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IntegratedTurbine &
CompressorControl
IntegratedTurbine &
CompressorControl
...at the Heart of the System
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Woodward provides control solutions for rotating equipment in the power
generation, cogeneration, processing, refining, pipeline, off-shore, marine, and
rail industries. Woodward controls are found all over the world, at the heart of the
system, keeping rotating equipment running safely and operations running efficiently.
For compressor applications, Woodward’s integrated turbine & compressor control
(ITCC) provides complete integrated control for the entire compressor train. Woodward
designs and manufactures a comprehensive range of control devices—both electronic
and mechanical—and combined with over 125 years of control experience, Woodward
can provide the control solution that is right for your compressor application.
If your operation is not successful, Woodward is not successful; therefore Woodward
emphasizes customer satisfaction in four important areas known as QDRC:
Quality. The first time, every time.
Delivery. On-time delivery so you get our products when you need them.
Responsiveness. We respond to your needs without delay.Cost. We constantly strive to reduce costs.
Woodward
— at the
heart of thesystem
s
Woodward Integrated Turbine
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s Equipment that’s not reliable
s Complexity of interfacing multiple
controllers
s Time-consuming troubleshooting
s No good time to schedule
maintenance
s High cost of maintaining equipmen
s Difficulty getting parts and service
Gain Control. Eliminate your aggravations.
And you probably think...
You have to hire multiple vendorsand invest significant time and capital to solve
these problems.
and Compressor Control
You’ve felt that aggravation.
What does integration mean at Woodward?...
Woodward has the solution.
With Woodward’s integrated turbine and compressor control (ITCC) you benefit from
our years of application experience and field-proven controls. You get a quick return
on your investment and having to coordinate with multiple vendors is eliminated.
s Jeopardizing reliability to balanceefficiencies
s Sacrificing process control to
prevent a surge condition
s Chaos with each alarm situation
s Lost revenues and damage to
equipment
s Acomplete shutdown due to an
instrument failure
You know the problems all too well.
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Multiple VendorInstalled Cost
T o t a l C o s t
otaCos
Your initial investment in hardware and
commissioning escalates with multiple
controllers for turbine control, surge control,
emergency shutdowns, process control
and mechanical equipment.
Woodward’s ITCCInstalled Cost
...but one integrated Woodward
solution has many economic
benefits
With Woodward’s ITCC system you can typically expect a return on investment
(ROI) of one to two years. This payback can differ with each application but
some Woodward customers have had even faster ROIs. For example, an ethylene
compressor retrofit in the People’s Republic of China, resulted in a 5% efficiency gain
which translates to less than one year for a 100% return on their investment.
ROI in as
little as
one year
s
Every customer and site is unique, so each application is reviewed for specific
needs. Woodward controls are preprogrammed with proven blocks of software
capturing over 125 years of control experience. This software is custom-configurable
so you just point and click to design your own control logic and fine tuning can be
done while you are operating. This system flexibil ity means you get the right solution
for your application.
Custom
programs
optimize
flexibility
s
Economic Benefitsof Integration
Integration at Woodward means a comprehensive package including compressor control, steam turbine,
gas turbine, or motor control, process control, emergency shutdowns, and multiple-unit control. Integration
also includes project management, field service, training, and representation no matter where you are in the
world. At Woodward, integration means even more because Woodward can provide a complete line offield-proven mechanical interface products such as actuators, valves, and fuel delivery systems.
Only one total price and contract
to negotiate
Only one specification to write
Only one factory acceptance test
Only one supplier for both electrical
& mechanical equipment
Only one Project Manager
Only one installation to coordinate
Only one system to qualify
& inspect
Only one start up
Only one call to make for service
& support
Only one system to train personnel on
Only one system to maintain
Only one set of spares to buy & stock
Woodward’s
ITCC saves
time and
money
becausethere’s
Only one means the installed cost is lower because there’s less hardware to buy.
It means simple coordination of a cost-effective reliable system.
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Integration means more at Woodward.
By using Woodward’s integrated control system and software designed
specifically for controlling the compressor and its driver, you get faster
more interactive control of many variables simultaneously.
With separate controllers, control modes for the compressor, its driver, and
the process act independently and adversely affect each other, especially when
surge control must intervene with the speed reference. In order to avoid this,
fast-acting close communication between controllers is required. Communication
between separate controllers usually imposes limitations such as ramp rates
in the speed reference circuit and slower communication baud rates.
Woodward’s single-controller integrated solution is not just combiningseparate controllers into one piece of hardware. The single controller eliminates
delays because the algorithms are in the same software and can communicate
at the required speeds.
Woodward’s control algorithms perform decoupling of interacting control routines
and high speed communication between the compressor, its driver, and the
process for the optimum solution to surge prevention without process upsets.
Integration
improves
process
stability
while
preventing
surge
s
Since the first integrated compressor control installed, Woodward has refined
control techniques from using simple anti-surge algorithms to today’s
patent-pending rate controller. Woodward’s anti-surge
control is a proactive control as opposed to a reactive
control. Our rate controller regulates the rate at which
the compressor’s operating point approaches the surge
line and allows for smooth transition to stable control.
Applying proper control algorithms is only half of
what makes a compressor control application
successful. Equally important is our experience
with electrical and mechanical interface with
the compressor. This includes selection and
location of instrumentation, filtering inputsignals, and sizing the recirculation
valve and the response time of the
complete recirculation loop.
Rate
controlleracts over
the entire
compressor
operating
range
s
De-Coupl
Surge
RateControl
Boost
w/PrePack
SCL PIDController
Rate
Controller
De-Coupling
Boost/wPrePack
SCL PIDController
Woodward prevensurge using four comprehensiv
control layers and using five surge detection methods
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Gas Turbine Control
• Precision EGT Limiting
• Control and Sequencing
• Standard Gas Turbine Software
• Helper (Steam) Turbine Control
• Total Refridgeration Process Control
Motor Driver Control
• Compressor Inlet ThrottlingControl
• Starter Turbine Control
• Synchronous Motor Sequencing
• Power Limiting
Integrated Turbine andCompressor ControlAcontrol solution for your compressor train
regardless of driver type or application.
The MicroNet ™ digital control
is one example of a cost-
effective control solution.
Available in simplex or
TMR, the MicroNet control is microprocessor- based and programmable
for any application. Control
schemes are processed within
5 msec recursion rate for precise,determinate control. Whether
controlling one compressor set or many, the
MicroNet control is expandable to meet
specific site needs.
The MicroNet™ TMR
digital control
Woodward offers many control solutions. Multiple levels of redundancy are available to fit any need, from the cost-effective
simplex systems to fully fault-tolerant coverage of nearly
100%. Triple modular redundant (TMR)
controls can even include triplex
I/O for the most critical
applications.Compressor Control
• Anti-Surge Control
• Capacity Control
• Process Control
• Suction Pressure Control
• Multiple Unit Control• Load Sharing
• Drum Level Control
• Drum Temperature Control
• Drum Pressure Control
• Discharge Pressure Control
• De-Coupling of Speed/Load• Anti-surge Variable Molecular
Weight Compensation
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Each control monitoring
scheme provides a
thorough operator interface
and troubleshooting system as well as remote control,
trending, and condition
monitoring. Screens can include System Overview,Turbine and Compressor
Details, Anti-surge Details,
Lube System, Turbine Bearings, and Start
Permissives. Click between screens to view
compressor maps, criti cal points, suction drum levels, journal bearings etc. Use it as a
teaching tool adding screens and information
as you go.
Local TouchScreen
Human Machine Interface (HMI)
• Operation and Performance Monitoring
• Easy Troubleshooting Tool
• Trending and Archiving
• Teaching/Training Tool
• Integrates Easily with a DCS
Steam Turbine Control
• Single- & Double-AutomaticExtraction/Admission Control
• Extraction Pressure/Flow Control
• Inlet Pressure Limiting
• Isochronous/Droop Modes
The MicroNet™ TMR
digital control
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ITCC Features...
Afactory acceptance testAnti-surge software module
Decoupling from speed control
Decoupling from process control
Review of customer P& I drawings
Review of compressor
performance maps
New P& I drawings with standard
ISAgraphics
Connect and pre-configure routinesVerification of flow meter sizing, locating,
and specification
Verification of sensors sizing, locating,
and specification
Verification of recycle valve size
and actuation
Create standard HMI screens
and alarms
ITCC Standard setup includes:
Detailed review of customer P& I
drawings
Detailed review of compressor
performance maps w/recommendations
Pre-tune routines
Flow meter specification sheets and/or
the flow meter
Recycle valve specification sheets and/or
the recycle valve
Sensors specification sheets and/or the
sensors
Custom HMI screens & alarms
New P& I drawings on customer format
(additional items)
You can add these custom features:
Horsepower calculations
Final commissioning, system tuning,
and training
Process improvement studies
Compressor mapping and surge testing
Static simulation of system modeling
Commissioning services
Site-specific/specialized training
Add these additional services or engineering studies:
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To prevent erroneous trips you can enhance the standard ‘smart-trip’
shutdown logic. Smart trip logic schemes monitor and intell igently evaluate
all alarm and trip conditions. When a single device indicates a trip, certain related
parameters must also indicate problems before a shutdown can be initiated. If the
related parameters are stable and within acceptable operating limits, the failing
device is only an alarm and not a trip. The failed device can then be repaired
without the system experiencing a trip. This also assures your equipment is running
safely and allows you to extend run time for many years without a shutdown.
Eliminatetrips due toinstrument
failures
s
The right solution is more than hardware, I/O count, and functional specs.
Equally important is the experience and the teamwork. Woodward
coordinates an interactive collaboration to best utilize the knowledge of the OEM,
end-user, and engineering staff.
Teamworkbrings it all
together
s
Woodward controls are modular and expandable so you are set for the future.
You can upgrade or integrate even further which eliminates buying additional
controllers later that might be awkward to integrate, and only one controller means
you need only one set of spares.
Plan foryourfuture
s
Once your system is installed, you’l l get support from any of Woodward’s100 offices, plants, or agents; as well as our extensive network of certified
and authorized dealers worldwide. We also have a technical assistance team to
talk you through routine situations or to help you decide if a field technician
needs to come to your site.
Support fromover 100 offices
worldwide
s
Woodward’s three-year warranty comes with every new product we sell,
including our remanufacture services and all replacement/exchange units.
This warranty is two years longer than most warranties offered today and reflects
our confidence in our products and our commitment to our customers.
The bestwarranty inthe business
s
Find out more about Woodward integrated
systems and control solutions. Call your nearest
office listed on the back of this brochure.
Worldwide service & support.
To simplify troubleshooting, time stamping is available. I/O is time and date
stamped to within 1 msec for discrete inputs and 5 msec for analog inputs.
This first out indication eliminates the guesswork. With traditional gauge panels,
operators have no indication as to which alarm has tripped first or in what sequence.
Time stamping allows operators to make quick educated decisions without
performing lengthy troubleshooting routines.
Self-diagnosticssimplifies
troubleshooting
s
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Woodward worldwide...
Kingsgrove, N.S.Wingsgrove, N .S.W.Australiaustralia
61 2-9758-2322 1 2-9758-2322
Haryana, Indiaaryana, India91 129-230419 1 129-230419
Abu Dhabi, U.A.E.bu Dhabi, U.A.E.971 2-273704 71 2-273704
PlzenlzenCzech Republiczech Republic
420 19-7226076 20 19-7226076
Warsawrsaw, PolandPoland48 22-8264156 8 22-8264156
Campinas, S.Pampinas, S.P.Brazilrazil
55 19-708-4800 5 19-708-4800
Mexico Cityexico City, MexicoMexico52 5-448-4916 2 5-448-4916
ChristchuhristchuNew Zeaew Zeal
64 3-33804 3-3380
Chiba, Jahiba, Ja81 476-931 476-93-
Beijing, Chinaeijing, China86 10-646513956 10-64651395
Hoofddorp, The Netherlandsoofddorp, The N etherlands31 23-56611111 23-5661111
Tettnang, Germanyttnang, G ermany0049 75-4254270 049 75-4254270
Reading, U.K.eading, U.K.44 118-9752727 4 118-9752727
Colorado, U.S.A.olorado, U.S.A.1 970-663-3900 970-663-3900
Singapoingapo65 270-05 270-0
Pusan, Koreausan, Korea82 51-647-8792 51-647-8796
Texas, U.S.A.xas, U .S.A.1 713-666-2211713-666-2211
For more information, contact your Woodward representative
above or one of the offices listed below:
Woodward Industrial Controls
http:/ /www.woodward.com
© 1997 All Rights Reserved Woodward Governor Company
Printed in U.S.A.
MicroNet is a trademark of the Woodward Governor Company.
5Headquarters –Colorado, USA
Phone: 1 970-663-3900
Fax: 1 970-962-7050
Brazil
Phone: 55 19-708-4800Fax: 55 19-708-4778
United KingdomPhone: 44 118-9752727
Fax: 44 118-9751599
The Netherlands
Phone: 31 2356-61111Fax: 31 2356-36529
JapanPhone: 81 476-93-4662
Fax: 81 476-93-7939
Singapore
Phone: 65 270-0081Fax: 65 271-6250