Woodward ProTech TPS User manual
®
`
Product Manual 26710V1
(Revision D, 10/2016)
Original Instructions
ProTechTPS
Total Protection System
With Voted Inputs
8237-1602, -1603, -1604, -1605, -1606, -1607, -1608, -1609
Manual 26710 consists of 2 volumes (26710V1 & 26710V2).
Volume 1—Installation and Operation
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 Out-of-date translations are marked with .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 26710V1
Copyright © Woodward, Inc. 2013–2016
All Rights Reserved
Manual 26710V1 ProTechTPS Total Protection System
Woodward 1
Contents
WARNINGS AND NOTICES............................................................................5
ELECTROSTATIC DISCHARGE AWARENESS ..................................................6
REGULATORY COMPLIANCE ........................................................................7
ACRONYMS AND DEFINITIONS....................................................................10
CHAPTER 1. GENERAL INFORMATION.........................................................11
Description............................................................................................................11
Applications ..........................................................................................................12
CHAPTER 2. INSTALLATION........................................................................15
Introduction...........................................................................................................15
Unpacking.............................................................................................................15
System Installation Procedure..............................................................................15
Enclosures............................................................................................................16
Module Removal and Installation—Bulkhead Mount Package ............................19
Module Removal and Installation—Panel Mount Package ..................................27
Mounting Location Considerations .......................................................................28
Environmental Specifications ...............................................................................29
Power Supply Requirements................................................................................29
Shielded Wiring ....................................................................................................31
Control Wiring Guidelines.....................................................................................32
CHAPTER 3. FUNCTIONALITY .....................................................................50
Introduction...........................................................................................................50
Features................................................................................................................50
Product Models.....................................................................................................55
Inputs and Outputs ...............................................................................................62
Overspeed and Over-Acceleration Detection and Trip ........................................69
Start Logic ............................................................................................................71
Configurable Logic................................................................................................74
Test Routines .......................................................................................................75
Alarm, Trip, and Event Latches ............................................................................78
System Logs.........................................................................................................80
Response Time Performance...............................................................................82
CHAPTER 4. MODBUS COMMUNICATIONS...................................................86
Modbus Communications.....................................................................................86
Monitor Only .........................................................................................................86
Monitor and Control ..............................................................................................87
Modbus Communication.......................................................................................87
Port Adjustments ..................................................................................................87
ProTechTPS Parameter Addresses .....................................................................88
CHAPTER 5. TROUBLESHOOTING...............................................................95
I/O Troubleshooting ..............................................................................................96
Trip Indications .....................................................................................................99
Alarm Indications ................................................................................................101
CHAPTER 6. SAFETY MANAGEMENT ........................................................104
Product Variations Certified................................................................................104
Safe State...........................................................................................................104
SIL Specifications ...............................................................................................104
Failure Rate Data ...............................................................................................105
Response Time Data..........................................................................................105
Limitations ..........................................................................................................105
ProTechTPS Total Protection System Manual 26710V1
2 Woodward
Management of Functional Safety......................................................................105
Restrictions.........................................................................................................106
Competence of Personnel ..................................................................................106
Operation and Maintenance Practice .................................................................106
Installation and Site Acceptance Testing ...........................................................106
Functional Testing after Initial Installation ..........................................................106
Functional Testing after Changes.......................................................................106
Proof Testing (Functional Test) ..........................................................................107
CHAPTER 7. ASSET MANAGEMENT...........................................................108
Product Storage Recommendations...................................................................108
Refurbishment Period Recommendation ...........................................................108
CHAPTER 8. PRODUCT SUPPORT AND SERVICE OPTIONS .........................109
Product Support Options ....................................................................................109
Product Service Options.....................................................................................109
Returning Equipment for Repair.........................................................................110
Replacement Parts .............................................................................................111
Engineering Services..........................................................................................111
Contacting Woodward’s Support Organization ..................................................111
Technical Assistance..........................................................................................112
APPENDIX.MODBUS ETHERNET GATEWAY INFORMATION.........................113
Introduction.........................................................................................................113
B&B Electronics Setup .......................................................................................113
Lantronix Setup...................................................................................................116
REVISION HISTORY ..................................................................................121
DECLARATIONS .......................................................................................122
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Illustrations and Tables
Figure 1-1. Typical ProTechTPS Application (Voted Trip Relay Models) ............13
Figure 1-2. Typical ProTechTPS Application (Independent Trip Relay Models)..13
Figure 1-3. Typical Gas Turbine Application (Voted Trip Relay Models) .............14
Figure 1-4. Typical Safety PLC Application (Voted Trip Relay Models)...............14
Figure 2-1. Typical ProTechTPS Bulkhead Package—Front View ......................17
Figure 2-2a. Typical ProTechTPS Bulkhead Package—Front Door Open ..........17
Figure 2-2b. Bulkhead Schematic Showing Front Panel A Connection to Module
A and Front Panel C Connection to Module C—Top View..............17
Figure 2-3. Mounting Outline Diagram for Bulkhead-Mounted Models................18
Figure 2-4a. Typical ProTechTPS Panel Mount Package—Front View...............22
Figure 2-4b. Typical ProTechTPS Panel Mount Package—Rear View with
Cover ...............................................................................................22
Figure 2-4c. Typical ProTechTPS Panel Mount Package—Rear View without
Cover ...............................................................................................23
Figure 2-4d. Panel Mount Schematic Showing Front Panel A Connection to
Module A and Front Panel C Connection to Module C—Top View.24
Figure 2-5a. Mounting Outline Diagram for Panel-Mount Models........................24
Manual 26710V1 ProTechTPS Total Protection System
Woodward 3
Figure 2-5b. Mounting Outline Diagram for Panel-Mount Models........................25
Figure 2-5c. Panel Cutout Diagram for Panel-Mount Models ..............................26
Figure 2-6. Screw Connection Terminal Block.....................................................32
Figure 2-7. Inside View of ProTechTPS ...............................................................34
Figure 2-8. ProTechTPS Control Wiring Diagram................................................35
Figure 2-9. Trip Module – Included within Voted Trip Relay Units Only ..............36
Figure 2-10a. Power Supply Field Wiring Routing & Stress Relief Diagram........36
Figure 2-10b. Configurable I/O Wiring Routing & Stress Relief Diagram ............37
Figure 2-10c. Relay Output Field Wiring Routing & Stress Relief Diagram .........37
Figure 2-11a. Example MPU (Passive Magnetic Pickup Unit) Wiring..................38
Figure 2-11b. Example Proximity Probe (Active Magnetic Pickup Unit) Wiring
(Internal Power) ...............................................................................39
Figure 2-11c. Example Proximity Probe (Active Magnetic Pickup Unit) Wiring
(External Power, Non-preferred) .....................................................39
Figure 2-11d. Example Eddy Current Probe (Active Magnetic Pickup Unit)
Wiring...............................................................................................39
Figure 2-12a. Example Standard Discrete Input Wiring (Internal Power Option) 40
Figure 2-12b. Example Standard Discrete Input Wiring (External Power
Option) .............................................................................................40
Figure 2-13a. Example Configurable Input Wiring—Discrete Input (Internal Power
Option) .............................................................................................41
Figure 2-13b. Example Configurable Input Wiring—Discrete Input (External
Power Option)..................................................................................42
Figure 2-14. Example Configurable Input Wiring—Analog Input .........................43
Figure 2-15. Example Analog Output Wiring........................................................43
Figure 2-16a. Example Trip Relay Output Wiring ................................................44
Figure 2-16b. Example Trip Relay Wiring (per Module) (Independent Trip Relay)
(Internal Supply) ..............................................................................44
Figure 2-16c. Example Trip Relay Wiring (per Module) (Independent Trip Relay)
(External Supply) .............................................................................45
Figure 2-16d. Example Trip Relay Wiring (Voted Trip Relay Models) .................45
Figure 2-16e. Example Programmable Relay Wiring (Internal Supply) ...............46
Figure 2-16f. Example Programmable Relay Wiring (External Supply) ...............46
Figure 2-17. Power Supply Relationship Diagram ...............................................48
Figure 2-18a. Serial Port Interface Diagram—RS-232.........................................48
Figure 2-18b. Serial Com Port Interface Diagram—RS-485................................49
Figure 2-19. Service Tool Cable/Interface Diagram.............................................49
Figure 3-1. Module Diagram with Speed Redundancy Manager Configured ......52
Figure 3-2. Module Diagram without Speed Redundancy Manager Configured .53
Figure 3-3. Basic Functional Overview of Independent Trip Relay Models .........56
Figure 3-4. Functional Diagram of single ProTechTPS module with Independent
Trip Relay Outputs...........................................................................56
Figure 3-5. Example TMR Trip Block Assembly Interface ...................................57
Figure 3-6. Basic Functional Overview of Voted Trip Relay Models....................58
Figure 3-7. Functional Diagram of Single ProTechTPS Module with Voted Trip
Relay Outputs..................................................................................59
Figure 3-8. Simplex Trip Block Assembly.............................................................60
Figure 3-9. Dual Redundant Trip Block Assembly ...............................................61
Figure 3-10. Discrete Input Example....................................................................66
Figure 3-11. Analog Input Example......................................................................66
Figure 3-12. Programmable Relay Output Diagram.............................................68
Figure 3-13. Over-Acceleration Enabling Diagram ..............................................69
Figure 3-14. Start Logic Diagram .........................................................................72
Figure 3-15. Speed Fail Trip Diagram..................................................................73
Figure 3-16. Speed Fail Timeout Trip Diagram....................................................73
Figure 3-17. Total System Response Time Based on Sensed Frequency Level
for Independent Trip Relay Models when Speed Redundancy
Manager Function is not Configured ...............................................83
ProTechTPS Total Protection System Manual 26710V1
4 Woodward
Figure 3-18. Total System Response Time Based on Sensed Frequency Level
for Independent Trip Relay Models when Speed Redundancy
Manager Function is Configured .....................................................83
Figure 3-19. Total System Response Time Based on Sensed Frequency Level
for 2oo3 Voted Trip Relay Models when Speed Redundancy
Manager Function is not Configured ...............................................84
Figure 3-20. Total System Response Time Based on Sensed Frequency Level
for 2oo3 Voted Trip Relay Models when Speed Redundancy
Manager Function is Configured .....................................................84
Figure 3-21. Response Time Definition................................................................85
Table 1-1. Available ProTechTPS Models ...........................................................12
Table 2-1. Input Specifications .............................................................................29
Table 2-2. High Voltage Input Specifications .......................................................30
Table 2-3. Low Voltage Input Specifications ........................................................30
Table 2-4. Configurable Input Power Supply Specifications ................................30
Table 2-5. Relay Output Power Supply Specifications.........................................30
Table 3-1a. Independent Trip Relay Specifications..............................................57
Table 3-1b. Voted Trip Relay Specifications ........................................................62
Table 3-2. General I/O Specifications ..................................................................63
Table 3-3a. Passive Probe Specifications............................................................63
Table 3-3b. Active Probe Specifications...............................................................64
Table 3-4. Dedicated Discrete Input Specifications..............................................65
Table 3-5. Configurable Input Specifications........................................................67
Table 3-6. Programmable Relay Output Specifications .......................................68
Table 3-7. Analog Output Specifications ..............................................................68
Table 4-1. Serial Port Specifications ....................................................................86
Table 4-2. Supported Modbus Function Codes....................................................87
Table 4-3. Modbus Serial Communication Port Settings .....................................88
Table 4-4. Boolean Write Addresses (Code 05)...................................................89
Table 4-5. Boolean Read Addresses (Code 02) ..................................................90
Table 4-6. Analog Read Addresses (Code 04) ....................................................94
Table 5-1. I/O Troubleshooting.............................................................................98
Table 5-2. Trip Indications ..................................................................................100
Table 5-3. Alarm Indications...............................................................................103
Table 6-1. Trip Relay Safe State Configuration..................................................104
Table 6-2. SIL Specifications..............................................................................105
Table 6-3. Failure Rate.......................................................................................105
Manual 26710V1 ProTechTPS Total Protection System
Woodward 5
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.
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.
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.
ProTechTPS Total Protection System Manual 26710V1
6 Woodward
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.
Manual 26710V1 ProTechTPS Total Protection System
Woodward 7
Regulatory Compliance
European Compliance for CE Marking
EMC Directive: Declared to Directive 2014/30/EU of the European Parliament
and of the Council of 26 February 2014 on the harmonization
of the laws of the Member States relating to electromagnetic
compatibility (EMC)
Low Voltage Directive: Directive 2014/35/EU on the harmonisation of the laws of the
Member States relating to the making available on the market
of electrical equipment designed for use within certain voltage
limits
ATEX – Potentially
Explosive Atmospheres
Directive:
Directive 2014/34/EU on the harmonisation of the laws of the
Member States relating to equipment and protective systems
intended for use in potentially explosive atmospheres
Zone 2, Category 3, Group II G, Ex nA IIC T4 X
Other European Compliance
Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
RoHS Directive: Exempt from 2002/95/EC of the European Parliament and of
the Council of 27 January 2003 on the restriction of the use of
certain hazardous substances in electrical and electronic
equipment. Exempt per Annex IA of Directive 2002/95/EC
referring to "monitoring and control instruments" within the
meaning of Category 9.
WEEE Directive: Exempt/Compliant as a component with 2002/96/EC of the
European Parliament and of the Council of 27 January 2003
on waste electrical and electronic equipment (WEEE)
EuP Directive: Exempt/Compliant from 2009/125/EC of the European
Parliament and of the Council of 21 October 2009 establishing
a framework for the setting of ecodesign requirements for
energy-related products
North American Compliance
CSA: Certified for Class I, Division 2, Groups A, B, C, and D, T4 at
60 °C Ambient for use in the United States and Canada.
Certificate 160584-2217246
Other International Compliance
C-Tick:Declared to Australian Radiocommunications Act of 1992 and
the New New Zealand Radiocommunications Act of 1989.
TÜV: TÜV certified for SIL-3 per IEC 61508 Parts 1-7, Functional
Safety of Electrical / Electronic / Programmable Electronic
Safety Related Systems
ProTechTPS Total Protection System Manual 26710V1
8 Woodward
Other Compliance
Gas Corrosion: IEC60068-2-60:1995 Part 2.60 Methods 1 and 4
(conformal coating)
Machinery
Protection: API670, API612, & API-611 compliant
Special Conditions for Safe Use
This Equipment is Suitable for use in Class I, Division 2, Groups A, B, C, D or
Non Hazardous Locations Only.
This equipment is suitable for use in European Zone 2, Group IIC environments
or Non Hazardous Locations Only.
Wiring must be in accordance with North American Class I, Division 2, or
European Zone 2, Category 3 wiring methods as applicable, and in accordance
with the authority having jurisdiction.
A fixed wiring installation is required and a switch or circuit breaker shall be
included in the building installation that is in close proximity to the equipment and
within easy reach of the operator and that is clearly marked as the disconnecting
device for the equipment. The switch or circuit breaker shall not interrupt the
protective earth conductor.
Protective Earth Grounding is required by the input PE terminal.
Field wiring must be rated at least 85 °C for operating ambient temperatures
expected to exceed 50 °C.
For European ATEX compliance on panel mount models, this equipment must be
installed in an area providing adequate protection against the entry of dust or
water. A minimum ingress protection rating of IP54 is required for the enclosure.
Personnel must discharge their electrostatic build up to the cabinet ground point
or use an ESD strap prior to touching the ProTech interior surfaces if the
engine/turbine is operational. The unit is designed to have one of three modules
be removed during operation; however ESD to the remaining operational
modules may cause signal deviations. Signal deviations due to direct ESD may
be large enough to result in the operational module to trip, shutting down the
engine since two modules are in a tripped mode. Signal deviations were noted
when ESD testing was done to the Speed pins, the IRIG-B pins, Service Port
pins, and RS-232/RS-485 Modbus communications port pins.
Do not remove module unless module is de-energized and all wire
connections have been disconnected
The Service Port (RS-232 communication) is not designed to remain connected
during operation except at servicing & programming intervals. It should not have
a cable connected to it other than during programming & servicing.
This device contains a single cell primary battery. This battery is not to be
charged and is not customer replaceable.
Control is suitable for installation in pollution degree 2 environments.
Manual 26710V1 ProTechTPS Total Protection System
Woodward 9
Measurement inputs are classified as permanently connected IEC
measurement Category I and are designed to safely withstand
occasional transient overvoltages up to 1260 Vpk. To avoid the
danger of electric shock, do not use these inputs to make
measurements within measurement categories II, III, or IV.
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 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 2 ou Zone 2.
Safety Symbols
Both direct and alternating current
Alternating current
Direct current
Caution, risk of electrical shock
Caution, refer to accompanying documents
Protective conductor terminal
Frame or chassis terminal
ProTechTPS Total Protection System Manual 26710V1
10 Woodward
Acronyms and Definitions
2oo3 2-out-of-3
Block Identifier The identifier used for each logic block for configuration
purposes (Chapter 9)
CAN Controller Area Network
DC Diagnostic Coverage
DCS Distributed Control System
Module Functionality contained within one of the three identical
sections
MPU Magnetic Pick-up
PC Personal Computer or laptop with Windows operating
system
PCT Programming and Configuration Tool
PFD Probability of Failure on Demand
PFH Probability of dangerous Failure per Hour
PLC Programmable Logic Controller
PROX Proximity Probe
RTU Remote Terminal Unit
Settings-File A file that contains the configuration settings loaded with the
ProTech Service Tool (.wset).
TPS Total Protection System
Manual 26710V1 ProTechTPS Total Protection System
Woodward 11
Chapter 1.
General Information
Description
The ProTechTPS (Total Protection System) is an overspeed safety device
designed to safely shut down steam, gas, and hydro turbines of all sizes upon
sensing an overspeed or over-acceleration event. This device accurately
monitors turbine rotor speed and acceleration via active or passive MPUs
(magnetic pickups) and issues a shutdown command to the turbine’s trip valve(s)
or corresponding trip system. In addition, it has programmable logic and
configurable inputs and outputs to address other safety critical functions.
The ProTechTPS consists of three independent modules whose trip outputs,
dependent upon model used, are either independent or voted in a 2-out-of-3
configuration. An isolated bus architecture is used to share all inputs and latch
status information between the three modules. Optionally each ProTechTPS
module can be configured to use only its sensed “local” input signals or the voted
result of all three modules’ signals in its event latch decision logic. Optionally
module trip and alarm latch statuses can also be configured to be shared with all
other modules.
The ProTechTPS includes Overspeed and Over-acceleration functions as well as
time stamped Alarm, and Trip logs. Indication that a test was active at the time of
the event is provided on all logs and first-out indications are provided for Trip and
Event logs. Trip response time monitoring and logging is also built into the
ProTechTPS.
The ProTechTPS provides various pre-defined and user-definable test features
including automated periodic tests.
There are several ways to interface with the ProTechTPS. The front panel allows
the user to view current values, and to perform certain configuration and test
functions. All of the features and most of the information available from the front
panel is also accessible via the Modbus interface. Finally, the Programming and
Configuration Tool (PCT) is software that is run on a PC to define configurable
inputs and programmable logic, download log files, and manage settings files.
This product is designed for critical applications and when installed correctly
meets API-670, API-612, API-611, and IEC61508 (SIL-3) standards.
ProTechTPS Total Protection System Manual 26710V1
12 Woodward
The following table shows the various hardware configurations (mounting
options, power supplies, and trip relay options) available:
PartNumberDescription
8237‐1602ProTechTPS,BulkheadMount,HV/LV,IndepRelay,VotedInput
8237‐1603ProTechTPS,BulkheadMount,HV/HV,IndepRelay,VotedInput
8237‐1604ProTechTPS,BulkheadMount,HV/LV,VotedRelay,VotedInput
8237‐1605ProTechTPS,BulkheadMount,HV/HV,VotedRelay,VotedInput
8237‐1606ProTechTPS,PanelMount,HV/LV,IndepRelay,VotedInput
8237‐1607ProTechTPS,PanelMount,HV/HV,IndepRelay,VotedInput
8237‐1608ProTechTPS,PanelMount,HV/LV,VotedRelay,VotedInput
8237‐1609ProTechTPS,PanelMount,HV/HV,VotedRelay,VotedInput
5437‐1128SpareModulefor8237‐1604,1608
5437‐1129SpareModulefor8237‐1605,‐1609
5437‐1130SpareModulefor8237‐1602,‐1606
5437‐1131SpareModulefor8237‐1603,‐1607
Table 1-1. Available ProTechTPS Models
Applications
The ProTechTPS is designed to be applied as a safety system for any size
steam, gas, or hydro turbine, reciprocating engine, or plant process equipment.
The device's fast response time (8–26 milliseconds depending on model and
configuration), 0.5 to 32 000 rpm speed range, and integrated overspeed and
acceleration detection/protection functionality, make it ideal for applications on
critical low-speed or high-speed rotating motors, compressor, turbines or
engines. This standalone safety device accepts 10 discrete or analog inputs per
module (30 total) and one speed (MPU or PROX) input (3 total). Each
ProTechTPS module provides 3 programmable relay outputs (9 total) and an
analog speed output (3 total) in addition to the trip relay outputs. Configurable
logic allows the customization required to meet specific application requirements
to ensure plant protection.
The ProTechTPS utilizes a triple modular redundant architecture and 2-out-of-3
voting logic to accurately determine unsafe conditions and ensure that no single-
point failure will affect system reliability or availability. With this design, system
failures (switches, transducers, modules) are detected, annunciated, and allowed
to be repaired or replaced while the monitored system continues to operate
on-line.
Alternatively, this standalone safety device can be configured to protect any plant
system or device, and report the system’s device’s status to the plant DCS. The
ProTechTPS control’s versatile inputs, outputs, programming environment, and
communications make it ideal as a safety protection device for use in small
applications that could possibly reach an unsafe state or condition and that must
communicate directly to the plant DCS. The ProTechTPS is designed for critical
applications where both personnel safety and unit availability (operation run time)
is a concern or necessity.
The ProTechTPS is certified as an IEC61508 SIL-3 (Safety Integrity Level 3)
safety device and can be applied as a stand-alone IEC61508-based device or
within an IEC61511-based plant safety system.
Manual 26710V1 ProTechTPS Total Protection System
Woodward 13
Figure 1-1. Typical ProTechTPS Application (Voted Trip Relay Models)
Figure 1-2. Typical ProTechTPS Application (Independent Trip Relay Models)
Trip Valve
Inlet Steam
Header
3 Redundant Speed Signals
Control
Actuator
Generator
or
Compressor
or
Pump
ProTechTPS
TS
TS
TS PS
Analog or Discrete Signals
Plant DCS
LS
Trip Valve
Monitor Signal
Drain
Trip Header
Serial
Com.
TS
Trip Valve
Inlet Steam
Header
3 Redundant Speed Signals
Control
Actuator
Generator
or
Compressor
or
Pump
ProTechTPS
TS
TS
TS
TS PS
Analog or Discrete Signals
LS
Trip Valve
Monitor Signal
PS 203 Trip
Block
TS
TS
PS
PS
Drain
Trip Header
Plant DCS
Serial
Com.
ProTechTPS Total Protection System Manual 26710V1
14 Woodward
Figure 1-3. Typical Gas Turbine Application (Voted Trip Relay Models)
Figure 1-4. Typical Safety PLC Application (Voted Trip Relay Models)
Trip Valve
Gas
Redundant Speed Signals
Control
Generator
or
Compressor
or
Pump
ProTechTPS
TS PS
Analog or Discrete Signals
Plant DCS
Serial
ModBus
TS
Trip Valve
Closed Indication
PS
Control
Valve
Manual 26710V1 ProTechTPS Total Protection System
Woodward 15
Chapter 2.
Installation
Introduction
This chapter provides instructions on how to mount and connect the ProTechTPS
overspeed safety device into a system. Hardware dimensions, ratings, and
jumper configurations are given to allow a customer to mount, wire, and
configure the ProTechTPS package to a specific application.
Electrical ratings, wiring requirements, and options are provided to allow a
customer to fully install the ProTechTPS into a new or existing application.
Unpacking
Before opening the shipping packaging, inspect the shipping container for
damage and document any damage.
Be careful when opening & removing the shipping container. You may retain the
original shipping container for unit storage or return shipping for suggested
refurbishment. (See Asset Management chapter for storage details.)
Be careful when unpacking the ProTechTPS system from the shipping container.
The precautions called out in the Electrostatic Discharge Awareness section
should be followed during unpacking, handling, installation and operation during
maintenance.
Once removed from the shipping packaging, check the device for signs of
damage such as a bent or dented case and loose or broken parts. If damage is
found, notify the shipper immediately.
System Installation Procedure
1. Review system manual to gain a complete understanding of the
ProTechTPS system.
2. Create a site specific wiring diagram by referencing included wiring
diagrams & constraints then perform mechanical and electrical installation
following this chapter’s instructions.
3. Visual inspection
a. Verify that all mounting hardware is tightened and that no wires are
pinched.
b. Verify that no wiring insulation is nicked or abraded.
c. Verify that all terminal blocks are installed and terminal screws are
tight. (Follow control wiring instructions for all terminal blocks.)
d. If used, verify that speed sensors have been correctly installed, and
have the correct clearance from the speed gear (adjust if necessary).
See manual 82510, Magnetic Pickups and Proximity Switches for
Electronic Governors.
4. Apply power to each module (one at a time), and verify that each module
boots up and its front panel screen displays turbine speed.
5. If no special programming logic is used skip to step 11.
6. If special programming logic is required install ProTechTPS programming
and configuration tool (PCT) from provided PCT Installation CD on to the
desired computer and create system application program.
ProTechTPS Total Protection System Manual 26710V1
16 Woodward
7. Once the system application program is complete connect an extension (i.e.
straight-through, not null-modem) RS-232 serial cable from the respective
computer to any module’s (A, B, C) service port, and download the program
into the module.
8. From the respective module’s front panel copy downloaded program to
other unit modules.
9. From each module’s front panel, verify that the correct program has been
installed in each module by comparing unit CRC codes.
10. From each module’s front panel, enter the configuration mode and verify
that each of the overspeed and over-acceleration settings are correct.
11. Enter the configuration mode and configure all settings to the specific
application’s requirements.
12. Perform a full system checkout by verifying all system trips, alarms, and test
routines function correctly before starting the machinery/system.
13. When ready, start the turbine/machinery following the equipment
manufacturer’s recommended starting procedure.
Enclosures
Module identification is always from left to right, with module A on
the left, module B in the center, and module C on the right. This
applies to either the bulkhead-mount versions with the front cover
open, or the panel-mount versions with the back cover removed.
Depending on the model purchased, the ProTechTPS has either a bulkhead-
mounted or a panel-mounted enclosure package.
The bulkhead-mounted enclosure models are designed to be mounted on a wall
or skid next to the turbine and are rated for IP56-based environments. With these
models, field wiring access is through gland plates located on the bottom of the
enclosure. Figures 2-1, 2-2, and 2-3 display the bulkhead mounted ProTechTPS
model’s physical layout and mounting pattern.
The ProTechTPS panel-mounted enclosure models are designed for installation
within a control room panel or cabinet, and by itself, it cannot be bulkhead
mounted. Once installed within an IP56 rated panel or cabinet, the ProTechTPS
panel-mounted models are rated for IP56-based environments. A gasket is
attached to the rear side of the package’s bezel to properly seal the ProTechTPS
control’s face-plate & around the mounting studs to a panel. With these models,
field wiring access is located on the ProTechTPS control’s back side, and a back
cover is included to protect wiring terminals after installation. Figures 2-4 and 2-5
display the Panel-Mount ProTechTPS model’s layout and mounting pattern.
Manual 26710V1 ProTechTPS Total Protection System
Woodward 17
Figure 2-1. Typical ProTechTPS Bulkhead Package—Front View
Figure 2-2a. Typical ProTechTPS Bulkhead Package—Front Door Open
Figure 2-2b. Bulkhead Schematic Showing Front Panel A Connection to Module
A and Front Panel C Connection to Module C—Top View
ProTechTPS Total Protection System Manual 26710V1
18 Woodward
Figure 2-3. Mounting Outline Diagram for Bulkhead-Mounted Models
Table of contents
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