Woodward PEAK200-HVAC 8200-1501 Digital Control for Steam Turbines

Peak200

PEAK200-HVAC  8200-1501

Digital Control for Steam Turbines

The Peak200 controller is designed to

operate small single valve, or single valve

rack industrial steam turbines. This cost

effective steam turbine controller includes

specifically designed algorithms and logic

to start, stop, control, and protect small

industrial steam turbines or turbo

expanders driving compressors, pumps, or

industrial fans.

The Peak200 control’s unique PID

structure makes it ideal for applications where it is required to control steam plant

parameters like turbine speed, turbine load, turbine inlet header pressure, turbine

exhaust header pressure, pump flow, or compressor discharge, or suction pressure.

The control’s special PID-to-PID logic allows stable control during normal turbine

operation and bumpless control mode transfers during plant upsets, minimizing

process over or undershoot conditions. The Peak200 controller senses turbine

speed via passive speed probes and controls the steam turbine through an actuator

connected to the turbine inlet steam valve(s). Peak 200 includes Woodward’s

patented adaptive PID controller that allows users automatic calculation for optimum

dynamic gains at their individual plant system.

Designed to function as a plant DCS node the Peak200 controller can be configured

to interface with the plant DCS via hardwired inputs/output signals or serial or

Ethernet communications. With the capability to monitor and control all turbine and

driven equipment based functions (i.e. bearing temperatures, vibration levels, control

oil levels, etc.) the Peak200 controller is ideal for use as a cost-effective turbine

control/protection as well as plant DCS monitoring node.

Alternatively the Peak200 can be configured to accept a remote turbine speed/load

demand from the plant DCS via a 4-20mA signal, discrete raise/lower commands, or

Ethernet or Serial Modbus communications.

The Peak200 control also includes a special “Cascade” PID control function that can

be optionally configured and used to control any system process, related to or

affected by turbine speed or load. Typically, this controller is configured and used to

control turbine inlet header pressure, turbine exhaust header pressure, pump flow, or

compressor discharge, or suction pressure. The Cascade PID compares a 4–20 mA

process signal with an internal set point to directly position the Speed PID

controller’s setpoint, thus changing turbine speed or load until the process signal and

set point match. By cascading these two PIDs in this fashion, bumpless transfers

can be performed as well as turbine min/max.

Ethernet and serial communications allow users to easily connect the Peak200 in to

plant or process control system. All controller inputs, outputs, and statuses can be

monitored and all start/stop or enable/disable commands can be given through

industry standard Modbus TCP. The Peak200 uses SNTP (synchronized network

time protocol) over Ethernet to allow users to synchronize the Peak200’s real-time

clock to the plant distributed control system.

PEAK200-HVAC 8200-1501

The Peak200 control is available in either bulkhead models designed to be mounted on a wall or skid near the

turbine or panel-mount models designed to be installed within a standard panel or cabinet door. The product is

designed to meet NEMA 4x corrosion resistance tests and has an ingress protection rating of IP56. protecting it

against dust and water jets.

The control’s front panel serves as both a programming station and operator control panel (OCP). This user-friendly

front panel allows engineers to access and program the unit to the specific plant’s requirements, and plant operators

to easily start/stop the turbine and enable/disable any control mode.

Password security is used to protect all unit program mode settings. The controller’s 5” graphical display allows

operators to view actual and setpoint values from the same screen, simplifying turbine operation.

Turbine interface input and output wiring access is located on the controller’s lower back panel. Un-pluggable

terminal blocks allow for easy system installation, troubleshooting, and replacement. Optionally users can increase

the number of inputs and outputs signals to/from the Peak200 control by connecting LinkNet-HT distributed I/O

nodes to the controller’s CAN communication ports and configuring the Peak200 control to use the connected

distribute inputs and outputs. The following additional I/O signals can be connected to the Peak200 control via CAN

communications:

• (8) 4-20mA input channels and 2 4-20mA output channels (via 1 LinkNet-HT AIO module)

• (8) RTD signals (via 1 LinkNet-HT RTD module)

• (16) Discrete Inputs (via 1 LinkNet-HT DI module)

• (16) Relay output drivers (via 1 LinkNet-HT DO module)

Designed for steam turbine control, the Peak200 control includes two PID controllers (Speed & Cascade) multiple

startup routines (manual, automatic, remote control), and multiple protection functions (overspeed, critical speed

range, etc.) which can be configured by a user depending on the specific turbine application’s requirements. Users

can configure the Peak200’s different PID controllers, start routines, and protection levels themselves without the

need for a special control engineer. Once configured, the Peak200 performs a configuration check routine to ensure

that the programmer did not make any basic configuration mistakes.

Optionally users can utilize Woodward’s RemoteView software program with the Peak200 to function as a remote

operator control panel and or engineering station. This software program once loaded onto a remote computer or

touch panel, allows the user the following additional functionality:

• Perform the identical Peak200 front panel display functions (monitor, operate, tune, and configure) on the

respective computer or touch panel.

• Full function free for 2 hours

• Licensable for continuous GUI operation

• Password based login level security is utilized allowing function management for RemoteView applications

Refer to Woodward product specification B03424 for additional information.

The Peak200 includes a suite of service tools to allow users to perform the following functions:

• Upload configuration settings files from the Peak200 to save on another device

• Download configuration settings files to the Peak200

• View real-time or saved trend files

Control

• Dual dynamics (Speed PID)

• Adaptive speed/load PID dynamics

• Cascade PID (turbine/driven equipment pressures or

flows)

• Manual or auto start sequence

• First-Out indication (alarms & shutdowns)

• Peak speed Indication for overspeed trip

• Multi-lingual Display (English & Additional

Languages TBD)

• Remote analog setpoints for Speed/Load & Cascade

• Bearing temperature monitoring/alarms/trips

• Vibration monitoring/alarms/trips

System Protection

• Overspeed protection logic & test capability

• Critical speed band protection (1 band)

• First-out Indication (5 individual shutdown inputs)

• Bearing temperature alarm and trip settings

• Turbine vibration alarm and trip settings

• Control CPU & memory failure detection logic

• Mode login level password security

Cost-Effective Design— The Peak200 control is

designed to function as the turbine control, system

sequencer, operator control panel, and first-out indicator.

This encompassing design minimizes external system

devices as well as system installation, wiring, and

troubleshooting. This field configurable controller allows

major functional changes to be made at site, often by

knowledgeable plant personnel, and minor functional

changes to be online as process changes require. The

Peak200 control’s first-out-indicator logic indicates

internal as well as external system related alarm and

shutdown conditions, greatly simplifying and reducing

system troubleshooting.

Communications— The Peak200 controls can

communicate directly with plant Distributed Control

Systems and/or operator control panels, through two

Ethernet ports using Modbus TCP or UDP

communication protocols or via a serial Modbus port.

The Peak200’s serial port supports RS-232 or RS-485

communications using ASCII or RTU Modbus protocols.

Communications between the Peak200 and a plant DCS

can also be performed through hardwired connections.