Product Specification

03298A

505CC-2
Steam Turbine and
Compressor Control

• Incorporated
control
One- or two-
valve steam
turbine
One- or two-
stage
compressor
Superior
performance
• Field-proven anti-
DESCRIPTION surge algorithms

The 505CC-2 is a microprocessor-based serves as the operator control interface. The • Based on popular
control with integral application software service panel is supplied in a panel-mount 505 Steam
designed to control a single-valve or two-valve configuration for maximum flexibility of field Turbine Control
steam turbine and its one- or two-stage location. Typically, the 505CC-2 control unit is
compressor load. The turbine control located in an enclosure rated for the site- Field-
architecture is patterned after the popular 505 specific environmental conditions. configurable
and 505E turbine controls. The anti-surge Change
control provides the user with a choice Options are available to upgrade the basic
system to specific needs of each application. A dynamics while
between two algorithms—the standard online
Woodward anti-surge algorithm or a universal 381 mm (15”) Human Machine Interface (HMI)
surge curve design that adapts the operating that is Ethernet based can be connected to the View turbine
point calculation to varying process conditions. control. This HMI provides full graphics of the and compressor
compression island as well as data logging
Like the 505, the 505CC-2 uses configurable
and performance trending.
parameters
software for maximum field flexibility.
The control hardware consists of four plug- In addition to the HMI and service panel • Includes user-
together modules housed in a rugged metal communications, two additional Modbus® * friendly
ports are included for remote connection to a
chassis. The SmartCore module contains the
plant DCS or other intelligent systems.
configuration
basic I/O for turbine control. An Analog I/O
module interfaces with the signal I/O
program
Key benefits include the combination of turbine
associated with the one- or two-stage load
compressor. The main processor and an
speed control with compressor control, which • Optional 381 mm
provides much improved performance. Integral
Ethernet port are located on the Pentium CPU de-coupling software between speed and anti- (15”) HMI
module. In addition, a Power Supply module surge functions allows fast, yet stable,
(24 Vdc) is provided to power the entire control response to system upsets. This combination • Two RS-232 serial
assembly. The modules are stacked into a also lowers overall costs. Existing solutions Modbus®
PC/104 configuration that eliminates the need require separate boxes that do not interface communication
for a costly motherboard. Connections between with each other or must be wired together
the modules are made with plug-together on- externally.
ports
board connectors that are environmentally
rated for industrial service in adverse The 505CC-2 complies fully with the • API 612
conditions. requirements of API 612 for installation in Compliant
petroleum, chemical, and gas processing
A user-friendly configuration program is plants.
included for configuration, tuning, and
monitoring of the control unit. This panel also * Modbus is a trademark of Modicon, Inc.
 Analog Inputs (21)
APPLICATIONS Eleven analog inputs are assigned pre-determined functions,
and ten are configurable.
Extensive applications for the 505CC-2 include multiple Ext/Adm/Inlet/Exhaust Steam Pressure (4–20 mA or 1–5 Vdc)
combination of one-or two-valve steam turbine prime movers Compressor Flow Signal No. 1 (4–20 mA or 1–5 Vdc)
and one- or two-stage compressors. The turbine control can Compressor Suction Pressure Signal No. 1 (4–20 mA or 1–5 Vdc)
be configured in the field to handle simple single-valve Compressor Discharge Pressure Signal No. 1 (4–20 mA or 1–5
condensing steam turbines on up to more complex extraction Vdc)
and admission units. Control strategies for straight-through, Compressor Suction Temperature Signal No. 1 (4–20 mA)
Compressor Discharge Temperature Signal No. 1 (4–20 mA)
iso-cooled, double flow, single sidestream, and back-to-back
Compressor Flow Signal No. 2 (4–20 mA or 1–5 Vdc)
compressor scenarios are also fully configurable to meet Compressor Suction Pressure Signal No. 2 (4–20 mA or 1–5 Vdc)
specific site requirements. Compressor Discharge Pressure Signal No. 2 (4–20 mA or 1–5
Vdc)
The 505CC-2 includes the following PID
Compressor Suction Temperature Signal No. 2 (4–20 mA)
(Proportional/Integral/Derivative) closed loop and non-PID Compressor Discharge Temperature Signal No. 2 (4–20 mA)
open loop functions: Configurable Analog Inputs (10) (4–20 mA or 1–5 Vdc)
Turbine OUTPUT SIGNALS:
• Speed PID Control (with Dual Dynamics) Discrete Outputs (12)
• Extraction/Admission PID Control Two discrete outputs are assigned pre-defined functions and
• Ratio & Limiter ten are configurable.
• HP & LP Valve Limiters Turbine/Compressor Shutdown
• Manual/Semi-Auto/Automatic Start Sequence Turbine/Compressor Alarm
Configurable Discrete Outputs (10)
• Overspeed Test
• Critical Speed Avoidance Actuator Drivers (4)
• Alarm & Shutdown Logic Four pre-defined actuator driver outputs are assigned.
HP Actuator (4–20 mA or 20–200 mA)
Compressor LP Actuator (4–20 mA or 20–200 mA)
• Anti-Surge PID Control Recycle Valve No. 1 (4–20 mA)
• Rate PID Control Recycle Valve No. 2 (4–20 mA)
• Boost Analog Outputs (6)
• Surge Recovery All analog outputs are configurable.
• Surge Minimum Position Configurable Analog Outputs (6) (4–20 mA)
• Start, Purge & Stop Position
• Alarm & Shutdown Logic
CONTROL FUNCTIONS
Alternatively, the following functions can be configured,
depending on the application requirements: Turbine Start-up/Shutdown
Turbine The 505CC-2 provides three selectable start-up modes—
Manual, Semi-Auto, and Automatic. In manual mode the
• Inlet Pressure PID Control
turbine is started by manually cracking the trip and throttle
• Cascade PID Control (Compressor Suction Pressure or
valve. The 505CC-2 will take control once the speed reaches
Other Process Parameters)
the control setpoint (min governor). In semi-automatic mode
Compressor the 505CC-2 controls the steam flow, and turbine speed is
manually controlled by the operator (service panel or discrete
Process Control (Suction or Discharge Pressure Override) raise/lower contact inputs). In full automatic mode the
505CC-2 controls the steam flow, and the control valve will
CONFIGURABILITY automatically ramp open at a user-defined rate until the
turbine speed reaches min governor speed. Turbine
shutdown is accomplished by manipulation of the HP and LP
The 505CC-2 inputs and outputs (I/O) are arranged into pre-
valve limiters.
defined and configurable groups. The pre-defined I/O is fixed
based on its usefulness for nearly all applications. The Speed Control
configurable I/O is selected based on the specific needs of The speed control receives turbine speed signals from one or
each application. two magnetic pickups or proximity probes. The Speed PID
compares the speed value against a speed reference
INPUT SIGNALS:
setpoint to determine the correct turbine valve position
Discrete Inputs (24)
demand. If the application is a single valve configuration, the
Eight discrete inputs are assigned pre-determined functions
valve position demand is sent directly to the HP actuator.
and sixteen are configurable.
Emergency Shutdown Extraction/Admission Control
Reset The Extr/Adm Control receives an extraction/admission
Raise Speed
pressure or flow signal. This signal is compared to a
Lower Speed
Open Anti-Surge Valve No. 1 reference setpoint to generate a second turbine valve
Close Anti-Surge Valve No. 1 position demand. Since an extraction/admission turbine has
Open Anti-Surge Valve No. 2 two control valves, the valve position demands from the
Close Anti-Surge Valve No. 2 speed control and the extraction/admission control are fed
Configurable Discrete Inputs (16) through Ratio/Limiter software that sorts out the correct
signals to be sent to the HP and LP control valves.
Speed Signals (2)
Two pre-defined inputs are available for MPUs or
proximity probes.
Speed Input No. 1
Speed Input No. 2
Turbine-based Process Control
A variety of process control options is available. By using cascade speed controls, the user can configure control of compressor
suction or discharge pressure, or any other process variable. The process control compares a signal proportional to the controlled
variable to a reference setpoint. Depending on the configuration that is selected, either the speed setpoint or the load demand
signal will be modified to accomplish the desired control.
Overspeed Test
The overspeed test capability allows the operator to increase the speed reference setpoint above its rated maximum so that the
electrical or mechanical overspeed protection systems can be tested. This includes the control’s internal overspeed protection
logic as well as any external protective devices. Testing can be performed from the service panel or from the external contact
inputs.
Anti-Surge Control (Closed Loop)
An anti-surge PID receives pressure and flow signals from the suction and discharge lines on the process compressor. These
values are compared to the surge map for the specific compressor. When the computed surge limit is exceeded, the output signal
will cause the recycle valve to open so that the compressor flow is increased and surge is avoided. If the system upset is severe, a
second rate-control PID is invoked to more quickly move the recycle valve demand.
Anti-Surge Control (Open Loop)
A variety of secondary control actions are available should the primary anti-surge corrections prove inadequate. A Boost feature
opens the recycle valve further than what the closed loop PID would normally demand. A Pre-Pack feature is included to
compensate for long piping runs that exhibit significant lags. If a surge event occurs in spite of these corrective actions, a Surge
Recovery system and a Surge Minimum Position capability take over until the primary anti-surge protection resumes control.
Compressor-based Process Control
Compressor suction pressure and compressor discharge pressure can be controlled by modulation of the compressor recycle
valve. These functions act in a backup role to help increase the suction pressure or decrease the discharge pressure when the
turbine speed is changed. A suction pressure override PID and a discharge pressure override PID take effect when turbine speed
alone cannot maintain these process setpoints.
Communications
An Ethernet port on the 505CC-2 provides an interface to the optional 381 mm (15”) HMI. This device allows the control to be
configured to the specific needs of the current application. After configuration, the service panel or HMI can be used to tune,
monitor, and control the 505CC-2. In addition, two RS-232/-422/-485 communication ports are available for connection to
customer plant level control and DCS.

LP Actuator
HP Actuator
LP
Inlet Pressure Signal Act
HP
Inlet Act
Steam
PT

505CC-2
Steam Turbine
&
Compressor
Control

MPU
PT
Speed Input
Extraction
Extraction/Admission Input Steam
Exhaust Recycle
Steam Valve 2

Recycle
No. 1 Suction Pressure PT Valve 1
No. 1 Suction Flow FT

No. 1 Discharge Pressure PT

Side Discharge Flow FT

No. 2 Discharge Pressure PT

Recycle Valve No. 1

Recycle Valve No. 2

505CC-2 Block Diagram

 SPECIFICATIONS
PO Box 1519
Fort Collins CO, USA Power Supply Rating 18–32 Vdc
80522-1519 Power Consumption Less than 65 W
1000 East Drake Road
Fort Collins CO 80525 Magnetic Pickup 100–24 950 Hz
Ph: +1 (970) 482-5811 Proximity Probe 0.5–24 950 Hz
Fax: +1 (970) 498-3058 Discrete Inputs 3 mA @ 24 Vdc, impedance 5.2 kΩ nominal
Analog Inputs (current or voltage) 4–20 mA, 0–5 Vdc
Analog Inputs (T/C) Type J or K
Distributors & Service
Woodward has an Analog Inputs (RTD) 100 or 200 Ω, 3-wire
international network of Actuator Outputs 4–20 mA or 20–200 mA
distributors and service Analog Outputs 4–20 mA
facilities. For your nearest Discrete Outputs Powered by external +12 or +24 Vdc source, output
representative, call the current 200 mA maximum
Fort Collins plant or see Communication Ports One Ethernet; two RS-232
the Worldwide Directory
on our website.
Control
Ambient Operating
Corporate Headquarters Temperature Range –20 to +70 °C
Rockford IL, USA Storage Temperature Range –40 to +85 °C
Ph: +1 (815) 877-7441 Vibration Lloyds RS ENV 2 (0.7g, 15–150 Hz)
Shock US MIL-STD-810C, 516.2-2 (30 g, 11 ms, ½ sine)
www.woodward.com Humidity 95% at +20 to +55 °C
Service Panel
Ambient Operating
Temperature Range –10 to +55 °C
Shock 10 g peak acceleration (11 ms duration)

Regulatory Compliance
CE Compliance Low Voltage Directive, EMC Directive, ATEX Directive
Other European European Class I, Zone 2, Group IIC when installed in an
IP-54 minimum rated enclosure per DEMKO certification
North American UL Class I, Division 2, Groups A, B, C, D

505CC-2 Outline Drawing

(Do not use for construction)
This document is distributed
for informational purposes For more information contact:
only. It is not to be construed
as creating or becoming part
of any Woodward Governor
Company contractual or
warranty obligation unless
expressly stated in a written
sales contract.

© Woodward 2002
All Rights Reserved
04/7/F