Category: Woodward

APPLICATIONS

EGCP-3 is a powerful microprocessor based generator system control and

management package designed for the most demanding power generation applications.

EGCP-3 combines engine, generator, power system, switchgear, and utility monitoring,

protection, and control functions in a single, compact, and cost-effective package.

Perfect for medium- and large-sized generation systems, the EGCP-3 is designed 

for use in stand-alone, peaking, or utility paralleled systems.

Up to 16 EGCP-3 controls can be networked together to provide total system

control, including multiple utility and  inter-bus tie breakers.

DESCRIPTION

EGCP-3 is available in standard configurations including:

DR—Distributed Resource:

• Single unit isolated

• Single unit parallel to mains

• Single unit ATS

LS—Load Share:

• Multiple unit isolated

• Multiple unit parallel to mains

MC—Master Controller:

• Mains tie breaker control

• Inter-bus tie breaker control

Using the sequencing functionality of the EGCP‐3. the control is configured to

start an additional unit two seconds after the load on the master unit exceeds 75%.

When the load reduces to below 30%, the slave unit is removed from the system after 60 seconds.

The controls needs to be able to trade master/slave relationships,

so a switch is used to place one control in Auto and Run w/ Load (Master)

and the second unit in Auto (Slave). Both controls have the option to operate in either

mode—so if sequencing needs to be avoided, the operator can place both

controls in Auto and Run w/ Load, and both units will share the entire electrical load.

The closed transition to shore power was solved by sending a remote fault input to the EGCP‐3 when the

shore power breaker is closed onto the system. When coming into port, ship’s power is reduced before

synchronizing to shore power. This means that only one unit is online with low load. When shore power is

connected, the operator adjusts a switch from “Generators” to “Shore” power. Instigating this switch turns

on the SPM‐D and allows the unit to begin sending digital signals to the EGCP‐3 LS to synchronize the

ship’s power to shore power.

When the breaker is closed, the aux feedback is sent to a remote input on the EGCP‐3 that opens the

generator breaker and shuts the generator down. The system is then completely supplied by shore power.

When the ship switches back to Generators, the remote input is cleared and the unit coming online

synchronizes to the shore power, closes its breaker, and the shore power breaker is immediately opened.

The system is then on Generator power.

Application

The ship’s chief engineer required several modes of operation in order to

optimize the performance of the yacht’s electrical system.

During normal operation, the load on the ship can be supplied by one genset, but when seas are

rough and the ship’s stabilizers are running, there is a need for additional generation.

In this mode of operation, both gensets must run continuously.

Also, the ship needs to be connected to shore power when in port.

In order to eliminate a blackout on the ship during the power transfer,

and to reduce the amount of load generated to the shore power,

a scheme was developed to provide an automatic closed transition using a Woodward SPM‐D.

Using the sequencing functionality of the EGCP‐3. the control is configured to

start an additional unit two seconds after the load on the master unit exceeds 75%.

When the load reduces to below 30%, the slave unit is removed from the system after 60 seconds.

The controls needs to be able to trade master/slave relationships,

so a switch is used to place one control in Auto and Run w/ Load (Master)

and the second unit in Auto (Slave). Both controls have the option to operate in either

mode—so if sequencing needs to be avoided, the operator can place both

controls in Auto and Run w/ Load, and both units will share the entire electrical load.

Electrical System

The Sea Jewel’s two Cat 3304 gensets are rated for 80 kW each. Each genset is

controlled by a Woodward EGCP‐3 LS and can connect to the ship electrical load via

its generator breaker. The load can also be supplied by shore power when in port.

To synchronize the boat to shore power, a Woodward SPM‐D delivers

synchronization signals to the two EGCP‐3 LS units and closes the breaker when

phase and frequency are matched.

Conclusions

The commissioning of the Sea Jewel was a success, and operation of an EGCP‐3 and SPM‐D illustrated the

adaptability of Woodward controls to any application. By applying the EGCP‐3 LS units to the control of

the Cat gensets and the SPM‐D for synchronizing the shore power, the Sea Jewel now has a reliable

system to begin their chartering business this summer. Woodward would like to thank Sea Jewel Ltd and

Governor Control Systems fortheir time and energy on this project and congratulates them on a great

control system.

Sea Jewel is a 160 ft (49 m) yacht that uses two Caterpillar 3304 gensets for electric

power. The ship’s original control system needed repair but had been discontinued;

additionally Lloyd’s registration was required to comply with new insurance

guidelines. So Sea Jewel Ltd contacted Governor Control Systems Inc. (GCS) to

purchase, install, and commission two Woodward EGCP‐3 LS units to control these

two Cat gensets. The EGCP‐3 LS combines engine, generator, power system,

switchgear, bus and generator monitoring, protection, and control functions in a

single, compact, and cost‐effective package. Woodward representatives were

present to help in the commissioning.

Electrical System

The Sea Jewel’s two Cat 3304 gensets are rated for 80 kW each. Each genset is

controlled by a Woodward EGCP‐3 LS and can connect to the ship electrical load via

its generator breaker. The load can also be supplied by shore power when in port.

To synchronize the boat to shore power, a Woodward SPM‐D delivers

synchronization signals to the two EGCP‐3 LS units and closes the breaker when

phase and frequency are matched.

The DVP is designed to control valves and actuators with either limited angle torque

(LAT) or brushless DC (BLDC) motor types. The driver positions based on resolver

feedback located on the valve or actuator. The DVP uses the latest in Woodward

control architecture, the robust controller to provide high-speed precise valve control.

The DVP is designed for plug-and-play installations on many valve types. Woodward

has integrated smart technology into the new generation of valves and actuators

called an ID (identification) module. Upon connection to a valve or actuator equipped

with an ID module, the DVP automatically reads critical valve-specific information to

set up the driver. After this auto-detection and customer configuration, the DVP is

ready for use. Both pre-manufactured connectorized cables and terminal connection

models are available.

The DVP is available in multiple configurations:

• Ingress Protected IP30 or IP66 models available

• Connector or terminal block outputs; conduit option available on IP66

• 125 Vdc or 24 Vdc power input options available

• EGD (Ethernet), CANopen, Analog (4–20 mA or 0–5 Vdc), PWM configurable input options

• Electric actuator driver

• Triple redundant EGD (Ethernet) or dual redundant CANopen digital communication options

• IP30 or IP66 enclosures

• ID module compatibility for plug-and-play operation

• Connector, terminal block, or conduit options

• Certified for International Hazardous Locations (CE Mark/ATEX, IECEx, CSA) and Marine

Applications

The Woodward DVP is the state-of-the-art driver for electric

actuation. It features a rugged and compact design.

The DVP is designed for use with various Woodward valves and actuators.

It provides positioning based on a demand signal from the control system.

Multiple input type configurations allow the DVP to be used with many different turbine controllers.

The driver supports redundant installations.

The DVP is available in multiple configurations:

• Ingress Protected IP30 or IP66 models available

• Connector or terminal block outputs; conduit option available on IP66

• 125 Vdc or 24 Vdc power input options available

• EGD (Ethernet), CANopen, Analog (4–20 mA or 0–5 Vdc), PWM configurable input options

• Electric actuator driver

• Triple redundant EGD (Ethernet) or dual redundant CANopen digital communication options

• IP30 or IP66 enclosures

• ID module compatibility for plug-and-play operation

• Connector, terminal block, or conduit options

• Certified for International Hazardous Locations (CE Mark/ATEX, IECEx, CSA) and Marine

Next Generation Electric

Valves and Actuators

Increase Turbine

Reliability and Availability

Heavy Duty Gas Turbines have increasingly been dispatched to support

the grid during renewable energy transition. These market conditions

drive fleet owners to operate their assets as peakers, creating the need

for frequent starts. Start-up reliability has become a key success factor

for these units.

Benefits of Electric

›Elimination of hydraulic fluid and associated problems

with contamination, cold weather and leakage

›Higher reliability design inherent to electric actuation

significantly increase maintenance intervals

› Improved control response and precision

›OEM Qualified and included with the majority of new

Gas Turbines

›Compliant with NERC standards for cold weather

preparedness

›Service Tool provides enhanced diagnostics for plant

personnel and early indication of performance issues

at the DCS operator terminal

Common Problems with Hydraulic Actuators in Heavy Duty Gas Turbines

›Hydraulic fluid viscosity dependent on ambient

temperatures – leads to slower response times in

cold temperatures – resulting in failed starts

›Fluid varnishing can lead to clogged servovalve

passages resulting in failed starts or stops

›Potential of high pressure hydraulic leaks pose safety risks

›Premature seal failure – noise on hydraulic control

circuits can lead to premature wear on hydraulic

and gas seals

›No actuator/valve data to predict failure in advance of outages

›Electric actuators are paired with a remote Digital

Valve Positioner (DVP) that controls the actuator

operation and serves as the customer interface for

power/signal wiring and digital communications.

Multiple DVP’s can be packaged within a stainless

steel cabinet and prewired from the factory to greatly

reduce commissioning time

This proven design has been an industry standard for many years and worldwide

acceptance ensures easy servicing in most engine and governor shops.

The mechanical governor backup capability of Woodward’s EGB governor/actuators

provides increased reliability and safety during the operation of dual-fuel and diesel engines or gas and steam turbines.

Woodward’s PG pressure-compensated governor line effectively controls the speed

of the largest engines and turbines with work capacities ranging from 12 to 500 ft-lb.

Key Product Variants Include

Simple Governor (SG) 5.7 – 40 foot-pounds of work.

Universal Governor (UG-25+) 10.8 – 21.7 foot-pounds of work.

Governor (3161) 18 foot-pounds of work.

Electronically Controlled Actuator w/ Mechanical Backup (EGB) 1-300 foot-pounds of work.

Large Pressure-Compensated (PG) 12-58 foot-pounds of work.

Key Features

Simple to operate and exceptionally reliable.

Precise control of engine speed and output.

For virtually all types of engine applications: power generation, marine, pump, compression and vehicle applications.

Proven, industry-standard design.

Worldwide acceptance and easy service.