Electro-hydraulic I/H Converters and WSR Way Valves

Actuator Technology for Positioning Cylinders on Turbomachinery

Well-established technology

Outstanding reliability

All the worlds our home

Electro-hydraulic I/H converters and WSR way valves are the ideal economic solution for controlling hydraulic positioning cylinders. This enables a valve to regulate the mass flow (e.g. steam) in a precise and highly dynamic manner. A current input signal (0/4 20 mA) in the I/H converters or WSR way valves is proportionally converted into an output pressure or an oil flow.

The electro-hydraulic I/H converters and WSR way valves design is a simple one: n Control magnet with integrated electronics n Hydraulic component This simple and compact design serves to ensure high operational reliability coupled with availability of the components, and your system.

We are a reliable partner to manufacturers and operators of turbo machines in all international markets. Voith Turbo actuator technology has established itself 10,000 times over in power plants across the globe and ensures economic operation of turbines and compressors.

I/H converters

Voith Turbo I/H converters convert a 0/4 20 mA current input signal quickly and precisely into proportional output pressure.

7 A T P 1 2 3 4 5 6 7 Consumer terminal (output) Tank connection Oil supply terminal (input) Control magnet housing Tappet Potentiometer Manual adjustment Electrical connection Hydraulic component Control piston

Design

A Voith I/H converter is an electrically-controllable pressure regulating valve, consisting of force-controlled solenoid and a hydraulic component.

Simple design and well-established operating principle

Application principle 1: Direct actuation of a hydraulic cylinder Application principle 2: Operation of a pilot valve with mechanical position return Application principle 3: Operation of a pilot valve with electronic position return

Mechanical position return s s A Steam valve Live steam

Position pick up sensor i s For process control engineering

Electronic position return s

Live steam

Pilot valve

Pilot valve

Live steam

X0 X1 Process control engineering

+24V

A T P X0, X1

+ UHALL

FMag

FHydr

T Hydraulic pilot control

FMag FHydr UHall U s i w

Control magnet

Consumer terminal (output) Tank connection Oil supply terminal (input) Parameters for output pressure range (potentiometer) Magnetic force Hydraulic force Hall voltage Voltage Stroke Position pick up sensor current signal Nominal value for output pressure

Function

Solenoid-force control generates a magnetic force of FMag in a 24V d.c. solenoid. This magnetic force is proportional to the 0/4 20 mA input signal (w), the limits are configured using the X0 and X1 parameters. The electronic control, magnetic flux measurement, engineering design of the magnet and the hydraulic pilot control together form a dynamic functional unit that is practically free of hysteresis.

The control magnet applies the force FMag to the control piston. This in turn counteracts hydraulic force FHydr as generated by the pressure at output A over the cross-sectional area of the control piston (pressure regulator).

As a result of this regulation, the output line of the actuator always receives the exact required pressure and the oil quantity for positioning the steam or fuel valves.

Versatile application made possible by robust design and maximum precision

Technical data and characteristics
n Supply

voltage 24 VDC consumption 1.0 A n Input signal 0/4 20 mA n Type of protection IP 65 n Input pressure up to 70 bar n Ambient temperature - 20 to + 80 C for standard design n Explosion-proof design EEx d IIC T4 available
n Current

Type

Maximum input pressure [bar] 40 40 20 40 40 70 70

Control range for output pressure [bar] 03 05 05 17 0 10 0 30 10 35

Flow rate [l/min] at p = 1 bar PA AT 30 30 140 30 30 30 30 Voith Turbo I/H converters to a 300 MW steam turbine

DSG-B03XXX DSG-B05XXX DSG-B05X48 DSG-B07XXX DSG-B10XXX DSG-B30XXX DSG-B35XXX Selection table

30 30 100 30 30 30 30

System-specific data must be taken into consideration when defining a suitable I/H converter. When selecting an I/H converter, please make full use of our comprehensive knowledge. Our experienced sales staff will be only too glad to be of assistance.

Customer benefits

Outstanding reliability and availability

n Well-established

Dynamic and precise positioning of the output pressure

Simple installation and initial startup

n Device

operating

n Reproducibility n Almost

principle
n Dirt-resistant

and robust design

< 0.1 % no hysteresis n Temperature compensation n No drifting n Input pressure at least 0.5 bar higher than maximum output pressure n Fast response time

inspected and configured at factory (plug & play) n min. and max. Output pressures can be changed simply using parameters X0 and X1 (potentiometers) n Turbine lubricating oil can frequently be used as an operating medium n Depending on the model in question, adapter plates, flushing plates and connecting cables are available

Voith Turbo I/H converters to a 3.4 MW steam turbine (Photo: AG KK&K www.agkkk.de)

Explosion-proof design (left) and standard design

WSR way valves

Voith Turbo WSR way valves with integrated positioner convert in combination with an hydraulic cylinder a 4 20 mA current input signal quickly and precisely into a proportional stroke. 3/3-WSR way valves or 4/3-WSR way valves can be used to position hydraulic cylinders in a highly dynamic manner.

3/3 -WSR way valve A T P 1 2 3 4 5 6 7 8 Consumer terminal (output) Tank connection Oil supply terminal (input) Control magnet housing Tappet Potentiometer Manual adjustment Electrical connection Hydraulic component Control piston Control spring

Design

A Voith Turbo WSR way valve (fuelquantity positioner) is an electrically-controllable directional control valve, consisting of force-controlled solenoids and a 3/3-WSR way valve hydraulic unit for single-acting cylinders or 4/3-WSR way valve hydraulic unit for dual-acting cylinders.

Integrated control electronics for dynamic and high-precision changes in flow rate
3/3-WSR way valve for single-acting hydraulic cylinders 4/3-WSR way valve for dual-acting hydraulic cylinders

Position pick up sensor i s

Hydraulic cylinder

Position pick up sensor Steam control valve i s

Hydraulic cylinder

Steam control valve

Live steam

Live steam

+ X0 Process control engineering x w + UHall T Control magnet Hydraulic pilot control P UMag +24V U FMag F Process control engineering X1

+ X0 X1 x w + UHall T Control magnet P Hydraulic pilot control T UMag A FF +24V U FMag F A B FF

KPU KPD

KPU KPD

Function

The specific system deviation (nominal value w - actual value x) and the set control gain KPU resp. KPD, yields a reference variable UMag for the solenoid force control. The magnetic force FMag generated in the magnet system is monitored indirectly through measurement of the magnetic flux over UHall and sent back to the controller. FMag acts via the tappet on the control piston of the hydraulic pilot control. This is deflected against the control spring

until the travel-specific spring force FF balances out against the force FMag. This results in a volumetric flow that can be changed in both direction and size, and which can adjust the stroke s of an externally mounted hydraulic cylinder. The actual position is monitored by means of a position pick up sensor and sent to the positioner integrated into the WSR way valve. The adjustment of hydraulic cylinder occurs position controlled.

Consumer terminals (outputs) Tank connection Oil supply terminal (input) Parameters for stroke adjustment (potentiometers) KPU, KPD Control gains (potentiometers) w Position nominal value (4 20 mA) x Position actual value (4 20 mA) Magnetic force FMag Force for control spring FF Hall voltage UHall Reference variable for solenoid UMag force FMag U Voltage s Stroke i Position pick up sensor current signal

A, B T P X0, X1

Large flow rates and maximum accuracy enable versatile application

Technical data and characteristics

Supply voltage 24 VDC Current consumption 1.0 A n Input signal 4 20 mA n Remote display 4 20 mA n Type of protection IP 65 n Input pressure up to 160 bar n Ambient temperature - 20 to + 80 C for standard design n Explosion-proof design EEx d IIC T4 available
n n

Type

Maximum input pressure [bar] 200 up to 40 up to 40 up to 40 up to 40 25

Flow rate [l/min] at p = 1 bar PA 17 22 35 30 50 600 AT 62 75 150 350 600 600

Type

Maximum input pressure [bar] up to 160 40 up to 40 40 40 25

Flow rate [l/min] at p = 2 bar P A/B 14 40 80 130 180 600 A/B T 14 40 80 130 180 600

WSR-C25XXX WSR-C45XXX WSR-C60XXX WSR-E60XXX WSR-E80XXX WSR-K120XXX

WSR-D16XXX WSR-D24XXX WSR-D45XXX WSR-D60XXX WSR-D80XXX WSR-K120XXX

Selection table for 3/3-WSR way valve

Selection table for 4/3-WSR way valve

System-specific data must be taken into consideration when defining a suitable WSR way valve. When selecting a WSR way valve, please make full use of our comprehensive knowledge. Our experienced sales staff will be only too glad to be of assistance.

Customer benefits
Outstanding reliability and availability
n Well-established

Dynamic and high-precision control

Simple installation and initial startup

n Device

operating

n Resolution

principle n Dirt-resistant and robust design

< 10 m n Almost no hysteresis n Temperature compensation n Load shedding < 300 ms can be realized

inspected and configured at factory (plug & play) n The stroke range and control response of the working cylinder can be easily changed and optimized using the potentiometers (X0, X1, KPU, KPD) n Turbine lubricating oil can frequently be used as an operating medium

Voith Turbo WSR way valves to a 40 MW steam turbine (photo: MAN Turbo)

Standard version, explosion-proof version optional

Redundant actuator technology maximum availability I/H converter module = 2 x I/H converter + maximum selection
Position pick up sensor x1 x2 x3 i i i s s s Live steam Hydraulic cylinder s

Steam control valve

For process control engineering

x1 x2 x3 w1 Process control engineering

A X0 X1 + UHall X0 X1 + UHall +24V U F pA2 T 2 x Control magnet Hydraulic pilot control P +24V U F FMag pA1 FHydr Maximum selection

w2

FMag

FHydr

Function

Dual-channel conversion of electrical actuating signals into a hydraulic pressure with maximum selection: The two electrical actuator signals w1 and w2 (4 20 mA) of a redundant turbine controller are each converted separately by a well-established Voith I/H converter into a proportional hydraulic pressure pA1 and pA2. Both pressures act on a hydraulic maximum selection. The higher pressure is switched through (A). The hydraulic function can be continuously 10

monitored with the aid of additionally-integrated pressure sensors under normal operating conditions through ramp-shaped lowering of the turbine controllers nominal value. This pressure variation enables diagnosis of each sub-system to be conducted during operation. Each I/H converter receives an electronic monitoring circuit which serves to ensure that in the event of any malfunction the I/H converter then regulates towards minimum

output pressure. The output pressure of the correctly operating I/H converter is switched through. The process then continues smoothly. The faulty device can be replaced during operation.

Tandem WSR way valve = 2 x control magnet + hydraulic component

Position pick up sensor x1in i x2in i Hydraulic cylinder s s s Steam control valve

Live steam

x2out Process control engineering x1out w1 + KPU KPD w2 UHall X1 U + X0 +24V FMag F + KPU KPD UHall X1

+ X0 +24V U FMag F A FF

Control magnet 1

Control magnet 2

Hydraulic pilot control

Function

Both control magnets are given a separate nominal value (w1 and w2) and a separate position pick up sensor (x1in and x2in) is connected to each control magnet. The control magnet 1 armature moves the control piston of the hydraulic pilot control via the control magnet 2 armature. If control magnet 1 is active then control magnet 2 is inactive, although switched on. In the event of a malfunction, the control magnet 1 is switched off

and control magnet 2 is activated over the nominal value (w2) using a specific transit time (warm redundancy). The switching logic is located externally in the control engineering and it monitors the control magnets (position pick up sensor displays x1out and x2out). It also generates the switchover signals. Tandem WSR way valves are also available as 3/3 and 4/3 versions.

Consumer terminal (output) Tank connection Oil supply terminal (input) Output pressure for I/H converter Parameters for stroke or pressure adjustment (potentiometers) KPU, KPD Control gains (potentiometers) w Stroke or pressure nominal value (4 20 mA) x Position actual value (4 20 mA) Magnetic force FMag Hydraulic force FHydr Force for control spring FF Hall voltage UHall U Voltage s Stroke i Position pick up sensor current signal

A T P pA1, pA2 X0, X1

11

Voith Turbo GmbH & Co. KG Electronic Drive Systems Voithstr. 1 74564 Crailsheim, Germany Tel. +49 7951 32-470 Fax +49 7951 32-605 turcon@voith.com www.voithturbo.com/actuation-control-turbomachinery

cr304en, S&F /WA, 06.2010, 1500. Dimensions and illustrations without obligation. Subject to modifications.