Refrigeration Governor 505D Upgradation.pptx

Governor ungraded from 505 to 505D

1. Upgradation of Speed Governing system of Refrigeration Compressor in Ammonia 1

2. WHY UPGRADE Frequent mechanical maintenance of PG-PL Governor Obsolete system Precise control of speed in range of 1 to 2 rpm which enhances the controllability and safety of the machine Graphical Interface available with trip and event logging in Governor

3. Starting and Loading Curve

4. Old PG-PL Governor

5. TURBINE HYDRAULIC GOVERNING DIAGRAM

6. PI1 P1 N1 PI2 P2 N2 PI3 P3 N3 TB2X CPC TB5X TB3X TB4X 22 23 25 26 19 20 4-20mA GOV out MPU 1 MPU 2 MPU 3 MPU 4 MPU 5 12 4 5 7 8 MPU 421 JB-905 603(F) /FCS0114 Analog Mar. Cab. PT-01 PDT-01 FT6 CH12 CH13 Local speed display 10 11 7 8 4 5 1 2 CCC CH14 CH15 CH16 1000 RPM Actual speed readout Q16 Q17 2 4 24VDC TO CPC 1 2 CH16 1 2 3 4 5 6 1RZ2 13 14 15 16 17 18 703/FCS0115 1FM14-1FZ1-27/28 2FM13-2FZ1-25/26 802(F) 1RM10-1RZ1-19/20 802(R) 13 14 No of teeth : Gear Ratio : Digital Mar. cab. Gov Panel FIELD GEAR 110VAC 230VAC

7. HYDRAULIC SYSTEM MODIFICATIONS: • The existing Woodward PGPL mechanical hydraulic governor was removed. • End plate/ dummy plate was provided. • The inlet supply line to CPC Gen II was tapped from existing line through duplex filter. Duplex filter have change over handle, Pressure gauge on oil inlet and outlet line, pressure gauge on CPC outline line. • Output of CPC Gen II was connected to servo control valve and Pressure transmitter was provided. • Drain line of CPC was connected to common drain line. Toothed gear was supplied & was mounted on the Turbine drive. • Bracket assembly for Magnetic pick up assembly was supplied and mounted.

8. NEW CONTROL SYSTEM The control system now used has been designed around the existing governor oil scheme. This is the latest version 505 D control that is a control meant for speed Control, Woodward CPC Gen II for control valve actuation and Woodward speed sensor for sensing the speed of the Turbine. The existing turbine can now be controlled efficiently and reliably by latest Woodward Electronic Governing System. Protech G II Control for Overspeed protection with 3 numbers Speed sensor input. SYSTEM DESCRIPTION Latest Woodward 505 D Electronic controls is installed in the control room in the Control panel and Protech G II also is installed. 505 D acts as speed controller, receive the speed signal from magnetic pick up, speed sensor gets the speed signal from magnetic gear mounted on the Turbine drive. Magnetic pick up gives a signal to 505 D, which has a dedicated PID for speed where the actual speed is compared with reference value and the correction signal is given by Woodward 505 D control to the Woodward CPC Gen II Actuator. 505 D gives an output signal of 4 – 20mA to Woodward CPC Gen II which converts current signal to hydraulic signal in the form of secondary oil pressure. The current to pressure converter provides secondary oil pressure to the pilot valve of the hydraulic mechanism. This secondary oil pressure is calibrated in such a way that 4mA signal corresponds to min. secondary oil pressure and 20mA as max. secondary oil pressure. Woodward CPC Gen II is installed in the Oil skid which contains Duplex filter, Differential pressure transmitter, Pressure transmitter. CPC is a sensitive current to hydraulic converter, which receives the regulated main oil pressure from the main oil pump and provides secondary oil pressure to the servo control valve.

9. ADVANTAGES OF LATEST WOODWARD ELECTRONIC GOVERNING SYSTEM: • The response time of the system has improved. The retrofit system provides response time in range of 5 to 55 milli sec. • Provides Automation and remote control operation. • Latest state of art technology provides modern controls equipment’s. • User-friendly field programmable hardware and software. Very simple to configure. • As the response of the new system is faster than the existing system, it provides energy conservation i.e. faster closing and opening of the throttle valves which saves steam energy. • Speed control / droop mode is possible. • Inlet pressure control is possible. • MTBF is very high. • Compact design. • Speed Control and Back pressure control from the same controller. • Precision in measurements and readouts display on main panel of the controller • Easy to operate and hence simple training for the operators was required. • Maintenance free control system. • Important critical speed avoidance by ramp rate adjustment is possible. • The new system is able to communicate with plant DCS.

10. Probe Fixing

11. Woodward Governor

12. Protech G-II

13. Oil Skid & CPC-II

14. Idle-1 Speed 1000 RPM Hold at Idle-1 Speed Cold 30 minutes Hold at Idle-1 Speed Hot 30 minutes Idle-2 Speed 2000 RPM Hold at Idle-2 Speed Cold 30 minutes Hold at Idle-2 Speed Hot 15 minutes Minimum Governor Speed 8408 RPM Maximum Governor Speed 11771 RPM Turbine Overspeed through Protech G-II 12800 RPM Turbine Overspeed through Governor 12500 RPM