VDMA-Einheitsblatt November 2013 VDMA Verband Deutscher Maschinen- und Anlagenbau e.v. (VDMA)

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1 VDMA-Einheitsblatt November 2013 VDMA ICS Turbomachinery and generators Application of the principles of functional safety Part 6: Risk assessment gas turbines Turbomaschinen und Generatoren Anwendung der Prinzipien der Funktionalen Sicherheit Teil 6: Risikobeurteilung Gasturbinen Continued page 1 to 43 Verband Deutscher Maschinen- und Anlagenbau e.v. (VDMA) The VDMA Specification is protected by copyright and remains the sole property of the VDMA Verband Deutscher Maschinen- und Anlagenbau e.v., Frankfurt/Main. Any alteration, addition, editing, inclusion, translation, copying and/or distribution requires the express written agreement of the VDMA in advance. VDMA Specifications are available for purchase only via Beuth Verlag GmbH, Berlin. VDMA : Price gr. 17

2 Contents Foreword Scope Normative references Definition of terms The calibrated risk graph and its parameters Risk graph Manpower plan Procedure during the risk assessment Product-specific definitions Protective functions for gas turbines Overspeed protection Starter motor overspeed protection Main flame monitoring on plants with downstream steam generator Main flame monitoring on plants without downstream steam generator Monitoring of the axial position of the rotor Monitoring of the radial shaft vibration referred to the machine Monitoring of the radial shaft vibration referred to the coupling Monitoring of the bearing temperature Monitoring of the lubricating oil pressure Oil level monitoring in the lubricating and hydraulic oil tank Flue gas temperature monitoring Drainage for unburnt fuel oil Monitoring of combustion gas pressure ahead of combustion gas valve Monitoring of fuel oil pressure after main fuel oil pump Emergency stop Monitoring of electrical combustion gas heaters Monitoring of the combustion gas temperature Monitoring of gas leaks Pumping protection Vacuum monitoring in the inlet duct Overpressure protection in the flue gas duct in plants without steam generator Overpressure protection in the flue gas duct in plants with steam generator Fire in the enclosure Asphyxiation due to triggering of the fire extinguishing system (CO2), including incorrect triggering Backflow from the combustion chamber into inactive supply lines Accumulation of potentially explosive mixtures during the ignition delay Explosion of ignition gas after external leak Monitoring of the rotor for low metal temperature Protection of the inlet filter against ignition due to electrical heating elements Protective function on usage of gearbox between gas turbine and generator Page

3 Foreword This VDMA Specification has the objective of ensuring a standardised perspective of the assessment of risks on gas turbines; risks that are reduced by a safety measure. For this purpose risk assessments are undertaken that lead to a categorisation of protective functions that can be used as the basis for projectspecific designs. The requirements on the protective functions (risk reduction required) have been determined using a risk graph that is orientated on turbomachine-specific requirements and that has been calibrated using the quantitative method. Detailed explanation and background information on the risk assessment can be found in part 1 of the VDMA Specification 4315 Turbomachinery and generators - Application of the principles of functional safety Part 1 Methods for determination of the necessary risk reduction. The evaluations were included in a common interpretation in joint meetings between manufacturers (VDMA member companies) and operating organisations (represented by the VGB) such that the estimations given represent the common view of manufacturers and operating organisations. This VDMA Specification and the risk assessments it contains can of course only be an exemplary description based on the broad experience of the experts involved and with a view to typical machines from the application area and their common applications. As boundary conditions, application-specific and process-specific effects and risk components stemming from the surrounding area need to be taken into account in the real case, the steps and results shown here are to be taken as a practical starting point for a specific assessment. As such the document can only be used as the basis for assessing risks. No claim is made to completeness, nor to exact interpretation of existing legal requirements. It is not allowed to be used to replace appropriate study of the relevant directives, laws and ordinances or, in particular, the checking of the specific case. This VDMA Specification is part of a series of specifications with the following titles: "Turbomachinery and generators Application of the principles of functional safety" Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Methods for determination of the necessary risk reduction Risk assessment existing plants spare spare Risk assessment steam turbines Risk assessment gas turbines Risk assessment compressor train Risk assessment power plant generators The following companies were involved in the project work on functional safety for gas turbine risk assessment Alstom Power Systems MAN Diesel & Turbo Siemens Energy Sector as well as the VDMA Fachverband Power Systems. This specification was prepared by the following experts: Dr. Andreas Belzner Alstom Power Systems Dr. Wilfried Blotenberg MAN Diesel & Turbo René Harbers-Frischmann MAN Diesel & Turbo Gerd Weber Siemens Energy Hans Weibel MAN Diesel & Turbo 3

4 The content of the specification has been agreed in detail with experts from the operating organisations Dr. Manfred Freimark VGB Power Tech The VDMA Specification is therefore published in co-operation with VGB PowerTech, Essen 4

5 1. Scope Gas turbines for power generating plants and industrial applications of all power ratings The specification applies to personal injury; damage and pollution are not considered here. More detailed explanations are given in part 1 of this series of specifications, section