Category: Woodward

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 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 dcs-sis.com 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

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 dcs-sis.com 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 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.

RemoteView also serves as the system’s HMI, allowing the operator to monitor the system, start/stop the turbine, enable/disable all control modes, and view/reset system alarms.

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 dcs-sis.com 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 dcs-sis.com 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.

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

Part Number 8237-2046: Francis Turbine dcs-sis.com 2301E-HT

2301E-HT includes

 1 Actuator driver, 4-20 mA, 0-20 mA, 0-200 mA

 2 MPU speed sensor

 1 configurable analogue output

 2 configurable analogue inputs

 8 discrete (switching) inputs – 5 fixed, 3 configurable

 4 discrete (relay driver) outputs – 1 fixed, 3 configurable

 RS-232 Communications Port: Modbus® RTU or Service/Configuration

 RS-422 Communications Port: Modbus RTU

 CAN Communication Port: LINKnet HT® I/O Expansion

The 2301E-HT has an operating temperature range of -40 to +70 °C (-40 to +158 °F).

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 2301E-J system has the following inputs/outputs:

– 1 kW sensing input, including 3-phase PT inputs and 3-phase CT inputs

– 1 speed sensing input (MPU input)

– 2 analogue inputs for (4-20 mA) current signals or (±2.5 V, 1-5 V, or 0-5 V) voltage signals

– 8 discrete inputs

– 1 actuator drive circuit

– 1 analogue 4-20 mA output (optionally with signal display via this output)

– 4 discrete outputs (low-side actuator; max. 200 mA potting current)

– 2 serial ports (RS-232 and RS-422)

The 2301E-J system has the following features:

– Speed control: isochronous operation, kW down operation, speed down operation

– Load control: isochronous load sharing, isochronous base load, soft loading/unloading

– Equal speed/deceleration operation transfer function when generator is loaded

– Fuel Limiters: Start Fuel Limiter, Torque Fuel Limiter, Manifold Fuel Limiter, Maximum Fuel Limiter

Equipment required to operate the engine generator set with the 2301E-J:

– 2301E-J Controls

– 24 Volt DC Power Supply

– Speed sensing device (MPU, etc.)

– Actuator to drive fuel rack or gas valve (proportional)

– CT and PT for generator kW sensing or analogue kW signals

The 2301E-J requires a nominal 24 Vdc voltage source. (Supply voltage range is 18 to 36 volts DC).

The controller is mounted in a sheet metal chassis and consists of a printed circuit board.

Functions

The 2301E-J has speed control, load control, equal dcs-sis.com speed/no load transfer, and fuel limiter functions.

Speed Control Function

– Rated speed range of 400-3600 rpm

– Constant speed speed control

– kW Reduced speed control

– Simple derating control is selectable (when selected, the load control function is not available)

– Idling/rated speed switching by discrete input signal

– Speed reference up/down using discrete input signals

– Fast synchronisation using analogue speed bias signal from synchroniser

– (Optional) Speed reference manipulation function using remote analogue signal

– Single point control gain setting (optional)

– A control gain curve consisting of 5 points with 4 ramps can be mapped to the engine to change gain under various operating conditions.

– Dual power function to switch control power according to engine load

Manual isolation valves are included in the package, allowing the user to easily repair or replace each individual current-to-pressure converter.

Both automatic and manual transfer logic is available for this skid block assembly, depending on the design of the system.

The skid block’s automatic transfer logic simplifies system design because it does not require external relay/switching logic to operate.

This minimises wiring at the converter-to-converter and control-to-converter interfaces.

The CPC’s configurable alarm/shutdown logic allows the user to easily configure which system conditions force an automatic transfer from the master CPC to the slave CPC.

The manual transfer feature is also available for systems where the user wishes to switch between pressure converters via external logic or manual switching.

The master select discrete input is used to allow the user to dcs-sis.com easily and quickly select the desired control CPC.

An integrated oil pressure gauge allows the user to visualise which converter is in control and verify the skid’s output oil collector pressure level.

Discrete output relay contacts can also be connected to system indications (lights, lamps, plant DCS) to assist in system operating condition monitoring.

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

Description

APECS™ 0175 linear actuators deliver precise positioning and form the foundation of a full electronic governing system. 

Many of the moving parts normally associated with electric actuators dcs-sis.com are eliminated, prolonging the MTBF (mean time between failure). 

The actuator design employs the principle of variable reluctance for consistent force over the entire stroke. 

This simple design of a proportional electric linear actuator utilizes a linear armature whose magnetic force is proportional to the input current to the coil. 

These actuators are easy to install by mounting near the fuel system with a direct connection to the fuel control rod or level. 

In most installations, the normal rotary-torotary connection is eliminated, resulting in a more trouble-free and accurate control system. 

APECS 0175 actuators are suitable for installation on diesel, gasoline, or natural gas engines with fuel system force requirements of less than 4.0 pounds (17.8 N) of force. 

Woodward also manufactures 0175 actuators integral to the engine block or fuel pump. 

New Features 

USB connectivity to PC 

ToolKit configuration support 

Password protection to all variants 

Same look & feel as SPM-D 

Drop-In replacement

DESCRIPTION

Woodward understands the time-intensive nature of Power Generation projects. Ensuring the longevity of components is one way we can make our customers successful. Woodward has supplied and supported the well-established SPM-D line of synchronizers for 20+ years. With the state of the art Drop-In replacement successor, SPM-D2 the life of this synchronizer line is now extended. 

All of the SPM-D2 synchronizers are password protected and are configurable either through HMI as before or through ToolKit configuration tool with USB connectivity.   

The SPM-D2-10 series are microprocessor-based synchronizers designed for use on two or three phase AC generators equipped with Woodward or other compatible speed controls and automatic voltage regulators. The SPM-D2-10 synchronizers provide automatic frequency, phase and voltage matching using either analog- or discrete output bias signals. These synchronizers are applied to a wide range of prime movers and generators, as its control signals may be set to fit several types of gensets – from fast reacting diesel engines to soft reacting gas turbines. 

FEATURES  

 Phase match or slip frequency synchronization dcs-sis.com with voltage matching 

 Two-Phase or three-phase true RMS voltage sensing of generator and bus with Class I accuracy 

 Selectable operating modes like SPM-A (Run, Check, Permissive and Off) 

 Synch-Check and synchronization time monitoring 

 Dead bus closing of CB on demand 

 2 setting blocks, each containing 7 configurable parameters (in PSY5 variants) selectable through DI: Frequency/Voltage control dead-band, Frequency/Voltage control time pulse, Frequency/Voltage control gain, Circuit breaker time compensation 

 Control outputs: Discrete raise/lower for speed and voltage in all variants, | X and XN variants: 

also configurable analog signals (Voltage, Current and PWM) 

 Voltage and frequency control in isolated operation 

 Two line bright liquid crystal display for operation, alarm, measuring values visualization and parametrization 

 Front face with synchronoscope and indication of breaker state/control activity 

 Multi-level password protection of parameters 

 Woodward ToolKit™ software for configuration via USB 

 Two built-in languages: English, German

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 www.cniacs.com 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.