Description

WOODWARD SPM-D11 8440-1706

• Speed Control: Precisely adjusts the speed of prime movers (such as steam turbines) to ensure the unit operates stably at the set speed (e.g., grid synchronization or single-unit constant speed).
• Load Distribution: Automatically distributes active loads during parallel operation of multiple units to maintain grid frequency stability.
• Process Parameter Control: Supports closed-loop control of process parameters such as pressure, temperature, and flow (e.g., steam pressure regulation, fuel flow control).
• Protection and Interlocking: Built-in logic for overspeed protection, load limiting, fault shutdown, etc., to ensure equipment safety.

Features

1. High-Precision Control Capability
• Digital Algorithm: Uses advanced PID (Proportional-Integral-Derivative) control algorithm with self-tuning parameters, fast response (adjustment cycle up to millisecond level), and control accuracy of ±0.1% of rated speed.
• Multi-Mode Switching: Supports seamless switching between speed control mode, power control mode, and process parameter control mode to adapt to different working conditions (e.g., unit startup, grid-connected load carrying, isolated network operation).
2. Flexible Input/Output Configuration
• Analog Output: 4–20 mA or 0–10 V DC for driving actuators (e.g., electro-hydraulic servo valves, frequency converters).
• Digital Output: Relay contacts (e.g., alarm, shutdown signals), supporting dry contacts or solid-state relay outputs.
• PWM Output: Optional pulse width modulation signal for controlling solenoid valves or stepper motors.
• Speed Signal: Supports reluctance or photoelectric speed sensors (frequency input, e.g., 0–10 kHz).
• Process Signal: Analog input (e.g., 4–20 mA, 0–10 V DC) for collecting parameters such as pressure and temperature.
• Digital Input: Supports switch signals (e.g., start/stop commands, mode switching signals).
• Input Types:
• Output Types:
3. Communication and Integration Capability
• Industrial Communication Protocols: Supports Modbus RTU/ASCII, Ethernet/IP, PROFINET, etc., for real-time data interaction with DCS (Distributed Control System), PLC, or host computers (e.g., Woodward Insight software).
• Modular Expansion: Can be combined with other SPM series modules (e.g., I/O modules, synchronization modules) via backplane buses to build complex control systems.
4. High-Reliability Design
• Hardware Redundancy: Supports dual-power redundancy and disturbance-free switching between master and standby controllers (requires redundant modules) to ensure continuous operation in critical scenarios.
• Anti-Interference Capability: Uses industrial-grade components, complies with IEC 61000 electromagnetic compatibility (EMC) standards, and adapts to strong electromagnetic interference environments (e.g., power plants, petrochemical sites).
• Fault Self-Diagnosis: Built-in watchdog timer, power monitoring, sensor disconnection detection, etc., with real-time feedback of fault codes via LED indicators or communication interfaces.
5. Convenient Operation and Maintenance
• User-Friendly Interface: Supports local button operation or parameter configuration, trend monitoring, and fault analysis via Woodward Compass software.
• Online Debugging Function: Allows modification of control parameters without interrupting operation and real-time observation of adjustment effects.
• Data Recording and Playback: Built-in historical data storage supports pre-fault/post-fault waveform capture for accident analysis.
6. Wide-Range Adaptability
• Power Compatibility: Supports 24 V DC or 100–240 V AC input, adapting to different industrial power environments.
• Environmental Tolerance: Operating temperature range of -40°C to +70°C, protection level up to IP20 (standard), with optional higher protection models for harsh environments (e.g., dust, humid scenarios).

Technical Parameters

1. Power Supply Parameters
• Operating voltage: 8 to 32 VDC.
• Maximum power consumption: 18W.
2. Measurement Parameters
• Voltage AC input: 120 VAC/240 VAC true RMS, accuracy class 0.1.
• Current AC input: 5 A true RMS, accuracy class 0.5.
3. Input/Output Parameters
• Discrete input: 18 to 40 VDC, 10 mA.
• Relay driver output: 18 to 40 VDC at 200 mA sink.
• Analog input: 4 to 20 mA/1 to 5 VDC.
• Analog output: Speed deviation ±2.5 VDC, 0.5 to 4.5 VDC, 1 to 5 VDC across 243 ohms, or 500 Hz PWM; voltage bias up to ±9 VDC, as low as ±3 VDC.
4. Environmental Parameters
• Operating temperature: -40°C to 70°C.
• Storage temperature: -55°C to 105°C.
• Environmental humidity: 95% at 38°C.
5. Other Parameters
• Dimensions: 264×461×58 mm.
• Housing: Backplate-mounted metal plate housing.

Working Principle

1. Sensor Signal Acquisition
   The module receives three types of key sensor signals from the steam turbine:
• Input channels support hardware filtering (e.g., noise filtering, frequency screening) to reduce electromagnetic interference (EMI) and signal distortion.
• Redundant input design (e.g., three-way speed signals) provides multi-source data for subsequent voting logic.
• Speed Sensor (Reluctance or Photoelectric): Measures rotor speed to determine if it exceeds the trip threshold (e.g., 110%–112% of rated speed).
• Axial Displacement Sensor (Eddy Current Sensor): Monitors rotor axial displacement to prevent rubbing between moving and stationary parts.
• Vibration Sensor (Velocity or Accelerometer): Collects shaft vibration or casing vibration signals to evaluate mechanical health.
• Signal Processing Features:
2. 2oo3 Voting Logic (Core Protection Mechanism)
   The SPM-D11 achieves high-reliability protection based on a triple-redundancy architecture:
• Example: If two of the three speed signals exceed the overspeed threshold (e.g., 3300 rpm), the module outputs a trip signal.
• Signal Redundancy: The same physical quantity (e.g., speed) is collected by three independent sensors and input into three independent channels of the module.
• Logical Voting: The module compares three-way signals in real time. When at least two signals exceed the preset threshold, it is determined as a real fault, triggering a trip command.
• Advantage: Avoids single-sensor failure or single-channel false triggering, complying with the SIL-level system requirements of the IEC 61508 functional safety standard.
3. Trip Output and Execution
   When the voting logic determines a fault, the module executes protection actions through the following methods:
• Trip output channels support fail-safe design, i.e., default trip triggering when the module loses power to ensure safety.
• Relay contact capacity is typically 5A/250V AC, meeting industrial-grade load requirements.
• Relay Output: Drives trip solenoids or shutdown mechanisms to quickly cut off steam turbine steam intake for emergency shutdown.
• Digital Signal Output: Sends fault alarm signals to the DCS (Distributed Control System) or host computer and records event timestamps (accuracy up to millisecond level).
• Hardware Features:
4. Self-Test and Diagnostic Functions
   The module has a built-in self-diagnostic program that continuously monitors its hardware status, including:
• If internal faults or sensor anomalies are detected, the module alarms via LED indicators (e.g., FAIL, ALARM) and can report to the control system via communication interfaces.
• Supports online hot-swapping, allowing module replacement without affecting other parts of the system.
• Channel Consistency Check: Compares differences in three-way input signals to identify sensor or channel faults (e.g., signal disconnection, drift).
• Memory Check: Detects the integrity of firmware and configuration data (e.g., CRC check).
• Temperature and Power Monitoring: Monitors internal module temperature and supply voltage to prevent misoperation caused by overheating or power anomalies.
• Fault Response:
5. Communication and Configuration
   The SPM-D11 module connects to the main control system (Mark VIe) via redundant communication buses (e.g., Woodward's SSI bus or industrial standard buses like Profibus):
• Parameter Configuration: Sets protection thresholds, voting logic, delay times, and other parameters via host computer software (e.g., Woodward ControlST).
• Data Interaction: Uploads sensor data, module status, and fault records in real time, supporting historical data tracing and trend analysis.

Typical Application Scenarios

• Overspeed Protection (OPC, Overspeed Protection Control): Prevents steam turbine speed runaway due to sudden load drop.
• Axial Displacement Protection (LVDT Monitoring): Avoids rotor axial movement caused by thrust bearing wear.
• Vibration Protection (API 670 Standard): Triggers alarms or shutdowns based on vibration amplitude (e.g., RMS or peak values).
• Redundant Trip System: Combined with other protection modules (e.g., SPM-D10) to form a 2oo3 redundant architecture, meeting high-availability requirements.

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