GCS Newsletter: September 2012

Safety First / Stop Guessing . . . Start Protecting GCS is committed to promoting a safe work environment and protecting plant safety. GCS maintains a vigorous Safety Program to protect the well-being of our customers, team members, neighbors and guests. Industrial sites often involve the use of hazardous materials and heavy equipment operating under high temperatures and pressures. Stringent safety norms and regulations have driven the process industries to closely review their safety systems. These systems are installed not only as a preventive measure to avert accidents but as an opportunity to increase plant profitability and productivity. GCS Quality and Safety Program GCS incorporates elements of our ISO 9001:2008 Quality Management System to set safety objectives, to measure our performance and to continually improve our Safety Program. The workplace safety indicator, Total Reportable Incident Rate (TRIR), measures the number of incidents per 200,000 working hours. The GCS TRIR is an impressive 1.19, well below the industry average of 4.20. GCS technicians hold safety accreditations for OSHA, SafeGulf®, SafeLand® and Helicopter Underwater Egress Training (HUET). Our customers can be confident that the engineer who services their equipment or facility is fully trained, equipped and safety conscious. The control and monitoring products we represent meet the highest industry specifications to ensure our customers’ equipment is operating under the safest conditions possible

Staying in Compliance with API611 / API612

Standards enhance the safety of industry operations, assure quality, help keep costs down, reduce waste, and minimize confusion. Since 1924, the American Petroleum Institute (API) has been a cornerstone in establishing and maintaining standards for the worldwide oil and natural gas industry. Their work helps the industry invent and manufacture superior products consistently, provide critical services, ensure fairness in the marketplace for businesses and consumers alike, and promotes the acceptance of products and practices globally.

API STANDARD 611, FIFTH EDITION, MARCH 2008 7.4.2.3 Overspeed Shutdown System 7.4.2.3.1 The turbine shall be equipped with an independent emergency overspeed system that shuts off steam to the turbine when running speed reaches trip speed (see Table4). The emergency trip system must have easy accessibility, the capability to be:

• manually tripped with maximum inlet steam pressure and flow in the line • to stop the turbine by activating a force-actuated trip valve under any load condition of the turbine • to be reset with maximum inlet pressure • spark - proof components and suitability for use in hazardous gas and outdoor locations.

API STANDARD 612, SEVENTH EDITION, MAY 2010 12.3 Turbine shutdown system 12.3.1.1 A shutdown system capable of shutting down the turbine shall be provided. The turbine shutdown system shall include, but no be limited to, the following:

• input sensors • logic solver devices (one or more including overspeed trip function) • electro=hydraulic solenoid valves • emergency trip valve(s)/combined trip and throttle valve(s)

The shutdown system shall not be prohibited in any way from executing a trip of the turbine by any other system. 12.3.1.7 The overspeed shutdown function shall be part of the turbine shutdown system. The overspeed function may be included in the shutdown system logic solver or in a dedicated overspeed logic solver. Detailed overspeed detection requirements are described in API 670. Woodward Advanced Independent Safety Systems Meet All API-611, API-612 and API-670 Specifications Woodward Distributed Safety Systems are designed to provide complete safety coverage to enhance

• Plant Safety & Control • Process Safety & Control • Turbine Safety & Control

Woodward’s NEW IEC61508 SIL-3 certified ProTech® safety and machinery protection platform leverages decades of pedigree and is designed to meet API specifications.

The platform ranges from the simplex version (ProTech®-SX) to a full TMR based control that also monitors up to 10 different machinery sensors/devices (ProTech TPS) to provide a full blanket of protection for your equipment. Many improvements to the ProTech® platform make it easier to use, maintain, customize, and standardize. In addition, security functionality is implemented to meet new Cyber Security requirements.

ProTech®-Gll ProTech®TPS SIL-3 MicroNetTM ProTech®-SX Safety Module

ProTech®-GII – Triple Modular Redundant protection device with speed inputs.

ProTech®TPS – Triple Modular Redundant protection device with speed inputs, 10 configurable inputs to provide additional safety/protection logic.

SIL-3 MicroNetTM Safety Module –Fault-Tolerant Protection System (Safety PLC with Integrated Overspeed Protection) –MicroNet based Triple Modular Redundant protection module with speed inputs, as well as 10 configurable inputs to provide additional safety/protection logic. The MSM is IEC61508 SIL-3 Certified and API670 & API612 Compliant.

ProTech®-SX – Simplex protection device with 2 redundant speed inputs, 7 configurable inputs to provide additional protection logic.

Woodward Digital Integrated System Controls Woodward digital speed and load controls provide one level of overspeed detection. For complete protection that will meet API requirements and preferred insurance standards, these controls must be interfaced to a Woodward turbine safety system. From Peak 150 digital controls designed to control a single-valve steam turbine driving a mechanical load to MicroNet-Plus and MicroNet TMR platforms certified for use in IEC61508 SIL-1, SIL-2 or SIL-3 (safety integrity level) applications, Woodward’s configurable and programmable digital steam turbine control platforms offer simplex, duplex, and TMR options that incorporate proven software and hardware.

Peak 150 505/505E 505DE MicroNetTM Plus

Fully programmable control platforms allow GCS to create a custom controller with site specific algorithms, logic, and protection functionality as required by the application. Utilizing Woodward’s GAP (Graphical Application Programming) environment, control engineers are able to create the required applications utilizing proven algorithms tailored for turbine control and Woodward’s hardware. To meet today’s safety requirements, Woodward has updated its MicroNet™ Plus and MicroNet TMR® platforms’ capabilities and related certifications. These updates include safety certified hardware, safety certified software, and safety certified production and engineering processes. Read more. Reliable Speed Indication with Self-Powered Tach Kits

Woodward Safety System Controls – TG611 Mechanical Governor Easily overspeed test your steam turbine using the Woodward TG611 governor with integral overspeed test device.

API 611* Compliant Overspeed Testing Woodward TG611 Governor with Overspeed Protection directly replaces TG Governors. Self-contained, mechanical-hydraulic, speed-droop governors are used on small steam turbines driving pumps, compressors, or generators. These governors are directly coupled to the steam-turbine’s rotor or auxiliary shaft to sense and control turbine speed.

WARNING

Reliable Speed Indication with Self-Powered Tach Kits Take the guesswork out of tracking your speed. GCS digital Tach Kits reliably monitor engine and turbine speed, reducing downtime, maintenance costs and potential failure. Easy to install & read, the GCS field-configurable Tach Kits provides easy, reliable speed monitoring and data logging. Digital tachometers are mounted directly on the engine or on the Woodward mechanical-hydraulic TG or PG governors used on general purpose turbines. TG and PG Tach Kits meet API Standard 611 and 612 requirements for “a manual method to safely increase the speed of the turbine over the maximum continuous speed of the governor to allow for a safe and controlled test of the independent emergency overspeed system.”

Picture on G drive: G:\MSHS\Marketing\Woodward Products\PG Tach Kit\PGPL sideview_w shadow.tif

Designed for API-611-based turbine applications, the TG-611 governors include a special Overspeed Test Device, allowing controlled and safe turbine overspeed trip testing. Easy to use, TG-611s are field-adjustable for overspeed test speed. For updated overspeed testing, GCS can upgrade your standard TG-13 or TG-17 governor a TG-611.

Governor Overspeed Trip Tests Safe Shutdown Scheduled maintenance and overhaul service ensure continued safe operation of your prime movers. The engine, turbine, or other type of prime mover should be equipped with an independent overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An over-temperature or overpressure shutdown device may also be needed for safety. GCS supports our products with comprehensive technical assistance and services to avoid unnecessary plant malfunctions and expensive down time. Protect Engines with Schaller Oil Mist Detectors

Dynalco Overspeed Trip Dynalco PNT202 Overspeed Trip - Derives signal and power from 2 Dynalco magnetic pickups. No external ac or dc power required. Unique marine applications; used in connection with the Dynalco SPV-200. Once an over-speed is sensed the PNT202 will switch the SPV200 pneumatic valve to redirect air pressure to your pneumatic actuation cylinder tripping the air-flapper valve, closing off the engines air intake manifold. When the preset overspeed setpoint is reached, the PNT-202™ trips the SPV-200™ Solenoid Pneumatic Valve. The valve opens, latches, bleeds to the atmosphere, and shuts down the engine if it is connected to the engine pneumatic control system. The PNT-202 also effects shutdown when one of the pickup signals disappears or when an attempt is made to start with only one operational pickup. The second setpoint can trip the same valve or a separate valve. It can be field-programmed as an underspeed setpoint or as a second overspeed setpoint or crank disconnect. When set for underspeed, no inhibit is necessary on start-up as this setpoint becomes enabled only when the speed first exceeds the setpoint.

When it comes to crankcase protection, leading manufacturers of large diesel, gas and dual-fuel engines trust Schaller Automation Oil Mist Detection Systems. Oil mist becomes ignitable whenever it reaches the LOWER EXPLOSION LEVEL, which is approximately 47mg/liter or 13% oil mist / air ratio, at which point any hot spot with temperature above 850oC (1562oF) can trigger an explosion. For over 30 years Schaller Automation's VISATRON Oil Mist Detector Systems have been protecting engines from crankcase explosion. Schaller Automation is the market leader in crankcase safety protection by oil mist detection, protecting over 40,000 large Diesel, Gas and Dual Fuel Engines in marine, offshore and land based power plants.

Our factory-trained technicians are available 24/7 for service‚ repair and regular maintenance. Contact GCS to ensure the optimum operation of your Schaller Visatron oil mist detector.