel
Page 5
Terry Gearwheel
Page 6
Speed pick-ups.
The size of the speed pick-ups is limited due to space restrains. Due to European selection
criteria is the smallest Jaquet probe selected. The end-user needs to install barriers to interface
between the controller and probe. The hazardous location of the installation makes the following
selection necessary.
Type: Jaquet
• DSE 1210.00 SHV Ex
• Active probe.
• Size : M12x1
• IP67
• Operating temp -40 _ +125C
• 2 meter cable sealed on head.
• Gear Module 1_ 4
The speed pick-up will be mounted in the worm gear casing shell.
Elliott Mounting
Page 7
Terry Mounting
Assembly drawing Magnet Pickups
Page 8
Actuator
The end-user insisted on using Fisher actuators.
Actuator stroke
Machine #1 Terry #2 Elliott #3 Elliott #4 Elliott #5 Elliott #6 Terry
Duty Exhauster Exhauster Exhauster Booster Booster Booster
Stroke 32.2 37.0 32.5 20 mm
mm
The first mm are the ones that count. The existing actuator fits this purpose. (Note: Effective
stroke will be less than above recorded)
Per customer request the actuator should be a fail to retract type with a manual adjustment
possibility. The controller will send out a 4-20 mA which has to linear with a position of the
actuator. For that reason the following items are to be selected:
Fisher actuator type 657 (direct acting), The size selection will be a 657, max Travel 19 mm,
Requirement Required Available Type
Action Fail to retract Fail to retract 657
Travel 19 mm 19 mm (act size = 34)
Handwheel Yes Top wheel
Air pressure Max 4.48 barg 5.5 barg
Ambient temp 80 C 104F
The actuator size 34 is sufficient.
Page 9
Ordering information Actuator with positioner and handwheel:
657-0BCL1021-2T-02TC-5G3N
• Actuator Type : 657
• Actuator Size : 34
• Operating range: 0-33 psi
• Bench set lower: 6 psi
• Bench set higher: 22 psi
• Travel : 7/16“
• Max Travel ¾ ”
• Actuator Signal Connections : 1/4 " NPT
• Switch Mtg Adaptation : None
• Yoke Matl : Cast Iron
• Diaphragm Matl : Silicon
• Side Mtd Handwheel : Without
• Top Mtd Handwheel : YES
• Yoke Boss Size : 2 1/8 Inch
• Stem Connection Size : 3/8 Inch
• Actuator Group : 1
• Valve Action : PDTC
• Casing/Cylinder Matl : Steel
• Spring Seat : Steel
• Spring Number : 1E8048
• Fail Direction : Fail Up
• Actuator Style : Spg & Diaph
• Ordering background Details:
• Type 657 (size 34)
• Throttling service
• 4-20 mA (Positioner 3582)
• Max supply pressure 4.48 barg
• Unknown body size (special steam turbine)
• Ambient temp 80C (On top of steam turbine) (High temp application)
• Top mounted hand wheel.
Page 10
Positioner spec.
Ordering information Positioner:
FS3582-SS-0D2A-4A1-A007E
• Instrument Type : 3582
• Input Signal : 3-15 PSI
• Output range: 6-30 psi
• Action : Direct
• Bypass : No
• Inst Gauge : Tire valves
• Output Gauges : None
• Hazardous Area Approval : ATEX Group II Cat 2 Gas and Dust
• Pressure Conn : 1/4 NPT
• Tubing and Fitting : 3/8 NPT
• Travel Range : 7/16- to 2 1/8 Inch
• Ordering background Details
• Type 3582
• 3-15 psig
• Max supply pressure 3.4 barg
• European (ATEX) Grp II, Cat. 2, Gas
Ordering information I/P:
• 846 pipe mounted.
• Instrument Type : 846
• Input Signal : 4-20 mA
• Output range: 3-15 PSI
• Action : Direct
• Pressure Conn : 1/4 NPT
• Conduit Conn : 1/4 NPT
• Ordering background Details
• Type 846
• 4-20 mA _ 3-15 psig
Page 11
Solenoid valve
• A new trip oil solenoid is foreseen.
• Type PARKER
• Model 12F23O2248ACFEC05
• Numbers mean:
• 12 ¾ NPT connection size
• F Female pipe threat NPT connection type
• 2 2 way construction
• 3 Diagfragm hung construction
• Normally open construction
• 2 Brass (Forging) body material
• 2 FKM Viton Trim
• 48 ¾” Orifice size
• A Parker series designation
• C 11 watts coil
• F High temperature (class 180)
• E Explosion proof/ water tight (Class 1 div1 group C&D)
• 05 110/50 120/60 Coil voltage AC
Mechanical change write-up
The mechanical system can be split up into several sections.
• Speed pick-up installation
• Speed gear installation
• Actuator installation
Page 12
Speed pick-up installation
The speed pick-ups are installed in the upper case of the wormgear casing for the Terry
turbine and right side for the Elliott turbine. They should be directed to the center of the
shaft. The best approach is
• Dismantle the casing of the wormgear casing
• Install the peace in a drilling machine and determine the center of the casing and gear
location.
• drill the tapped holes from the outside in.
• Tap the threat in the holes (M12x1).
• Spot face the outside of the casing (to get sufficient surface for the nuts)
Page 13
Elliott Turbine
Page 14
Page 15
Speed gear installation
Replace the existing wurmwheels with the new gears.
Actuator installation
Elliott
• Dismantle the linkage of current system and install the actuator support,
(made by Customer)
• Examples were shown during the visit.
• Install the actuator on the support, and connect the actuator to the valve stem.
• Connect the actuator to the pneumatic system.
• Stroke and calibrate the actuator/positioner. (Initial actuator stroke to be 11.1 mm
(7/16”))
• Stroke the valve several times, to check the functionality.
• Remove complete linkage and support
• Install cover plate.
• Install Actuator support and actuator stem connection
Page 16
Page 17
Terry
• Dismantle the linkage and spring of current system and install the actuator support,
(made by
• Customer) Examples were shown during the visit.
• Install the actuator on the support, and connect the actuator to the valve stem.
• Connect the actuator to the pneumatic system.
• Stroke and calibrate the actuator/positioner. Initial actuator stroke to be 19.0mm (3/4”)
• Stroke the valve several times, to check the functionality.
• Remove linkage and spring.
• Install actuator support and stem connection
Page 18
Page 19
Control system
CCC developed for the smaller Turbines a dedicated controller called the Vantage which is a
perfect solution for the smaller machines with limited I/O and single critical speed.
If customer already has CCC on site (S3plus/S3++) it might be a better option to use the
S3plus/S3++ speed controller.
Vantage®GP
Purpose-built digital governor
• Precise control of API-612 general purpose steam turbines
• Integrated process control functions
• 4x20 character vacuum florescent display
Series 3++ Controllers
•The Series 3++ controller family builds on the phenomenally successful and reliable Series 3
Plus product line
•Perfect for new applications, machine retrofits, and CCC hardware upgrades
•Series 3++ controllers share the identical mounting hardware with Series 3 Plus controllers
Page 20
Overspeed Prevention System (OSP)
Guardian®
•2oo3 Voted overspeed trip system
•On-line Overspeed Testing
•Fully API-670 Compliant
•CSA Certification
- Class 1, Div 2, Groups A,B,C, and D
- Class 1, Zone 2, Exn IIC T4
•Enclosure IP-65 (NEMA 4)
•Alarms and history status
•Digital Tachometers for each Speed Module
•Flexible Mounting (19” rack mount or back mount)
