Woodward Cpc-dx User manual

[

Individual CPC-II Converter Replacement Procedure 26824

(Revision NEW)

Original Instructions

CPC-DX

Current to Pressure Converte

Dual Transfer Skid,

Individual CPC-II Converter Replacement Procedure

Manual 26824 CPC-II Unit Replacement Procedure

ii Woodward

General

Precautions

Read this entire manual and all other publications pertaining to the work to be

performed before installing, operating, or servicing this equipment.

Practice all plant and safety instructions and precautions.

Failure to follow instructions can cause personal injury and/or property damage.

Revisions

This publication may have been revised or updated since this copy was produced.

To verify that you have the latest revision, check manual

26455

, Customer

Publication Cross Reference and Revision Status & Distribution Restrictions, on

the publications page of the Woodward website:

www.woodward.com/publications

The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative

to get the latest copy.

Proper Use

Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or

property damage, including damage to the equipment. Any such unauthorized

modifications: (i) constitute "misuse" and/or "negligence" within the meaning of

the product warranty thereby excluding warranty coverage for any resulting

damage, and (ii) invalidate product certifications or listings.

Translated

Publications

If the cover of this publication states "Translation of the Original Instructions"

please note:

The original source of this publication may have been updated since this

translation was made. Be sure to check manual

26455

, Customer Publication

Cross Reference and Revision Status & Distribution Restrictions, to verify whether

this translation is up to date. Out-of-date translations are marked with . Always

compare with the original for technical specifications and for proper and safe

installation and operation procedures.

Revisions—Changes in this publication since the last revision are indicated

by a black line alongside the text.

Woodward reserves the right to update any portion of this publication at any time. Information

provided by Woodward is believed to be correct and reliable. However, no responsibility is

assumed by Woodward unless otherwise expressly undertaken.

Manual 26615

Manual 26824 CPC-II Unit Replacement Procedure

Woodward iii

Contents

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IX

CHAPTER 1. GENERAL INFORMATION...........................................................1

Definitions and used abbreviations ........................................................................1

List of Woodward Reference Literature..................................................................1

List of Woodward Required Software.....................................................................2

List of Required Hardware or Materials..................................................................2

Introduction.............................................................................................................3

CHAPTER 2. ONLINE CPC-II UNIT REPLACEMENT .........................................8

System preparation to unit replacement...............................................................10

CPC-II Unit disassembly from the CPC-DX Skid .................................................16

Electrical wires disassembly from removed CPC-unit (failed)..............................24

New CPC-II Unit hardware Installation procedure ...............................................29

New CPC-II unit software settings loading procedure..........................................36

CHAPTER 3. PRODUCT SERVICE OPTIONS..................................................48

Replacement Parts...............................................................................................49

Engineering Services............................................................................................49

Contacting Woodward’s Support Organization ....................................................49

Technical Assistance............................................................................................50

REVISION HISTORY....................................................................................51

Manual 26824 CPC-II Unit Replacement Procedure

iv Woodward

Illustrations and Tables

Figure 1-1. CPC-DX main components..................................................................3

Figure 1-2. CPC-DX Installation Drawing, Front view............................................4

Figure 1-3. CPC-DX Installation Drawing, Top view. .............................................4

Figure 1-4. CPC-DX Installation Drawing, customer interface view.......................5

Figure 1-5. CPC’s wiring diagram...........................................................................6

Figure 1-6. Electrical Terminal Box, wiring diagram...............................................7

Figure 2-1. Saving CPC-II Settings File (creating back-up)...................................9

Figure 2-2. Unit In Control verification using CPC-DX pressure gauges. ............10

Figure 2-3. Unit In Control verification using CPC-DX pressure gauges .............10

Figure 2-4. Unit In Control verification using CPC-DX pressure gauges .............11

Figure 2-5. Wiring Connections for Master Designation.......................................11

Figure 2-6. Power Supply Input Connections.......................................................12

Figure 2-7. Isolation valve OPEN / CLOSED lever position.................................13

Figure 2-8. Control Isolation valve CLOSED and locked-out with padlock..........13

Figure 2-9. Open/ Close markings on isolation locking plate...............................13

Figure 2-10. Supply Isolation valves CLOSED and locked-out with padlock.......14

Figure 2-11. CPC-DX Installation Drawing, Drain ports location..........................15

Figure 3-1 CPC-II voltage measurement and verification....................................18

Figure 3-2 TWIN - Terminals system handling.....................................................18

Figure 3-3 Replaced CPC-II wires disconnected inside Electrical Terminal box. 19

Figure 3-4. Unscrew a conduit nut from Electrical Terminal Box fitting (CCW

direction)..........................................................................................19

Figure 3-5. Lifting strap installation.......................................................................20

Figure 3-6. Lifting strap properly installed............................................................20

Figure 3-7. Lifting slug properly installed (CPC-II unit on the CPC-DX hydraulic

manifold)..........................................................................................20

Figure 3-8. Long socket wrench...........................................................................21

Figure 3-9. CPC-II mounting bolts view (bottom of the hydraulic manifold).........21

Figure 3-10. CPC-II mounting bolts unscrewing (CCW direction)........................22

Figure 3-11. Oil spillage from removed CPC-II unit..............................................22

Figure 3-12. Fitting with installed plastic plug.......................................................23

Figure 3-13. CPC-DX manifold with secured hydraulic passages after CPC-II unit

removal............................................................................................23

Figure 3-14. CPC-II unit removed from CPC-DX assembly.................................23

Figure 4-1. Loosening CPC-II cover retaining clamp (CCW direction)................24

Figure 4-2. Loosening CPC-II cover with bar......................................................24

Manual 26824 CPC-II Unit Replacement Procedure

Woodward v

Figure 4-3. CPC-II terminal blocks view (CPC-II cover removed).......................25

Figure 4-4. CPC-II terminal blocks 4 (four) mounting screws localization (CPC-II

cover removed)................................................................................25

Figure 4-5. Unscrewing 2 (two) CPC-II terminal blocks (CCW direction). ..........25

Figure 4-6. CPC-II wire blocks pulling out............................................................26

Figure 4-7. CPC-II cable ties cutout.....................................................................26

Figure 4-8. CPC-II Ground wire unscrewing. .......................................................27

Figure 4-9. CPC-II wires removal from terminal block. ........................................27

Figure 4-10. CPC-II conduit nut unscrewing. .......................................................27

Figure 4-11. CPC-II cable and conduit removal...................................................28

Figure 5-1. New sealing O-rings installed on hydraulic manifold.........................32

Figure 5-2. CPC-II wires inside Electrical Terminal Box ......................................33

Figure 5-3. Long socket wrench...........................................................................33

Figure 5-4. CPC-II mounting bolts view (bottom of the hydraulic manifold).........34

Figure 5-5. CPC-II mounting bolts tightening (CW direction)...............................34

Figure 5-6. CPC-II conduit nut tightening (CW direction).....................................34

Figure 5-6. CPC-II wires installation.....................................................................35

Figure 6-1. CPC-II with installed RS-232 connection cable.................................36

Figure 6-2. CPC-DX health link (orange switches) in run position and secured

with switching locks (white piece)....................................................36

Figure 6-3. CPC-DX with applied electrical power – green LED illuminate. ........37

Figure 6-4. Loading the Settings File to the CPC-II device..................................37

Figure 6-5. Basic parameters verification.............................................................38

Figure 6-6. Basic parameters verification.............................................................39

Figure 6-7. Manual Control Mode Enabled. .........................................................40

Figure 6-8. Isolation valve OPEN / CLOSED lever position.................................41

Figure 6-9. CPC-DX unit with all isolation valves in CLOSED position................42

Figure 6-10. Primary Gain adjustment .................................................................42

Figure 6-11. Performance verification on Performance Trend chart....................43

Figure 6-12. Performance verification on Performance Trend chart....................43

Figure 6-13. Manual Control Mode Disabled........................................................44

Figure 6-14. Pressure offset value verification between CPC-II units..................45

Figure 6-15. PC Service Tool communication disconnection with CPC-II...........46

Figure 6-16. RS-232 cable disconnection from CPC-II communication port. ......46

Figure 6-17. CPC-II cover tightening....................................................................47

Figure 6-18. CPC-II locking clamp tightening.......................................................47

Manual 26824 CPC-II Unit Replacement Procedure

vi Woodward

Warnings and Notices

Important Definitions

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

DANGER—Indicates a hazardous situation which, if not avoided, will result

in death or serious injury.

WARNING—Indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION—Indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

NOTICE—Indicates a hazard that could result in property damage only

(including damage to the control).

IMPORTANT—Designates an operating tip or maintenance suggestion.

On-Line Modification,

Reconfiguration or

Start-Up

The configuration and dynamic settings for CPC-II converters must

be precisely matched prior to engaging in concurrent “live” (on-line)

operation or “live” transition between converters on an end

application. Failure to precisely match and tune the configuration of

converters to the proper control range prior to engaging in a “live”

(on-line) replacement could result in turbine overspeed, loss of

control, plant shutdown, property damage and severe bodily injury,

including death.

Proper converter configuration and dynamic settings are unique to

specific end applications. It is the responsibility of the end user to

determine the specific configuration and dynamic settings necessary

for each specific converter application. This CPC-II Unit

Replacement Procedure is a guideline that is dependent upon user-

supplied configuration and dynamic setting data. Because of the

variability of end applications, Woodward makes no warranty,

express or implied, as to the suitability of this procedure for any

given “live” installation.

End users must develop site procedures suitable for specific end

applications, and ensure that personnel are fully trained on such

procedures prior to attempting to replace a converter on a “live”

running turbine. All safety protective systems (overspeed, over

temperature, overpressure, etc.) must be in proper operational

condition prior to the start of an on-line replacement procedure.

Personnel should be equipped with appropriate personal protective

equipment to minimize the potential for injury due to release of hot

hydraulic fluids, exposure to hot surfaces and/or moving parts

located in the area of control of the CPC-II.

Manual 26824 CPC-II Unit Replacement Procedure

Woodward vii

Overspeed /

Overtemperature /

Overpressure

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against

runaway or damage to the prime mover with possible personal injury,

loss of life, or property damage.

The overspeed shutdown device must be totally independent of the

prime mover control system. An overtemperature or overpressure

shutdown device may also be needed for safety, as appropriate.

Personal Protective

Equipment

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage. Always

wear the appropriate personal protective equipment (PPE) for the job

at hand. Equipment that should be considered includes but is not

limited to:

Eye Protection

Hearing Protection

Hard Hat

Gloves

Safety Boots

Respirator

Always read the proper Material Safety Data Sheet (MSDS) for any

working fluid(s) and comply with recommended safety equipment.

Start-up

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against

runaway or overspeed with possible personal injury, loss of life, or

property damage.

Overspeed /

Overpressure

Never close the drain line when supply pressure is present on the

CPC unit, otherwise the control output pressure can increase

suddenly and cannot be controlled by the input setpoint. This could

cause the turbine to overspeed. The supply pressure isolation valve

and the control pressure isolation valve should always be closed

prior to closing the drain line.

Never disconnect redundancy linkage between CPCs when both

units are powered.

Manual 26824 CPC-II Unit Replacement Procedure

viii Woodward

Only trained personnel are allowed to work on this device during

operation.

Battery Charging Device

To prevent damage to a control system that uses an alternator or

battery-charging device, make sure the charging device is turned off

before disconnecting the battery from the system.

It is recommended when performing the removal of a CPC-II

converter from the CPC-DX skid that the isolation valves be secured

with appropriate locks and tags, in accordance with the installation

sites safety procedures.

Manual 26824 CPC-II Unit Replacement Procedure

Woodward ix

Electrostatic Discharge Awareness

Electrostatic Precautions

Electronic controls contain static-sensitive parts.

Observe the following precautions to prevent damage to

these parts:

Discharge body static before handling the control

(with power to the control turned off, contact a

grounded surface and maintain contact while

handling the control).

Avoid all plastic, vinyl, and Styrofoam (except

antistatic versions) around printed circuit boards.

Do not touch the components or conductors on a

printed circuit board with your hands or with

conductive devices.

To prevent damage to electronic components caused by

improper handling, read and observe the precautions in

Woodward manual 82715, Guide for Handling and

Protection of Electronic Controls, Printed Circuit Boards,

and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing

made of synthetic materials. Wear cotton or cotton-blend materials as much as

possible because these do not store static electric charges as much as

synthetics.

2. Do not remove the printed circuit board (PCB) from the control cabinet

unless absolutely necessary. If you must remove the PCB from the control

cabinet, follow these precautions:

Do not touch any part of the PCB except the edges.

Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.

When replacing a PCB, keep the new PCB in the plastic antistatic

protective bag it comes in until you are ready to install it. Immediately after

removing the old PCB from the control cabinet, place it in the antistatic protective

bag.

Special Conditions for Safe Use

Wiring must be in accordance with North American Class I, Division 1 or 2, or

European Zone 1, Category 2 or Zone 2, Category 3 wiring methods as

applicable, and in accordance with the authority having jurisdiction.

Field wiring must be suitable for at least 85 °C and 10 °C above the maximum

fluid and ambient temperatures.

Manual 26824 CPC-II Unit Replacement Procedure

x Woodward

The CPC-DX must be used in an ambient temperature range from –40 to +85°C

(-40 to + 185⁰F).

The working fluid temperature must be in range +15 to +70°C (+59 to 158⁰F).

For proper operation and safety, ensure the safety ground is properly terminated

to a proper earth ground.

Compliance with the Machinery Directive 2006/42/EC noise measurement and

mitigation requirements is the responsibility of the manufacturer of the machinery

into which this product is incorporated.

Explosion Hazard—Do not connect or disconnect while

circuit is live unless area is known to be non-hazardous.

Substitution of components may impair suitability for

Class I, Division 1 or 2 or Zone 2 applications.

Risque d’explosion—Ne pas raccorder ni

débrancher tant que l’installation est sous

tension, sauf en cas l’ambiance est décidément

non dangereuse.

La substitution de composants peut rendre ce

matériel inacceptable pour les emplacements de

Classe I, applications Division 1 ou 2 ou Zone 2.

Manual 26824 CPC-II Unit Replacement Procedure

Woodward 1

Chapter 1.

General Information

Definitions and used abbreviations

CPC-DX – Current to Pressure Converter Dual Transfer Skid

CPC-II – Current to Pressure Converter

Master / Slave – The unit designated as the Master has yielded control to the

other unit (Slave) by link between the two CPC-IIs. The Unit designated as the

Master will take control during CPC-DX startup.

In Control – The unit actually controlling the position of the servo system

Not In Control – The unit acting as the backup to the In Control unit

DCS – Distributed Control System

CCW – Counter Clockwise

CW – Clockwise

List of Woodward Reference Literature

Manual 26455 –Customer Publication Cross Reference and

Revision Status & Distribution Restrictions

Product Manual 26615 – CPC-II Current-to-Pressure Converter with

Enhanced Dynamics

Reference Manual 26455 –

Woodward Energy Segment Customer

Publications:

Cross-Reference by Application

Revision Status & Distribution Restrictions

Product Manual 26758 – CPC-DX Current to Pressure Converter

Dual Transfer Skid

CPC-II Unit replacement

Procedure 26824 –

CPC-DX Current to Pressure Converter

Dual Transfer Skid, CPC-II Unit replacement

procedure

Manual 82715 – Guide for Handling and Protection of Electronic

Controls, Printed Circuit Boards, & Modules

Woodward software-download section website

(www.woodward.com/searchpublications).

Manual 26824 CPC-II Unit Replacement Procedure

2 Woodward

List of Woodward Required Software

9927-1885 – CPC-II PC Service Tool

Woodward software-download section website

(www.woodward.com/software).

List of Required Hardware or Materials

Torque wrench(es)

Installation required torques ranges, wrench end type and size

100.0 – 128.0 lbf-ft (136 – 174 Nm), Type: Open End; Size: 1 1/2 in

56.0 – 64.0 lbf-ft (76 – 87 Nm), Type: Open End; Size: 1 3/8 in

20.0 – 25.0 lbf-ft (27.0 – 34 Nm), Type Hex Head; Size 8 mm

Wrench(es)

Type: Open End; Size: 1 1/2 in

Type: Open End; Size: 1 3/8 in

Type Hex Head; Size 8 mm

Torque

Screwdriver(s)

Installation required torques ranges, screwdriver end type and size

5.3 – 7.0 lbf-in (0.6 – 0.8 Nm), Type: Slotted; Tip Size: 0.6 x 3.5 mm

35 – 39 lbf-in (3.9 - 4.4 Nm) Type: Slotted; Tip Size 6.5 X 1.2 mm

22.0 – 26.5 lbf-in (30 – 36 Nm) Type: Phillips; Tip Size: PH 3

Screwdriver(s)

Type: Slotted; Tip Size 3.5 X 0.6 mm

Type: Slotted; Tip Size 6.5 X 1.2 mm

Type: Type: Phillips; Tip Size: PH 3

Others

RS-232 cable (male connector- both ends)

Multimeter

Insulation tape

Cable ties (approx. 8 inch (200 mm) long

Oil absorbent pads / mats

Lifting strap (minimum capacity 100 lbs / 50 kg)

Cable Tie Removal Tool

PC computer with Woodward PC Service Tool installed

beam (approx. 40x100 mm, 1 meter long (2x4 inch; 3.3 ft. long))

Manual 26824 CPC-II Unit Replacement Procedure

Woodward 3

Introduction

The CPC-DX is a complete packaged and tested assembly which consists of two

Woodward current-to-pressure converters (CPC-II’s) connected together to a

single manifold with all interconnect piping, gauges and wiring included and

factory tested.

The two CPC-II’s are mounted to an anodized aluminum manifold containing the

transfer valve, isolation valves and pressure test points. The manifold and CPC-

II’s are mounted to a steel support frame.

Figure 1-1. CPC-DX main components.

The complete assembly is designed for use in a hazardous environment, see

Manual 26758 for more details.

Integrated oil pressure gauges allow users to visually verify which CPC-II is in

control and check the CPC-DX output oil header pressure level. Discrete output

relay contacts also can be connected to system indication (lights, lamps, plant

DCS) to assist with system health monitoring.

The CPC-DX uses a specially designed fast-switching hydraulic valve to ensure

minimal control switchover time and minimal system control pressure

disturbance. This special valve allows the pressure converter with the highest

pressure output to control the process, while blocking the output pressure of the

converter with the lower pressure output.

The CPC-DX ports are represented as SUPPLY for the supply oil port,

DRAIN CPC 1 and DRAIN CPC 2 for the drain (tank) lines, and CONTROL for

the CPC-DX control oil connection to the control system.

ELECTRICAL

TERMINAL BOX

CPC-II UNIT #2

SUPPORT FRAME

CONTROL ISOLATION VALVE

FOR CPC-II UNIT #2

SUPPLY ISOLATION VALVE

FOR CPC-II UNIT #2

PRESSURE GAUGE FOR CPC-II

UNIT #2

CPC-II UNIT #1

CONTROL PRESSURE

GAUGE

SUPPLY ISOLATION VALVE

FOR CPC-II UNIT #1

CONTROL ISOLATION

VALVE

FOR CPC-II UNIT #1

PRESSURE GAUGE FOR

CPC-II UNIT #1

HYDRAULIC MANIFOLD

ELECTRICAL CONDUIT

Manual 26824 CPC-II Unit Replacement Procedure

4 Woodward

Figure 1-2. CPC-DX Installation Drawing, Front view.

Figure 1-3. CPC-DX Installation Drawing, Top view.

Manual 26824 CPC-II Unit Replacement Procedure

Woodward 5

Figure 1-4. CPC-DX Installation Drawing, customer interface view.

Manual 26824 CPC-II Unit Replacement Procedure

6 Woodward

Figure 1-5. CPC’s wiring diagram

WIRE

J-B

WIRES TO J-BOX

-II Unit#

TERMINALS

-II Unit

TERMINALS

Manual 26824 CPC-II Unit Replacement Procedure

Woodward 7

WIRES FROM CPCs

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 15 20 20

16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34

4 5 6 7 8 9 10 11 12 13 14 21 22 23 24 25 26 27 28 29 30 31 32 33 34

1 2 3

SIGNALS FROM CPC-II

UNIT #1

SIGNALS FROM CPC-II

UNIT #2

CUSTOMER SIGNALS TO

CPC-II UNIT #2 CUSTOMER SIGNALS

TO CPC-II UNIT #1

15 20

16 17 18 19

TERMINAL #

Figure 1-6. Electrical Terminal Box, wiring diagram

Manual 26824 CPC-II Unit Replacement Procedure

8 Woodward

Chapter 2.

Online CPC-II unit replacement