Category: Woodward

The 505DR® Dual Redundant Turbine Controller is a state-of-the-art digital control platform designed to reliably control and protect single-valve and single-pump steam turbines.

The benefits of dual redundancy maximise turbine reliability and availability.

Redundancy is managed at the operating system level using Woodward’s RTN (Real Time Network), allowing ultra-fast switching and ‘bufferless’ transitions.

The controller utilises the same unique PID architecture as the proven 505XT, making it the ideal controller for controlling speed, load,

parameters such as pumping collector pressure, exhaust collector pressure or connection line power. The dual redundant version inherits features such as the Opti-Tune self-tuning PID and ratio limiter.

The controller includes the following turbine protection features to ensure that the turbine and its driven loads (compressors, pumps, generators) operate within design limits:

– 3 critical speed avoidance bands

– Overspeed prediction and shutdown protection

– Configurable under- or over-pressure shutdown logic

– Minimum and maximum speed and load settings

– Maximum low-pressure stage overpressure limitation

– Minimum high pressure stage flow limiting

Ethernet and serial communications allow for easy integration into plant controls or process control systems.

The 505DR can be configured with an optional integrated user interface, including an 8.4-inch multi-language graphical display.

Description

Like the MicroNet Plus, the 505XT system designates one controller as the System Controller (Syscon), actively controlling the fan.

The second device is configured as a www.cniacs.com backup. The system automatically evaluates the health of the Syscon and initiates a fast switchover in the event of a failure.

Switchover can also be initiated manually. The system closely synchronises the Syscon’s software status and memory with the backup, ensuring that the control output remains stable and does not affect turbine operation (a true ‘bufferless’ switchover).

If the optional HMI version is selected, the display and keypad are redundant (input from either keypad will command Syscon, and the display can be independently selected to show different screens.

For example, one screen can display speed and speed settings, and another can display a steam map.

Woodward’s optional RemoteView programme allows remote monitoring from any networked PC.

The programme can be used either with the rear panel mounted version (as the main HMI) or as an additional remote monitor to the HMI version.

The optional FTM (Field Terminal Module) allows easy multiplexing of redundant signals and facilitates fast installation and commissioning.

Part 8271-468 Generator Loading Control from Woodward.

It runs on 115/230 volt AC power and has a beige case. This unit is primarily used in commercial applications.

When used in conjunction with the Woodward Load Sharing and Speed Control System, it allows you to adjust the electrical load being carried by the generator set.

Product Description

The standard commercial features of the Generator Load Control Unit 8271-468 have been programmed into the unit.

This allows the unit to control user-selected electrical load adjustment of the generator set.

Operation www.cniacs.com and adjustment of the 8271-468 to the desired specifications is highly dependent on the unit’s use of the power system.

It can be used with an isolated power system or with a local system connected in parallel with an infinite bus.

In an isolated system, the 8271-468 generator load control is used in conjunction with each load sharing and speed control.

The 8271-468 is wired in parallel with these two units to detect generator loads.

The output of this unit is designed to bias the line voltage to control a portion of the total system load.

If connected in parallel to an infinite bus, the voltage at the generator load control device load signal test socket should be measured when the unit is fully loaded.

In an isochronous parallel application, Generator Load Control Part No. 8271-468 regulates power while the utility maintains frequency.

The advantage of this control system over standard parallel buck operation is that, when separated from the utility, the

The now isolated busbar is automatically under isochronous speed control, eliminating the need for the operator to readjust the speed setting.

Within Woodward Equipment’s line of generator controls, the 8271-468 has the widest market availability compared to other components.

Woodward Unit 9907-164. from 505 Digital Microprocessor Controller for Steam Turbines with Single or Split Range Actuators.

Product Description.

The unit listed here is model 9907-164 and is part of the 505 and 505E microprocessor based governor control units.

These control modules are specifically designed to operate steam turbines, turbine generators and turbo-expander modules.

The 505/505E series was originally developed, produced and manufactured by Woodward.

Woodward is the oldest industrial manufacturer in the United States, founded in 1870. and remains one of the leading industrial companies in the marketplace.

The 9907-164 unit is designed to control a steam turbine by operating a single extraction and/or intake of steam from the turbine.

It utilises the turbine’s staged actuators (either one or both) to actuate the steam inlet valve.

As with any 505 governor module, the unit can be configured in the field by a field operator.

The menu-driven software is controlled and changed by an operator control panel integrated into the front of the unit. The panel displays two lines of text with 24 characters per line.

The 9907-164 is equipped with a range of www.cniacs.com discrete and analogue inputs:16 contact inputs (of which 4 are dedicated and 12 programmable) followed by 6 programmable current inputs, 4 to 20 mA.

Standard features of the 9907-164 include critical speed avoidance, valve limiter, automatic start sequence, and shutdown first-out indicator.

Prepare for an emergency stop when starting an engine, turbine, or other type of prime mover to prevent personal injury from loss of control or overspeed.

Applications.

Compressor control and protection

Steam turbines

Gas turbines

Hydraulic turbines

Gas and diesel engines

Features.

Optional rear panel

Remote view

Virtual terminal connection

Powerful real-time microprocessor control

Fast, accurate on-board I/O channels

Combines real-time control with PLC programming

Deterministic I/O scan rates as fast as 5 ms.

Distributed input/output RTCnet and LINKnet HT compatible

Compliant with time synchronisation protocol SNTP

Network control connection to DCS

Low-cost alternative to general-purpose PLCs

Sulphur-resistant conformal coating

Standard or hazardous location certified

Distributed control systems

Designed for use as a distributed control system based on Woodward’s RTCnet and/or LINKnet HT distributed I/O modules.

They can be used in conjunction with the Flex500 platform to expand the number and type of input and output signals according to the requirements of a particular application.

Ethernet, serial and CAN communication ports and the associated Modbus TCP/IP and CANopen protocols also make the platform

ideal for use as part of a plant-wide DCS or as a stand-alone controller.

Four Ethernet ports and four CAN ports provide the network flexibility and redundancy required for today’s critical control system architectures.

The 2301E-ST controller is equipped with internal algorithms designed to start/stop, control and protect small turbines driving generators, pumps and compressors.

Features and Functions

The 2301E-ST performs the core control and protection functions of a small turbine unit.

The application software is field configurable, allowing it to be configured and modified to meet site-specific requirements.

Modbus communication also allows easy interfacing with a packaged PLC or plant DCS.

The 2301E-ST controller is backwards compatible with the existing 2301D-ST controller as it has the same form, fit and function.

The new controller ensures the continued availability of a proven, versatile product with enhanced functionality: -Accepts two redundant MPU speeds.

-Accepts two redundant MPU speed signal inputs

-Independent RS-232 and RS-422 serial ports, both with 9-pin connectors

-Additional status led for power and RS-422 communications

-Fault data logging function that collects 16 seconds of data every 10 milliseconds in the event of a shutdown, peak speed, and load detection

Low current PWM output for driving Woodward L-Series, F-Series, P-Series and PISC actuators

-New terminal block accommodates additional I/O, with most terminals located in the same locations as the 2301D-ST model.

-Major compliance certifications

The 2301E-ST has four modes of operation.

-Speed control.

-With multiple dynamic flexibility. Will operate on pumps or compressors. Capable of remote 4-20mA speed referencing via configurable analogue input.

-Synchronised load sharing

-Compatible with most existing analogue load sharing speed control systems. Now with soft loading and unloading capabilities.

-Basic Load Drop

-Adjustable load control using discrete rise and fall contacts.

-Synchronised base load

-Provides constant load level operation for the common bus. Load settings can be fixed or changed using discrete raise and lower inputs or remote 4-20mA inputs.

The 5009XT is a standard off-the-shelf, single-pump steam turbine control for industrial steam turbines in reliability-critical applications.

The controller utilises Woodward’s field-proven MicroNet TMR triple-redundant fault-tolerant hardware platform combined with Woodward’s state-of-the-art XT steam control core and algorithms.

Features and Functionality

The 5009XT’s triple redundant fault tolerant design allows it to continue to safely operate the turbine at any single point of failure.

The modular design and hot-swappable features maximise uptime and minimise maintenance downtime required for control.

The unique PID architecture of the 5009XT controller makes it ideal for applications that require precise control of parameters.

These parameters include turbine speed, load, extraction header pressure, intake header pressure and exhaust header pressure or contact line power.

The field-programmable controller allows users to easily change system configurations without the need for OEM expertise.

The system can be controlled and configured using the optional 17-inch touch screen monitor or any workstation running Woodward RemoteView software.

workstation to control, configure, calibrate and tune the system.

Applications.

Speed/Frequency Control

Turbine or generator load control/limiting

Pumping and/or inlet manifold pressure control

Turbine inlet manifold pressure control/limiting

Turbine exhaust manifold pressure control/limiting

Plant input/output power control/limiting

Synchronised load sharing between units

Any process directly related to unit load

Proportional or integral servo position control with LVDT/RVDT excitation (with optional module)

Features.

Subject to C61508 SIL-3 certification (MSM required)

Triple-mode redundancy

API 612 and 670 compliant

Field-proven controller

Online configurable and repairable

Optional integrated HMI/engineering workstation

Problem Ahead Indication

Fault tolerant power supply

One millisecond timestamp alarms and faults

Integrated overspeed protection

CANOpen for integrated Woodward valves and I/Os

Features and Functions

Large bore engines using dilute gas fuel mixtures typically experience slower fuel burn rates and incomplete combustion.

These conditions reduce combustion efficiency and result in problematic exhaust emissions.

Typical J-gap spark plugs attempt to address these performance issues by increasing spark energy, which can shorten spark plug life.

To counteract the shortened spark plug life, J-gap manufacturers often increase the electrode area, which can have a detrimental effect on the ignition spark.

This has a “quenching” effect on the ignition spark, which increases combustion variability;

Or they use precious metals, which increase manufacturing complexity and reduce plug durability.

FTI’s unique, patented design provides consistent ignition without the need for a high-energy ignition system, reducing the need for precious metal electrodes for long life.

It can also be customised to meet specific engine combustion requirements.

FTI Advantages.

Fast, consistent fuel combustion

Improved engine efficiency

Reduced exhaust emissions

No hot running and good detonation margins

Longer life

Customisable design

Objectives achieved: Improved engine efficiencyContinuous fuel ignition – More complete fuel combustionFaster combustion – Just in Time Departure Point (ATDC) for improved combustion efficiencyImproved combustion stability

j-gap with FIT.

FTI’s patented pre-combustion chamber combustion technology improves combustion start-up with J-gap and conventional pre-combustion chamber spark plugs.

J-gap1 Typical J-gap spark plugs have a spherical flame front that burns slowly as it passes through the combustion chamber. This type of flame front is susceptible to high turbulence in the combustion chamber, which can quench or even blow out the spark, again increasing ignition variability. In addition, smaller spark surfaces corrode more quickly, shortening the life of the spark plug.

FTI addresses these issues by using a separate flame core for ignition. The multi-jet flame front from the FTI igniter creates its own combustion chamber turbulence. This self-generated turbulence adds to existing chamber turbulence while being highly resistant to other chamber turbulence that promotes rapid flame growth throughout the fuel mixture.

APPLICATIONS

The 2301E-HT for Francis Turbines is a standard off-the-shelf control system designed to control small Francis turbines.

This turbine controller contains specially designed algorithms and logic to start, stop, control, and protect the turbine.

With two serial communication ports, users can easily connect the 2301E-HT to a plant or process control system.

The controller’s inputs, outputs and status can be monitored and all start/stop or enable/disable commands can be issued via industry standard Modbus® RTU.

The controller can be configured in the field using Control Assistant software installed on an external PC.

Description

The control is housed in a sheet metal enclosure for general premises and consists of a single printed circuit board.

The 2301E-HT controller is designed for turbine control.

It includes three PID controllers (offline, online and load), startup routines and a variety of protection functions (overspeed, etc.) that can be configured by the user to meet the requirements of a specific turbine application.

The 2301E-HT can be configured by the user to use different PID controllers, start-up routines, discrete and analogue I/O functions without the need for a dedicated control engineer.

The 2301E-HT controls the speed and load of a Francis hydraulic turbine in a generator application with a single gate analogue output.

Features.

Field configurable optional start (auto/manual)/stop/unload routines

Liquid level control (pond or tailrace)

Creep detection

Local/remote control

Generator circuit breaker logic

Horizontal switching of speed, gate position and loads

Overspeed test logic

Speed/descent (power and position)/base load control

Remote analogue setpoints for speed, level and power

Selectable actuator outputs (4-20mA/0-200mA/0-20mA)

Dual speed inputs

Linknet hyperthreading extension function

Speed/load/gate switching

Brake Permit Logic

Gate Limit Values

Breaker open commands

Trips and alarms

Serial port communication (RS-232 or RS422)

System Protection:

Overspeed protection logic

Nondisturbance switching between control modes

Local/remote control priority

OVERVIEW

The 2301E-J is a microcomputer based digital controller for engine genset control with automatic load sharing.

The controller is designed to control medium to high speed diesel engines or medium to high speed gas engines.

Control speed range (for medium to high speed engines): 400-3600 rpm.

Similar in function to the 2301A LSSC, the 2301E-J is Woodward’s traditional analogue controller plus a DRU (Digital Reference Unit) with soft load/unload.

The 2301E-J also has the same features as the 2301D.

While the engine is operating, the 2301E-J can switch its operating mode from isochronous to sag and vice versa without buffering.

The 2301E-J can be switched to the 2301D by using the same function as the 2301 LSSC, the 2301A LSSC, the 2301D LSSC, and the 721DSC with Automatic Load Sharing,

723DSC with automatic load sharing, or other Woodward Electric controls with load sharing capability to operate in automatic load sharing mode.

In conjunction with an external inlet/outlet controller, the 2301E-J can control the inlet/outlet power to the mains (i.e., commercial bus) by simulating a remote speed setting signal (optional feature).

The 2301E-J can operate in isochronous mode, isochronous base load mode, kilowatt drop mode, normal speed drop mode, and mains parallel operation mode with GCP/EGCP.

In Isochronous operation mode, the 2301E-J can perform the following operations

– Parallel operation with multiple engine-generator sets connected to the bus via automatic load sharing functions (including soft load and soft unload).

– Base load operation in isochronous mode. (The load level can be preset or manually adjusted to the desired level using discrete or analogue inputs).

– Single engine generator operation. (Speed reference is manually adjusted to the desired level via discrete or analogue inputs).

In kW down operation, the 2301E-J can perform the following operations:

– Run in parallel with the mains. (Load level or speed reference preset or manually adjusted to the desired level via discrete or analogue inputs).

– Parallel operation with other engine generator sets. (Manual adjustment of the speed reference to the desired level via discrete or analogue inputs).

– Single engine genset operation. (Manual adjustment of the speed reference to the desired level via discrete or analogue inputs).

– In reduced speed operation, the 2301E-J can perform the following operations:

– Run in parallel with the power supply. (Manually adjust the load level or RPM reference to the desired level via the discrete inputs or analogue inputs).

– Operate in parallel with other engine generator sets. (Manually adjust the load level to the desired level via the discrete inputs or analogue inputs).

– Single engine genset operation. (Manually adjust the speed reference to the desired level via the discrete or analogue inputs).

The CPC-DX 10 bar, 2 zone, redundant, has an enhanced dynamic dual transmission current-to-pressure converter skid for on-line (automatic and manual switching) service capability for uninterrupted operation to position single acting turbine valve servos in critical applications.

Features and Functions

Woodward’s redundant skid-mounted current-to-pressure converter (CPC-DX) is an electro-hydraulic pressure-regulating control valve for positioning single-acting steam turbine valve servos/actuators.

The redundant version of the CPC-DX accepts a 4-20 mA pressure demand signal and accurately controls oil pressure to precisely position the single-acting steam turbine speed control valve.

Accurate and stable steam valve control is directly related to increased steam turbine speed and load control and reduced mechanical wear on the system.

The integrated design of the CPC-DX redundant version allows for the cost-effective purchase and installation of a hydraulic assembly that provides all the isolation and support benefits of a fully segmented current-to-pressure converter.

Features:

Anti-fouling .

. No small passages to block .

.111 N (25 lb) rotary chip shear .

. Self-cleaning valve design

Automatic and manual switching

Fast changeover time

. Minimised system disturbances

Precise pressure control

Increased reliability

. High Pressure Signal Selection Design

. In-line Repairable

. Master/Slave Logic

Includes isolation valves

Protected with padlock

Large pressure gauge

Remote master/slave indication

Compact size

Available in 10 and 25 bar models

Division 2 and Zone 2 Hazardous Location Approved