WOODWARD 5009XT Fault-Tolerant Control

WOODWARD 5009XT Fault-Tolerant Control

Description

The 5009XT is a standard-off-the-shelf steam turbine control for use on industrial steam turbines in reliability- critical applications. This controller utilizes Woodward’s field-proven MicroNet TMR® hardware platform combined with Woodward’s state-of-the-art XT steam control core and algorithms. The 5009XT is designed for use both in OEM turbine packages and for upgrade of existing turbines

The 5009XT’s triple-redundant, fault-tolerant design allows it to continue operating the turbine safety under any single point of failure. Modular design and hot-swapping capability allow maximum uptime and minimize maintenance shutdowns required for the control.  

The 5009XT control’s unique PID structure makes it ideal for applications requiring accurate control of parameters such as turbine speed, load, extraction header pressure, inlet header pressure, and exhaust header pressure or tie-line power.

The control’s PID-to-PID logic allows stable control during normal turbine operation and bumpless control mode transfers during plant upsets, minimizing process over or undershoot conditions. The 5009XT controller senses turbine speed via passive or active speed probes and controls the steam turbine through actuators connected to the turbine inlet steam valves.

This field programmable controller allows users to easily make system configuration changes without the need of an OEM expert. The system can be controlled, configured, calibrated and tuned using the optional 17” touchscreen display or any workstation running Woodward’s RemoteView software. RemoteView can also function as an HMI for the system, allowing operators to monitor the system, start/stop the turbine, enable/disable all control modes, and view/reset system alarms. Multiple password security levels are available to provide different plant personnel with access to the different levels of the 5009XT’s configurations/ adjustments depending on site requirements. The RemoteView display can be networked to all three CPUs for maximum redundancy. See Specification 03424 for more information on RemoteView.  

The 5009XT can be purchased as a kit or Woodward can package the system in a free-standing cabinet with an integral RemoteView HMI/engineering workstation. The 5009XT can be configured to operate as a stand-alone unit or in conjunction with a plant’s Distributed Control System, depending upon the site’s requirement.  

Woodward or our partners can integrate the 5009XT software with our Vertex compressor-control core on a MicroNet TMR to create a fault-tolerant ITCC steam and compressor control.

Applications

The 5009XT is designed to control industrial steam turbines of all sizes and types in system-critical applications requiring maximum reliability and availability. This steam turbine controller includes specifically designed algorithms and logic to start, stop, control, and protect industrial steam turbines or turbo-expanders that drive compressors, generators, or pumps.

Designed for today’s plant standardization practices, the 5009XT control system’s versatile programing can be configured to control single valve, single extraction, single admission, or single extraction/ admission steam turbines. The 5009XT control’s unique PID structure makes it ideal for petrochemical or power generation applications requiring tight control of parameters like compressor speed, generator frequency, turbine load, turbine inlet or exhaust header pressures, or tie-line power.

The control’s TMR (triple modular redundant) architecture, TMR CPU and I/O modules, on-line configuration, and on line repair capability make it ideal for use in safety or reliability critical applications. This control’s fault tolerant design allows it to accept redundant inputs sensors, drive redundant actuators, and interface with redundant RemoteView operator stations, extending redundancy throughout the entire turbine package.

For applications requiring multiple human-machine-interfaces (HMIs), users can purchase additional licenses of Woodward’s RemoteView™ software for installation on any Windows PC installed on the network.   Woodward also offers full HMI packages based on iFIX or Citect graphics packages.

For applications requiring IEC61508 SIL-3 certification, a MicroNet Safety Module (MSM) may be added to the base 5009XT system.  The MSM functions as the system’s SIL-3 logic solver, and its fast (12 millisecond) response time and integrated overspeed and acceleration detection/protection functionality make it ideal for applications on critical turbines. For more information on the MicroNet Safety Module, refer to Woodward product spec 03375.

Triplex Architecture Advantages

• 2-out-of-3 voting provides accurate signal selection by excluding bad signals. 

 • 2-out-of-3 voting increases system fault coverage close to 100%, which provides an availability of 99.998% or higher. 

 • CPU or I/O module failures are accurately detected, and related calculations safely removed, while the turbine continues to operate.