52110 ITCC

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IntegratedTurbine &

CompressorControl

IntegratedTurbine &

CompressorControl

...at the Heart of the System

8/3/2019 52110 ITCC


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

8/3/2019 52110 ITCC


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

Documents

52110 ITCC