Overspeed Protection Retrofits

The overwhelming majority of small
turbine overspeed trip devices are mechan-

ical; they incorporate a spring-activated trip
bolt that moves out and contacts a trip lever whenever a
preset overspeed is reached. A number of factors make it
necessary to check, and possibly recalibrate, these built-
in devices yearly. Needless to say, process plants are not
always performing this preventive maintenance activity in
a timely and procedurally correct fashion. Unscheduled
downtime events and serious injury, even deaths, have
resulted from such oversights.
Well-engineered and highly reliable electronic over-
speed prevention (OSP) systems are now available for
new and retrofit applications. These systems offer end
users the security and dependability of a two-out-of-
three voting system, with the flexibility and ease of do-
it-yourself installation and
configuration.
One relatively recent OSP
system incorporates a two-
out-of-three voting feature
that monitors turbine speed
and will initiate a trip com-
mand to prevent overspeed
events (Fig. 1). Designed and
manufactured by Des Moines,
Iowa-based Compressor Con-
trols Corporation (www.ccc-
global.com), the system
includes three identical speed
modules that individually
measure a frequency input
signal froma passive or active
magnetic pickup sensor. A supervisory module continually
monitors the three speed modules for proper operation,
which helps to eliminate unnecessary downtime and increase
system availability.
Multilevel password ensures security. The OSP system
provides users with a multilevel password function for
added security. Each level provides access to higher sys-
tem functions, including Peak Speed Reset, Overspeed
Test Mode, Configuration Mode and Set New Passwords.
The three speed modules provide a greater level of
dependability. Open-pickup detection on passive sen-
sors is provided as well as dynamic sensor failure detec-
tion via the supervisory module, which knows when a
speed module should be receiving a valid frequency input.
Active sensor power is provided as an output as well. Each
speed module can display its speed and current setpoint.
Additionally, each speed module includes four dedicated
LEDs for indicating overspeed test, trip, MPU failure and
fault conditions.
Self- diagnostics: supervisory module. CCCs overspeed
protection system also features complete continuous self-
diagnostics. The supervisory module monitors proper
operation of the speed modules and power supplies. A 4-
line by 20-character alphanumeric display is integrated into
the operator interface. A test mode provides testing of
each speed module, including verification of the voting
relays operation. This module also includes a dedicated
LED for indicating an alarm condition.
Speed module configuration is performed from the
supervisor user interface.
The OSP system is config-
ured through the supervisor
module during setup. A sin-
gle supervisor module fail-
ure will not affect normal
operation of the OSP sys-
tem. The supervisor operates
as a background device, col-
lecting information and
monitoring speed module
operation.
The supervisor module
provides additional features
not available from most other
two-out-of-three voting OSP
systems. For example, the
supervisor module handles such high-overhead tasks as
Modbus communication. This allows the speed modules
to concentrate on their primary task of monitoring the
frequency input signal. With CCCs Guardian OSP sys-
tem, an operator with proper access privilege can enable
the overspeed test mode and test each speed module. All
overspeed tests are verified and time-stamped in the his-
tory log. Alarms and peak-speed recordings are also time
stamped. An overspeed test can not be activated if an
alarm, trip or fault condition is present, thereby elimi-
nating accidental trips. During an overspeed test, the
supervisor module turns on an LED indicator on the front
panel of the affected speed module to indicate that a mod-
ule is being tested.
The relay board contains socketed output relays and
Consider overspeed protection retrofits
Heinz P. Bloch, Reliability/Equipment Editor
Fig. 1. Thi s OSP syst em f eat ures a t wo- out - of - t hree vot i ng f eat ure t hat
moni t ors t urbi ne speed.
Reprinted from: magazine, Jan. 2002 issue, p. 17. Used with permission.
HPIN RELIABILITY
For more information about our new Guardian
Overspeed Prevention (OSP) system and

other state-of-the-art products from the world leader in turbomachinery control, please
contact a CCC office near you. We are uniquely qualified to solve turbomachinery con-
trol problems. We will help you to achieve maximum performance of your turbomachin-
ery, regardless of your equipment or process.
includes Overspeed Trip Output #1: DPDT relay; Overspeed
Trip Output #2: DPDT relay and alarm: DPDT relay.
Online replacement (hot swapping) of failed supervisor, power
supply and speed modules is a standard feature. The relay board
includes the power supply diode-voting circuitry and contains con-
nectors for the different boards in the system to obtain DC power.
Flexibility. Two power supply modules provide redundant power
to the relay board, speed modules and supervisor. These two mod-
ules provide all the system power, and each can be powered by
18 to 32 VDC and/or 85 to 265 VAC. Outputs of the two power
supply modules provide system power through circuitry located
on the relay board. With the OSP system, users no longer have
to order separate systems for specific power requirements or
required trip logic. Deenergize-to-trip or energize-to-trip logic
is jumper selectable.
By meeting a broad range of installation requirements, this
OSP system can be installed with any turbomachinery train for
virtually any application. Whats more, installation and config-
uration can be completed by your in-house personnel.
API/ ISO compliant. The Guardian OSP system is API 670 and
ISO compliant, making integration with an existing system eas-
ier. Even though some competitive systems are available with sim-
plex, redundant and triplex speed switches, not all of them com-
ply with the latest API and ISO requirements. Many OSP systems
lack self-diagnostic testing and data communication capability.
These are standard features with this OSP system. Together
with the many other advanced features, the resulting package
opens up safety, reliability and maintenance enhancement pos-
sibilities that merit serious consideration.
Reliability . . .
The author is Hydrocarbon Processings Reliability/Equipment Editor. He
advises process and power plants worldwide on reliability improvement and
maintenance cost reduction and can be reached at hpbloch@juno.com.
COMPRESSOR CONTROLS CORPORATION
International Headquarters
4725 121st Street
Des Moines, Iowa 50323-2316, U.S.A.
Phone: (515) 270-0857
FAX: (515) 270-1331
An ISO 9001 CERTIFIED COMPANY
CCC E- mail: solutions@cccglobal.com
Web Site: www.cccglobal.com
CCC Worldwide:
Houston, Texas
Rio de J aneiro, Brazil
London, U.K.
Amsterdam, The Netherlands
Frankfurt, Germany
Milan, Italy
Moscow, Russia
Singapore, Republic of Singapore
New Delhi India
Dammam, Saudi Arabia
Dubai, United Arab Emirates
Beijing, China
L K /1 M /2 -0 2 A rtic le c o p yrig h t 2 0 0 2 b y G u lf P u b lish in g C o m p a n y. A ll rig h ts re se rve d . P rin te d in U S A .
Publication #MS 106

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The overwhelming majority of small

turbine overspeed trip devices are mechan-

Overspeed Prevention (OSP) system and

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