Woodward 505E (Extraction/Inlet) Steam Turbine Digital Controller

Woodward 505E (Extraction/Inlet) Steam Turbine Digital Controller

Application scenarios

The 505E controller is designed for single extraction and/or inlet steam turbines of various sizes and applications, and can start, stop, control, and protect single extraction and/or inlet steam turbines or turbine expanders that drive generators, compressors, pumps, or industrial fans. Its unique PID structure is suitable for controlling steam equipment parameters, such as turbine speed, load, inlet pressure, exhaust manifold pressure, extraction or inlet manifold pressure, or tie line power. The controller achieves stable control during normal operation of the steam turbine through special PID to PID logic, and switches to disturbance free control mode in case of equipment abnormalities, reducing process overshoot or undertuning.

Product description

Hardware and appearance

Adopting industrial grade reinforced casing, it can be installed in the system control panel of the factory control room or next to the turbine.

The front panel combines programming station and operator control panel (OCP) functions, with a user-friendly interface that facilitates engineers to program according to specific factory requirements. Operators can easily start and stop the turbine and enable/disable any control mode, with password security protection program mode settings. The two-line display screen of the equipment allows the operator to view the actual and set values on the same screen, simplifying the operation of the turbine.

The input and output wiring of the turbine interface is located on the lower back panel of the controller, and the pluggable terminal block is convenient for system installation, troubleshooting, and replacement.

Core features: on-site configurability, integrated operator control panel, integrated first issue indicator logic, user-friendly menu format, online (standalone) configuration changes, large LED display screen Modbus ®  Communication function, integrated valve decoupling and protection calculation logic, multiple decoupling modes, and the use of sulfur resistant conformal coating.

Cost benefit design

The 505E controller integrates turbine control, system sequence controller, operator control panel, and first output indicator functions, reducing external system equipment and system installation, wiring, and troubleshooting work. This controller can be configured on site, and professional factory personnel can make major functional changes on site. Minor functional changes can be made online when process changes require it. Its first indicator logic can indicate internal and external system related alarm and shutdown situations, greatly simplifying and reducing system troubleshooting work.

Communication function

The 505E controller can be controlled through two Modbus protocols ®  The communication ports directly communicate with the factory distributed control system and/or CRT based operator control panel, and these ports support RS-232, RS-422, and RS-485 communication using ASCII or RTU Modbus protocols. It can also communicate with the factory DCS through a hard wired connection, and all 505E PID settings can be controlled through analog input signals without sacrificing interface resolution and control performance.

System protection

It has functions such as integrated overspeed protection logic, first out indication (10 independent shutdown inputs), turbine operating range limiter, disturbance free switching between control modes when sensor faults are detected, local/remote control priority and selection, and fail safe shutdown logic.

Control function 

Available PID controllers: speed/load PID (with dual dynamic characteristics), extraction/intake PID, auxiliary PID (limiter or controller), cascade PID (manifold pressure or tie line control).

Control capability: including speed/frequency control, extraction/inlet manifold pressure control, turbine or generator load control or limitation, turbine inlet manifold pressure control or limitation, turbine exhaust manifold pressure control or limitation, factory inlet and outlet power control or limitation, synchronous load distribution between units (with DSLC) ™ Control, etc.

Main features: critical speed avoidance (3 speed bands), automatic start program (hot start and cold start), valve limiter, safety protection (password protected program), dual speed/load dynamic characteristics, first out indication (shutdown), zero speed detection through proximity probe (<0.5Hz), overspeed trip peak speed indication, two programmable function keys on the 505E front panel, two independent Modbus communication links, remote simulation settings for speed/load, extraction/admission, auxiliary and cascade, program upload/download function, compressor feedforward decoupling algorithm, etc.

Control Specifications

Input

Power supply: Supports multiple power inputs, including 18-32 Vdc、90–150 Vdc、88–132 Vac（47–63 Hz）、180–264 Vac（47–63 Hz）

Speed: 2 magneto electric sensors (MPUs), input range 1-30 Vrms; Or proximity probe (providing 24 Vdc power supply), frequency range 0.5 to 15 kHz

Discrete inputs: There are a total of 16 contact inputs, of which 4 are dedicated inputs and 12 are programmable inputs

Analog inputs: 6 programmable current inputs, with an input range of 4-20 mA

Output

Valve/actuator driver: 2 actuator outputs with an output range of 4-20 mA or 20-160 mA

Discrete output: 8 relay outputs, of which 2 are dedicated outputs and 6 are programmable outputs

Analog output: 6 programmable current outputs, with an output range of 4-20 mA