Category: Woodward

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, www.abb-drive.com 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 Flex500 is a programmable, real-time deterministic dedicated digital controller that optimises the performance and protection of compressors, steam turbines, gas turbines and water turbines.

Woodward builds on our reliable, field-proven 505D hardware platform.

Designed and manufactured in conjunction with our industry trusted and easy to use GAP programme and advanced service tools.

This model is a backplane mounted low www.abb-drive.com voltage 18-36 Vdc power input rated for Class 1 Div. 2 standard position.

Features and Functionality

The Flex500 control system represents a new generation of dedicated controller remote view virtual terminal connections.

The industrial hardware platform provides stable, low-cost control for a wide variety of turbine, engine and compressor applications.

As a low-cost alternative to general-purpose PLCs, the Flex500 provides a simple, user-friendly gap-planning architecture as well as

True industrial-grade long production and support lifecycles eliminate frequent high-cost obsolescence issues.

The platform’s real-time operating system and dedicated inputs and outputs provide deterministic performance for critical prime mover control functions.

Its fast I/O scan times, high accuracy and software program synchronisation make it ideal for controlling and protecting critical high-speed rotating equipment.

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.

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 www.abb-drive.com 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 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.

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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 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 www.abb-drive.com 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.

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 www.abb-drive.com 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 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.

Cost-effective design

The 505DR is a G-efficient redundant turbine controller. It consists of a turbine controller, system sequencer, operator control panel and first-out indicator.

The design minimises external equipment and wiring for easy troubleshooting.

Like the 505XT, the 505DR can be fully configured in the field (under password control by knowledgeable personnel) and minor functional changes can be made while the turbine is running online.

Minor functional changes can be made online while the turbine is running.

Communication

The 505DR can communicate directly with the plant DCS and/or operator control panel using Modbus TCP or OPC communications.

Serial communication is also supported using RS-232 or RS-485 and ASCII or RTU Modbus.

Control PIDs can perform process control or be used as limiters for speed/load dynamics, pumping/discharge pressures, cascade, auxiliary, intake plenum, exhaust plenum, and rotor acceleration.

System Protection

– Integrated overspeed protection logic and test functions

– First open indication on 15 shutdown inputs

– External alarm indication on 15 inputs

– Stuck at critical speed band logic

– Bufferless transfer between control modes and during Syscon switchover

– Operation and configuration password security

Control specifications

Inputs

– Power Supply Low voltage models 18-32 VDC High voltage models 88-264 VAC and 90-150 VDC

– Speed: 2 passive MPUS or active proximity probes (0.5 – 32000 Hz)

– Discrete Inputs 19 configurable contact inputs (16 additional contact inputs can be added using LinkNet HT)

– Analogue Inputs 8 configurable 4-20 mA (16 inputs or 8 RTD inputs can be added using LinkNet HT)

Outputs

– Valve/actuator driver: 2 actuator outputs, 4-20 mA or 20-200 mA

– Discrete Outputs:

– 7 configurable relay outputs (16 discrete outputs can be added using the LinkNet HT module)

– Analogue Outputs 6 programmable 4-20 mA outputs (4 inputs can be added using the LinkNet HT module)

Communications

– Ethernet 3 ports (Modbus TCP or OPC)

– Serial 1 port (ASCII or RTU, RS-232 or RS-485)

– CAN: 4 ports, supports LinkNet HT, VariStroke, and power management devices

Operating Conditions

– Ambient air temperature: -25 to +65C

– Humidity Lloyd’s ENV2 Test #1

– Dry heat Lloyd’s ENV3

– Salt Spray: US MIL-STD-810. Method 509.2 proc. 1

– Shock: US MIL-STD-810C, Method 516.2-1 proc. 1B

– Vibration Lloyd’s ENV2 Test #1

– Resistance to particulate contamination IEC 60664-1 Class 2

– IEC 60068-2-60 part 2.60 methods 1 and 4

– Resistance to gaseous contamination: coating is resistant to NO2. CO2. SO2 and H2S.

– Battelle Laboratories Class III (IEC 60721-3-3 Categories 3C1 and 3C2)

Actuator 8256-008 from the Woodward Electric Governor (EPG) series.

This unit uses a 24V battery and rotates clockwise to increase fuel. The speed controller and actuator must be compatible for proper operation.

Product Description

Part of the Woodward Electric Governor Series is the actuator model 8256-008.This is a speed control system that is compatible with a variety of engines.

This model can be used on gas, petrol or diesel engines. The product rotates clockwise to ensure the most efficient use of fuel.

To use the Model 8256-008 actuator, the engine’s speed control must be compatible with the system.

It is powered by a 24V battery and weighs just over a pound. The supply voltage for this model is a minimum of 10 Vdc and a maximum of 16 Vdc.

The Model 8256-008 has a maximum power consumption of 60 watts. It is also equipped www.abb-drive.com with an overtravel feature

The ambient temperature around this EPG should be maintained between -40 and 200 degrees Fahrenheit.

Mounting of this product must be done on sheet metal and should be done with torque screws.

This Woodward model is constructed from corrosion-resistant materials to ensure a longer product life.

The EPG 8256-008 model can be operated in single phase step-down control and will then share the load when operated in step-down mode.

Features

 Actuators and self-cleaning valves are 4 times stronger with ‘sludge buster’ technology

 Patent-pending ‘Sludge Buster’ cleaning technology

 Advanced control algorithms and diagnostics

 Redundant optimum control configuration

 Same mounting base footprint as the CPC*

 Enhanced feature benefits:

 Removes 40 μm size dirt and reduces or eliminates filter/screen service work

 Removes sludge build-up without compromising www.abb-drive.com operational integrity

 Industry-leading stability and buffer-free, precise throttle control

 Configuration flexibility to meet your system needs

 Easily upgrade your existing CPC* or Voith E360 I/H

CPC-II Upgrade Programme

(Current Pressure Converter, Generation II)

Maximise uptime with Woodward’s Dirt Buster technology Upgrade with Woodward’s CPC-II Electrohydraulic Current Pressure Converter

your Woodward CPC* or Voith E360 I/H throttle controller.

The CPC-II solves the turbine market’s number one reliability problem: oil contamination.

CPC-II:

 removes 40 μm sized dirt, reducing or even eliminating turbine control filter maintenance altogether!

 removes sludge build-up without compromising operational integrity

 features industry-leading stability and snubberless precision throttle control

 Easily upgrades existing CPC or Voith converters

The power of the CPC-II is combined with Woodward’s industry-leading control point algorithms, advanced diagnostics and PC-based service tools.

This powerful solution provides stable control during normal turbine operation and trouble-free control in the event of a plant failure.

By minimising process overshoot or undershoot conditions, you can maximise uptime and increase productivity.

Easily Upgrade Your Existing CPC* or Voith E360 I/H to the CPC-II

Description

The 9905/9907 series of the Woodward 2301A controls load sharing and www.abb-drive.com speed of generators driven by diesel or gasoline engines, or steam or gas turbines.

These power sources are referred to as “prime movers” throughout this manual.

The control is housed in a sheet-metal chassis and consists of a single printed circuit board. All potentiometers are accessible from the front of the chassis.

The 2301A provides control in either isochronous or droop mode.

The isochronous mode is used for constant prime mover speed with:

 Single-prime-mover operation;

 Two or more prime movers controlled by Woodward load sharing control systems on an isolated bus;

 Base loading against an infinite bus with the load controlled by an Automatic Power Transfer and Load (APTL) Control, an Import/Export Control, a Generator Loading Control, a Process Control, or another load-controlling accessory.

The droop mode is used for speed control as a function of load with:

 Single-prime-mover operation on an infinite bus or

 Parallel operation of two or more prime movers.

The following is an example of the typical hardware needed for the 2301A system controlling a single prime-mover and generator:

 A 2301A electronic control

 An external 20 to 40 Vdc power source for low-voltage models; 90 to 150 Vdc or 88 to 132 Vac for high-voltage models

 A proportional actuator to position the fuel-metering device

 Current and potential transformers for measuring the load carried by the generator.

Applications

The 2301A 9905/9907 series electronic controls have switch-electable speed ranges. Any of these control models can be set to operate within one of the following rated speed ranges:

 500 to 1500 Hz

 1000 to 3000 Hz

 2000 to 6000 Hz

 4000 to 12 000 Hz

These controls are available for forward- or reverse-acting applications, and for use with either single or tandem actuators. Models for three different actuator current ranges are available, as well as a high-voltage model (90 to 150 Vdc or 88 to 132 Vac, 45 to 440 Hz), and a low-voltage model (20 to 40 Vdc). The high voltage model is identified as such on the front; the low voltage model is not.

In reverse-acting systems, the actuator calls for more fuel when the actuator voltage decreases. Complete loss of voltage to the actuator will drive the actuator to full fuel. This allows a backup mechanical ballhead governor to take control rather than shut down the prime mover as would a direct-acting system.

An optional deceleration ramp is also offered. When this option is present, the time to ramp from rated speed to idle speed is approximately 20 seconds. If this option is not present, this happens instantly.