Woodward 03365 505E (Extraction / Admission)

Product Specification 03365

505E (Extraction / Admission)

Digital Control for Steam Turbines Applications

The 505E controller is

designed to operate

single-extraction

and/or admission

steam turbines of all

sizes and

applications. This

steam turbine

controller includes

specifically designed

algorithms and logic

to start, stop, control,

and protect single

extraction and/or

admission steam

turbines or turboexpanders, driving generators, compressors, pumps, or industrial fans. The 505E

control’s unique PID structure makes it ideal for applications where it is required to

control steam plant parameters like turbine speed, turbine load, turbine inlet

pressure, exhaust header pressure, extraction or admission header pressure, or tie

line power.

The control’s special 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 505E controller senses turbine speed

via passive or active speed probes and controls the steam turbine through HP and

LP actuators connected to the turbine steam valves.

The 505E controller senses extraction and or admission pressure via a 4–20 mA

transducer and uses a PID through a ratio/limiter function to accurately control

extraction and/or admission header pressure, while protecting the turbine from

operating outside of its designed operating envelope. The controller uses the specific

turbine’s OEM steam map to calculate its valve-to-valve decoupling algorithms and

the turbine operating and protection limits.

Description

The 505E control is packaged in an industrial hardened enclosure designed to be

mounted within a system control panel located in a plant control room or next to the

turbine. The control’s front panel serves as both a programming station and operator

control panel (OCP). This user-friendly front panel allows engineers to access and

program the unit to the specific plant’s requirements, and plant operators to easily

start/stop the turbine and enable/disable any control mode. Password security is

used to protect all unit program mode settings. The unit’s two-line display allows

operators to view actual and setpoint values from the same screen, simplifying

turbine operation.

Turbine interface input and output wiring access is located on the controller’s lower

back panel. Unpluggable terminal blocks allow for easy system installation,

troubleshooting, and replacement.

Cost‐Effective Design

The 505E control is designed to function as the turbine control,

system sequencer, operator control panel, and first-out

indicator. This encompassing design minimizes external

system devices as well as system installation, wiring, and

troubleshooting.

This field configurable controller allows major functional changes

to be made at site, often by knowledgeable plant personnel, and

minor functional changes to be on-line as process changes

require. The 505E control’s first-out-indicator logic indicates

internal as well as external system related alarm and shutdown

conditions, greatly simplifying and reducing system

troubleshooting.

Communications

The 505E controls can communicate directly with plant

Distributed Control Systems and/or CRT-based operator

control panels, through two Modbus® * communication ports.

These ports support RS-232. RS-422. and RS-485

communications using ASCII or RTU Modbus protocols.

Communications between the 505E and a plant DCS can also

be performed through hardwired connections. Since all 505E

PID setpoints can be controlled through analog input signals,

interface resolution and control is not sacrificed.

*—Modbus is a trademark of Schneider Automation Inc.

System Protection

 Integral Overspeed Protection Logic

 First-out Indication (10 individual shutdown inputs)

 Turbine Operating Envelope Limiters

 Bumpless transfer between control modes if a transducer

failure is detected

 Local/Remote Control priority and selection

 Failsafe Shutdown Logic

Control

The following PIDs are available to perform as process

controllers or limiters:

 Speed/Load PID (with Dual Dynamics)

 Extraction / Admission PID

 Auxiliary PID (limiter or control)

 Cascade PID (Header Pressure or Tie-Line Control)

Control Specifications

INPUTS

 Power: 18–32 Vdc, 90–150 Vdc, 88–132 Vac

(47–63 Hz), 180–264 Vac (47–63 Hz)

 Speed: 2 MPUs (1–30 Vrms) or proximity probes

(24 Vdc provided), 0.5 to 15 kHz

 Discrete Inputs: 16 Contact Inputs (4 dedicated,

12 programmable)

 Analog Inputs: 6 Programmable Current Inputs

(4–20 mA)

OUTPUTS

 Valve/Actuator Drivers: 2 Actuator Outputs (4–20 mA or

20–160 mA)

 Discrete Outputs: 8 Relay Outputs (2 dedicated,

6 programmable)

 Analog Outputs: 6 Programmable Current Outputs

(4–20 mA)

COMMUNICATION

 Serial: 2 Modbus (ASCII or RTU) Comm Ports

(RS-232. RS-422. or RS-485 compatible)

Control Accessories

Control Assistant (Configuration Management Tool)

The Woodward Control Assistant software program is a

computer-based service tool that can be used with the 505E

control to upload, save, and download controller

configurations. Optionally, this service tool can also be used to

trend unit parameters, to compare differences in configuration

files, and to verify if control settings have been changed.

Functionality

The 505E’s control capabilities are:

 Speed/Frequency Control

 Extraction / Admission Header Pressure Control

 Turbine or Generator Load Control or Limiting

 Turbine Inlet Header Pressure Control or Limiting

 Turbine Exhaust Header Pressure Control or Limiting

 Plant Import/Export Power Control or Limiting

 Isochronous Load Sharing between units (with DSLC™

control)

Features

 Critical Speed Avoidance (3 speed bands)

 Auto Start Sequence (hot & cold starts)

 Valve Limiter(s)

 Security (Program is Password Protected)

 Dual Speed/Load Dynamics

 First-Out Indication (Shutdowns)

 Zero Speed Detection with proximity probe (< 0.5 Hz)

 Peak Speed Indication for overspeed trip

 Two Programmable Functions Keys on the 505E’s front

panel

 Two independent Modbus comm links

 Remote analog setpoints for Speed/Load, Ext/Adm, Aux,

and Cascade

 Program upload/download capability

 Feed-forward decoupling algorithm for compressors

Operating Conditions

 –25 to +65 °C ambient air temperature range

 Optional NEMA type 4 (watertight and dust-tight, indoor/outdoor) enclosure for bulkhead mounting with a temperature range

from –25 to +55 °C

 Approximate dimensions 14L x 11H x 4D inches (356 x 279 x 102 mm)

 Approximate bulkhead enclosure dimensions 20L x 20H x 7.6D inches (508 x 508 x 193 mm)

 Humidity: Lloyd’s ENV2 test #1

 Dry heat: Lloyd’s ENV3

 Salt fog: US MIL-STD-810 method 509.2 procedure 1

 Shock: meets US MIL-STD-810C, method 516.2-1. procedure 1B

 Vibration: Lloyd’s ENV2 test #1

 Certifications: CE (18–32 Vdc version only), UL, & cUL

Pollution Resistance

 Particulate Pollution Resistance: IEC 664-1 Pollution Degree 2 (Normally only nonconductive pollution occurs. Temporary

conductivity caused by condensation is to be expected.)

 Gaseous Pollution Resistance: The polyacrylate conformal coating withstands NO2. CO2. SO2. and H2S gases per IEC

60068-2-60:1995 Part 2.60 Methods 1 and 4 (Flowing Mixed Gas Corrosion Test). It will withstand levels typical of

telecommunications and computer installations as defined by Battelle Labs Class III (between IEC 60721-3-3 classification

3C1 and 3C2. light industrial to urban industrial, heavy traffic).