Woodward 9905-005 | SPM-A Synchronizer for Industrial Turbine Speed Control

Description

Product Overview

Key Technical Specifications

• Input Signals:
  • Accepts speed reference signals from Woodward 2301A controllers (e.g., 4-20 mA or 0-10 V DC).
  • Supports 50/60 Hz frequency input (compatible with global power systems).
• Output Signals:
  • Generates synchronized speed control signals to turbine actuators (e.g., fuel valves, steam inlet valves) for precise speed adjustment.
  • Relay outputs for alarm indication (e.g., speed mismatch, synchronization failure).
• Communication:
  • Compatible with Woodward 2301A series controllers via RS-232/RS-485 ports.
  • Supports Modbus RTU protocol for integration with plant DCS/SCADA systems.
• Environmental Ratings:
  • Operating temperature: -40°C to +70°C (-40°F to +158°F) (withstands extreme industrial environments).
  • Storage temperature: -40°C to +85°C (-40°F to +185°F).
  • Humidity: 95% non-condensing (up to 48 hours at 20-55°C).
• Physical Characteristics:
  • Dimensions: ~15.2 cm × 5.1 cm × 20.3 cm (6 in × 2 in × 8 in) (compact for cabinet installation).
  • Weight: ~0.7 kg (1.5 lbs) (lightweight for easy handling during maintenance).
• Certifications: CE, UL (compliant with international industrial safety standards).

  

  WOODWARD 9905-005

Field Application & Problem Solved

1. Precision Speed Synchronization:
   The module uses phase-locked loop (PLL) algorithms​ to match the turbine’s rotational speed to the grid frequency (e.g., 50 Hz for Europe, 60 Hz for North America) with an accuracy of ±0.1%. This stability is critical for power plants, where frequency deviations can trigger grid penalties or equipment shutdowns.
2. Seamless Integration with Woodward Ecosystem:
   The 9905-005 is designed to work with Woodward 2301A series controllers, allowing for unified control of speed, load, and process variables. This integration eliminates the need for custom interfaces, reducing installation time and cost.
3. Fault Protection & Diagnostics:
   The module’s speed mismatch alarm​ alerts operators to deviations beyond acceptable limits, enabling prompt corrective action. For instance, a refinery using the 9905-005 reduced turbine downtime by 20% due to faster fault detection and resolution.

• Power Generation: Synchronizing steam turbines/gas turbines with the grid in coal-fired, gas-fired, or nuclear power plants.
• Oil & Gas: Matching compressor turbine speed to pipeline pressure requirements in upstream/downstream operations.
• Industrial Manufacturing: Synchronizing turbine-driven generators with process loads in chemical plants or paper mills.

Installation & Maintenance Pitfalls (Expert Tips)

1. Verify Compatibility with 2301A Controllers:
   • Always confirm that the 9905-005 is paired with a compatible Woodward 2301A series controller (e.g., 2301A-1, 2301A-2). Mismatched components can lead to communication errors—we once resolved a synchronization failure by replacing an incompatible controller with a 2301A-1.
2. Calibrate Speed Reference Signals:
   • Calibrate the speed reference signals (e.g., 4-20 mA) from the 2301A controller to the 9905-005 using a precision multimeter. Incorrect calibration can lead to speed mismatch—we fixed a recurring frequency deviation in a power plant by adjusting the reference signal gain.
3. Test Synchronization Logic:
   • After installation, test the synchronization logic using a signal generator to simulate grid frequency changes. Verify that the 9905-005 adjusts the turbine speed within ±0.1% of the setpoint—this step prevents issues like “out-of-sync” shutdowns during operation.
4. Perform Regular Maintenance:
   • Inspect the 9905-005 annually for signs of wear (e.g., cracked casings, loose connections). Clean the module’s connectors with isopropyl alcohol to remove dirt and debris, which can cause communication failures.

     

     WOODWARD 9905-005

Technical Deep Dive & Overview

1. Signal Reception:
   The 9905-005 receives speed reference signals from the Woodward 2301A controller (e.g., 4-20 mA for speed setpoint) and grid frequency signals from a phase-locked loop (PLL) circuit.
2. Processing & Synchronization:
   The microprocessor processes the input signals using PLL algorithms​ to calculate the required turbine speed. The adaptive nature of the algorithm allows it to adjust gains dynamically based on operating conditions (e.g., load changes, temperature variations).
3. Output & Actuation:
   The 9905-005 sends synchronized speed control signals to the turbine’s actuators (e.g., fuel valves) to adjust the fuel flow, thereby regulating the turbine’s speed. Simultaneously, it monitors for fault conditions (e.g., speed mismatch) and triggers alarms if necessary.
4. Communication & Monitoring:
   The 9905-005 transmits real-time data (speed, frequency, fault status) to the plant DCS via Modbus RTU. Operators can use 2301A Explorer​ software to visualize trends, adjust setpoints, and perform diagnostics remotely.

Final Notes