WOODWARD LQ6 Liquid Fuel Valve Actuator with On-board Driver
Product Overview
WOODWARD LQ6 Liquid Fuel Valve Actuator with On board Driver is an advanced device designed specifically for industrial gas turbine liquid fuel control. It integrates an electric rotary metering valve, bypass regulator, and onboard driver module, which can provide precise liquid fuel flow control in industrial gas turbines ranging from 3mw to 15mw power, ensuring stable and efficient engine operation. It plays a key role in gas turbine systems in multiple fields such as power generation, mechanical drive, and ocean.
Product Structure and Principle
Integrated with electric rotary metering valve, bypass regulator, and onboard driver module. The rotary metering valve achieves high-precision flow control through rotating plate components and precision machined metering ports. The sealing shoe and plate are tightly matched to control the flow area. The bypass regulator maintains stable pressure difference at the metering valve port. When the pressure difference exceeds the set value, the regulator piston opens and bypasses the excess inlet flow back to the fuel pump inlet.
Specification parameters
Flow range: 80-10800 pounds per hour (36-4900 kilograms per hour), based on a liquid fuel specific gravity of 0.82.
Suitable fuel pump types: can be used in conjunction with gear pumps and other positive displacement fuel pumps.
Performance characteristics
Accurate flow control: Adopting a rotating plate and precision metering port design, combined with a large valve stroke and high-precision position feedback rotary transformer, the flow regulation ratio exceeds 100:1, and the flow control accuracy is high.
Self cleaning function: The shearing action can prevent pollutant deposition and system debris from blocking the metering port, ensuring the normal operation of the valve and extending its service life.
High reliability: Rare earth permanent magnets and efficient electromagnetic circuits provide powerful driving force while reducing size. Single axis design reduces moving parts, lowers the risk of failure, and improves reliability.
Diverse electrical interfaces: equipped with digital and (4-20) mA interfaces, convenient for integration with control systems, enabling remote control and monitoring. It also has discrete fault output and independent shutdown functions to enhance system safety.
Product specifications: The flow range is 80-10800 pounds per hour (36-4900 kilograms per hour), based on a liquid fuel specific gravity of 0.82. Can be used in conjunction with gear pumps and other positive displacement fuel pumps.
Precautions
Installation environment requirements: Although the equipment has a certain degree of environmental adaptability, it should be installed in a dry and well ventilated environment as much as possible, avoiding places with humidity, dust or corrosive gases, to ensure the normal operation and service life of the equipment.
Fuel compatibility: Ensure that the liquid fuel used meets the fuel type and quality standards specified by the equipment, and avoid valve blockage or damage caused by the use of inappropriate fuel, which may affect equipment performance.
Regular maintenance: Although the equipment has self-cleaning and other functions, it is still necessary to perform regular maintenance according to the maintenance manual provided by WOODWARD, check the operating status, electrical connections, and wear of key components of the equipment, and promptly identify and solve potential problems.
Application area
Mainly used in industrial gas turbines, including gas turbine engines for power generation, mechanical drive, and marine applications. In the field of power generation, ensuring stable combustion of gas turbines and improving power generation efficiency; In mechanical drive, provide stable power for the driving equipment; In marine applications, adapting to complex marine environments and ensuring reliable operation of gas turbines.
Product advantages: Onboard drivers simplify system design, reducing installation space, time, and cost. The overall design is compact and cost-effective. Highly integrated, reducing external components, lowering system complexity and fault points. As a Woodward brand product, it has professional technical support and quality assurance. The product has been validated by the market and has high reliability.
Built in driver eliminates the need for additional external control modules, simplifying system wiring and installation complexity.
Multiple specifications compatible
Interface size: 2 inches (2IN), suitable for fuel pipelines of different diameters.
Pressure rating: RF600 # (flange connection) or SAE (threaded connection), meeting the requirements of high-pressure working conditions.
Material: The main body is made of stainless steel (SST) or aluminum alloy (ALUM) to meet the corrosion requirements of different environments.
Electrical characteristics
Working voltage: Supports 125V DC or 24V DC, compatible with multiple power systems.
Action type: Depending on the model, precise control of different strokes (such as 1.0 ACD, 1.5 ACD, 2.0 ACD) can be achieved.
Security and Authentication
Compliant with non SIL (Safety Integrity Level) and non RTE (Remote Terminal Equipment) standards, suitable for general industrial scenarios.
Protection design: Electrical interface protection is achieved through conduits or connectors to adapt to industrial environments.
Model and Part Number
Model Description Part Number
GS50，2IN RF600#，SST，1.0 ACD，125V， Non SIL, non RTE, catheter connection 9908-1605
GS50，2IN RF600#，SST，1.5 ACD，125V， Non SIL, non RTE, catheter connection 9908-1606
GS50，2IN RF600#，SST，2.0 ACD，125V， Non SIL, non RTE, catheter connection 9908-1607
GS50，2IN SAE，ALUM，1.0 ACD，125V， Non SIL, non RTE, connector connection 9908-1665
GS50，2IN SAE，ALUM，1.0 ACD，24V， Non SIL, non RTE, connector connection 9908-1666
GS50，2IN SAE，ALUM，1.5 ACD，125V， Non SIL, non RTE, connector connection 9908-1668
GS50，2IN SAE，ALUM，1.5 ACD，24V， Non SIL, non RTE, connector connection 9908-1669
GS50，2IN SAE，ALUM，2.0 ACD，125V， Non SIL, non RTE, connector connection 9908-1671
GS50，2IN SAE，ALUM，2.0 ACD，24V， Non SIL, non RTE, connector connection 9908-1673
Application scenarios
Industrial gas turbine: used to regulate fuel flow, control engine speed and power output.
Energy generation: Achieving precise fuel metering in gas-fired power generation units to improve power generation efficiency.
Compressor unit: Cooperate with gas turbine to drive the compressor and stabilize the fuel supply in the process flow.
Documentation and Support
Product specification: Refer to “Product Spec: 03456”.
User Manual: “Manual: 35136” provides installation, debugging, and maintenance guidelines.
Technical Support: For more information, please contact Woodward Industrial Support Team（ industrial.support@woodward.com ）Refer to publication 25182.
Advantage Analysis
Integrated design, simplifying system architecture
The onboard driver and actuator are integrated without the need for additional independent driver modules, reducing control cabinet space occupation and wiring complexity, and lowering installation costs and maintenance difficulties.
Adapt to the “plug and play” requirements of industrial sites and shorten system debugging time.
Diversity of specifications, suitable for a wide range of scenarios
Interface and pressure rating: Provides 2-inch RF600 # flange and SAE interface, compatible with high-pressure fuel pipelines (such as 600 pound pressure systems), suitable for high-pressure conditions such as gas turbines and power generation equipment.
Material selection: Stainless steel (SST) model is corrosion-resistant and suitable for harsh environments; Aluminum alloy (ALUM) models are lightweight and easy to install and maintain.
Electrical compatibility: Supports 125V DC and 24V DC power supplies, adapts to different industrial power systems, and has a stroke coverage of 1.0 ACD to 2.0 ACD, meeting different flow control accuracy requirements.
Strong adaptability to industrial environment
The electrical interface is protected by conduits or connectors, and has certain dust and splash resistance, suitable for complex environments in industrial sites.
Although non SIL standard design is not suitable for high safety level scenarios, it meets the needs of ordinary industrial control and has high cost-effectiveness.
The GS40 features a 1.5” inlet/discharge stainless – steel valve body with ANSI 600# flanges. This construction ensures high – pressure resistance and durability, making it suitable for a wide range of industrial applications. The stainless – steel material also provides excellent corrosion resistance, even when dealing with harsh gas compositions. The self – cleaning, shear – type metering action is a standout feature. It effectively keeps the metering port free from deposits of gas condensates, contaminants, and system debris. This is crucial as such deposits can limit the performance of the valve over time. Whether the gas source is clean pipeline gas or wellhead gas with more impurities, the GS40 can maintain its optimal performance.
1.2 Actuator
Integrated electric direct drive (gearless) technology is employed in the actuator. This design offers several advantages over traditional geared actuators. Firstly, it reduces mechanical wear and tear, leading to an extended mean time between overhauls (MTBO). This is highly beneficial for plant operators as it aligns with longer production cycles and major overhaul periods. The actuator also has a spring – return fail – safe mechanism. In the event of a power failure or system malfunction, the spring – return feature ensures that the valve moves to a safe position, preventing any potential hazards associated with uncontrolled gas flow.
1.3 Driver
The on – board driver of the GS40 comes with embedded service tools, which simplifies maintenance and troubleshooting. It also has a conduit – connect feature, allowing for easy connection to the overall control system. This integration of the driver on – board the actuator reduces the need for external, complex wiring setups, enhancing the system’s reliability and ease of installation.
2. Technical Specifications
2.1 Fuel Temperature Range
The GS40 is designed to operate in a wide fuel temperature range, from – 40 °F to 350 °F (- 40 to + 177 °C). This broad temperature tolerance makes it suitable for various operating environments, whether in cold regions or in applications where the gas fuel is subject to high – temperature processes before reaching the turbine.
2.2 Fuel Pressure Rating
With a rated gas supply pressure of up to 1440 psig (9928 kPa), the GS40 can handle high – pressure gas fuels. As OEMs and operators continue to explore ways to push the limits of fuel quality and energy content in combustion, higher fuel pressures are often required. The GS40’s ability to withstand such high pressures makes it a reliable choice for modern gas turbine applications. It enables reliable light – off, emissions control, and turbine efficiency even under challenging fuel pressure conditions.
3. Applications
The GS40 is primarily used in API 616 aeroderivative and small heavy – duty gas turbine control. It finds applications in driving generators, compressors, turbo – expanders, fans, and pumps. In power generation plants, for example, it accurately meters the gas fuel to the combustion system of the gas turbine during different operating phases such as acceleration, steady – state operation, and deceleration. This precise fuel metering is essential for maintaining stable power output and ensuring the efficient operation of the turbine, ultimately contributing to reliable electricity generation. In gas compression applications, the GS40 helps in controlling the gas flow to the compressor, optimizing the compression process and enhancing the overall efficiency of the gas transportation system.
The QuickTrip trip block component is carefully designed for steam, gas, and turbine shutdown systems, suitable for mechanical or generator driven turbines using low-pressure (5-25 bar/73-363 psi) hydraulic trip oil manifolds. Its core function is to quickly discharge the tripping oil main of the turbine, providing a solid guarantee for the safe shutdown of the turbine in emergency situations.
Model and Features
Represented by the 9907-1978 model, this component has a unique design and notable features.
Fault tolerant design: Three independent rotary valves are used, working together based on a 3-to-2 voting mechanism. This design ensures that in the event of any component failure, such as valve actuators, valves, circuits, or connectors, it will not cause false tripping, greatly improving the reliability of the system and fully complying with the API-670 industry standard. For example, in a complex industrial environment, a valve driver may experience a brief malfunction due to electrical interference, but due to the 3-to-2 voting mechanism, the system can still accurately determine and operate normally without causing unnecessary downtime, ensuring the continuity of production.
Corrosion resistant and self-cleaning design: The components are made of corrosion-resistant materials, with a rotating chip shear force of 25 lbf and a self-cleaning port design. This enables it to operate stably in harsh conditions with dirty or contaminated oil, especially suitable for steam turbine applications. During the operation of steam turbines, their lubricating oil is usually used to drive hydraulic turbine control valve actuators, and the oil system of steam turbines often mixes with dirt, metal shavings, water, and other pollutants such as Babbitt metal, ammonia, etc. In addition, due to the high operating temperature of the steam turbine, the turbine oil is prone to decomposition, producing sludge like substances, resulting in varnishing of internal system components. The 9907-1978 model trip block component, with its special design, can effectively address these issues and ensure the normal operation of the system.
Online maintenance function: This component supports online maintenance. When the turbine is in online operation, users can replace key components such as electrical modules, solenoid valves, circuits, drivers, etc. This feature greatly improves the maintainability of the system and reduces downtime caused by equipment maintenance. For example, during peak production periods, if a certain solenoid valve malfunctions, it can be replaced online without stopping the machine, avoiding the impact of downtime maintenance on production progress.
Technical parameters
Working voltage: 24 VDC, stable low voltage power supply, suitable for various electrical system environments, ensuring the stable operation of component control circuits.
Maximum supply pressure: 500 psi, capable of withstanding high pressure hydraulic oil input, meeting the demand for discharge pressure of the trip oil main pipe under different operating conditions.
Applicable oil types: Mineral oil, synthetic oil, or Fyrquel EHC base oil can be used, with a wide range of oil adaptability and compatibility with different types of turbine oil systems.
Operating temperature range: -40 to+85 ° C (-40 to+185 ° F), can operate normally in extreme environmental temperatures, ensuring stable performance whether in cold outdoor environments or high-temperature industrial plants.
Operating oil temperature range:+15 to+70 ° C (+59 to+158 ° F). There are clear requirements for the oil temperature during operation to ensure that the hydraulic components inside the components can work normally within the appropriate oil temperature range, avoiding the impact of high or low oil temperature on component performance.
Diagnostic testing
Given the adoption of a 3-to-2 configuration, diagnostic testing can be conducted while QuickTrip is online and the turbine is running. The testing program will set the tripping output of the tested module to a tripping state (configured as a power-off state for power-off tripping), and only test one module at a time.
Users can automate the testing process by using the built-in “Automatic Sequence Testing” feature in ProTech TPS, or by leveraging ProTech’s programmability and test mode configuration. During the testing process, it is necessary to verify whether there is a running alarm (failure to power on and enter the running state), and to verify the trip time of each module by checking the trip cycle time log. This log will display the last 20 trip events, as well as the time interval from the control signal dropping to the QuickTrip valve rotating to the open position and the trip position sensor sending a trip signal to ProTech. Under normal circumstances, this trip time should be less than 50 ms. If the QuickTrip module (valve) malfunctions upon receiving a command to rotate to open or close, or if the trip time exceeds 50 ms, timely maintenance and troubleshooting are required to ensure the normal operation of the components and the safety of the turbine.
Key advantages
1. High reliability fault-tolerant design
3-for-2 voting mechanism: By working together with three independent rotary valves, any single component failure (such as valve driver, circuit or connector) will not trigger false tripping, meeting the API-670 industry standard and suitable for critical industrial scenarios of continuous operation. For example, when a certain solenoid valve fails due to voltage fluctuations, the other two valves can still maintain normal system logic and avoid unnecessary shutdowns.
Fault isolation capability: Each module operates independently, and the faulty module can be isolated online without affecting the overall system operation, improving the stability of turbine operation.
2. Adaptability to harsh working conditions
Corrosion resistant materials and self-cleaning design: Using corrosion-resistant materials (such as stainless steel valve body), combined with 25 lbf rotating chip shear force and self-cleaning ports, can effectively deal with dirt, metal shavings, and decomposition products (such as Babbitt alloy particles and ammonia pollution commonly found in steam turbines) in the oil, preventing port blockage or valve body corrosion.
Wide temperature operation capability: The operating temperature range is -40 to+85 ° C, suitable for extreme environments (such as outdoor low-temperature or high-temperature factories), and the operating oil temperature range is+15 to+70 ° C, compatible with hydraulic oils of different viscosities.
3. Maintain convenience and efficiency
Online maintenance function: Key components such as electrical modules and solenoid valves can be replaced without stopping the machine, reducing unplanned downtime. For example, during peak production periods, faulty solenoid valves can be directly replaced to avoid production capacity losses caused by maintenance.
Automated diagnostic support: Through the “automatic sequence testing” function of ProTech TPS, module trip time (<50 ms) and operating status can be verified online, potential faults can be detected in advance, and maintenance costs can be reduced.
4. Compliance with safety standards
Multi certification guarantee: Designed to comply with API-670 standards, supporting Canadian/US hazardous site certification and EU ATEX directive, suitable for high-risk industries such as petroleum and chemical, ensuring safety regulatory requirements.
Quick response capability: Trip time ≤ 50 ms, can quickly cut off the power source of the turbine in emergency situations, preventing the expansion of dangerous working conditions such as overspeed and overpressure.
Precautions
1. Installation and environmental requirements
Oil cleanliness control: It is necessary to ensure that the hydraulic oil cleanliness meets the ISO 4406 standard (recommended ≤ 18/16/13) to avoid valve jamming caused by oil contamination. If the oil contains water or particulate matter, it needs to be paired with a high-precision filter (filtration accuracy ≤ 10 μ m).
Temperature limit: The operating oil temperature should be controlled between+15 and+70 ° C. If the oil temperature exceeds 70 ° C, it may lead to increased oxidation of the oil, and a cooling system needs to be configured; When the temperature is below 15 ° C, the viscosity of the oil increases, which may affect the tripping response speed and requires preheating in advance.
2. Maintenance and testing standards
Regular diagnostic testing: Perform a trip time test at least once every quarter, and record the last 20 trip events through ProTech TPS. If a module trips for more than 50 ms, immediately investigate valve wear or hydraulic system leaks.
Precautions for component replacement: When replacing solenoid valves or electrical modules online, the corresponding module power should be disconnected first, and special tools should be used for disassembly to avoid short circuits caused by live operation; After replacement, it is necessary to perform functional verification again.
3. Oil compatibility management
Do not mix oil: Mixing different types of oil (such as mineral oil and synthetic oil) may cause viscosity changes or additive precipitation. It is necessary to ensure that the system uses a single type of oil and regularly test the physical and chemical indicators of the oil (such as acid value and viscosity index).
Fyrquel EHC base oil special treatment: When using this type of oil, attention should be paid to its flame retardant properties, which may affect the sealing material. Fluororubber (FKM) seals should be selected to avoid swelling and failure of ordinary rubber parts.
4. Emergency handling of faults
Troubleshooting of accidental tripping: In case of unexpected tripping, priority should be given to checking the alarm logs of ProTech TPS to confirm whether it is caused by sensor failure or line interference; At the same time, check whether the pressure of the tripped oil main is abnormal (normal working pressure 5-25 bar).
Emergency manual operation: If the automated diagnostic system fails, the trip valve can be forcibly opened by manually operating the knob, but it is necessary to ensure that the operator wears protective equipment to avoid the risk of high-pressure oil spray.
WOODWARD TM linear actuator is a key component for achieving precise linear motion control in the field of industrial control. It is mainly used to convert electrical signals into precise linear mechanical displacement outputs to drive the actuators of various industrial equipment. It is widely used in the control system of power equipment such as steam turbines and engines. By accurately adjusting the flow of steam, fuel and other media, it achieves precise control of equipment speed, power and other parameters, ensuring stable and efficient operation of equipment under different working conditions.
Product model and features
TM-25LP and TM-200LP: belong to electro-hydraulic proportional actuators, suitable for controlling steam or fuel control valves that require low/high linear driving force. TM-25LP has a working capacity of 72J (53 ft lb) and a maximum bidirectional output force of 2833N (637 lb) when the input oil pressure is 2586 kPa (375 PSI); The TM-200LP has a working capacity of 231 J (170 ft lb) and a maximum bidirectional output force of 9074 N (2040 lb) when the input oil pressure is 8274 kPa (1200 PSI). The actuator housing is made of aluminum, and the internal components are made of hardened stainless steel, with a corrosion-resistant structure. The output shaft is made of hardened 17-4 stainless steel, with different thread specifications and options. The rod end has a pin hole for fixing the connecting rod mechanism.
TM 55 and TM 55P: TM 55 is an integral actuator used to control diesel and gas engines or steam and industrial gas turbines, and can be used in conjunction with Woodward liquid and gas fuel valves through an adapter. TM 55P is an electro-hydraulic proportional actuator suitable for control systems that require output of rotating machinery proportional to electrical input. It is equipped with an electrical position sensor and can achieve closed-loop control of the actuator output shaft.
Key advantages
High precision control: Excellent displacement control accuracy that can meet the stringent requirements for equipment position adjustment in industrial production processes. In the control of steam turbine steam valves, precise adjustment of valve opening is used to achieve precise control of steam flow, thereby ensuring stable turbine speed, improving power generation efficiency and electrical energy quality.
High reliability: The sturdy and durable mechanical structure, high-quality material selection, and advanced manufacturing processes make the actuator highly reliable. In harsh industrial environments such as petrochemicals, steel metallurgy, etc., it can operate stably for a long time, reduce equipment downtime, and improve the overall reliability and availability of the production system.
Quick response: The extremely short response time ensures that the equipment can respond to changes in operating conditions in a timely manner, improving the dynamic performance of the system. When the device needs to quickly adjust its operating status, such as in the case of sudden load changes, the actuator can quickly act, adjust control parameters in a timely manner, and ensure the stability and safety of the device’s operation.
Easy to integrate: Multiple control signal compatibility and standardized installation interface design make it easy to integrate with various industrial control systems and equipment. Whether it’s building a new industrial automation project or upgrading existing equipment, WOODWARD TM linear actuators can quickly integrate into the system, reducing the difficulty and cost of system integration.
Long service life: Through optimized design and strict quality control, the key components of the actuator have a longer service life. Under normal use and maintenance conditions, it can operate for more than [X] hours, reducing equipment replacement frequency and overall operating costs.
Precautions
Installation and debugging: During the installation process, it is necessary to strictly follow the requirements of the product installation manual to ensure that the actuator is installed in the correct position and firmly fixed. After installation, conduct comprehensive debugging work to check whether the control signal connection is correct and whether the parameter settings meet the actual application requirements, in order to avoid improper installation and debugging that may cause the actuator to malfunction or pose safety hazards.
Work environment: Although the actuator has good environmental adaptability, it is still necessary to avoid using it in extreme environments beyond its design specifications. If the ambient temperature should be controlled between [specific temperature range] ℃, avoid operating at too high or too low temperatures to avoid affecting the performance and service life of the actuator. At the same time, it is necessary to ensure the cleanliness of the working environment and avoid excessive dust, oil stains, and other impurities from entering the interior of the actuator, which may affect its normal operation.
Maintenance: Regular maintenance of the actuator is key to ensuring its long-term stable operation. Regularly check the appearance of the actuator for damage, whether the connection parts are loose, and whether the hydraulic or lubricating oil needs to be replaced. Clean, lubricate, and calibrate key components according to the prescribed maintenance cycle, promptly identify and address potential issues, and ensure that the actuator is always in good working condition.
Parameter setting: In the process of use, if it is necessary to adjust the control parameters of the actuator, it must be operated by professionals according to the guidance of the equipment operation manual. Unreasonable parameter settings may lead to abnormal operation of actuators and even damage to equipment. After parameter adjustment, sufficient testing and verification should be conducted to ensure that the actuator can work normally and meet control requirements under new parameters.
Application scenarios
Power generation industry: In thermal power plants, it is used to control the opening of steam valves for steam turbines, accurately adjust steam flow, achieve stable control of turbine speed and power, ensure efficient and stable operation of power generation equipment, and meet the requirements of the power grid for power supply stability and reliability. In hydroelectric power plants, it can be used to control the opening of the guide vanes of the turbine, regulate the water flow rate, achieve precise control of the turbine output, and adapt to different water levels and power generation needs.
Petrochemical industry: used in petroleum refining, chemical production and other processes to control the opening and closing of various valves, such as controlling the feed valve and discharge valve of the reaction kettle, adjusting the material flow rate, and ensuring the continuity and stability of the production process. In natural gas transmission pipelines, the opening of control valves is controlled to regulate the pressure and flow of natural gas, ensuring the safety and stability of natural gas transmission.
Industrial manufacturing: In the fields of mechanical processing, papermaking, textile and other industrial manufacturing, it is used to drive the actuators of various mechanical equipment, such as controlling the displacement of the worktable of machine tools, adjusting the pressure of the mesh and pressing parts of paper machines, controlling the yarn tension of textile machines, etc., to achieve precise control of the production process, improve product quality and production efficiency.
Transportation: In the ship’s power system, the throttle opening of the ship’s engine is controlled, and the output power of the engine is adjusted to meet the power requirements of the ship under different navigation conditions, ensuring the safety and stability of the ship’s navigation. In some automated logistics transportation equipment, such as Automated Guided Vehicles (AGVs), linear actuators are used to control the lifting and extension of their forks, enabling loading, unloading, and handling operations of goods.
WOODWARD CPC-II current pressure converter is a key equipment used in the industrial control field for steam turbine control systems, mainly applied for precise positioning control of single action steam turbine valve servo systems. It can convert the input 4-20mA current signal into a stable and precisely controllable oil pressure output according to a precise proportional relationship, thereby achieving precise adjustment of the opening of the steam turbine speed control valve, ensuring that the steam turbine can operate stably and efficiently under different working conditions.
Brand background
WOODWARD has over 130 years of experience in designing and manufacturing engine controllers, and is renowned in the global industrial control field. Its products are widely used in key fields such as aviation, industrial engines, turbines, and power generation control. Woodward has always focused on developing advanced control technologies, establishing a high reputation in the industry with excellent reliability, precise control performance, and high adaptability to complex working conditions. The WOODWARD CPC-II current pressure converter is the crystallization of its profound technological accumulation and continuous innovation.
Specification parameters
Accuracy: The error within the full range working range is less than ± 0.2%, ensuring the accuracy of pressure conversion and making the control of turbine valves more precise.
Repeatability: Achieve 0.1% of the full range working range to ensure consistency in each conversion and maintain stable turbine operation.
Temperature drift: Within the full range operating temperature range (-40 to+85 degrees Celsius), less than or equal to ± 0.01%, greatly reducing the impact of environmental temperature changes on equipment performance.
Pressure stability: Set value fluctuation is less than or equal to ± 2%, maintain stable output oil pressure, and avoid unnecessary fluctuations in turbine valves.
Physical characteristics: H x W x T is about 290x270x270mm, and it weighs 25kg (55lb) without oil. The installation method is flexible and can be installed in any posture. There are four M10 threaded holes with a depth of 23 millimeters at the front of the hydraulic end.
Protection standards: Complies with EN61000-6-2 (2005) protection standards and EN61000-6-4 (2007) emission standards, and can adapt to complex electromagnetic environments.
Core functions
High precision pressure conversion: With built-in high-precision pressure sensors and advanced PID controllers, it accurately receives 4-20mA pressure demand signals, precisely regulates oil pressure, and achieves precise positioning of the steam turbine speed control valve, providing solid support for the speed and load control of the steam turbine.
Anti oil pollution operation: Adopting a unique “dirt killing star” technology, it meets the ISO 20/16 anti oil pollution standard. Even in harsh working conditions where oil is contaminated or contaminated, it can still operate stably with the help of self-cleaning valve algorithms, effectively reducing equipment failures and downtime caused by oil pollution.
Redundant control: supports redundant input and sensor configuration, can accept pressure demand input from one or two (redundant) controllers, and vote on it; It can also simultaneously receive internal and external (redundant) oil pressure sensor signals, and after voting, use health signal control equipment to operate. Some models (such as 9907-1253) have redundant (dual) CPC (master/slave) functionality, greatly improving the system’s fault tolerance and reliability.
Valve Linear Control: Equipped with a built-in valve linearization table, the full range linearity error is less than 0.2%, providing stable and linear control for steam turbine valves, ensuring smooth operation of the turbine, and improving system control accuracy.
Status monitoring and diagnosis: Equipped with comprehensive status and health indication functions, real-time monitoring of key parameters such as pressure sensors, input demand signals, internal unit health status, and input power quality, and providing control pressure readings. At the same time, it is equipped with software service tools with trend analysis function, which facilitates users to monitor and analyze data in real time, and timely identify potential problems.
Working principle
CPC-II receives a 4-20mA current signal, which is first transmitted to the internal circuit. In the circuit, the current is converted into voltage through a precise 10 Ω sampling resistor, and then amplified into a voltage signal of 0V -4.5V through the OPA2227 operational amplifier circuit, which is sent to the analog-to-digital converter of the microprocessor. The microprocessor analyzes and processes signals based on built-in control algorithms and real-time oil pressure data feedback from high-precision pressure sensors, and then outputs control commands to the drive circuit. The driving circuit controls the hydraulic control valve, regulates the flow and direction of hydraulic oil, and precisely controls the output oil pressure to achieve precise driving of the steam turbine speed control valve.
Key advantages
High reliability: With mature mechanical structure design, redundant configuration, and strong oil resistance, the equipment can operate stably for a long time even under harsh working conditions, reducing the probability of failure.
High control accuracy: High precision pressure conversion and linear valve control ensure the accuracy of turbine speed and load control, improve energy utilization efficiency, and reduce equipment wear.
Strong compatibility: Adopting standard installation and hydraulic connection methods, it can seamlessly integrate with various turbine control systems and easily upgrade existing CPC or Voith converters.
Good safety: When an internal unit failure occurs, the valve reset spring immediately acts, causing the CPC to switch to the fault safe position, draining the oil, ensuring the safe closure of the turbine control valve, and effectively protecting the equipment.
Fully certified: Meets North American hazardous site certification requirements, complies with CE directives such as ATEX, Machinery Directive, PED, and EMC, and can be safely used in a variety of complex environments.
Precautions
Installation environment: Although it can be installed in any posture, it should be avoided as much as possible in environments with strong vibration, high humidity, and corrosive gases to ensure stable equipment performance.
Oil quality: Clean hydraulic oil that meets the equipment requirements should be used, and the oil quality and level should be checked regularly to prevent oil problems from affecting the normal operation of the equipment.
Maintenance: Regularly use software service tools to monitor and diagnose the status of equipment, replace vulnerable parts such as seals in a timely manner, and ensure long-term stable operation of the equipment.
Parameter setting: When using Service Tool for configuration and parameter setting, it is necessary to strictly follow the equipment manual to avoid equipment failure caused by incorrect parameter settings.
Core function: As the “execution terminal” of the control system, UG actuators receive signals from speed controllers (such as TG, UG25+Governors) or electronic controllers, and drive valves, fuel racks, etc. through mechanical displacement to adjust parameters such as speed, flow rate, and pressure.
Working principle: It adopts electro-hydraulic, electric or mechanical hydraulic drive to convert electrical signals or hydraulic power into linear or rotational motion, with fast response speed and suitable for real-time control requirements.
Main models and features
1. UG2 series
Application scenario: Basic control of small turbines or engines, compact structure.
Model example:
UG2 actuator (CW, Double Lip Drive Seal) (part number: 8251-212): suitable for clockwise rotation scenarios, dual lip drive seal, reducing the risk of oil leakage.
UG2 actuator (High Speed, Serrated Drive) (part number: 8251-218): High speed serrated drive, suitable for high-speed requirements.
Serrated Drive: such as UG15 actuator (Serrated Drive Shaft, High Speed, MPU) (part number: 8251-719), compatible with magnetic electric sensor (MPU) signal input.
Keyed Drive: such as UG15 Actuator (Keyed Drive Shaft, High Speed, MPU) (part number: 8251-720), the mechanical connection is more stable.
Special configuration: equipped with models such as Miss Tooth Term Shaft and Marine Gland, suitable for special working conditions (part numbers: 8251-724, 8251-734).
3. UG20 series
High torque design: suitable for medium-sized turbines or engines, with an output torque of 20 FT-LB (approximately 27 N · m).
Model example:
UG20 Actuator（Serrated Drive Shaft, Low Speed）（ Part number: 8251-766): Low speed serrated drive, suitable for low-speed and high torque scenarios.
UG20 actuator (with LVDT) (part number: 8251-764): Integrated linear variable differential transformer (LVDT), providing position feedback and improving control accuracy.
UG15 actuator with Heat Exchanger (part number: 8251-0002): equipped with a heat exchanger, suitable for high temperature environments to prevent hydraulic oil from overheating.
Core parameters and configuration
Driving mode:
Mechanical hydraulic drive (through hydraulic oil pressure) or electric drive (some models), adapted to different control logics.
Rotation direction:
Clockwise (CW) or counterclockwise (CCW) should be aligned with the direction of the equipment axis.
Feedback system:
Some models integrate sensors such as LVDT and MPU, providing real-time position feedback and supporting closed-loop control.
Certification and Protection:
Some models have been certified by CSA and ATEX and are suitable for hazardous areas (such as part number 8251-734 with marine certification).
Accessories and System Integration
Governor matching:
When used in conjunction with TG series governors (such as TG13, TG17) or UG25+Governors, it forms a complete chain of “control signal execution action”.
Monitoring and Communication:
Connect to industrial networks through MicroNet system, Flex500 platform or GAP software to achieve remote monitoring and parameter adjustment.
Maintenance kit:
Seals, springs, drive shafts and other spare parts (refer to Woodward spare parts catalog) to ensure long-term reliable operation.
Application scenarios
Industrial power generation: The main steam valve of the steam turbine generator set is adjusted to maintain stable speed.
Oil and natural gas: When a gas engine drives a compressor, the fuel input is adjusted to match the load.
Mechanical drive: drives equipment such as pumps and fans, and adjusts output power according to process requirements.
Ship power: throttle control of marine turbines or diesel engines to adapt to changes in navigation conditions.
Advantages and Characteristics
Reliability: Mature mechanical structure, redundant hydraulic system design, vibration resistance, wear resistance, suitable for harsh working conditions.
Flexibility: Multiple driving modes and feedback configurations are available, supporting on-site manual adjustment or remote electronic control.
Compatibility: Seamless integration with other Woodward control products, such as ProTech overspeed protection devices and MicroNet systems, to build a complete automation solution.
Core function: Receive control signals from UG25+speed controller, adjust the opening of steam valve through mechanical or electro-hydraulic drive, and achieve precise control of steam turbine speed.
Working principle: Convert electrical or hydraulic signals into mechanical displacement, drive valve action, respond quickly, and adapt to industrial real-time control requirements.
Model and specifications
Basic model classification
Divided by torque and configuration:
31 LB FT Torque Series:
UG25+Actuator (P3, 31 LB FT): Suitable for medium to high load scenarios, part numbers such as 8528-027 (key drive, CW rotation, with oil level gauge on the right, manual), 8528-028 (serrated drive, CCW rotation, with oil level gauge on the right, manual).
25 LB FT Torque Series:
Adapt to the basic torque requirements of UG25+governor, part numbers such as 8528-303 (25 LB FT, key drive, 0.875 “pump, 0.625” terminal shaft, CW rotation, with oil level gauge on the right), 8528-305 (25 LB FT, key drive, 0.875 “pump, 0.625” terminal shaft, CW rotation, with oil level gauge on the left).
Core parameters:
Drive mode: Keyed Drive or Serrated Drive, compatible with different turbine shaft interfaces.
Rotation direction: clockwise (CW) or counterclockwise (CCW), to match the direction of the turbine shaft.
Structure and working characteristics
Mechanical Drive Design:
Adopting a hydraulic cylinder or mechanical lever structure, the driving force is provided by hydraulic oil or spring force to ensure the stability of valve adjustment.
compatibility:
Seamless integration with UG25+Governors forms a “governor actuator” closed-loop system, which is also compatible with other brands of speed control units.
Environmental adaptability:
Some models support harsh industrial environments, are resistant to vibration and high temperatures, and are suitable for scenarios such as power generation and chemical engineering.
Application scenarios
Steam turbine control:
The main steam valve is regulated in the power station to maintain the stability of turbine speed and ensure the constant power grid frequency.
Process industry:
When driving compressors and pumps in chemical plants, adjust steam input according to load changes to ensure process continuity.
Power drive system:
Drive fans, rolling mills and other equipment to adapt to the speed requirements under different working conditions.
Accessories and Maintenance
Governor matching:
It must be used in conjunction with UG25+Governors (such as 8528-122 to 8528-137) to ensure compatibility of control signals.
Spare parts and maintenance:
Spare parts such as sealing kits, drive shafts, springs, etc. (refer to Woodward product catalog), support regular maintenance and replacement, and reduce downtime risks.
monitoring system:
Can be connected to MicroNet or Flex500 platforms to remotely monitor actuator position and hydraulic status through GAP software.
Advantages and Characteristics
Reliability: Mature mechanical structure, redundant hydraulic system design, suitable for long-term continuous operation.
Adjustment accuracy: Fast response speed, precise displacement control, ensuring that the steam valve opening matches the governor signal.
Easy installation: Multiple installation methods are suitable for different turbine equipment, and on-site debugging is simple without the need for complex programming.
Core function: By adjusting the steam input to control the speed of the steam turbine, it can operate stably within a set range and is suitable for scenarios such as power generation and mechanical drive.
Working principle: Utilizing centrifugal force or electronic sensors to sense turbine speed, driving steam valves through mechanical or electro-hydraulic mechanisms to achieve closed-loop control.
Model and specifications
Basic model classification
Divided by output torque and configuration:
Standard type:
UG25+Governor (P3, 25 LB FT): Suitable for medium power steam turbines, part numbers such as 8528-122 (CW rotation, left with oil level gauge, no stop button), 8528-123 (CCW rotation, right with oil level gauge, no stop button), etc.
Different driving modes:
Serrated Drive: such as 8528-132 (CCW rotation, with oil level gauge on the left), 8528-133 (CW rotation, with oil level gauge on the right).
Keyed Drive: such as 8528-134 (CW rotation, with oil level gauge on the right), 8528-135 (CW rotation, with oil level gauge on the left).
Core parameters:
Output torque: 25 LB FT (approximately 34 N · m), suitable for small and medium-sized steam turbines.
Speed range: customized according to turbine model, commonly ranging from 3000-6000 rpm.
Structure and working characteristics
Mechanical design:
Adopting a centrifugal flying hammer structure, the centrifugal force of the flying hammer drives the hydraulic servo valve to adjust the opening of the steam valve when the speed changes.
Flexible configuration:
The speed set point and droop coefficient can be manually adjusted to adapt to single machine operation or load distribution with multiple machines in parallel.
compatibility:
Used in conjunction with Woodward UG25+actuators to form a “governor actuator” control chain, part number 8528-027 (actuator, 31 LB FT, key drive).
Application scenarios
Industrial power generation: Speed control of small steam generator units to ensure stable grid frequency.
Mechanical drive: drives equipment such as water pumps and compressors to maintain speed matching load requirements.
Process industry: Power control of steam turbines in chemical and pharmaceutical plants, suitable for frequent start stop conditions.
Accessories and Maintenance
Actuator matching:
UG25+actuators (such as 8528-027 to 8528-327), supporting different torques and installation methods.
Spare parts kit:
Spare parts such as seals, springs, drive shafts, etc., refer to the maintenance list in the Woodward product catalog.
monitoring system:
Can be connected to MicroNet or Flex500 platforms, and remotely monitor the status of the speed controller through GAP software.
Advantages and Characteristics
Reliability: Mature mechanical structure, wear-resistant, suitable for long-term continuous operation.
Cost effectiveness: High cost-effectiveness, suitable for small and medium-sized steam turbines, with low maintenance costs.
Usability: It can be manually adjusted on site without the need for complex programming, making it suitable for simple control systems.
Core function: Receive control signals from speed controllers (such as TG Turbine Governors), drive valves, throttle valves and other mechanisms through hydraulic or electric means, regulate the steam or fuel input of the turbine, and achieve speed control.
Working principle: The electrical signal is converted into mechanical displacement through an electro-hydraulic servo system, which drives the actuator to act with fast response speed and high control accuracy.
TGE17 series: higher torque design, compatible with the same speed range, part number such as:
TGE17, 2400 rpm (part number: 9904-113).
TGE17, 4000 rpm (part number: 9904-114).
TGE17, 6000 rpm (part number: 9904-115).
Core parameters:
Output torque: Depending on the model, adapt to the turbine power requirements to ensure the driving force for valve adjustment.
Response time: Quickly respond to governor signals and reduce speed fluctuations.
Structure and working characteristics
Electro hydraulic design:
Built in hydraulic cylinder and servo valve, control the flow of hydraulic oil through electrical signals, drive the piston rod to move linearly, and drive mechanical loads.
compatibility:
Seamless integration with turbine governors such as TG13 and TG17, forming a closed-loop control chain of “governor actuator”.
Protection and Certification:
Some models support ATEX certification and are suitable for Zone 2 hazardous areas. The structural design is vibration resistant and oil resistant.
Application scenarios
Industrial turbine control:
Adjust the steam valve and fuel valve of steam turbine and gas turbine to maintain stable speed.
Power drive system:
When driving equipment such as compressors, pumps, generators, etc., adjust the turbine output according to load changes.
In the field of energy and chemical engineering:
Ensure reliable operation of turbine equipment in power plants, oil pipelines, and refining facilities under different operating conditions.
Accessories and Maintenance
Sealing kit: used for replacing cylinder seals during maintenance to ensure that the hydraulic system is leak free (refer to Woodward spare parts catalog).
Hydraulic oil: It is recommended to use hydraulic oil that meets the specifications to maintain the performance of the actuator.
Monitoring and debugging:
Real time monitoring of actuator position and hydraulic status through Woodward MicroNet system or Flex500 platform, supporting remote debugging.
Advantages and Characteristics
High precision control: The electro-hydraulic servo system achieves millimeter level displacement control, adapting to precision adjustment requirements.
High reliability: Durable mechanical structure, redundant hydraulic system design, reducing the risk of downtime due to malfunctions.
Flexible adaptation: Multiple speed specifications cover different turbine models and support customized configuration.
