Download
Share
Print this page
Woodward 505CC-2 Installation And Operation Manual
  1. Manuals
  2. Brands
  3. Woodward Manuals
  4. Controller
  5. 505CC-2
  6. Installation and operation manual
Woodward 505CC-2 Installation And Operation Manual

Woodward 505CC-2 Installation And Operation Manual

Steam turbine and compressor control
Hide thumbs

Advertisement

Quick Links

Download this manual
Product Manual 26451V2
(Revision A)
Original Instructions
505CC-2 Steam Turbine
and Compressor Control
Volume 2
Steam Turbine Control Manual
Part Number 8701-1356
Manual 26451 consists of 4 volumes (26451V1, 26451V2, 26451V3, & 26451sup).
Installation and Operation Manual

Advertisement

loading
Need help?

Need help?

Do you have a question about the 505CC-2 and is the answer not in the manual?

Questions and answers

Related Manuals for Woodward 505CC-2

Summary of Contents for Woodward 505CC-2

  • Page 1 Product Manual 26451V2 (Revision A) Original Instructions 505CC-2 Steam Turbine and Compressor Control Volume 2 Steam Turbine Control Manual Part Number 8701-1356 Manual 26451 consists of 4 volumes (26451V1, 26451V2, 26451V3, & 26451sup). Installation and Operation Manual...
  • Page 2 Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.
  • Page 3 3. T ........... 50  HAPTER URBINE ENERAL ESCRIPTION Introduction ......................50   Additional Features ....................50   505CC-2 Inputs and Outputs ................50   4. T ........54  HAPTER URBINE ONFIGURATION VERVIEW Introduction ......................54   505CC-2 Turbine Configuration Screens ............. 55  ...
  • Page 4 505CC-2 Steam Turbine Control Manual Manual 26451V2 Illustrations and Tables Figure 2-1. Overview of 505CC-2 Control Functionality Notes ......3   Figure 2-2. Overview of 505CC-2 Turbine Control Functionality ......4   Figure 2-3. Overview of 505CC-2 Turbine Control Functionality ......5  ...
  • Page 5 Figure 5-16. Turbine Actuator Cal/Linearization Screen ........96   Figure 5-17. Turbine Actuator Cal/Linearization Screen ........96   Table 2-1. 505CC-2 Shutdown Initiators .............. 44   Table 2-2. 505CC-2 Alarm List ................47   Table 2-3. 505CC-2 Turbine Datalog ..............49  ...
  • Page 6 Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...
  • Page 7 Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715 , Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
  • Page 8 505CC-2 Steam Turbine Control Manual Manual 26451V2 Woodward...
  • Page 9 Chapter 1. General Information Introduction The 505CC-2 is a steam turbine and compressor control designed for use on a single- or two-valve steam turbine and/or a one- or two-loop dynamic compressor. This manual should be used along with the standard Atlas-II™...
  • Page 10 Chapter 2. 505CC-2 Turbine Control Description Introduction The 505CC-2 is designed to control single-valve, as well as extraction, extraction/admission, or admission steam turbines. The difference between the single-valve turbine and the latter two-valve turbines is the capability of the turbine to allow low pressure steam, which is at a lower pressure than the inlet, to enter and/or exit the turbine.
  • Page 11 ANALOG SWITCH. THE SWITCH CHANGES STATE INDICATES FINAL DRIVER (ACTUATOR) OUTPUT. WHEN THE LOGIC TO THE (C) INPUT IS TRUE. ALL SWITCHES ARE SHOWN IN THE FALSE STATE. INDICATES INTERCONNECTING LOGIC IN FUNCTIONAL. SELECT SUMMING JUNCTION Figure 2-1. Overview of 505CC-2 Control Functionality Notes Woodward...
  • Page 12 505CC-2 Steam Turbine Control Manual Manual 26451V2 Figure 2-2. Overview of 505CC-2 Turbine Control Functionality Woodward...
  • Page 13 Manual 26451V2 505CC-2 Steam Turbine Control Manual Figure 2-3. Overview of 505CC-2 Turbine Control Functionality Woodward...
  • Page 14 The 505CC-2 can be configured to operate single automatic extraction turbines by controlling the interaction of the governor (HP or high pressure) valve and the extraction (LP or low pressure) valve. (The 505CC-2 can also operate the governor valve and the first extraction valve of multiple extraction turbines).
  • Page 15 HP Valve position and the LP Valve position must be changed to maintain speed/load and admission. The movement of both valves is automatically calculated by the 505CC-2’s ratioing logic, based on the turbine performance parameters, to minimize valve/process interaction.
  • Page 16 The Speed PID then compares this signal to the speed setpoint to generate an output signal to the Ratio-Limiter. The 505CC-2 Speed PID operates in a Speed control mode at all times, which means that the Speed PID will control the turbine at the same speed regardless of the load it is supplying (up to the unit’s load...
  • Page 17 Manual 26451V2 505CC-2 Steam Turbine Control Manual Supplemental Speed PID features include a configurable droop mode, based upon Speed PID demand feedback, which may be needed to prevent process instabilities (extraction pressure) when using the Inlet/Speed Decoupling mode. In addition, two bias signals from the compressor control (one for each compressor) may be configured to interact with the speed controller.
  • Page 18 One of the configurable 4–20 mA analog inputs can be assigned to remotely position the speed reference. Typically, some process control external to the 505CC-2 (e.g. PLC, DCS) may interface with this input to regulate the turbine’s speed or load to control a related process.
  • Page 19 Manual 26451V2 505CC-2 Steam Turbine Control Manual The minimum (4 mA) and maximum (20 mA) engineering unit values for this analog input should normally be configured as (or within) Minimum and Maximum Governor. The analog signal is limited accordingly, regardless of the upper and lower range values of the input.
  • Page 20 Speed Control Dynamics (PID Tuning) The 505CC-2 offers two sets of configurable dynamics for the Speed PID, the second of which is available at one of three configurable switch points. The two...
  • Page 21 Manual 26451V2 505CC-2 Steam Turbine Control Manual Cascade control may be enabled and disabled from the HMI/CCT, remote contact input, or Modbus. The last command given from any of these three sources dictates the Cascade PID’s control state. If the contact input is used, Cascade is disabled when the contact is open and enabled when closed.
  • Page 22 Remote Cascade Setpoint, allowing an external device (e.g. DCS, PLC) to remotely position the Cascade setpoint. When the 505CC-2 is powered-up, the setpoint is reset to the configured Setpoint Initial Value. The Cascade setpoint range must be defined by Min Cascade Setpoint and Max Cascade Setpoint in the Turbine Cascade Control Configuration screen.
  • Page 23 Manual 26451V2 505CC-2 Steam Turbine Control Manual Cascade Setpoint Tracking To allow a bumpless transfer from turbine Speed/Load control to Cascade control, the Cascade PID can be configured to track its controlling process input when disabled. When this tracking feature is programmed, the Cascade PID will be satisfied when enabled, providing a bumpless transfer to Cascade control.
  • Page 24 One of the configurable 4–20 mA analog inputs can be assigned to remotely position the Cascade reference. Typically, some process control external to the 505CC-2 (e.g. PLC, DCS) may interface with this input to regulate the turbine’s speed or load to control a related process in a Cascade Control scheme.
  • Page 25 Manual 26451V2 505CC-2 Steam Turbine Control Manual Remote Cascade Setpoint Status Messages Remote Cascade Setpoint may be in one of the following states as displayed on the HMI/CCT:  Disabled - The Remote Cascade Setpoint function is not enabled and will have no effect on the Cascade setpoint.
  • Page 26 HMI/CCT or Modbus. In addition, a 4–20 mA analog input may be configured for Remote Extr/Adm Setpoint, allowing an external device (e.g. DCS, PLC) to remotely set the Extr/Adm setpoint. When the 505CC-2 is powered-up, the setpoint is reset to the configured Setpoint Initial Value.
  • Page 27 Manual 26451V2 505CC-2 Steam Turbine Control Manual Figure 2-8. Extr/Adm Control Functional Diagram Extr/Adm Setpoint Tracking To reduce the number of steps required to enable Extr/Adm control bumplessly, the Extr/Adm setpoint can be programmed to track the Extr/Adm process input when disabled.
  • Page 28 If the Extr/Adm input signal fails (defaulted to 2–22 mA) during operation, the 505CC-2 can be configured to trip, continue running and ramp the LP Valve to its open limit, continue running and ramp the LP Valve to its closed limit, or switch directly to Manual Pressure (Flow) Demand control.
  • Page 29 Remote Manual Pressure (Flow) Demand, allowing an external device (e.g. DCS, PLC) to remotely set the demand. When the 505CC-2 is powered-up, the setpoint is reset to the configured Setpoint Initial Value. The Manual Pressure (Flow) Demand range must be defined by Min Flow Setpoint and Max Flow Setpoint (typically 0 and 100%) in the Turbine Manual Flow Control Configuration screen.
  • Page 30 505CC-2 Steam Turbine Control Manual Manual 26451V2 The Manual Pressure (Flow) Demand may be specified directly by entering the desired value through the HMI/CCT or Modbus. These entered setpoints are limited by the configured Min and Max Flow Setpoint and will ramp at the configured Default Rate.
  • Page 31 100% during startup, the LP Valve cannot be controlled below its 100% open position. All related Extraction enable permissives must be met before the 505CC-2 will allow the Extr/Adm PID to take control of the Extraction steam process.
  • Page 32 Similarly, the control responds to Modbus commands on the positive edge transition, regardless of whether they are pulsed or toggled. Upon receiving a disable command, the 505CC-2 will instantly step the LP Valve Limiter to the LP Valve’s present position, then raise the LP Limiter to its maximum (open) position at the configured LP Valve Limiter Rate.
  • Page 33 Manual 26451V2 505CC-2 Steam Turbine Control Manual All related Extr/Adm enable permissives must be met before the 505CC-2 will allow the Extr/Adm PID to take control of the Extr/Adm steam process. To perform a bumpless transfer into Adm or Extr/Adm control, the pressures on each side of the Admission trip valve or T&T Valve should be matched.
  • Page 34 There are cases when the ratioing described above is not desired, requiring decoupling of one or both valve outputs. There are three decoupling options available in the 505CC-2 that have been designed to continuously control speed (necessary for compressor drive applications) and a third parameter, instead of extr/adm pressure (flow).
  • Page 35 Responding to a change in either process, both valves are repositioned so as not to affect the other process. Turbine exhaust pressure can be controlled through the 505CC-2’s Exhaust PID. Speed/load can be controlled through either the Speed or Cascade PIDs.
  • Page 36 505CC-2 Steam Turbine Control Manual Manual 26451V2 Figure 2-9. Inlet/Exhaust Decoupling Control Functional Diagram HP & LP Total Decoupled (No Ratioing) This mode is typically used when the two controlled parameters during normal operation are turbine inlet pressure (or flow) and exhaust pressure (or flow). The turbine’s HP and LP Valve actions are fully decoupled, bypassing the Ratio-Limiter.
  • Page 37 Manual 26451V2 505CC-2 Steam Turbine Control Manual The turbine’s HP and LP Valve actions are also decoupled to control turbine exhaust pressure/flow without interaction from turbine inlet pressure/flow changes. Turbine inlet pressure is controlled by only moving the HP Valve, thus no change in exhaust pressure/flow is created.
  • Page 38 505CC-2 Steam Turbine Control Manual Manual 26451V2 Min/Max Limiter S @ MaxHP (Max Lmtr) Ratio Logic S @ MaxLP (Min Lmtr) Spd/load Demand S’ S’ S @ MinLP (Max Lmtr) HP Min S @ MinHP (Min Lmtr) HP/ P HP Offset...
  • Page 39 Manual 26451V2 505CC-2 Steam Turbine Control Manual COUPLED R/L LOGIC Min/Max Lim S @ MaxHP (Mx Lmtr) Ratio Logic S @ MaxLP (Min Lmtr) Digital Ramp S’ S @ MinLP (Mx Lmtr) S @ MinHP (Min Lmtr) HP Offst HP Min...
  • Page 40 505CC-2 Steam Turbine Control Manual Manual 26451V2 COUPLED R/L LOGIC Min/Max Lim S @ MaxHP (Mx Lmtr) Ratio Logic S @ MaxLP (Min Lmtr) Digital Ramp S’ S @ MinLP (Mx Lmtr) S @ MinHP (Min Lmtr) HP Offst HP Min...
  • Page 41 The valve limiters also can be used to troubleshoot system dynamic problems. If it is believed that the 505CC-2 is the source of system instability, the valve limiters can be positioned to manually take over control of the valve positions.
  • Page 42 Modbus list. Turbine Starting Features The 505CC-2 provides three different starting modes: automatic, semi-automatic, and manual. One of these modes must be programmed to get the turbine from a shutdown state to speed control at minimum speed. Once a Start/Run command...
  • Page 43 Manual 26451V2 505CC-2 Steam Turbine Control Manual Zero Speed Signal Override The 505CC-2 issues a shutdown if no speed signal is detected (e.g. magnetic pickup voltage less than the typical detectable threshold ~1V ), or speed is less than the configured Failed Speed Level). To allow the control to start with speed not being sensed, this shutdown logic must be overridden.
  • Page 44  The 505CC-2 will ramp open the HP Valve to its maximum position at the configured HP Valve Limiter Rate.  The speed setpoint will ramp from zero to the minimum controlling speed setting at the configured Rate to Min.
  • Page 45 3. Issue a Start/Run command.  The 505CC-2 will ramp open the LP Valve Limiter to its maximum position at the configured LP Valve Limiter Rate. (For Extraction-only Turbines, the LP Valve position will ramp to the maximum limit until extraction is enabled.
  • Page 46 3. Issue a Start/Run command.  The 505CC-2 will ramp open the LP Valve Limiter to its maximum position at the configured LP Valve Limiter Rate. (For Extraction-only Turbines, the LP Valve position will ramp to the maximum limit until extraction is enabled.
  • Page 47 HMI/CCT, remote contact inputs, or Modbus. When deselected, the turbine speed ramps down to Idle. The Idle/Rated function can be used with any 505CC-2 start mode (Manual, Semiautomatic, Automatic). When a Start/Run is initiated, the speed setpoint will ramp from zero up to, and hold at, the configured Idle Speed.
  • Page 48 505CC-2 Steam Turbine Control Manual Manual 26451V2 Ramp to Rated Feature The Idle/Rated function can be configured as a Ramp to Rated. In this configuration, the speed setpoint holds at the Idle speed setting until the Rated command is given. Upon command the speed setpoint will accelerate to Minimum Governor.
  • Page 49 Auto Start Sequence is not the same as Automatic Start Mode. Auto Start Sequence can be used with any of the three start modes. The Auto Start Sequence logic allows the 505CC-2 to perform a completely automatic, controlled system startup from zero speed to Minimum Governor, and may be used with any Start Mode (Manual, Semiautomatic, Automatic).
  • Page 50 MINIMUM GOVERNOR SETPOINT = 3400 RPM If, at the next start, the unit’s Hours Since Trip timer was at 12 hours, the 505CC-2 would interpolate between the Hot and Cold parameters and use the following rates and delays: LOW IDLE DELAY = 20 MIN...
  • Page 51 By wiring trip initiators directly into the control instead of a hard-wired trip string, the 505CC-2 can pass a trip signal directly to its output relay (to trip the T&T valve) and indicate the first trip condition sensed. All trip conditions are indicated through the HMI/CCT and Modbus.
  • Page 52 Table 2-1. 505CC-2 Shutdown Initiators Controlled Shutdown The 505CC-2’s Controlled Shutdown function is used to stop the turbine in a controlled manner, as opposed to an Emergency Trip. When a Stop command (controlled shutdown) is issued the following sequence is performed: 1.
  • Page 53 The Controlled Shutdown sequence can be aborted at any time. By issuing a Controlled Shutdown Abort command, the control will interrupt the turbine’s stop ramp. If above Minimum Governor, the 505CC-2 will be in the online state and await further action by the operator. If below Minimum Governor and above Idle, the unit will be in the Start Sequence Hold state and await further action.
  • Page 54 See Volume 1, Chapter 2 for a complete Modbus list. Alarms The 505CC-2 alarm list is based upon that from the Woodward 505/505E control. Thus, if replacing a 505/505E with the 505CC-2, any alarm interface will require minimal modifications. Specifically, a few new alarms were added to the end of the alarm stack to accommodate new turbine control functions and the compressor control’s alarms.
  • Page 55 Manual 26451V2 505CC-2 Steam Turbine Control Manual Alarm Number Alarm Description Alarms Cleared Speed Sensor #1 Failed Speed Sensor #2 Failed 4–20 mA Cascade Input Signal Failed Not Used Not Used Not Used 4–20 mA Inlet/Exhaust Decoupling Pressure Signal Failed 4–20 mA Remote Speed Setpoint Signal Failed...
  • Page 56 Manual 26451V2 High-Speed Datalog The 505CC-2 includes a high-speed datalogging facility that can assist in troubleshooting a unit shutdown or other event. It records all typical data for the turbine at a 10-millisecond sample rate. The data that are recorded are fixed. The sample rate can be changed but only with special software tools.
  • Page 57 Manual 26451V2 505CC-2 Steam Turbine Control Manual Discrete Values (TRUE/FALSE = 1/0) Analog Values Shutdown Condition Active Turbine Speed (HSS Output) Shutdown on CPU Reset Turbine Speed (MPU #1) Shutdown Initiated from HMI Turbine Speed (MPU #2) Shutdown on Overspeed...
  • Page 58 (15” or 381mm) touch-screen HMI (Human Machine Interface). Additional operational and monitoring capabilities are available over Modbus. The 505CC-2 interfaces with two turbine control valves (HP & LP) to control two parameters and limit an additional parameter, if desired. These two controlled parameters are typically speed (or load) and extraction/admission pressure (or flow).
  • Page 59 Manual 26451V2 505CC-2 Steam Turbine Control Manual Not Configured Remote Speed Setpoint–If configured, this input may be used to provide a speed setpoint from an external device. Not Used Not Used Not Used Cascade Input–If configured, this input may provide a process variable for Cascade control on turbine speed.
  • Page 60 505CC-2 Steam Turbine Control Manual Manual 26451V2 27. HP Valve Limiter Raise–(momentary or sustained) 28. HP Valve Limiter Lower–(momentary or sustained) 29. LP Valve Limiter Raise–(momentary or sustained) 30. LP Valve Limiter Lower–(momentary or sustained) 31. Manual Extr/Adm Pressure Demand Raise–(momentary or sustained) 32.
  • Page 61 Manual 26451V2 505CC-2 Steam Turbine Control Manual Six (6) relay outputs are available. These outputs are low-side relay drivers providing up to 200 mA and powered by an external +12 Vdc or +24 Vdc (9–32 Vdc). The outputs are not isolated from each other but are isolated from the control’s internal power supplies.
  • Page 62 Turbine Configuration Overview Introduction The 505CC-2 may be configured using the Configuration & Commissioning Tool (CCT) software running on a connected computer or via the optional 15” display. See Manual 26451V1 for a description of system level configuration and Volume 3 for compressor configuration.
  • Page 63 After initial configuration, bring the turbine on-line to complete the tuning of these controls. 505CC-2 Turbine Configuration Screens Turbine General Configuration Screen The selections on this screen configure the 505CC-2 for the turbine type and very basic functionality, as well as HMI appearance. Figure 4-2. Turbine General Configuration Screen Woodward...
  • Page 64 505CC-2 Steam Turbine Control Manual Manual 26451V2 Steam Turbine Type Select the appropriate turbine type from the list: Single Valve, Extraction Only, Admission Only, or Extraction/Admission. Decoupling Type If a two-valve turbine was configured above, select the desired Decoupling type from the list: ...
  • Page 65 Sequence. See the Turbine Start Speeds section in Chapter 3. For Min Governor and Single Idle (Idle/Rated), also configure the Min Controllable and Idle Speeds, respectively. The 505CC-2 uses the Min Controllable speed in a Minimum Governor start to enable/disable some functions and timers.
  • Page 66 Configuration mode). Therefore, for these settings to take effect, they should be tuned in Online Configuration. The maximum frequency sensed by the 505CC-2’s speed inputs is 25,000 Hz. And, the maximum speed, an internal limit used by the control, is calculated as 105% of the configured Overspeed Test Limit.
  • Page 67 Manual 26451V2 505CC-2 Steam Turbine Control Manual Figure 4-4. Turbine Speed Control Configuration Screen    Overspeed Test Limit (rpm) 1.05 Gear Ratio Number Teeth  25000 (Hz)  25000 (Hz)   Gear Ratio Number Teeth  Overspeed...
  • Page 68 505CC-2 Steam Turbine Control Manual Manual 26451V2 Dynamics Settings Select the desired Dynamics configuration from the list: Single or Dual. For the latter, there are three available switch points. Configure the initial PID settings for Single or Dual Dynamics as appropriate. Fine-tuning can be performed while the turbine is running.
  • Page 69 Manual 26451V2 505CC-2 Steam Turbine Control Manual If desired, select Feed-Forward Enable to manipulate the base speed reference in response to compressor recycling. Configure the Feed-Forward Amount as a scalar in percent speed per percent Anti-Surge Valve movement. This scalar is applied to both Anti-Surge Valve demands in a 2-valve system.
  • Page 70 Manual 26451V2 Cascade Control Settings Select Use Cascade Control to configure the 505CC-2’s Cascade controller. Select the Cascade Units of measure from the list. Unlike most other controllers, where units selection has no impact on control (screen appearance only), the Cascade controller will be affected by engineering units if the source is configured below as one of the internal compressor variables (pressure or flow).
  • Page 71 Manual 26451V2 505CC-2 Steam Turbine Control Manual Select the desired Cascade Control Source process variable from the list. If one of the internal compressor process variables is selected (flow or pressure), verify that the Cascade Units selection (above) is appropriate for the selected PV.
  • Page 72 Pressure (Flow) Demand. This selection allows commands from the HMI/CCT and Modbus to put the Extr/Adm controller into manual mode. If deselected, the 505CC-2 will still use Manual Pressure (Flow) Control as a default mode, as noted previously, but the go-to-manual commands from the HMI/CCT and Modbus will be ignored.
  • Page 73 Manual 26451V2 505CC-2 Steam Turbine Control Manual Remote Extr/Adm Manual Pressure / Flow Settings If a configurable 4–20 mA analog input will be assigned to remotely position the Pressure (Flow) Demand, select Use Remote Setpoint and configure the desired Remote Rate that will be applied. Also configure the Min and Max Pressure (Flow) Settings that will be used to limit the remote demand.
  • Page 74 505CC-2 Steam Turbine Control Manual Manual 26451V2 Select the desired response to an Extr/Adm Pressure Input failure. If the signal from the field transmitter fails, the control can be configured to trip the turbine, move the LP/V2 valve to its minimum or maximum position, or switch to manual pressure/flow control.
  • Page 75 LP=0 (Extraction Valve closed) and LP=100 (Extraction Valve fully open). Note that the LP=0 line is parallel to the LP=100 line, as required. The 505CC-2 can be configured for three different types of steam turbines, Extraction-Only, Admission-Only, or Extraction/Admission. Following are examples for each of these configurations.
  • Page 76 505CC-2 Steam Turbine Control Manual Manual 26451V2 Extraction-Only Steam Map Before an Extraction steam map can be configured into the control, Points A, B, and C must be identified (See Figure 4-9). Typically, Point C, the intersection of the LP=0 line and the P=0 line does not exist.
  • Page 77 Manual 26451V2 505CC-2 Steam Turbine Control Manual Admission Only Steam Map Before an Admission steam map can be configured into the control, Points A, B, and C must be identified (See Figure 4-10). If Points A and B already exist, the only conversion necessary is the extension of the LP=100 line and the P=100 line until they intersect, which defines Point C.
  • Page 78 505CC-2 Steam Turbine Control Manual Manual 26451V2 If only Point A exists, the map must be modified to include Points B and C. The LP=0 line must be created. To do so, the minimum required steam flow through the back-end of the turbine must be defined. In this example, the minimum required flow is 10,000 lb/hr.
  • Page 79 Manual 26451V2 505CC-2 Steam Turbine Control Manual 1. Max Power is the load corresponding to the S=100 line, about 10,000 kW in this example. 2. Max HP Flow is the flow corresponding to the HP=100 line, about 105,000 lb/hr in this example.
  • Page 80 505CC-2 Steam Turbine Control Manual Manual 26451V2 If Points A and B already exist, the only conversion necessary is the extension of the LP=0 line and the zero Extraction/Admission flow line until they intersect, which defines Point C. If Point A does not exist, extend the LP=100 line and the zero Extraction/Admission flow line until they intersect, which defines Point A.
  • Page 81 Given these steam map interpretations, proceed with the configuration as follows. Figure 4-12. Turbine Extr/Adm Steam Map Configuration Screen Select Use Automatic Enable to configure the 505CC-2 to automatically enable Extr/Adm Control upon an enable command from the HMI/CCT, remote contact input, or Modbus. See the Extraction-Only Control—Automatic Enable/Disable section in Chapter 3.
  • Page 82 505CC-2 Steam Turbine Control Manual Manual 26451V2 Turbine Inlet/Exhaust Control Configuration Screen The selections on this screen will configure the Inlet/Exhaust Controller, if a two- valve turbine with HP (Inlet/Speed) or LP (Exhaust/Speed) Decoupling was configured previously. See the Ratio-Limiter--Decoupling section in Chapter 3.
  • Page 83 Manual 26451V2 505CC-2 Steam Turbine Control Manual If desired for control stability, configure an Inlet/Exhaust Droop percentage. This droop percentage is subtracted from the reference, usually to keep multiple controls from “fighting” over a single parameter. If droop is configured, the inlet/exhaust process variable input will not match the reference when in control—The difference will be the amount of droop.
  • Page 84 505CC-2 Steam Turbine Control Manual Manual 26451V2 Figure 4-14. Turbine Discretes Configuration Screen There are four (4) configurable discrete outputs available from the turbine control. Enable the use of the relay drivers as needed and select the appropriate function from the list box. If the Shutdown Indicator is selected, it energizes on a shutdown condition while the Trip Relay de-energizes.
  • Page 85 Manual 26451V2 505CC-2 Steam Turbine Control Manual Turbine Analogs Configuration Screen The selections on this screen configure the analog inputs and outputs related to the turbine control. Figure 4-16. Turbine Analogs Configuration Screen Turbine Analog Inputs There are five (5) configurable analog inputs available for the turbine control.
  • Page 86 505CC-2 Steam Turbine Control Manual Manual 26451V2 Figure 4-17. Analog Input Calibration Pop-Up Turbine Analog Readouts There are two (2) configurable analog outputs available from the turbine control. Select the appropriate function from the list box. Similar to the inputs, a calibration pop-up, shown in Figure 4-18, facilitates configuration of the 4–20 mA range values, offset, and gain.
  • Page 87 They correspond to the P (proportional), I (integral), and D (derivative) terms, and are displayed by the 505CC-2 as follows: ...
  • Page 88 In cases where a small change in the 505CC-2’s output results in a large load change (high mechanical gain) it may not be possible to take the 505CC-2’s gains low enough to reach stable operation.
  • Page 89 Manual if available, or use the respective Valve Limiter to gain control of the valve. If the system continues to oscillate when the 505CC-2 output is clamped, the system instability is caused by an external device/function. If the controller is causing the oscillation, time the oscillation cycle.
  • Page 90 Operational requirements of steam turbines are as varied as the processes in which they operate. This chapter is intended to provide an overview of turbine operation with respect to the 505CC-2’s functionality only. For more complete, process-specific turbine or plant operating instructions, contact the plant- equipment manufacturer.
  • Page 91 Manual 26451V2 505CC-2 Steam Turbine Control Manual Unit Overview The Unit Overview screen, shown in Figure 5-2, provides a general system view of the turbine and compressor unit, graphically displaying the physical equipment, field measurements, valve statuses, etc. The graphic is dynamic with respect to the specific configuration of turbine type and decoupling mode, I/O selections, compressor layout, etc.
  • Page 92 505CC-2 Steam Turbine Control Manual Manual 26451V2 Figure 5-3. Turbine Start Screen The messages in the upper part of screen indicate the configured start mode and the current status as one of the following:  Waiting For Reset  Waiting For Permissive ...
  • Page 93 Manual 26451V2 505CC-2 Steam Turbine Control Manual To the right is the HP/V1 Valve Limiter faceplate, shown in Figure 5-4, which indicates both the Limiter and Demand values in a vertical bar graph. The raise/lower buttons act on the valve limiter and can be used to limit the valve demand at any time.
  • Page 94 1. Press the Reset button to clear all alarms and trips. If the 505CC-2’s Reset Clears Trip Output configurable is selected, the Trip Relay output, if configured, will reset or re-energize after issuing the Reset command.
  • Page 95 Manual 26451V2 505CC-2 Steam Turbine Control Manual Once all start permissives (valid turbine configuration; contact input, if configured; speed not in critical band) are satisfied, the green Start Permissive indicator will be visible. If the unit is reset and ready to start, a blue Waiting for Start indicator will also be displayed.
  • Page 96 If the external overspeed test was enabled, the unit will ramp above the 505CC- 2’s overspeed trip to reach the external trip point. If the external test is disabled while speed is above the 505CC-2’s internal overspeed setting, the unit will trip. Turbine Run Screen...
  • Page 97 Manual 26451V2 505CC-2 Steam Turbine Control Manual Figure 5-7. Turbine Run Screen Each available controller may be monitored and manipulated with its respective interface, the appearance of which is dependent upon the turbine configuration and current operating mode. Within each interface is a trend button, which will jump to a trend page corresponding to that controller.
  • Page 98 505CC-2 Steam Turbine Control Manual Manual 26451V2 Each control interface displays the measured process variable, current setpoint or reference value, and demand and preset values. The demand value acts as a target for the setpoint. Select the demand value and adjust as desired—The setpoint will ramp to meet that demand.
  • Page 99 Manual 26451V2 505CC-2 Steam Turbine Control Manual Figure 5-9. Turbine Run Screen Cascade Controller The Cascade Controller is also available if the unit is configured for Compressor-Only Mode, but the Turbine Run Screen is not. In this mode, the Cascade Controller faceplate is available from the Overview Screen.
  • Page 100 505CC-2 Steam Turbine Control Manual Manual 26451V2 The Extraction/Admission and Inlet/Exhaust Decoupling faceplates are similar to the Cascade faceplate shown previously. See the Extraction Controller faceplate shown in Figure 5-10. In addition to enable/disable, a manual/automatic button is provided to transition between automatic, closed-loop control and manual pressure/flow demand.
  • Page 101 Manual 26451V2 505CC-2 Steam Turbine Control Manual Figure 5-12. Turbine PID Control Screen Figure 5-13. Turbine PID Control Screen Woodward...
  • Page 102 505CC-2 Steam Turbine Control Manual Manual 26451V2 Turbine Dynamics Tuning Screens (Speed, Cascade, Extr/Adm, Inlet/Exhaust) Tuning of the various controllers is available via individual dynamics tuning screens accessible from the PID Control screen shown in Figure 5-12. Select the desired button (available in Engineering or higher login) above the controller faceplate to access the respective tuning screen.
  • Page 103 Manual 26451V2 505CC-2 Steam Turbine Control Manual Turbine Steam Map Screen If an Extraction and/or Admission steam turbine is configured, the configured operating steam map is displayed on the Steam Map screen, as shown in Figure 5-15. Figure 5-15. Turbine Steam Map Screen At any time, the current turbine operation will be displayed by the dynamic cursor within, or on a limit of, the drawn steam map.
  • Page 104 505CC-2 Steam Turbine Control Manual Manual 26451V2 Figure 5-16. Turbine Actuator Cal/Linearization Screen Figure 5-17. Turbine Actuator Cal/Linearization Screen Woodward...
  • Page 105 Manual 26451V2 505CC-2 Steam Turbine Control Manual The Trip & Throttle Valve(s) must be closed, and verified, before calibrating the valve output(s). If a calibration is performed while a Trip & Throttle Valve is open, there exists a possibility of turbine runaway, possibly resulting in serious equipment damage, personnel injury, or loss of life.
  • Page 106 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.