Turbine Controls and Associated Devices

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Flex 500 Digital Control for Turbines, Engines, or Compressors

The Flex500 control system represents a new generation of turbine and engine control. This controller is based on a standard industrial hardware platform that offers robust, low-cost control for a wide variety of turbine, engine, and compressor applications. The platform’s real-time operating system and dedicated inputs and outputs provide deterministic performance for key prime-mover-control functionality. The control is available in both Front Panel Mount (with integrated HMI) and Rear Panel Mount versions and may be configured for either Simplex or Dual-Redundant applications.

Product Features
  • Powerful real-time control
  • Deterministic scan rates as fast as 5ms
  • Low-cost, high-performance alternative to a general-purpose PLC
  • Fast, accurate onboard I/O expandable with RTCnet and LinkNet HT distributed I/O modules
  • Optional integrated HMI
  • Achilles Cybersecurity certified

2301E-ST Steam Turbine Control for Small Generator Applications

The 2301E-ST is a steam turbine control with internal algorithms designed to start/stop, control, and protect a small steam turbine driving a generator, pump, or compressor. This control’s field configurability allows it to be easily configured by the user for a diverse range of applications. The 2301E-ST’s integrated generator power sensor and load-sharing capabilities also make it ideal for small turbine generator sets where a cost-effective control solution is essential.

Product Features
  • Single-valve small steam turbine applications
  • Load sharing and speed control capability
  • API-611compliant
  • Accepts two speed sensors
  • kW or speed droop
  • Modbus serial
  • Isochronous control capability
  • Designed for turbines operating at 90–32 000 rpm
  • Actuator current range of 4–20 mA or 20–200 mA

ProTech® TPS – Total Protection System

The ProTech TPS is a safety programmable logic controller (PLC) with integrated overspeed protection designed to safely shut down any plant process equipment, engine, or steam, gas, or hydro turbine upon sensing a safety event. This stand-alone safety device accepts 10 discrete or analog inputs per module (30 total) and one speed (MPU or PROX) input (3 total), uses custom-programmed logic to determine when a true safety event has occurred, then issues a shutdown command to safely shut down the equipment or turbine.

Product Features
  • IEC61508 SIL-3 Certified
  • API670 & API612 Compliant
  • Overspeed protection
  • Acceleration & deceleration protection
  • User-programmable logic
  • 2-out-of-3 voting
  • High availability (TMR)
  • Online testing
  • Online repair
  • Auto test routines
  • Trip valve health monitoring function
  • Trip, alarm & test logs
  • Modbus communications
  • Password security protection
  • 12 millisecond response time (independent voted models)
  • Internal frequency generator

Peak200 Digital Control for Steam Turbine Control

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 turboexpanders 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.

Product Features
  • Integrated graphical operator control panel
  • Internal Turbine Simulator
  • Real-time clock synchronization via SNTP
  • Bulkhead & Front Panel Mount versions available
  • Integrated first-out problem indicator
  • Same form-fit function as previous Peak150 controller

505 Digital Control for Steam Turbines

Woodward 505 Digital Control for Steam Turbines
The 505 controller is designed to operate industrial steam turbines of all sizes and applications. This steam turbine controller includes specifically designed algorithms and logic to start, stop, control, and protect industrial steam turbines or turbo-expanders, driving generators, compressors, pumps, or industrial fans.

The 505 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, exhaust header pressure, or tie-line power.

Product Features
  • Field-configurable steam turbine controller
  • Integrated operator control panel
  • Integrated first-out problem indicator logic
  • User-friendly menu format
  • Make minor program changes on-line (single unit)
  • Make major program changes on-line (redundant units)
  • Large LED display
  • Modbus communications
  • Redundant (master/slave) operation for critical applications
  • On-line repair and replacement (redundant units)
  • Same form-fit-function as previous 505 versions

ProTech-GII® Overspeed Protection Device

The ProTech-GII is an overspeed safety device designed to safely shut down steam, gas, and hydro turbines of all sizes upon sensing an overspeed or over-acceleration event. This device accurately monitors turbine rotor speed and acceleration via active or passive MPUs (magnetic pickups) and issues a shutdown command to the turbine’s trip valve(s) or corresponding trip system.

Product Features
  • IEC61508 SIL-3 Certified
  • API670 & API612 Compliant
  • 2-out-of-3 voting
  • High availability (TMR)
  • Acceleration protection
  • Online testing Online repair
  • Overspeed trip and test logs
  • Modbus communications
  • Password security protection
  • 12 millisecond response time (independent voted output models)
  • Internal frequency generator
  • Optional Ethernet communication gateway

MicroNet TMR Control System

The MicroNet TMR (triple modular redundant) controller is a state-of-the-art digital control platform designed to reliably control and protect steam turbines, gas turbines, and compressor trains used in system-critical applications where the chance of a safety issues or large economic losses may be possible. The MicroNet TMR’s 2-out-of-3 voting architecture ensures that correct decisions are made, correct responses are performed, and the prime mover continues to safely operate with or without any single-point failure. This controller’s robustness, accuracy, and availability make it the choice of turbine and compressor OEMs and operators.

Product Features
  • IEC61508 SIL-3 Certified
  • Superior reliability and availability
  • Unmatched diagnostics
  • Deterministic scan rate using synchronized I/O
  • Online repairable
  • Online software changes
  • No single points of failure
  • High density I/O modules
  • IEC61131 programming tools
  • OEM qualified algorithms
  • Interfaces to all major DCS systems
  • Engineering, installation, and training services

Products

Madsen offers the full line of Woodward engine and turbine products, TDI starters, Testo emissions testing equipment and FPE valves. →

Services

We offer a comprehensive range of services and full support for all of our product lines. Call us for more information or request a quote. →

Projects

Click here to view our featured projects section for samples of recent Madsen projects with engines, turbines, and power management. →

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