Integrated

Turbine &
Compressor
Control

...at the Heart of the System

Woodward Integrated Turbine
Woodward ■ Woodward provides control solutions for rotating equipment in the power
generation, cogeneration, processing, refining, pipeline, off-shore, marine, and
— at the 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.
heart of the
For compressor applications, Woodward’s integrated turbine & compressor control
system (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.
and Compressor Control
You know the problems all too well.
■ Jeopardizing reliability to balance ■ Chaos with each alarm situation
efficiencies
■ Lost revenues and damage to
■ Sacrificing process control to equipment
prevent a surge condition
■ A complete shutdown due to an
instrument failure

You’ve felt that aggravation.

■ Equipment that’s not reliable
■ Complexity of interfacing multiple
controllers
■ Time-consuming troubleshooting
■ No good time to schedule
maintenance
■ High cost of maintaining equipment
■ 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 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.

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 Your initial investment in hardware and

Installed Cost commissioning escalates with multiple
controllers for turbine control, surge control,
emergency shutdowns, process control
Total Cost

and mechanical equipment.

...but one integrated Woodward
solution has many economic
benefits

Woodward’s ITCC
Installed Cost

Only one total price and contract Only one system to qualify
Woodward’s to negotiate & inspect
ITCC saves Only one specification to write Only one start up
time and Only one factory acceptance test Only one call to make for service
money Only one supplier for both electrical
& support
& mechanical equipment Only one system to train personnel on
because
Only one Project Manager Only one system to maintain
there’s
Only one installation to coordinate Only one set of spares to buy & stock

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.

ROI in as ■ 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
little as 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
one year which translates to less than one year for a 100% return on their investment.

Custom ■ Every customer and site is unique, so each application is reviewed for specific
needs. Woodward controls are preprogrammed with proven blocks of software
programs 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
optimize done while you are operating. This system flexibility means you get the right solution
flexibility for your application.
Integration ■ By using Woodward’s integrated control system and software designed
specifically for controlling the compressor and its driver, you get faster
improves more interactive control of many variables simultaneously.

process With separate controllers, control modes for the compressor, its driver, and
the process act independently and adversely affect each other, especially when
stability surge control must intervene with the speed reference. In order to avoid this,
while fast-acting close communication between controllers is required. Communication
between separate controllers usually imposes limitations such as ramp rates
preventing in the speed reference circuit and slower communication baud rates.
surge Woodward’s 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.

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.

Rate ■ Since the first integrated compressor control installed, Woodward has refined
control techniques from using simple anti-surge algorithms to today’s
controller patent-pending rate controller. Woodward’s anti-surge
Boost/w
control is a proactive control as opposed to a reactive
acts over control. Our rate controller regulates the rate at which
PrePack
SCL PID
Controller
the entire the compressor’s operating point approaches the surge Rate
Controller
line and allows for smooth transition to stable control.
compressor Surge

Applying proper control algorithms is only half of

operating what makes a compressor control application
Boost
range successful. Equally important is our experience w/PrePack
De-Coupling

with electrical and mechanical interface with

SCL PID
the compressor. This includes selection and Controller
location of instrumentation, filtering input Rate
signals, and sizing the recirculation Controller

valve and the response time of the De-Coupling

Woodward prevents
complete recirculation loop. 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. • Drum Level Control
• Anti-Surge Control
• Drum Temperature Control
• Capacity Control
• Drum Pressure Control
• Process Control
• Discharge Pressure Control
• Suction Pressure Control
• De-Coupling of Speed/Load
• Multiple Unit Control
• Anti-surge Variable Molecular
• Load Sharing
Weight Compensation

The MicroNet™ TMR

digital control
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.

Gas Turbine Control Motor Driver Control

• Precision EGT Limiting • Compressor Inlet Throttling
• Control and Sequencing Control
• Standard Gas Turbine Software • Starter Turbine Control
• Helper (Steam) Turbine Control • Synchronous Motor Sequencing
• Total Refridgeration Process Control • Power Limiting
 Human Machine Interface (HMI)
• Operation and Performance Monitoring
• Easy Troubleshooting Tool
• Trending and Archiving
• Teaching/Training Tool
• Integrates Easily with a DCS

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,
The MicroNet™ TMR Turbine and Compressor
digital control 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.

Local Touch
Steam Turbine Control Screen
• Single- & Double-Automatic
Extraction/Admission Control
• Extraction Pressure/Flow Control
• Inlet Pressure Limiting
• Isochronous/Droop Modes
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
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
Add these additional services or engineering studies:
Horsepower calculations
Final commissioning, system tuning,
and training
Process improvement studies
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
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)
Compressor mapping and surge testing
Static simulation of system modeling
Commissioning services
Site-specific/specialized training
 Self-diagnostics ■ 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.
simplifies 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.
troubleshooting Time stamping allows operators to make quick educated decisions without
performing lengthy troubleshooting routines.

Eliminate ■ To prevent erroneous trips you can enhance the standard ‘smart-trip’
shutdown logic. Smart trip logic schemes monitor and intelligently evaluate
trips due to 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
instrument related parameters are stable and within acceptable operating limits, the failing
failures 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 ■ Woodward controls are modular and expandable so you are set for the future.
You can upgrade or integrate even further which eliminates buying additional
your controllers later that might be awkward to integrate, and only one controller means
you need only one set of spares.
future

Teamwork ■ The right solution is more than hardware, I/O count, and functional specs.
Equally important is the experience and the teamwork. Woodward
brings it all coordinates an interactive collaboration to best utilize the knowledge of the OEM,
together end-user, and engineering staff.

Support from ■ Once your system is installed, you’ll get support from any of Woodward’s
100 offices, plants, or agents; as well as our extensive network of certified
over 100 offices 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
worldwide needs to come to your site.

The best ■ Woodward’s three-year warranty comes with every new product we sell,
including our remanufacture services and all replacement/exchange units.
warranty in 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 business

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

Chiba, Japan
81 476-93-4662

Texas, U.S.A. Tettnang, Germany

1 713-666-2211 0049 75-4254270 Pusan, Korea
82 51-647-8796

Mexico City,
City, Mexico Haryana, India Singapore
Plzen 91 129-230419
52 5-448-4916 65 270-0081
Czech Republic
420 19-7226076

Campinas, S.P.
S.P. Kingsgrove, N.S.W.
N.S.W. Christchurch
Brazil Australia New Zealand
55 19-708-4800 Abu Dhabi, U.A.E. 64 3-3380479
971 2-273704 61 2-9758-2322

For more information, contact your Woodward representative

above or one of the offices listed below:

Woodward Industrial Controls

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