Integrated Turbine & Compressor Control

...at the Heart of the System

Woodward Integrated Turbine

Woodward at the heart of the system
s 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, Woodwards integrated turbine & compressor control (ITCC) provides complete integrated control for the entire compressor train. Woodward designs and manufactures a comprehensive range of control devicesboth electronic and mechanicaland 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.

and Compressor Control

You know the problems all too well.
s Jeopardizing reliability to balance efficiencies s Sacrificing process control to prevent a surge condition s Chaos with each alarm situation s Lost revenues and damage to equipment s A complete shutdown due to an instrument failure

Youve felt that aggravation.

s Equipment thats not reliable s Complexity of interfacing multiple controllers s Time-consuming troubleshooting s No good time to schedule maintenance s High cost of maintaining equipment s Difficulty getting parts and service

And you probably think...

You have to hire multiple vendors and invest significant time and capital to solve these problems.

Woodward has the solution.

With Woodwards 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.

Gain Control. Eliminate your aggravations.

What does integration mean at Woodward?...

Economic Benefits of 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 of field-proven mechanical interface products such as actuators, valves, and fuel delivery systems.

Multiple Vendor Installed Cost

Total Cost

Your initial investment in hardware and commissioning escalates with multiple controllers for turbine control, surge control, emergency shutdowns, process control and mechanical equipment. ...but one integrated Woodward solution has many economic benefits

Woodwards ITCC Installed Cost

Woodwards ITCC saves time and money because theres

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

Only one means the installed cost is lower because theres less hardware to buy. It means simple coordination of a cost-effective reliable system.

ROI in as little as one year Custom programs optimize flexibility

s With Woodwards 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 Peoples Republic of China, resulted in a 5% efficiency gain which translates to less than one year for a 100% return on their investment.

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 flexibility means you get the right solution for your application.

Integration improves process stability while preventing surge

s By using Woodwards 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. Woodwards single-controller integrated solution is not just combining separate 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. Woodwards 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.

Rate controller acts over the entire compressor operating range

s Since the first integrated compressor control installed, Woodward has refined
control techniques from using simple anti-surge algorithms to todays patent-pending rate controller. Woodwards anti-surge control is a proactive control as opposed to a reactive control. Our rate controller regulates the rate at which the compressors operating point approaches the surge line and allows for smooth transition to stable control. Surge 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 input signals, and sizing the recirculation valve and the response time of the complete recirculation loop.
Boost/w PrePack SCL PID Controller Rate Controller

Boost w/PrePack SCL PID Controller

De-Coupling

Rate Controller De-Coupling

Woodward prevents surge using four comprehensive control layers and using five surge detection methods.

Integration means more at Woodward.

Integrated Turbine and Compressor Control

A control solution for your compressor train regardless of driver type or application.
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 Compressor Control applications.

Anti-Surge Control Capacity Control Process Control

Drum Level Control Drum Temperature Control Drum Pressure Control Discharge Pressure Control De-Coupling of Speed/Load Anti-surge Variable Molecular Weight Compensation

Suction Pressure Control Multiple Unit Control Load Sharing

The MicroNet TMR digital control The MicroNet digital control is one example of a costeffective control solution. Available in simplex or TMR, the MicroNet control is microprocessorbased 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.

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 Throttling Control Starter Turbine Control Synchronous Motor Sequencing Power Limiting

Human Machine Interface (HMI)

Operation and Performance Monitoring Easy Troubleshooting Tool Trending and Archiving Teaching/Training Tool Integrates Easily with a DCS

The MicroNet TMR digital control

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, critical points, suction drum levels, journal bearings etc. Use it as a teaching tool adding screens and information as you go.

Steam Turbine Control

Single- & Double-Automatic Extraction/Admission Control Extraction Pressure/Flow Control Inlet Pressure Limiting Isochronous/Droop Modes

Local Touch Screen

ITCC Features...
ITCC Standard setup includes:
A factory acceptance test Anti-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 ISA graphics Connect and pre-configure routines Verification 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

You can add these custom features:

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)

Add these additional services or engineering studies:

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

Self-diagnostics simplifies troubleshooting

s 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.

Eliminate trips due to instrument failures

s To prevent erroneous trips you can enhance the standard smart-trip

shutdown logic. Smart trip logic schemes monitor and intelligently 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.

Plan for your future Teamwork brings it all together Support from over 100 offices worldwide The best warranty in the business

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.

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.

s Once your system is installed, youll get support from any of Woodwards
100 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.

s Woodwards 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.

Worldwide service & support.

Find out more about Woodward integrated systems and control solutions. Call your nearest office listed on the back of this brochure.

Woodward worldwide...
Colorado, U.S.A. 1 970-663-3900 Reading, U.K. 44 118-9752727 Hoofddorp, The Netherlands 31 23-5661111 Warsaw, Poland arsaw, 48 22-8264156 Beijing, China 86 10-64651395

Chiba, Japan 81 476-93-4662 Texas, U.S.A. 1 713-666-2211 Tettnang, Germany 0049 75-4254270

Pusan, Korea 82 51-647-8796

Mexico City, Mexico City, 52 5-448-4916

Plzen Czech Republic 420 19-7226076

Haryana, India 91 129-230419

Singapore 65 270-0081

Campinas, S.P. S.P. Brazil 55 19-708-4800

Abu Dhabi, U.A.E. 971 2-273704

Kingsgrove, N.S.W. N.S.W. Australia 61 2-9758-2322

Christchurch New Zealand 64 3-3380479

For more information, contact your Woodward representative above or one of the offices listed below:

Woodward Industrial Controls

5 HeadquartersColorado, USA Phone: 1 970-663-3900 Fax: 1 970-962-7050 Brazil Phone: 55 19-708-4800 Fax: 55 19-708-4778 United Kingdom Phone: 44 118-9752727 Fax: 44 118-9751599 The Netherlands Phone: 31 2356-61111 Fax: 31 2356-36529 Japan Phone: 81 476-93-4662 Fax: 81 476-93-7939 Singapore Phone: 65 270-0081 Fax: 65 271-6250

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.

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