ML20236M449

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Summary of 980622 Meeting W/Power Control Svcs & Woodward Governor Co to Present Company Model 505 microprocessor- Based Turbine Controls
ML20236M449
Person / Time
Issue date: 07/06/1998
From: Mckenna E
NRC (Affiliation Not Assigned)
To: Essig T
NRC (Affiliation Not Assigned)
References
NUDOCS 9807140082
Download: ML20236M449 (42)


Text

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NUCLEAR REGULATORY COMMISSION WASHINGTON, D.C. 20555 0001 July 6, 1998 MEMORANDUM TO: Thomas H. Essig, Acting Chief Generic issues and Environmental Projects Branch l

Division of Reactor Program Management Office Of Nuclear Reactor Regulation Eileen M. McKenna, Senior Reactor Engineer h{f)/f)[

FROM:

Generic issues and Environmental Projects Branch Division of Reactor Program Management Office of Nuclear Reactor Regulation

SUBJECT:

SUMMARY

OF JUNE 22,1998, MEETING WITH POWER CONTROL SERVICES AND WOODWARD GOVERNOR COMPANY On June 22,1998, representatives of Power Control Services (PCS) and Woodward Governor Company (Woodward) met with U.S. Nuclear Regulatory Commission (NRC) staff to present the Woodward model 505 microprocessor-based turbine controls. The 505 digital control is an existing commercial product that PCS and Woodward are considering offering for use in nuclear safety systems. Attachment 1 provides a list of attendees. The presentation material from the meeting is included as Attachment 2; none of this information was identified as being proprietary.

Following an overview of the 505 digital controller design and capabilities, the staff, PCS and Woodward discussed the criteria that the staff would use to review the control;er. PCS and Woodward noted that they were familiar with the general NRC requirements and criteria as a result of reviews of their previous mechanical systems but they had not previously undergone a computer-based product review. The staff directed them to the Standard Review Plan (SRP)

Chapter 7 (NUREG-0800, June 1997), " Instrumentation and Controls" with a particular emphasis on Branch Technical Position 14, " Guidance on Software Reviews for Digital Computer-Based Instrumentation and Control Systems." The staff discussed how a review would be conducted in accordance with the SRP. PCS and Woodward described the qualification testing that had been completed. The staff described some examples of commercial products that were latter dedicated for use in a safety system and the possibility that some documentation and/or testing may need to be supplemented.

The options that PCS and Woodward have for obtaining a NRC safety evaluation report were discussed. PCS and Woodward indicated that their preference would be for PCS to assemble the needed information and submit a topical report. They would include the electro-hydraulic part of the turbine control system as well as the microprocessor control. The staff noted that a N!

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July 6, 1998 full scope system review may require participation from members of the mechanical engineering branch in addition to the instrumentation and quality assurance representatives at this meeting. PCS and Woodward indicated that they would consider the several options for 4

licensing that are available and inform the NRC which way they would like to proceed.

Attachments: As stated

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-2 July 6, 1998 full scope system review may require participation from members of the mechanical engineering branch in addition to the instrumentation and quality assurance representatives at this meeting. PCS and Woodward indicated that they would consider the several options for licensing that are available and inform the NRC which way they would like to proceed.

Attachments: As stated cc: See next page DISTRIBUTION: See attached page Document Name:g:Wmm\\msum0622.98 OFFICE PM:PGEB rpg,,

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he POWER CONTROL SERVICES AND WOODWARD GOVERNOR COMPANY AND US NUCLEAR REGULATORY COMMISSION MEETING ATTENDEES June 22,1998 NAME ORGANIZATION Jim Stewart NRC/HICB Matt Chiramal NRC/HICB PaulLoeser NRC/HICB Cliff Doutt NRC/HICB Jerry Wermiel NRC/HICB Juan Peralta NRC/HQMB Tom Horner Power Control Services Jack C. Miller Power Control Services Frank Amend Power Control Services Rich Kamphaus Woodward Governor Company Tom Garske Woodward Governor Company

. Doug Nolan Woodward Governor Company Steve Thompson Woodward Governor Company

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I Distribution: Mtg. Summary w/ Power Control Services and Woodward Governor Dated July 6,1998 Hard Cooy

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PGEB R/F OGC ACRS EMcKenna JStewart.

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AGENDA FOR.NRC MEETING June 22,1998 1.

Introductions

2.

' Reasons Power Control Services and Woodward Governor Company requested meeting.

Determine the economic feasibility of pursuing the qualification.

Obtain complete listing of qualification requirements for Terry Turbine Governor Retrofit Package.

l:

3.

Explain c,omposition of proposed retrofit package - Woodward Governor Company will give l

presentation.

l 4.

Woodward Governor Company to review functions ofindividual components in the proposed package.

5.

Discussion of 505 Digital Control Discuss the portions of the software that will be utilized by the proposed control system.

e 6.

Software Validation Issues and Rec uirements What software standards shoukl be used in the V & V process?

a e

Step-by-step walk through of software validation tasks and requirements 7.

EMI Testing Issues and Requirements - (also see Electromagnetic Compatibility Compliance Summary Document contained in this folder).

l Radiated Susceptibility - Testing per MIL-STD 461 is at one (1) meter. Presently Woodward Governor Company's tests are being run at a distance of three (3) meters in the frequency range of 80 to 1000 MHz. In this range they meet the European requirements of fieki uniformity as described in ENV 50140. Would it be acceptable to run a portion of this ast at a 3 meter distance maintaining a 10 V/M field?

i Conducted Susceptibility- (30 to 50 KHZ, CS101) This is a test for input power only. The power requirements vetween MII STD 461C and MIL-STD 461D are different; 50 Watts verses 80 Watts Wouki 50 Watts be acceptable? If we do try to increase the output level to 80 Watts, we may be unable to produce the required 6.3 VRMS level below 100 Hz. Is this acceptable?

Surge - The pulse required would be difficult to inject using an injection probe. Woodward e

Governor Company has contacted two injection probe manufacturers who have c uestioned

' the ability to do this test with an injection probe. Taking this into account, Wooc. ward Governor Company would prefer to use capacitive coupling as described in IEC 801-5. Is this acceptable? -

EFT - Again there seems to be some question as to using an injection probe for this test.

e One probe manufacturer has a probe with the required bandwidth, but the maximum voltage induced is limited to 2,100 Volts. Woodward Governor Company wouki like to use the capacitive coupling method as described in IEC 801-4. Is this acceptable?

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AGENDA FOR NRC MEETING June 22,1998 8.

Other qualification issues that need to be addressed.

Actuator will be qualified for liarsh Environment per IEEE-323-1974 505 will be qualified for Mild Environment per IEEE-323-1983 9.

Identification of additional tasking /information required to qualify the digital package.

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10. Adjourn Meeting.

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M W Rfn WrJ)OWMLD 00VERNOR COMI'ANY survi : w 4 t.ovet,Awo. crx.ortAeo TECHNICAL DOCUMENT FILE:

ELECTROMAGNETIC COMPATIBILITY COMPLIANCE

SUMMARY

DOCUMENT 505/50$E TTMBINE CONTROL Prepared by: Warren J.Tannia March 15,1996 1.0

SUMMARY

This EMC Compliance Summery Document summarizes the EMC testing and test results performed on the three power-supply versions and an updated, production-level version of the 505/50$B Turbine Control per the EMC 1est plan. Reference Document: 70245-R6, EMC TEST PLAN: 505/50$E Turbine Content.

The 505/503E Turbine Control was tested per the " heavy industrial" standards as defined by the European Eco-nomic Communities and comply with the requirements of Directive R9/336/EEC, as amended. A Declaration of Conformity, as required by Article 10 (1) of the Directive for the self declaration option, willbe a result of this EMC Compliance Summary Document.

Details and descriptions of the Equipment Under Test (EUT), test procedures / setups, test facilities / conditions, and l

standards / directives can be obtained in the listed reference documents / reports.

2.0 SCOPE This document identiften the reference documents / reports. IR.fT, revisions to the EUT, EMC test standards, and l

compliance status.

1 3.0 REFERENCE DOCUMENTS / REPORTS 89/336/EEC: Councli Directive of 03 May I989 on the approximation of the laws of the Member States relating to 3.1 electromagnetic compatibility. OPECNo. L 139/19-26,23 May 1989.

EN 50081-2 (CENELEC): E/cetromagnetic Compatibfltry-Genere EmLrsion strem4 rd, Part 2: Industrial Envi-3.2 senment. Issuc 2,25 March 1994 hN 50082 2 (CENELEC): Electmmagnetic Compatibiltry Generic 1mmunityStandard, Past 2: Industrial Envi-3.3 roament. Issue 2,15 March 1995.

l 70245-146 (Woodward Governor Company (WGC)): EMC TESTp/AN $05/ JOSE Twbine Control.

3.4 TECllNICAL DOCUMENT FILE: 505/$U$E Turbine Crmtrol-Duign ModtfFeations andim-3.5 1024%-R7 (WGC):

pact Upon FinalEMC.

10245 R8 (WGC): Electromognotic Compatibility Immunity Test Report. 50$/ JOSE Turbine Content.

3.6 3.T 10245 R9 (WGCitntellistor OATS): WGL 9601_II01. Tat Relas Model$05/505E content l

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- 4.0 EQUIPMENT UNDER TEST Reference Document: 70245.R6.

Four versions of the EUT based upon the [nput power supply: +24 VDC: 120 VAC,60 Hz(pre production and production-level hardware); and 220 VAC. 50 llz were tested, ne EUT description. test configurations (incl auxillary equipment, wiring, positioning, and operating modes) are detailed in the EMC Test Plan.

l Two sets ofimmunity testing were performed on the EUT. He first set was performed with pre production hard.

l were with added.on modifications listed in 4.3.1 through 4.3.5 helow. De second wet was performed on the 120 VAC. 60 Hz version with new production hardware with the changes in Section 4.3 incorporated, emcept 4.3.6, 4.3.7 and 4.3.8. Additionally, the analog output signals were monitored on the second test to verify their immunity; whereas. they were not on the first.

The emission tests were perronued with the pre-production hardware, idendcal to that orthe first yet ofimmunity tests. The changes listed in 4.3.6,4.3.7 and 4.3.8 have no cirect un the emissions tests.

The Front Panel Display board used was the pre production version for all EMC tests.

HARDWARE CONFIGURATION FOR EMISSIONS TESTS AND FIRST SET OF IMMUNITY TESTS 4.1 4.1.1 Common liardware and Assembly Numbers-Table t.

TA13LE I. COMMON !!ARDWARE TO FIRSTIMMUNITY TRST EUT VERSIONS

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CPU 3077-664. New 5455-011, Rev.19 5501-231. Rev.14 FRONT PANEL DISPt.AY 3077-702. New 5455-073. Rev. 7

$ $01 233. Rev. 6 _.

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SUPPLY 3077-668.New

$45a-072. Rev.12 1~- E-- @ T :

4.1.2 Differing itardware and Assembly Numbers - Table 2, TABt.E 2. DIFFERINO HARDWARE AND ASSEMBLYNUMBERS FOR FIRST IMMUNITY 1EST Et.rl' YERSIONS EUT POWER SUPPLY BOARD UPPER LEVEL VERSION ASSEMBl.Y ASSEMBLY l

+24 VDC 5501-232, Rev.19 9907-053. Rev. 4 120 VAC

$501 240. Rev.15 9905 699. Rev. 4 220 VAC 5$01-241. Kev 14 9905-698. Rev. 4 l

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~ 4.2 MARDWARl! CONFIGURATION FOR SFCOND SET OF (MMUNITY TESTS Ilardware and Assembly Numbers Table 3.

TADLE 3. HARDWARE CONFIGURATION FOR SECOND IMMUN!TY TEST EUT l-St JRF ACF.

HOARD CIRCUfT BOARD PCll MOUNT ASSEMBLY CPU J077 664. Rev. A 5458 071. New 550 t-231. New FRONT PANCL DISPLAY 3077-702. New 5458 073.Rev.7 550l 233. Rev. 6 pow!!RSUPPLY (120 VAC) 3077 668. Rev. A 5458 072. New 5501-240. New 4J DisSIGN MODIFICATIONS AND IMPACT UPON FINAL EMC Reference Document: 70245-R7.

Yarlous design changes to the 505/505E Turtpine Control were necessary to pass certain EMC tests and/or to im-prove the functionality of the Control. These changes did not affect other EMC tests and did not necessitate retest-ing of previously tested tsat methods. The assembly alTected is listed in parenthesis. ().

43.1 Removed VRil and VR12 to eliminats current Icakage/o(Tsets on ANIN_6 (CPU).

43.2 Removed R251 to climinate current loop / offsets on AN!N_6 (CPU).

4 J.3 Relocated and redesignated C?72 and C226 to eliminate i offsets (CPU).

4J.4 Added inverter-driven NAND logic to Mod. Bus Communication Lines (CPU).

4J.5 Rerouted traces to facilitate locating tiduelais for flash memory (CPU).

43.6 Added fbse to +5 VDC power input per UL recommendation (Power Supplies).

43.7 Added four resistors to push-button latch loputs to prevent damage of inputs (Front Panel Display).

43.8 Changed heatsink insulator material per UL recommendation (Chassis).

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%HH'r4 IIIVFf AM7 (1)I t #4 ADO 5.0 EMC TEST STANDARDS Table 3 details the European EMC rest standards and the compliance status of all versions of the EUT.

TABLE 3. EUROPEAN ECONOMIC COMMUNITY EMC TEST STANDARDS GENERIG 14ASIC ENVIRONMENTAL.

PERFORMANCE COM PI,IANCE REQUIREMENTS STANDARDS STANDARD PHENOMENA CRITERIA STATtJS Emissions I;;N 50081 2 EN 55011 Radiated Emissions Class A PASS Conducted Emissions

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EN 61000-4 2 Electrostatic Discharge Performance B ENV 50140 RF EM field Performance A PASS Immunity EN 50082-2 RN 610(X)-4-4 Fast Transients Performance B EN 6 8000-4-5

  • Power 1,ine Surges NA

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tiNV 5014i RF CM Performance A PASS HN 6 8 000-4 8 *

  • PF Magn =tsc Ficid NA EN 61000-4 5 was not required by EN 50082 2 at time of testing.

EN 61000 4 8 is applicable only to apparatus containing devices susceptible to magnetic Gelds. The 505/505E Turbine Control does not contain any magnetic-susceptible devices.

5.1 SN 50081-2: EMC Ceneric Emtulon Standard Part 2: Industrial Errvfronment.

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j' Reference Documents: EN 50081-2.

70245-R9.

Emiujons test facillry: Intellister Open Air Test Site (OA*13), Rollinsville, Colorado, USA.

5.2 EN $O0S2-2: EMC Generic immunity Standard Part 2: Indkrtrial Environment.

Reference Documents: EN 50082-2.

70245 R8.

Immunity test facility Woodward Governor Company. Loveland. Colorsdo. USA.

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1 Qualification Plan for the Dedication of New Terry Turbine Control System by Power Control Services 4 i D

l Plan: TTRPQP-100 Revision: 0 l Date: 6/19/98 Page: 20f5

1.0 PURPOSE

1.1 This plan is written to qualify Woodward Governor Company's solution for the obsolete EGM/EGR control systems currently installed on IIPCI, RCIC, and AFW turbines in nuclear power stations using Engine Systems incorporated's 10 CFR 50, Appendix B Quality Assurance Program Manual 1st Edition, Revision 0 dated 8/l4/96.

2.0 SCODE

2.1 The retrofit package will consist of the following equipment: 2.1.1 Woodward 505 Digital Control Part Number 9907-163. 2.1.2 Wmdward TM-25LP Linear-Proportional Actuator Part Number 9905-763. 2.1.3 Mounting Bracketry for TM-25LP Actuator. 2.1.4 Woodward TG-13 Governor. 2.2 While this plan is applicable to Woodward 505 Digital Control Part Number 9907-163, it can also be used to qualify other hardware / software versions of the control.

3.0 REFERENCES

3.1 IEEE 323-1983, Qualifying Class 1E Equipment for Nuclear Power Generating Stations. 3.2 IEEE 344-1975/1987, Recommended Practices for Seismic Qualification of Class 1E Equipment for Nuclear Power Generating Stations. 3.3 IEEE 6C3-1991,"lEEE Standard Criteria for Safety Systems for Nuclear Power Generating Stations". 3.4 IEEE Std. 7-4.3.2-1993, "!EEE Standard Criteria for Digital Computers in Safety Systems of Nuclear Power Generating Stations". 3.5 EPRI TR-102323-R1, Guidelines on Evaluation and Acceptance of Commercial Grade Digital Equipment for Nuclear Safety Applications. 3.6 ESI Procedure PSP-201, Dedication of Commercial Grade items. 3.7 ESI QAM,1st Edition, Revision 0. 3.8 MIL-STD-462, Measurement of Electro-Magnetic Interference Characteristics. 3.9 MIL-STD-461," Electromagnetic Emission and Susceptibility Requirements for the Control of Electromagnetic Interference".

4.0 PREREQUISITES

^ 4.1 All aspects of Engine Systems Incorporated's Quality Program apply for this qualification plan.

Plan: 'ITRPQP.100 Revision: 0 t Date: 6/19/98 ) Page: 3 of 5 l

5.0 RESPONSIBILITIES

5.1 The Engineering Manage or designee is responsible for implementing this plan. l 5.2 The Quality Manager or designee is responsible for providing audit, inspection, and verification i services to qualify the equipme it.

6.0 PROCEDURE

6.1 In addition te the normal requirements of Engine Systems tricorporated's dedication program, the following criteria need to be addressed in qualifying the retrofit package: Seismic and Environmental Qualineation, EMI Qualification, Soilware Verification and Validation (for 505 Digital Control only). 6.2 Seismic and Environrnental Qualification: i 6.2.1 ESI's seismic and environmental test equipment shall be utilized for the qualification effort. A detailed test procedure shall be develuped by ESl's Engineering Group for the seismic / environmental testing. The parts shall be qualified to meet the requirements of IEEE 344-1975/1987 seismic and IEEE 323-1983 " mild" environment. 6.2.2 Seismic Testing: the equipment shall be seismic tested using the requirements of IEEE 344-1975/1987 to the parameters described below: Horizontal Frequency (Hz) 0.2 0.75 2 8 15 33 50 OBE (2% damping) Acceleration (g's) 1.2 1.25 10 10 3.75 1.5 1.5 SSE (3% dampmg) Acceleration (g's) 1.2 1.25 8 8 3 1.5 1.5 Vertical Frequency (Hz) 0.2 0.75 2 10 20 33 50 l OBE (2% damping) Acceleration (g's) 1.2 1.45 12 12 5 1.5 1.5 SSE (3% dampmg) Accelaation(g's) 1.2 1.45 10 10 4 1.5 1.5 6.2.2.1 During seismic testing, the 505 Digital Control shall be mounted in vertical position against a rigid fixture using manufacturer specified bolt sizes to realistically simulate mounting on a control cabinet's panel. I 6.2.2.2 The TM-25LP Actuator shall be securely fixed to its bracket using manufacturer specified bolt sizes and the entire assembly mounted against a rigid fixture using manufacturer specified bolt sizes to realistically simulate mounting on the Terry Turbine. 6.2.2.3 The TG-13 Governor shall be securely fixed to its bracket (if applicable) using manufacturer specified bolt sizes and the entire assembly mounted against a rigid fixture using manufacturer specified bolt sizes to realistically simulate mounting on the Terry Turbine. 6.2.3 Environmental Testing: the equipment shall be environmentally tested using the requirements of IEEE 323-1983 to 10 F (tested for 8 hours continuous),140 F (tested for 8 hours continuous),0-100% relative humidity non-condensing, and ambient pressure. the equipment shall be retested to OEM baseline requirements subsequent Post Qualification Testing:ic testing. 6.2.4 to environmental and seism

Plan: TTRPQP-100 Revision: 0 Date: 6/19/98 Page: 4cf5 6.3 EMI Qualification: 6.3.1 Woodward Governor Company has previously EMI tested the equipment to the criteria listed in MIL-STD-461 and MIL-STD462 to obtain their CE registration for sales to their European customers. With this in mind, EMI Qualification in accordance with EPRI TR-102323-R1 shall proceed as follows: ) 6.3.1.1 A comparison shall be made between the results from testing conducted under MIL-STD-462 to the requirements of EPRI TR-102323-R1. 6.3.1.2 If any parameters are not satisfied by the previous MIL-STD-462 testing, testing shall be performed to envelop EPRI TR-102323-R1 by Woodward Governor Company. 6.3.1.3 Engine Systems incorporated's quality assurance department shall audit the testing to verify conformance. 6.3.1.4 Duringall EMI testing all components of the retrofit package shall be electrically connected together to verify compliance of the entire system. i I j, 6.4 Software Verification and Validation (V&V): 6.4.1 Engine Systems incorporated has conducted quality audits of Woodward Governor Company and learned that they have in place all the requirements necessary to complete the V&V process. To qualify the sonware to IEEE STD 7-4.3.2-1993, the followmg is required: 6.4.1.1 Engine Systems Incorporated's Quality Department shall devise a sonware specific audit plan that shall verify the software's V&V and shall contain independent review, independent witnessing, inspection, analysis, testing, functional testing, and/or structural testing requirements as appropriate. 6.4.1.2 Engine Systems Incorporated shall conduct a sonware specific audit to obtain objective evidence to support the software's verification and validation process. 6.4.1.3 Alst Mcluded in this audit plan shall be provisions for identifying that the following validation and verification requirements are incorporated in Woodward Governor Company's software development process: test plans, test design specifications, test case specifications, test procedure specifications, test logs, test meident reports, and test summary reports as well as all other information deemed l necessary to qualify the sonware. 6.4.1.4 Upon successful completion of the V&V process, Engine Systems incorporated shall identify and l freeze the release of the applicable software package. I 7.0 ACCEPTANCE CRITERIA: 7.1 As defined in the body of this procedure,

4 l Plan: TTRPQP-100 Revision: 0 Date: 6/19/98 Page: 5 of 5 {

8.0 RECORDS

i 8.1 All data derived from the audit and surveillance of the software V&V, EMI, seismic, and environmental testing will become a permanent record for the hardware and/or sofhvare components package.

9.0 FORMS

9.1 Not applicable I e l l

4 ~~ n, c.xcm. 85005F-fd ,aw y . m a v m m en:w w w g v p ( w'%gy's 505/505E A}l,) n Digital Control For 0K4 Steam Turbines g'ge g 7. ~; . p; g:p - m# m, a %a w m.

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g ..9 m r r M bep N dikYfn NE, Y . igm., 4 4 APPLICATION panel. An optional NEMA 4X The 505 and 505E are enclosure is available to allow these g. controls to be mounted within harsh microprocessor-based controls "y designed to operate steam turbines of environments. An Operator Control all sizes. The 505 is designed to Panel is provided on the 505's front operate steam turbines using one or Panel. Easy to follow instructions are 3 e two (split-stage) actuators to drive inlet presented in English through the 0;V g g @a> steam valves. The 505E is designed to OCP's two-line display and operators operate single extr tion and/or can view actual and setpoint values m;) admission steam turbines. These from the same screen. Removable Mk i digital controls are field terminal blocks allow for easy wiring ' gh and installation. m ] programmable. They use menu-driven software to instruct site engineers on d% COST-EFFECTIVE DESIGN ss,y programming the control to a specific generator or mechanical drive The 505/505E is a field conflgurable ]gg application. The 505 or 505E can be steam turbine control and operator j "Q, V-4 configured to operate as a stand-alone control panel integrated into one [ \\jj{ m;%p)/ ' unit or in conjunction with a plant's package. A comprehensive operator U A$ Distributed Control System. control panel, including a two-line (24 5 p,, %@! M characters each) display, and a set of DESCRIPTION 30 keys is located on the 505/505E's .y 4 Woodward's 505 and 505E digital front panel. This OCP is used to 9 yf JW% ;f Q. + g g l@P]p[]gg contmls use a 32-Bit Microprocessor configure the 505/505E. make On-to contml industrial sized steam I'ine Program adjustments, and ( turbines, small utility turbogenerators. Perate the turbine / system. j; m -' Q ' ' or turboexpanders. The 505/505E The 505/505E also performs as a gj[W Gy y a package consists of printed circuit First-Out indicator for system M ? " Mr2 M_ boards in an enclosure designed to be shutdowns, thus reducing mounted within a system control troubleshooting time. Multiple system Qj,iy'[_ #,' g, g* M +,

uf shutdowns (3) can be brought into the 505/505E

  • Bumpless transfer between control modes if a to allow it to shut down the system safely, and transducer failure is detected latch-in the cause of the shutdown.

, local / Remote Control priority and selection COMMUNICATIONS

  • Fall-safe Shutdown Logic The 505/505E controls can communicate directly CONTROL with plant Distributed Control Systems and/or The following PIDs are available to perform as CRT based operator control panels, through tw process controllers or limiters:

ModBus* communication ports. These ports S eed/ Load PID (with Dual Dynamics) P support RS-232, RS-422, and RS-485 communications using ASCII or RTU ModBus

  • Auxiliary PID (limiter or control) transmission protocols.
  • Cascade PID Communications between the 505/505E and a Extraction and/or Admission PID (505E only) a plant DCS can also be performed through hardwired connections. Since all 505 PID CONTROL SPECIFICATIONS setpoints can be controlled through analog input jggg73 signals, interface resolution and controlis not
  • P wer: 18-32Vdc 90-150Vde,88-132Vac sacrificed.

(47-6311z),180-264Vac (47-6311z) FLEXIBILITY < Speed: 2 - MPUs (1-30Vrms) or Proximity Probes The 505/505E is field programmable, allowing site (24Vdc provided),.5 to 15 kilz engineers to configure the control to their specific Discrete inputs: 16 - Contact inputs application, and make future control (4 dedicated,12 Programmable) configuration changes. The 505/505E can be

  • Analog Inputs: 6 - Programmable Current field programmed for mechanical drive or inputs (4-20mA) generator applications. Over 100 On-Line tunables are available to allow program OUTPUTS refinements while a unit is mnning. Inputs and

. Valve / Actuator Drivers: 2 - Actuator Outputs Outputs are programmable as required by the (4 20mA or 20-160mA) application or interface.

  • Discrete Outputs: 8 - Relay Outputs (2 dedicated, 6 Programmable)

SYSTEM PROTECTION . Anal g Outputs: 6 - Programmable Current e Integral Overspeed Protection logic Outputs (4-20mA)

  • Fimt-out Indication (3 individual Shutdown inputs) l 1

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l COMMUNICATION

  • Serial: 2 - ModBus (ASCII or RTU) Comm Ports
  • Two independent ModBus comm links.

(RS232, RS422 or RS485 compatible)

  • Remote analog setpts for Speed /Imad, Aux, FUNCTIONALITY Cascade, and Extraction / Admission.

505 and 505E's control capabilities are:

  • Program upload / download capability.
  • Speed / Frequency control OPERATING CONDITIONS
  • Turbine or Generator Load control / limiting
  • -25'C to +65*C ambient air temperature range

. Turbine inlet header pressure control / limiting

  • Optional NEMA type 4 (watertight and dust-
  • Turbine exhaust header pressure light, Indoor / outdoor) enclosure for bulkhead control / limiting m unting with a temperature range from -25 C to +55 C
  • Plant Import / Export power control / limiting
  • Approximate dimensions 14L x 1IH x 4D inches
  • Isochronous Loadsharing between units (356 x 279 x 102 mm)

(with DSir)

  • Approdmate bulkhead enclosure dimensions
  • Extraction and/or Admission _ header pressure 20L x 2011 x 7.6D inches (508 x 508 x 193 mm) control (505E) e ilumidity: Lloyd's ENV2 test #1
  • Any process directly related to unit load j
  • Dry heat: Lloyd's ENV3 FEATURES
  • Salt fog: MIL-STD-810 method 509.2 procedurr 1
  • Critical Speed Avoidance (2 speed bands) e, Shock: meets MIL-STD-810C, method 516.2-1,
  • Auto Start Sequence (hot & cold starts) procedure IB
  • Valve Limiter (s)
  • Vibration: Lloyd's ENV2 test #1
  • Security (Program is Password Protected)
  • ESD immunity: IEC 61000-4-2
  • Dual Speed / Load Dynamics
  • Emissions: EN55011, Class A, Gr 1

/G

  • First-Out Indication (Shutdowns)
  • Radiated RF immunity: IEC 61000-4-3
  • Zero Speed Detection with proximity probe (<.511z)
  • Fast transient immunity: IEC 61000-4-4
  • Peak Speed Indication for Overspeed t 1p
  • Conducted RF immunity: IEC 61000-4-6
  • Two Programmable Functions Keys on the 505's Certifications: CE (18-32 Vdc version only), UL, front panel and CUL
  • Iland Valve operation (using First Stage Pressure)

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== ar) l 3 j I g w 3 505/505E DIMENSIONS i r f t For more information contact; e 1 2 bbf ' ,( - ic A l n. f$ Yl%l$$&ldr Mh_ $ l 1 M jifl0[[ l p i DESCRIPTION signal. The rate ofincrease movement can The TM-25/200LP actuators are electro-be made slower than the rate of decrease hydraulic, proportional actuators for vement as a safety factor. positioning steam and fuel-control valves requiring high-force linear inputs. output shaft extends or retracts to increase The actuators are designed for use with Woodward 43027 or 2301 electronic controls and digital control systems and will interface APPLICATION directly to Woodward or other makes of valves. The TM-25LP and the TM-200LP actuators provide one inch oflinear movement of valves in the actuator a torque-motor servo valve is f r steam or gas turbines. energized by the electronic control to generate a pressure differential applied to the FEATURES ends of, and to operate, a second-stage spool The actuators have aluminum cases and valve. Supply pressure is regulated bf the through-hardened stainless-steel intemal spool valve to move a double-acting servo parts. piston and provide one inch oflinear output shaft travel. Internal mechanical feedback flydraulle fluid is sealed from the torque causes the location of the actuator shaft to motor by a preformed packing ring between be in direct proportion to the input-current the armature and the servo-valve housing.

en-w---m-,m-------_,-----.-____-------.-----. which climinates pickup of fluid contaminants. A TM-200LP TM-25LP 40 micron low-capacity filter is provided in the . Work Copacity supply inlet to protect against failure of the 10-200 ft Ibs 25 ft lbs micron nominal external filter. at 1200 psig at 150 psig The units will operate with either centrifugal or O@t Fm fixed-displacement type pumps providing 2400 lbs max. 300 lbs max hydraulic pressure. at 1200 psig in at 150 psig in either direction either direction The actuators are calibrated at the factory for bias in the minimum-fuel direction in event of the loss , g 3, ofinput current. .045 seconds .065 seconds A dual-coil torque motor it optional for at 1000 psi at 250 psi .150 seconds redundancy. The dual-coil actuator has an optional position-feedback transducer, at 100 psi Hysteresis REFERENCES

  • 1 percent of il percent of Manual 82450A travel travel TM-200LP and TM-25LP Actuator Side Load

"~ ~ SPECIFICATIONS Output Shaft Hardened 17-4 stainless steel.625-inch round. HYDRAULIC PRESSURE, FLOW with one-inch square 17-4 stainless steel rod REQUIREMENTS end attached by.375-inch /24-tpi threads: Optional rod end features.625-inch slot with .500-inch hole to pin linkage to valve; other TM-200LP TM-25LP designs are available Maximum Supply Pressure 1200 psig 375 psig Work Output Minimum Supply Pressure GOVERN TRAVEL 400 psig 80 psig 0{ FULL PRIME N uovER TRAVEL Pressure Regulation wo ruLL 15% 15 % LOA L AD ,o ee% c Minimum Supply Flow (Steady State) 4 7 0.5 gpm 0.5 gpm PRIME PRIME $"o'p" "shfp" Maximum Supply Flow (Transient) 5.0 gpm 5.0 gpm HYDRAULIC SUPPLY REQUIREMENTS A OVERTRAVEL TO INSURE PRIME MOVER STOPS ARE REACHED Fluid Types B-NO LOAD TO FULL LOAD TRAVEL - NORMALLY 2/3 OF FULL Mineral or s7"thetic based oil GOVERNOR TRAVEL 13 RECOMMENDED l C TRAVEL REQUIRED TO ACCELERATE THE PRIME MOVER i D - TRAVEL REQUIRED TO DECELERATE OR SHUT DOWN PRIME Specific Gravity MOVER 0.6 to 1.0 MAXIMCM WORK CAPACITY OVER FULL GOVERNOR TRAVEL OF P IS

  • FT-LBS. SEE ABOVE FOR RECOMMENDED GOVERNOR Recommended Viscosity OUTPUT TRAVEL IN SPECIAL APPuCATIONS MIN AND MAX 0.6 to 400 centistokes PRIME MOVER STOPS MAY BE OUTSIDE THE GOVERNOR STOPS.

l cooeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee This sheet is distributed for informational purposes only. It is not to be construed as becoming part of any contractual or worronty obligations of the Woodword Governor Company unless expressly so stated in a soles contract. @ Woodward Govemor Company,1983 + All Rights Reserved

_ =, External Filtration Required CONNECTIONS 10 micron nominal 25 micron absolute 2-wire connection in.500-inch /14-TPI rigid conduit connector; two 18 ga. wires extend D (ELECTRICAL CHARACTERISTICS approximately 36 inches For both TM-25LP and TM-200LP) .750 inch /16 TPI liydraulle Supply connection UNJF-3A (-08) (MS 33656) input Current Range 20 to 200 mA .875-inch /14 TPI Ilydraulic Drain connection per UNJF-3A (-10) (MS 33656) Coll Resistance (at 100' F) 26 ohms (single-coll) MOUNTING 40 ohms (dual-coll) The attitude ofinstallation does not affect the Maximum Coll Current performance of the actuator. 250 mA. Six-inch mounting flange with 2.938-inch hub Position Feedback Transducer contains six.438-inch bolt holes on 4.875-inch-Optional on dual-coil models only inch bolt circle; flange is approximately.625-inch thick WElGHT 20 pounds, approximate dry weight LEVEL ADJUSTMENT q \\ l 'a 8'aiN %"ut. 'AE e man ::c,gg,=gg,,, g OainCE ll0l0ll0ld100lNl0h lll ll Pc1 -/ COLL s E URE P FLAPPER

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\\ TORQUE MOTOR ) e-,- ,, \\ VALVE ASSEMSLY ,____ J ~ ~ 77 .y NOZZLE l 6'M Pe1MMZ9 Ps 7. /. /. - E S S -*= .h-== DR AIN f (Pg) ~- SERVO { f / PISTON "^H.WW"7EE 7. ~ * '" " " NTROL ARMATURE COlb A SPOOL VALVE ~ CONTROL LAND m P 7 SECOND STAGE h2Mhllllll SPOOL VALVE e k b FLAPPEftl DO NOT USE FOR CONSTRUCTION OUTPUT N SHAFT CmL 9 DUAL COIL R TORQUE MOTOR D SCHEMATIC ,=;% Single Coil Schematic TM25/200 LP Actuator I

e i i 1 MYDRAuuc Fluc Sus' PLY ~ 79 4 ~ CONNE C ftON II III 7 W ASS (JLu F RR (8 HYDRAUllC FLU 80 ( *) 1 DRA E flON

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PEN ut-F-3504A g ~ f uu-u c-io) g _m i-o e 0 ~ h h o i 3 o U }- o 7.'l4 i e O- @0 ~ a,, 3g o 4'o'd 0 [83 4) j O o i T lll?> l i h, k,(ifh y .7.. i i L.o uAs $l25 jo-- 0;;gS yj i-4_o waxJ ll ) d (e2 94) fis) i gg [] 12.7(.s M uiN PosTioN

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( W iJ" E"N9 -- p'". - /_ _,,._ T (....) 4W% ,,so.s,..,i) ( ~' e'2"2 2 (iaI)$Ac'x /1 P NOTES: SPOWACE ,h/ 1. .500-14 (INCH) NPTF RIGD CONOUlf CONNECTION. N ' ~ ACTUATOR ELECTRIC INPUT SGNAL,18 GAUGE j wE Nott si 0 j f glf.) (A w.c.) wRE (2) EXTENOS APPROX 914.4 FROM siguAs OPENING. Z, I* ,,+,y' l':- - - ($) 2. 25.4 STROKE AVAILABLE. RECOMMENDED STROKE j BETWEEN NO LOAD AND FULL LOAD 1516.9. 30 9 3. PISTON RETRACTS TOWARD WAX POSITION WITH g'h S' 8 "*8 ] V( 41.s CURRENT WCREASE. a-I I N '- 'J j 4 uL uSTED roR uSE N CLASS 1. DivisoN 1, .p# s GROUPS C.D, AND CLASS 1, DiV 2, GROUPS B.C.D. 8 12 7, S. REFER TO WOODWARD SALES SPEC SHEET FOR ( SOR) NRING l INSTRUCTIONS. g-g-. 6, NCHES SHOWN N PARENTHES$. ('55)

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eNiYE DO NOT USE FOR CONSTRUCTION Outline Drawing-Single Coll-TM 25/200LP Actuator

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( 8 l (h5h ( ) ) SEE NOTE 7 1 1 L 1 HYDRAUUC FLUID 1 0 HYDRAUUC FLUID SUPP Y CPAIN CONNECTION L 875-14(INCH) CONNECTION UNS-3A (-10) 750-16(INCH) UNJ-3A (-08) (DO NOT REWOv[) 70 MICRON ABSOLUT FILTER / PER MIL-F-SSO4A 406 4 (00 NOT PEMOVE) (16 00) Q- .Il Q_ a d( h ) I O G H O C ) O .o o (259510.21) 2.1) 0 271.s j 074 (10 69) a O o l n g r 162 7 l 7 65) (6 40) e j l ) 7a 2 i 47 e i i e i (3 00) (1.8 ) ltl l l lll lll ll lll ! e, 4,( 4;,2,)M A x e15.8(e 62) 1 (' g3 g9 0) g = 12.7 (, b10.3 ('40) ACROSS FLATS 12.7 --i (.50)(ORIENTAT10N NOT IMPORTANT) 4g-G ~#14.7 (e 58) j I mRU E St E eisO.o Max PRIMARY k'OM) COLL WRES NOTES: SEE NOTE 6 6a #11.2 THRU (e 44) 12x S* .375-24(INCH) DEEP Q1 MIN CURRENT POSITION FOR RETRACTING TYPE ACTUATOR. A e22.2 (e 88) eACK 31.7 (1.25) SPOwACE \\ d min CURRENT POSITION FOR EXTENDING TYPE ACTUAT 'k # ! (sl., d MAxlMUM CURRENT POSITION FOR RETRACT T'rPE. [] \\ j p4 l',, l 2 26.57 (NOM) STROKE AVAILABLE. b .44) [. (f0.9 ( O ) b MAXfMUM CURRENT POSITION FOR EXTEND TYPE. 19 75) .22) 26.57 (NOM) STROKE AVAILABLE. ' 0'I / 30.9 S. ACTUATOR INPUT S(GN AL. 500-14(INCH) NPTF ELECTRICAL l 56.4 j

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g 4n WRE EXTENDS APPROX 3048.0 f, as EACH OPENING. ~ h y N 6. ACTUATOR POSITION TRANSDUCER SIGNAL, t [ , y .500-14(INCH) NPTF ELECTRICAL CONDUli CONNECTION. / Sn 18 GA ( AwC) WRE. g) S W D D M N M M.0 m W E. SECONDARY 6-- 5 SEE N T 6 133 4 NSTRUL (5.25) i 79.4 _ 8. INCHES SHOWN IN PARENTHESIS. { ( 1 (3.12) d 1 DO NOT USE FOR CONSTRUCTION lMETRICl ,= = Outline Drawing-Dual Coil TM25/200 LP Actuator With Position Feedback ~

-.m.:-- ';;=r::m or mn - c - i g",7cv= " N dt)~ "UJ M L7' d'aC ~ \\i /40^44

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o @b";~'" ( of) y- ,e yo l y ~ o e i f8 1 O ('0 ) 1 44 (6 0) Tj TI j i u dj L..J w ( Sk) i. a._ ('s2 94) ( to) etS 8 6) { } ( SO (OR N N0f IMPORTANT) -4 -ete7(e36)

  1. 130 0 was y ny (eS C1) 22 (e )0 i

S) DCEP NOTES: I \\ d WrN1WUW CURRENT POSTION FOR RETRACTING j +/, ,4 TYPE ACTUATOR. /,,, s { l 72) L-- .) ($' d 50 8 ( 44) k WINiWUW CURRENT POSTION FOR EXTENDfNC 4 g 9 (2.00) TYPE ACTUATOR. N# O 2J) 19 1 d WAxlWUW CURRENT POSITION FOR RETRACT TYPE. 26.57 (NOW) STROKE AVAILABLE. 36.4 d WAXIWUW CURRENT POSTION FOR EXTEND g;. .' ] S08 61 9 j q ~ g.',, l TYPE. 26.57 (NOW) 5TROKE AVAILABLE. f /1 / x e 5. ACTUATOR INPUT SCNAL 'M K .500-14(INCH) NPTF ELECTRICAL CONDUlf / e CONNECTION en 18 CA ( AWC) NRE. Ps."a"! 1M-714~ !"C""!PER 5 ^"""

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.. REFER To.OOO.ARo s=Es SPEC sNEET FOR WIRING INSTRUCTIONS. (6 1h (ft2) 7. INCHES SNOWN IN PARENTHESs. DO NOT USE FOR CONSTRUCTION Outline Drawing - Dual Coll TM25/200LP Actuator Without Position Feedback oo.................................................................. WOODWARD GOVERNOR COMPANY TURBOMACHINERY CONTROLS 3800 N. Wilson Avenue P.O. Box 3800 = Loveland, CO 80539-3800 Phone: 1970-663-3900 Fax: 1 970-962-7050 I@ i.d.l. b .= Regemeered Ptem ISO 988Lil01 Castensees QNS 157 I international Woodward Offices Austrollo 612-758-2322 + Brazil 5519-242-4788 + Chino 8610-501-1119 Czech Republic 42 019-7226076 Germany 0049 75-4254270 + Indio 91 129-232840 - Japan: Chibo 81476-93-4662 + Kobe 8117-928-8500 Mexico 52 5-628-1224 - Poland 48 22-264156 - Singapore 65 270-0081 - The Netherlands 3123-5661111 U. A. E. 9712-327704 U.K. 441-734-752727 + U.S.A.: Alabomo 1 205-987-8686

  • California 1 510-937-9880 lilinois 1 708-747-2565 - Pennsylvania 1610-278-1900 + Texas 1713-666-2211 + Washington 1 206-637-8370 CORPORATE HEADQUARTERS / AIRCRAFT CONTROLS + Rockford. IL U.S.A. 1 815-877-7441 ENGINE CONTROLS Fort Collins CO, U.S.A. 1 970-482-5811 gm,

9 1 l COMPARISON OF EGM CONTROL SYSTEM VERSUS 505 CONTROL SYSTEM JUNE 1998 l EGM Ramp Gen-Sig Conv. Dropping Resistor EGR actuator Remote Servo 505 Control TM25 Actuator TG gov for pump Maintenance, Advantages, Benefits EGM system dropping resistor requires the resistor be changed out every two years. 580.00 for rnaterial plus labor and down tune. Not required with 505. Ramp initiation switch can be eliminated from the steam valve. Less equipment in the system to maintain and monitor. We are planning i system package so all plants will use the same equipment and same part numbers. Using the TG as a pump sump means self contamed oil system and is not dependent on turbine oil. Contamination and supply oil for start up becomes a nummal issue. Spare 505 controls in storage can be powered up simply by providing 115 VAC power from a wall outlet. This is necessary and should be donc periodically to maintain the capacitors on the power supply inputs. He EGM family is obsolete and parts availability are an issue. The same is about to be true of the equipment discussed here as part of the system with the EGM. He 505 is current technology wnh a proven track record. The same is true of the actuator. The 505 offers VASTLY improved fast start control capability! i The 505 display window reads RPM as well as other parameters so the need for an auxiliary tach is l climmated. We can still feed the auxiliary tach if so desired. Question The input water level speed bias signal is 4-20 MA at some plants and 10-50 MA at other plants. We s would like these to all be 4-20 MA. g j l I

c. l 1 i I 1 $NelommD} Typical EGM/EGR Application 4 -Tp g: _ _. _u (a t =,~) -;;,::: a-a i - ~ - ,L':n r ,s

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.u 5*' \\ mV EN 2 4 "[" LdIlg C i n R U T P r zi I A n i Hp v v N 5 L Ga C C Ac n n d q.V ' A L Wr e t t u u 88 Y t O O O E E s R R r r = / Ow L f F m / e / e / / e C Em J E R T f E A R P L R M ) WL O,, }g ! O g ORO P G C L t E T so ( F N or O f. O C W b-4 s e RE - D - I'k A E - 3' M i . J_ 8 4 ge* iII ', H y WE t OCN L L =E t R A FE t T A E t S -- "~ F / s E ^ R y ^ e_ N i r A ,o;

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.L L g m. I f ? g' 1 t p*< o f. v u,';'. IeI H H 8 g_1 W; L w ^# C ~ ,8l C C A O OaI T C L L r ,8l3 3 8i8iI gte'g ,I 8 _4 + i,l ? Il .g4S e + _ n eYG i T E p LO t AR f ,I<8' E V CE N NZ I O A V C H y . 8 t I. 8[ "L C M A E M M 7l G 1. r I n S m t y o eO s n p A otE f, G c R e= nt t O E f T f Oa p L rm A O A A pk I .L N va u I g R u R E I a d eo E G cr 3 P e r e s. m l 1 A R F' \\; 2 g A n. " o s. 0 1 u t -so 7 i !{t

l I s 7MP1 Typical EGM start-up Characteristics l seu M s' . %"J"*""-......_g,_ 3 \\ i = =.:-'" " { E I ,,.... u "fl w cio.1 m,w. ,,,,, T. ~ 0 ame vne fis seemanu j tua i i l 1 1

d Wasmzimp1 Advantages of the 505 System a Corrects Overshoot at Idle Reduces spares = Eliminates-Voltage dropping resistor Max Valve position indicator Ramp generator and Ramp initiation switch Need for external tachometer Potentiometers = Programmable and Flexible = Local Disp!ay Can be mounted up to 1500 Ft away from unit = Alarms and Shutdowns aid in trouble-shooting i u_ _ ___ _ _ _ _ _. _ _ _ _ _ _ _ _ _ _

a 7 6 pl l SNGLE VALVE - TLsNE CNIGURATKN (SPEED PID WITH REMOTE SETPOND p _ _ _ _ _ __ _ =ge,e us seam g-se TWBE SPEED-+ SCALNG VALVE ~ LHTER RAG

T R C D A G N s s I r LA x C a S N O ) IT T A N S I R O S U P L G T I F E N S O C ET E O N M D R I B E E E E R R E V T U P LI T H , S - AM T VI L IW EV D D L I A P E E V D T P E N S E E LG P OI E N S u P IN T B ( IS E R S U T '++ E R S E AI W O R L 4 D E E OUm LT TT BU AP NN MP 2 E E N - I i. RI (

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t O WeccawET0 I Sasa2 at Sput RANet - TJese C3FHiJtATM ( AJlt.lmRf PC CWflGtAED A5 & LIMITER ) f a summ encor Benaf GEu WEmeD=mm== fAC ! _ _ _ __ _ _... q ._.; _ rawn= I l==a l + m H grTposa %. CAEC to apn + rwanF pyVT comese g TM SPEED-+ = ~ lim., F-. + = ALR&lARY sRN =* A LHTUt g l i i l r l [. I l l i. l

1l l !llI I1!ll1 lll) a R R 2 I O O TR TR UE mV A E T R TI R C D C D A lg l GN ILAC m S DA l; l u O L T IN U /W K SS N ~ L O I l TA ) R R P U E O G T OR I I FN M D D E tM E X V I O L E U L I I C P A +S + A - AM lg VI E L N S A IB E R D D T U E U T gy l U E f T P T l G i N S N I o I Y W I E O R E m NI W IA G O N C B L R I A X R D U U I T A l P gg T IL Y P R S A I R L I N O X T O E U NMS I L A EP R CR E G ( R OV N E T N I P O S c P ELC O I O BG 1 C A O R NL S D E A +C- + T H + U )l ) l P R R E T N E E D N I K K A I E A A C O E E S D R R A W A B B C t C E N E S S T E L A I G B l A C N E

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8 L - a cc: Frank Amend Power Control Services 1400 Vance Street P.O. Box 1928 Rocky Mount, NC 27802-1928 Steven L. Thompson Nuclear Coordinator Woodward Governor Company Industrial Controls ' 3800 N. Wilson Ave. Loveland, CO 80538 1 i s s1. _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ - _ _ - _ -}}