Application

The Peak200 controller is designed to operate small single valve, or single valve rack industrial steam turbines. This cost effective steam turbine controller includes specifically designed algorithms and logic to start, stop, control, and protect small industrial steam turbines or turbo expanders driving compressors, pumps, or industrial fans.  

The Peak200 control’s unique PID structure makes it ideal for applications where it is required to control steam plant parameters like turbine speed, turbine load, turbine inlet header pressure, turbine exhaust header pressure, pump flow, or compressor discharge, or suction pressure.

The control’s special PID-to-PID logic allows stable control during normal turbine operation and bumpless control mode transfers during plant upsets, minimizing process over or undershoot conditions. The Peak200 controller senses turbine speed via passive speed probes and controls the steam turbine through an actuator connected to the turbine inlet steam valve(s). Peak 200 includes Woodward's patented adaptive PID controller that allows users automatic calculation for optimum dynamic gains at their individual plant system.

Designed to function as a plant DCS node the Peak200 controller can be configured to interface with the plant DCS via hardwired inputs/output signals or serial or Ethernet communications. With the capability to monitor and control all turbine and driven equipment based functions (i.e. bearing temperatures, vibration levels, control oil levels, etc.) the Peak200 controller is ideal for use as a cost-effective turbine control/protection as well as plant DCS monitoring node. 

Alternatively the Peak200 can be configured to accept a remote turbine speed/load demand from the plant DCS via a 4-20mA signal, discrete raise/lower commands, or Ethernet or Serial Modbus communications.

The Peak200 control also includes a special “Cascade” PID control function that can be optionally configured and used to control any system process, related to or affected by turbine speed or load. Typically, this controller is configured and used to control turbine inlet header pressure, turbine exhaust header pressure, pump flow, or compressor discharge, or suction pressure. The Cascade PID compares a 4–20 mA process signal with an internal set point to directly position the Speed PID controller’s setpoint, thus changing turbine speed or load until the process signal and set point match. By cascading these two PIDs in this fashion, bumpless transfers can be performed as well as turbine min/max. 

Ethernet and serial communications allow users to easily connect the Peak200 in to plant or process control system. All controller inputs, outputs, and statuses can be monitored and all start/stop or enable/disable commands can be given through industry standard Modbus TCP. The Peak200 uses SNTP (synchronized network time protocol) over Ethernet to allow users to synchronize the Peak200’s real-time clock to the plant distributed control system.

Description

The Peak200 control is available in either bulkhead models designed to be mounted on a wall or skid near the turbine or panel-mount models designed to be installed within a standard panel or cabinet door. The product is designed to meet NEMA 4x corrosion resistance tests and has an ingress protection rating of IP56, protecting it against dust and water jets.

The control’s front panel serves as both a programming station and operator control panel (OCP). This user-friendly front panel allows engineers to access and program the unit to the specific plant’s requirements, and plant operators to easily start/stop the turbine and enable/disable any control mode.

Password security is used to protect all unit program mode settings. The controller’s 5” graphical display allows operators to view actual and setpoint values from the same screen, simplifying turbine operation.

Turbine interface input and output wiring access is located on the controller’s lower back panel. Un-pluggable terminal blocks allow for easy system installation, troubleshooting, and replacement. Optionally users can increase the number of inputs and outputs signals to/from the Peak200 control by connecting LinkNet-HT distributed I/O nodes to the controller’s CAN communication ports and configuring the Peak200 control to use the connected distribute inputs and outputs. The following additional I/O signals can be connected to the Peak200 control via CAN communications:  

• (8) 4-20mA input channels and 2 4-20mA output channels (via 1 LinkNet-HT AIO module) 

• (8) RTD signals (via 1 LinkNet-HT RTD module) 

• (16) Discrete Inputs (via 1 LinkNet-HT DI module) 

• (16) Relay output drivers (via 1 LinkNet-HT DO module)

Designed for steam turbine control, the Peak200 control includes two PID controllers (Speed & Cascade) multiple startup routines (manual, automatic, remote control), and multiple protection functions (overspeed, critical speed range, etc.) which can be configured by a user depending on the specific turbine application’s requirements. Users can configure the Peak200’s different PID controllers, start routines, and protection levels themselves without the need for a special control engineer. Once configured, the Peak200 performs a configuration check routine to ensure that the programmer did not make any basic configuration mistakes.

Optionally users can utilize Woodward’s RemoteView software program with the Peak200 to function as a remote operator control panel and or engineering station. This software program once loaded onto a remote computer or touch panel, allows the user the following additional functionality:

• Perform the identical Peak200 front panel display functions (monitor, operate, tune, and configure) on the respective computer or touch panel. 

 • Full function free for 2 hours 

 • Licensable for continuous GUI operation 

 • Password based login level security is utilized allowing function management for RemoteView applications Refer to Woodward product specification B03424 for additional information. The Peak200 includes a suite of service tools to allow users to perform the following functions: 

 • Upload configuration settings files from the Peak200 to save on another device 

 • Download configuration settings files to the Peak200 

 • View real-time or saved trend files

Peak200 – Bulkhead Mount, LV 8200-1500

Peak200 – Bulkhead Mount, HV 8200-1501

Peak200 – Bulkhead Mount, LV, ATEX Zone 2 8200-1502

Peak200 – Front Panel Mount, LV 8200-1503

Peak200 – Front Panel Mount, HV 8200-1504

Peak200 – Front Panel Mount, LV, ATEX Zone 2 8200-1505

Peak200 – Bulkhead Mount, HV, Class1 Div2 Haz. Loc. Compliant 8200-1508

Peak200 – Front Panel Mount, HV, Class1 Div2 Haz. Loc. Compliant *Documentation: Product Spec: 03438, Manual: 35051 8200-1509