Woodward 505DR Dual Redundant Turbine Controller

The 505DR® Dual Redundant Turbine Controller is a state-of-the-art digital control platform designed to reliably control and protect single-valve and single-pump steam turbines.

The benefits of dual redundancy maximise turbine reliability and availability.

Redundancy is managed at the operating system level using Woodward's RTN (Real Time Network), allowing ultra-fast switching and ‘bufferless’ transitions.

The controller utilises the same unique PID architecture as the proven 505XT, making it the ideal controller for controlling speed, load,

parameters such as pumping collector pressure, exhaust collector pressure or connection line power. The dual redundant version inherits features such as the Opti-Tune self-tuning PID and ratio limiter.

The controller includes the following turbine protection features to ensure that the turbine and its driven loads (compressors, pumps, generators) operate within design limits:

- 3 critical speed avoidance bands

- Overspeed prediction and shutdown protection

- Configurable under- or over-pressure shutdown logic

- Minimum and maximum speed and load settings

- Maximum low-pressure stage overpressure limitation

- Minimum high pressure stage flow limiting

Ethernet and serial communications allow for easy integration into plant controls or process control systems.

The 505DR can be configured with an optional integrated user interface, including an 8.4-inch multi-language graphical display.

Description

Like the MicroNet Plus, the 505XT system designates one controller as the System Controller (Syscon), actively controlling the fan.

The second device is configured as a backup. The system automatically evaluates the health of the Syscon and initiates a fast switchover in the event of a failure.

Switchover can also be initiated manually. The system closely synchronises the Syscon's software status and memory with the backup, ensuring that the control output remains stable and does not affect turbine operation (a true ‘bufferless’ switchover).

If the optional HMI version is selected, the display and keypad are redundant (input from either keypad will command Syscon, and the display can be independently selected to show different screens.

For example, one screen can display speed and speed settings, and another can display a steam map.

Woodward's optional RemoteView programme allows remote monitoring from any networked PC.

The programme can be used either with the rear panel mounted version (as the main HMI) or as an additional remote monitor to the HMI version.

The optional FTM (Field Terminal Module) allows easy multiplexing of redundant signals and facilitates fast installation and commissioning.

Cost-effective design

The 505DR is a G-efficient redundant turbine controller. It consists of a turbine controller, system sequencer, operator control panel and first-out indicator.

The design minimises external equipment and wiring for easy troubleshooting.

Like the 505XT, the 505DR can be fully configured in the field (under password control by knowledgeable personnel) and minor functional changes can be made while the turbine is running online.

Minor functional changes can be made online while the turbine is running.

Communication

The 505DR can communicate directly with the plant DCS and/or operator control panel using Modbus TCP or OPC communications.

Serial communication is also supported using RS-232 or RS-485 and ASCII or RTU Modbus.

Control PIDs can perform process control or be used as limiters for speed/load dynamics, pumping/discharge pressures, cascade, auxiliary, intake plenum, exhaust plenum, and rotor acceleration.

System Protection

- Integrated overspeed protection logic and test functions

- First open indication on 15 shutdown inputs

- External alarm indication on 15 inputs

- Stuck at critical speed band logic

- Bufferless transfer between control modes and during Syscon switchover

- Operation and configuration password security

Control specifications

Inputs

- Power Supply Low voltage models 18-32 VDC High voltage models 88-264 VAC and 90-150 VDC

- Speed: 2 passive MPUS or active proximity probes (0.5 - 32000 Hz)

- Discrete Inputs 19 configurable contact inputs (16 additional contact inputs can be added using LinkNet HT)

- Analogue Inputs 8 configurable 4-20 mA (16 inputs or 8 RTD inputs can be added using LinkNet HT)

Outputs

- Valve/actuator driver: 2 actuator outputs, 4-20 mA or 20-200 mA

- Discrete Outputs:

- 7 configurable relay outputs (16 discrete outputs can be added using the LinkNet HT module)

- Analogue Outputs 6 programmable 4-20 mA outputs (4 inputs can be added using the LinkNet HT module)

Communications

- Ethernet 3 ports (Modbus TCP or OPC)

- Serial 1 port (ASCII or RTU, RS-232 or RS-485)

- CAN: 4 ports, supports LinkNet HT, VariStroke, and power management devices

Operating Conditions

- Ambient air temperature: -25 to +65C

- Humidity Lloyd's ENV2 Test #1

- Dry heat Lloyd's ENV3

- Salt Spray: US MIL-STD-810. Method 509.2 proc. 1

- Shock: US MIL-STD-810C, Method 516.2-1 proc. 1B

- Vibration Lloyd's ENV2 Test #1

- Resistance to particulate contamination IEC 60664-1 Class 2

- IEC 60068-2-60 part 2.60 methods 1 and 4

- Resistance to gaseous contamination: coating is resistant to NO2. CO2. SO2 and H2S.

- Battelle Laboratories Class III (IEC 60721-3-3 Categories 3C1 and 3C2)