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Actuators and control systems for turbomachinery

Turbomachinery control systems, turbine actuators and control systems, actuation and controls

Voith actuators and control systems ensure that gas turbines, steam turbines and compressors can be operated more efficiently, safely and reliably.


Our product portfolio includes:

  • ​Actuators
  • Turbomachinery control systems
  • Turbomachinery protection systems
  • Engineering, service and retrofitting

We not only offer components, but also complete solutions – hardware and software, all from one source. An advantage that simplifies a lot and lowers costs. The control system of turbines and compressors runs smoothly.

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I/H converter

DSG I/H converter

    Current to pressure converter (CPC), electro-hydraulic converter with electro-hydraulic actuator control for steam turbines and other applications

    I/H converter type DSG, CPC current to pressure converter
    Voith electro-hydraulic I/H converters are current-to-pressure converters (CPC), which adjust hydraulic positioning cylinders by means of a pilot valve. The positioning cylinders operate a valve that controls the mass flow needed to drive machinery. Voith I/H converters (CPC) ensure very precise and high dynamic control of the mass flow. I/H converters change a constant input pressure into a variable output pressure. A standard 0/4 – 20 mA signal specifies the output pressure. The major components of the I/H converter are a hydraulic unit and a force-controlled electromagnet.

    The I/H converter features a simple and compact design which ensures reliable operation. The Mean Time Between Failure (MTBF) for a Voith I/H converter is over 600 years. Your equipment will run for an exceptionally long period of time without unplanned interuptions. Additionally, the I/H converter (CPC) is also available in a redundant design (hot redundancy): DSM I/H Converter Module (DX-CPC).

    Technical data

    Flow rate Up to 140 l/min [37 gpm] at 1 bar [14.5 psi] differential pressure
    Input pressure Up to 70 bar [1,015 psi]
    Maximum output pressure range 0 – 35 bar [0 – 508 psi]
    MTBF (Mean Time Between Failure) 600 years (calculated in accordance to MIL‑HDBK‑217 and Siemens SN 29500,
    actual MTBF evaluations from installed products show even higher values)
    Supply voltage 24 VDC
    Current consumption 1.0 A (3.0 A for t < 1 s)
    Input signal 0/4 – 20 mA
    Fail-safe operation Fail-safe position through output pressure
    Explosion proof rating (optional)
    • ATEX (II 2G IIC T4, Ta = -30 to +60°C)
    • CSA C/US (Class 1, Div. 1, 2, Group B, C, D, Temp. Code T4)
    • IECEx (Ex db llC T4, Ta = -30 to +60°C)
    • KOSHA (Ex db llC T4, Ta = -30 to +60°C)
    • Others on request
    Protection class IP 65
    Safety integrity level SIL 2

     

    Advantages and benefits

    • The Mean Time Between Failure (MTBF) is over 600 years. Your equipment operates very reliably. Productivity increases and the costs associated with lost production remain low
    • Voith I/H converters are insensitive to contaminated pilot oil. Turbine lubricating oil is suitable as the operating fluid. One oil supply system for both lubricating and pilot oil suffices. Maintenance is simple, which helps you lower operating costs
    • Very good control response, almost no hysteresis, and a resolution better than 0.1% ensures very fast and accurate control. You benefit from having a stable process with high product quality
    • Reduced system integration costs facilitated as connections are industry-standard which means the I/H converter can be easily integrated into your equipment. Standard adapter plates are available to allow the I/H converter to interface with systems designed for Woodward CPC and CPC‑II converters
    • The output pressure range can be adjusted easily on-site by means of pot­enti­ometers. This allows you to adjust the output pressure for the application quickly and without any delays
    • For use in hazardous areas, we offer certified explosion proof I/H converters 

    Typical fields of use

    • Control valve operation for:
      • Steam turbines
      • Gas turbines
      • Compressors
    • Retrofit of mechanic-hydraulic valve controls
    • Upgrade of systems with Woodward CPC or CPC-II converters

    Product enquiry

    Technical information

    Design

    DSG I/H Converter – Design

    Functionality

    With the aid of a controller, a force FMag is generated in a 24-V DC magnet. This magnetic force is proportional to the 0/4 – 20 mA input signal. The desired output pressure range is set by means of two potentiometers X0 and X1. The combination of electronic control, measurement of the magnetic flux, the physical design of the magnet and hydraulic pilot control results in an almost hysteresis-free, dynamic functional unit. The control magnet applies the force FMag to the control piston. This force acts in opposition to the hydraulic force FHydr, which results from the pressure at the A port applied to the face of the control piston (pressure balance). As a consequence of this control, the exactly required pressure and oil flow needed to position the steam or fuel valve are always available in the output line A of the I/H converter.

    DSG I/H Converter – Functionality

    Control schematic

    DSG I/H Converter – Control schematic

    Selection table

    Type Maximum
    input
    pressure [bar]
    Control range
    of the output
    pressure [bar]
    Flow rate [l/min] at
    1 bar differential pressure
    P > A A > T
    DSG -B03XXX 40 0 – 3 30 30
    DSG -B05XXX 40 0 – 5 30 30
    DSG -B05X48 20 0 – 5 100 140
    DSG -B07XXX 40 1 – 7 30 30
    DSG -B10XXX 40 0 – 10 30 30
    DSG -B30XXX 70 0 – 30 30 30
    DSG -B35XXX 70 10 – 35 30 30

     

    I/H converter module

    DSM I/H converter module

      Redundant I/H converter, redundant current to pressure converter assembly with a dual/duplex current to pressure converter (DX-CPC)

      I/H converter module type DSM and redundant current to pressure converter CPC-DX
      Voith I/H converter modules are redundant dual/duplex current-to-pressure converters (DX-CPC), which adjust hydraulic positioning cylinders by means of a pilot valve in processes requiring high availability. The positioning cylinders operate a valve that controls the mass flow needed to drive machinery. The pressure control module provides very precise and high dynamic control of the mass flow. An I/H converter module consists of two I/H converters connected in parallel. The I/H converter changes a constant input pressure into a variable output pressure. A stand­ard 4 – 20 mA signal specifies the output pressure. The major components of the I/H converter are a hydraulic unit and a force-controlled electromagnet.


      Every I/H converter has a monitoring circuit that detects a malfunction of the con­verter. In the event of converter malfunction, a hydraulic maximum selection circuitry ensures that the other I/H converter assumes control automatically. This makes it possible to remedy the cause of the malfunction during operation. The Mean Time Between Failure (MTBF) for a Voith pressure control module is over 20,000 years. Your equipment runs for an exceptionally long period of time without unplanned downtime thereby ensuring increased productivity.

      Technical data

      Flow rate

      Up to 30 l/min [7.9 gpm] at 1 bar [14.5 psi] differential pressure

      Input pressure

      Up to 40 bar [580 psi]

      Maximum output pressure range 0 – 10 bar [0 – 145 psi]
      MTBF (Mean Time Between Failure) 20,000 years (calculated in accordance to MIL‑HDBK‑217 and Siemens SN 29500,
      actual MTBF evaluations from installed products show even higher values)
      Supply voltage

      24 VDC

      Current consumption 1.0 A (3.0 A for t < 1 s)
      Input signal 4 – 20 mA
      Fail-safe operation

      Fail-safe position through output pressure

      Redundancy Hot redundancy
      Ambient temperature -20 to +80°C [-4 to +176°F] (standard version, not rated for use in potentially explosive areas)

      Explosion proof rating (optional)

      • ATEX (II 2G IIC T4, Ta = -20 to +60°C)
      • CSA C/US (Class 1, Div. 1, 2, Group B, C, D, Temp. Code T4)
      • Others on request
      Protection class IP 65
      Safety integrity level SIL 2

       

      Advantages and benefits

      • Thanks to the redundancy provided by the two I/H converters, the Mean Time Between Failure (MTBF) for the pressure control module is over 20,000 years. Your equipment operates with maximum availability. Productivity increases and the costs associated with lost production remain low
      • It is possible to replace a faulty I/H converter during operation. You avoid un­planned downtime and their associated high costs
      • Voith pressure control modules are not sensitive to contaminated pilot oil. Turbine lubricating oil is suitable as the operating fluid. One oil supply system for both lubricating and pilot oil suffices. Maintenance is simple, which helps you lower operating costs
      • Exceptional control response, almost no hysteresis, and a resolution better than 0.1% ensures very fast and accurate control. You benefit from having a stable process with high product quality
      • Low system integration costs as connections are industry-standard which means the I/H converter module can be easily integrated into your equipment. Standard adapter plates are available to allow the I/H converter module to interface with systems designed for Woodward CPC and CPC‑II converters 
      • The output pressure range can be adjusted easily on-site by means of potenti­ometer which allows you to adjust the output pressure for the application quickly and without any delays
      • For use in hazardous areas, we offer certified explosion proof pressure control modules 

      Typical fields of use

      • Control valve operations within:
        • Steam turbines
        • Gas turbines
        • Compressors
      • Retrofit of mechanic-hydraulic valve controls         
      • Upgrade of systems with Voith DSG I/H converters
      • Upgrade of systems with partially or non-redundant
        Woodward CPC or CPC‑II converters

      Product enquiry

      Technical information

      Functionality

      DSM I/H Converter - Functionality

      The pressure control module employs a two-channel design. A redundant control system provides the two input signals w1 and w2 for the two I/H converters. The hydraulic output pressure pA1 or pA2 from each of the I/H converters is proportional to the applied 4 – 20 mA input signal. The two pressures are connected to a hydraulic maximum selection circuitry, which then selects the higher pressure. Lowering the setpoint from the control system gradually during operation allows additional built-in pressure sensors to provide continuous monitoring of the hy­draulic function. This pressure variation makes it possible to diagnose each of the subsystems while operating. Each I/H converter has an electronic monitoring circuit that detects a malfunction of the converter. If one I/H converter fails, a hydraulic maximum selection circuitry ensures that the other converter assumes control automatically.

      Should a malfunction occur during operation, the fault can be remedied as the output pressure from the correctly operating I/H converter can be used to identify the cause.

      Control schematic

      DSM I/H Converter - Control schematic

      Selection table

      Type Maximum
      input
      pressure [bar]
      Output
      pressure
      range [bar]
      Flow rate [l/min] at
      1 bar differential pressure
      P > A A > T
      DSM -B05XXX

      40

      0 – 5 30 30
      DSM -B10XXX 40 0 – 10 30 30

       

      Way valve

      WSR way valve

        E/H converter, a servo directional control valve with servo-proportional valve

        Way Valve Type WSR, Proportional Directional Control Valve

        Voith electro-hydraulic way valves are servo directional control valves. They have integrated position control and provide direct control of hydraulic positioning cylinders. The positioning cylinders operate a valve that controls the mass flow needed to drive machinery. Voith way valves ensure very precise and high dynamic control of the mass flow.

        Working in conjunction with a hydraulic cylinder, the way valve converts a constant input pressure into a variable stroke. A standard 4 – 20 mA signal specifies the stroke of the positioning cylinder. The major components of a way valve are a 3/3 way hy­draulic unit for single-acting positioning cylinders or a 4/3 way hydraulic unit for double-acting positioning cylinders and a force-controlled electromagnet with integrated position control. No additional pilot valve is needed when using a Voith electrohydraulic way valve.

        The way valve features a simple, compact design which ensures consistent and reliable operation. The Mean Time Between Failures (MTBF) of a Voith way valve is  over 180 years. Your equipment therefore runs for an exceptionally long period of time ensuring continued productivity.

        The way valve is available in two redundant designs:

        • T-WSR tandem way valve (dual coil way valve) with redundant control magnets (warm redundancy)
        • WSM way valve module (hot redundancy)

        Technical data

        Flow rate Up to 600 l/min [158 gpm] at 1 bar [14.5 psi] differential pressure
        Input pressure Up to 200 bar [2,900 psi]
        MTBF (Mean Time Between Failure) 180 years (calculated in accordance to MIL‑HDBK‑217 and Siemens SN 29500,
        actual MTBF evaluations from installed products show even higher values)
        Supply voltage

        24 VDC

        Current consumption

        1.0 A (3.0 A for t < 1 s)

        Input signal 4 – 20 mA
        Communication (optional)
        • EtherNet/IP
        • Sercos
        • EtherCAT
        • VARAN
        • PROFINET
        • Others on request
        Fail-safe operation Internal return spring
        Ambient temperature -20 to +80°C [-4 to +176°F] (standard version, not rated for use in potentially explosive areas)
        Explosion proof rating (optional)
        • ATEX (II 2G IIC T4, Ta = -30 to +60°C)
        • CSA C/US (Class 1, Div. 1, 2, Group B, C, D, Temp. Code T4)
        • IECEx (Ex db llC T4, Ta = -30 to +60°C)
        • KOSHA (Ex db llC T4, Ta = -30 to +60°C)
        • Others on request
        Protection class IP 65
        Safety integrity level SIL 2

         

        Advantages and benefits

        • The Mean Time Between Failure (MTBF) is over 180 years. Your equipment operates reliably, productivity increases and the costs associated with lost production remain low
        • Voith way valves aren't sensitive to contaminated pilot oil. Turbine lubricating oil is suitable as the operating fluid. One oil supply system for both lubricating and pilot oil suffices and keeps maintenance simple, which helps you lower operating costs
        • During load rejection, the way valve shifts the control valve to the partial-load position very rapidly (approx. 300 ms). When a shutdown command is received, the way valve shifts the control valve to the safe position (open or closed) rapidly (approx. 300 ms) which ensures high equipment availability 
        • The way valve incorporates fast and exact position control. Very good control response, almost no hysteresis, and a resolution better than 0.1% will ensure very fast and accurate control. High product quality together with a stable process is one of many benefits experienced
        • Lower intergration costs are experienced as connections are industry-standard with the way valve mounting easily to your equipment
        • The stroke and control gain can be adjusted easily on-site by means of potenti­ometer which allows you to adjust both quantities to the application quickly and without any delay
        • For use in hazardous areas, we offer explosion certified proof way valves 

        Typical fields of use

        • Control valve operation of:
          • Steam turbines
          • Gas turbines
          • Compressors
        • Retrofit of mechanic-hydraulic valve controls
        • Upgrade of systems with Voith DSG I/H converters
        • Upgrade of systems with Woodward CPC or CPC-II converters

        Product enquiry

        Technical information

        Design

        3/3 & 4/3 Way Valve WSR – Design

        Functionality

        3/3 & 4/3 Way Valve WSR – Functionality

        On the basis of the control deviation (setpoint w – actual value x) and the control gain settings KPU and KPD, a command variable UMAG is generated for the magnetic force's controller. The magnetic force FMag is determined indirectly by measuring the magnetic flux with the aid of UHall and sent to the controller.
        FMag acts on the control piston in the hydraulic pilot valve via the plunger. The piston is forced against the control spring until the stroke-dependent spring force FF equals FMag. This provides a volume flow that varies in direction and magnitude, and produces stroke s in an externally mounted hydraulic cylinder.
        A position sensor determines the actual position and feeds an electrical signal back to the position controller. This ensures closed-loop control of hydraulic cylinder positioning.

        Control schematic

        3/3 & 4/3 Way Valve WSR – Control schematic

        Selection table

        Selection table for 3/3 way valves

        Type Maximum 
        input
        pressure [bar]
        Flow rate [l/min] at
        1 bar differential pressure
        P > A A > T
        WSR-C25XXX 200 17 62
        WSR-C45XXX up to 40 22 75
        WSR-C60XXX up to 40 35 150
        WSR-E60XXX up to 40 30 350
        WSR-E80XXX up to 40 50 600
        WSR-K120XXX 25 600 600

         

        Selection table for 4/3 way valves

        Type Maximum
        input
        pressure [bar]
        Flow rate [l/min] at
        1 bar differential pressure
        P > A/B A/B > T
        WSR-D16XXX up to 160 14 14
        WSR-D24XXX 40 40 40
        WSR-D45XXX up to 40 80 80
        WSR-D60XXX 40 130 130
        WSR-D80XXX 25 180 180
        WSR-K120XXX 25 600 600

         

        Tandem way valve

        T-WSR tandem way valve

          Servo directional control valve with redundant control magnet unit (dual coil system)

          Tandem Way Valve Type T-WSR
          Voith tandem way valves are way valves with two control magnets (dual coil system). The control magnets are connected in a series creating a redundant unit. Tandem way valves with integrated position control adjust hydraulic positioning cy­lin­ders by means of a pilot valve in processes requiring high availability. The positioning cy­linders operate a valve that controls the mass flow needed to drive machinery. Voith tandem way valves ensure very precise and high dynamic control of the mass flow.

          A tandem way valve consists of two electromagnets with integrated position control connected in series and a 3/3 way hydraulic unit for single-acting positioning cylinders or a 4/3 way hydraulic unit for double acting positioning cylinders. Working in con­junc­tion with a hydraulic cylinder, the way valve converts a constant input pressure into a variable stroke.

          A standard 4 – 20 mA signal specifies the stroke of the positioning cylinder. An additional pilot valve is no longer needed with the Voith electrohydraulic tandem way valve.

          In the event of a malfunction, control magnet 1 switches off automatically and control magnet 2 switches on. The switching logic is located in the external control system and monitors the control magnets. The Mean Time Between Failure (MTBF) for a Voith tandem way valve is over 360 years which guarantees your equipment will run for an extensive period of time without unplanned down­time..

          Technical data

          Flow rate

          Up to 600 l/min [158 gpm] at 1 bar [14.5 psi] differential pressure

          Input pressure Up to 200 bar
          MTBF (Mean Time Between Failure) 360 years (calculated in accordance to MIL‑HDBK‑217 and Siemens SN 29500,
          actual MTBF evaluations from installed products show even higher values)
          Supply voltage

          24 VDC

          Current consumption 1.0 A (3.0 A for t < 1 s)
          Input signal 4 – 20 mA
          Communication (optional)
          • Sercos
          • EtherCAT
          • EtherNet/IP
          • VARAN
          • PROFINET
          • Others on request
          Fail-safe operation Internal return spring
          Redundancy 2 Control magnets (warm redundancy)
          Ambient temperature -20 to +80°C [-4 to +176°F] (standard version,
          not rated for use in potentially explosive areas)
          Explosion proof rating (optional)
          • ATEX (II 2G IIC T4, Ta = -30 to +60°C)
          • CSA C/US (Class 1, Div. 1, 2, Group B, C, D, Temp. Code T4)
          • IECEx (Ex db llC T4, Ta = -30 to +60°C)
          • KOSHA (Ex db llC T4, Ta = -30 to +60°C)
          • Others on request
          Protection class

          IP 65

          Safety integrity level SIL 2 (on request)

           

          Advantages and benefits

          • Thanks to the redundancy provided by the two way valve magnets, the Mean Time Between Failure (MTBF) for the tandem way valve is over 360 years. Your equipment operates with maximum availability, productivity increases and the costs associated with lost production remain low
          • Voith tandem way valves are not sensitive to contaminated pilot oil. Turbine lubricating oil is suitable as the operating fluid and a common oil supply system for both lubricating and pilot oil suffices. Maintenance is simple, which helps keep operating costs low
          • During load rejection, the way valve shifts the control valve to the partial-load position rapidly (approx. 300 ms). When a shutdown command is received, the way valve shifts the control valve to the safe position (open or closed) almost immediately (approx. 300 ms) which ensures high availability of your equipment
          • The way valve incorporates fast and exact position control. Exceptional control response, almost no hysteresis, and a resolution better than 0.1% ensures very fast and accurate control. You benefit from a stable processcombined with exceptional product quality
          • The tandem way valve mounts to your equipment easily which reduces integration costs
          • The stroke and positioning function can be adjusted easily on-site by means of potentiometers which
            allows you to adjust the stroke to the application quickly and without any delays
          • For use in hazardous areas, we offer certified explosion proof tandem way valves

          Typical fields of use

          • Control valve for:
            • Steam turbines
            • Gas turbines
            • Compressors
          • Retrofit of mechanic-hydraulic valve controls
          • Upgrade of systems with Voith DSG I/H converters or
            WSR way valves
          • Upgrade of systems with partially or
            non-redundant Woodward CPC or CPC-II converters

          Product enquiry

          Technical information

          Functionality

          3/3 Tandem Way Valve T-WSR – Function

          A redundant control system provides the two setpoints w1 and w2 in the form of standard 4 – 20 mA signals for the two control magnets. A separate position sensor (x1in and x2in) is connected to each control magnet. The armature of control magnet 1 acts through control magnet 2 to move the control piston of the hydraulic pilot valve. If control magnet 1 is energized, control magnet 2 is de-energized, but powered. In the event of a malfunction, control magnet 1 is
          de-energized and control magnet 2 is energized via setpoint w2 with a brief delay ("warm redundancy"). The switching logic is located in the external control system and monitors the control magnets (position sensor displays x1out and x2out). The switching logic also generates the switching signals.

          Control schematic

          Control schematic for a 3/3 T-WSR tandem way valve

          3/3 Tandem Way Valve T-WSR – Schematic

          Control schematic for a 4/3 T-WSR tandem way valve

          4/3 Tandem Way Valve T-WSR – Schematic

          Way valve module

          WSM way valve module

            Redundant way valve with redundant servo directional control valve

            Voith way valve modules are redundant servo directional control valves. They have integrated position controls and provide direct control of hydraulic positioning cylinders in processes re­quiring high availability. The positioning cylinders operate a valve that controls the mass flow needed to drive ma­chin­ery. Voith way valves ensure very pre­cise and highly dynamic control of the mass flow.

            A way valve module consists of two way valves that are connected parallel to one another. Working in conjunction with a hydraulic cylinder, the way valve converts a constant input pres­sure into a variable stroke. A standard 4 – 20 mA signal specifies the stroke of the pos­itioning cylinder. The major components of the way valves are a
            3/3 way hy­draulic unit for single-acting positioning cylinders and a force-controlled electro­magnet with integrated position control.

            An additional pilot valve is not needed when using the Voith electrohydraulic way valve module. Every way valve has a monitoring circuit which detects malfunction of a way valve. In the event of way valve malfunction, a hydraulic maximum selection circuitry ensures that the other way valve assumes control. This makes it possible to remedy the cause of the malfunction during operation. The Mean Time Between Failure (MTBF) of a Voith way valve module is over 8,800 years. Your equipment runs for an exceptionally long period of time without unplanned down­time thus ensuring  the utmost in terms of machine availability.

            Technical data

            Flow rate Up to 700 l/min [182 gpm] at 4 bar [58 psi] differential pressure
            Input pressure Up to 40 bar [580 psi]
            MTBF (Mean Time Between Failure) 8,800 years (calculated in accordance to MIL‑HDBK‑217, Siemens SN 29500 and taking into
            account diagnostic capability and reparability during operation at the actual redundancy)
            Supply voltage 24 VDC
            Current consumption 2.0 A (6.0 A for t < 1 s)
            Input signal 4 – 20 mA
            Communication (optional)
            • EtherNet/IP
            • Sercos
            • EtherCAT
            • VARAN
            • PROFINET
            • Others on request
            Fail-safe operation Internal return spring in each way valve
            Redundancy Hot redundancy
            Ambient temperature -20 to +80°C [-4 to +176°F] (standard version, not rated for
            use in potentially explosive areas)
            Explosion proof rating (optional)
            • ATEX (II 2G IIC T4, Ta = -20 to +60°C)
            • others on request
            Protection class IP 65
            Safety integrity level SIL 2 (on request)

             

            Advantages and benefits

            • Thanks to the redundancy provided by two way valves, the Mean Time Between Failure (MTBF) for the way valve module is over 8,800 years. Your equipment operates with maximum availability. Productivity increases and the costs associated with lost production remain low
            • It is possible to replace a faulty way valve during operation. You avoid unplanned downtime and their associated high costs
            • Voith way valve modules are not sensitive to contaminated pilot oil. Turbine lubricating oil is suitable as the operating fluid. One oil supply system for both lubricating and pilot oil suffices. Maintenance is simple, which helps you lower operating costs
            • During load rejection, the way valve shifts the control valve to the partial-load position very rapidly (approx. 300 ms). When a shutdown command is received, the way valve shifts the control valve to the safe position (open or closed) very rapidly (approx. 300 ms). This ensures high availability of your equipment
            • The way valve incorporates fast and exact position control. Very good control response, almost no hysteresis and a resolution better than 0.1% ensure very fast and accurate control. You benefit from having a stable process with high product quality
            • Connections are industry-standard and the way valve module mounts easily to your equipment which  reduces the costs for integration
            • The stroke and positioning speed can be adjusted easily on-site by means of a potentiometers this allows you to adjust the stroke to the application quickly and without any delays
            • For use in hazardous areas, we offer certified explosion proof way valve modules 

            Typical fields of use

            • Control valve operation for:
              • Steam turbines
              • Gas turbines
              • Compressors
            • Retrofit of mechanic-hydraulic valve controls
            • Upgrade of systems with Voith DSG I/H converters,
              WSR way valves or T‑WSR tandem way valves
            • Upgrade of systems with Woodward current-to-pressure converters CPC, CPC-II or CPC-DX

            Product enquiry

            Technical information

            Control schematic

            Functionality

            The way valve module employs a two-channel design. A redundant control system provides the two setpoints w1 and w2 in the form of a standard 4 – 20 mA signal for the two way valves. The control gain setting is the same for both valves. The output pressures pA1 and pA2 or the corresponding volume flows are directed to the "Max. Module", the A port of which is connected to the single-acting cylinder. If one of the two way valves fails, the associated force exerted by the magnetic force FMag and the output pressure drop to zero. The resulting connection of the A port in the way valve to the tank return line T causes the ball in the "Max. Module" to block the output of the failed way valve automatically. The pressure gauge and pressure transmitter on the associated way valve module display 0 bar. The functional way valve assumes control automatically and keeps the equipment operating. It is possible to replace the faulty way valve during operation.

            Control servo motor

            SMR control servo motor

              A linear electro-hydraulic actuator for steam turbines, gas turbines and other applications


              A Voith control servo motor is a linear electro-hydraulic actuator which operates a valve that controls the mass flow needed to drive machinery. Voith servo motors ensure very precise and high dynamic control of the mass flow.

              The control servo motor is an intelligent and compact functional unit consisting of a hydraulic cylinder, control magnet with integral position control, hydraulic pilot valve and position sensor. When a servo motor is used, no additional components such as pilot valve and hydraulic cylinder, for instance, are needed on order to operate the control valves.

              A standard 4 – 20 mA signal specifies the position of the piston rod. The control servo motors are simple and compact in design and ensure con­sist­ent and reliable operation. The Mean Time Between Failure (MTBF) for a Voith control servo motor is over 103 years. Your equipment will run for an exceptionally long period of time without unplanned downtime. The control servo motor is also available in a redundant design (position feedback system and way valve control).

              Technical data

              Full-stroke closing time (Trip) < 0.3 s
              Maximum pressure Up to 200 bar [2,900 psi]
              Effective forces Up to 500 kN [112,000 lbf]
              MTBF (Mean Time Between Failures) 103 years (calculated in accordance to MIL‑HDBK‑217 and Siemens SN 29500,
              actual MTBF evaluations from installed products show even higher values)
              Supply voltage 24 VDC
              Current consumption 1.0 A (3.0 A for t < 1 s)
              Input signal 4 – 20 mA
              Communication (optional)
              • EtherNet/IP
              • Sercos
              • EtherCAT
              • VARAN
              • PROFINET
              • Others are available on request
              Fail-safe operation Internal return spring in way valve and additionally in hydraulic cylinder on single acting designs
              Redundancy (optional)

              Position feedback system and way valve control magnets

              Ambient temperature -20 to +80°C [-4 to +176°F] (standard version, not rated for use in potentially explosive areas)
              Explosion proof rating (optional)
              • ATEX (II 2G IIC T4, Ta = -20 to +60°C)
              • others on request
              Protection class

              IP 65

              Safety integrity level SIL 2

               

              Advantages and benefits

              • The Mean Time Between Failure (MTBF) is over 103 years. Your equipment operates very reliably. Productivity increases and the costs associated with lost production remain low
              • Simple maintenance that assists in lowering operating costs.Voith control servo motors aren't sensitive to contaminated pilot oil. Turbine lubricating oil is suitable as an operating fluid and one oil supply system for both lubricating and pilot oil suffices 
              • During load rejection, for instance, the control servo motor reaches the safe position in less than
                300 ms. This ensures that your equipment operates with high reliability and availability. After a malfunction, the equipment is ready to operate again in no time
              • The high dynamic behavior (response time in the closing direction: < 200 ms) and almost no hysteresis (< 0.01% of maximum stroke) ensures fast and accurate control. You benefit from having a stable process with high product quality
              • The integral electronic position control in the Voith servo motor eliminates the need for
                time-consuming tuning of controller, position sensor and actuator during test runs and commissioning.
                This results in quicker commissioning and monetary savings
              • Design flexibility is assured as we design our servo motors to be compatible with existing equipment.  Engineering costs are lowered and the time you need for design is shortened
              • For use in hazardous areas, we offer certified explosion-proof control servo motors. The interface to the machine control system is the same for conventional and explosion-proof versions

              Typical fields of use

              •  Control valve actuation of:
                • Steam turbines
                • Gas turbines
                • Compressors
              • Retrofit of mechanic-hydraulic valve controls
              • Retrofit of hydraulic, electro-mechanical and
                pneumatic linear actuators
              • Upgrade of systems with Voith I/H converters DSG
                or way valves WSR
              • Upgrade of systems with Woodward actuators:
                • Varistroke linear electro-hydraulic actuator
                • EHPC electrohydraulic power cylinder
                • EHPS electrohydraulic power servo
                • PGPL hydraulic powered electric actuator
                • EG-3P hydraulic amplifier
                • TM‑25LP or TM‑200LP linear proportional actuators
                • CPC or CPC‑II current to pressure converters

              Product enquiry

              Technical information

              Functionality

              SMR Control Servo Motor – Function

              The servo motor is controlled by a standard 4 – 20 mA signal from the control system. The piston rod position is proportional to this standard signal w. In the position control loop, the setpoint w is compared with the actual position x of the piston rod measured by the position sensor and any deviation causes the controller to adjust the magnetic force FMag. This force (FMag) shifts the control piston in the way valve against a spring, causing a change in the direction and magnitude of the volume flow to the actuating chamber of the cylinder. In conjunction with the spring pack, the hydraulic force resulting from the volume flow changes the position s of the piston rod. The piston rod moves at a speed determined by the volume flow into or out of the actuator.

              Control schematic

              SMR Control Servo Motor – Control Schematic

              Selection table

              SelCon linear actuator

              SelCon linear actuator for actuating valve control equipment

                SelCon self-contained electrohydraulic linear actuator with fail-safe function, linear servo hydraulic valve actuator and linear actuator for governor valve control with trip function is typically used in gas turbine or steam turbine applications

                Providing a highly dynamic and precise control of the mass flow; the SelCon is a self-contained, electrohydraulic linear actuator with a spring-assisted trip function. It operates, for example, a valve that regulates the mass flow in a prime mover or a driven machine. Typical machine applications are gas turbines, steam turbines or compressors.
                 
                This innovative actuator is a reliable plug-and-play solution with fail-safe function. Compact in design it provides high force density and is a true alternative to conventional actuators. When utilizing the SelCon you don't need an additional hydraulic power pack with an oil tank, control block and additional pipework. Also, the amount of hydraulic fluid in the system is minimal.

                Electrical and mechanical interfaces are easily accessible ensuring easy handling and system integration, Further more no knowledge of hydraulics is required for installation and commissioning.

                The core components consist of a servo motor, a Voith internal gear pump, a cylinder with an internal return spring and a displace­ment transducer.  Furthermore, a control unit with implemented application software acts as the brain of the system. The actuator exhibits a high degree of operational safety and reliability with an estimated mean time between failure (MTBF) of 35 years.


                * The SelCon is optionally available as a trip actuator with no control function (switch actuator).

                Technical data

                Closing time for full stroke (trip) Typically < 0.3 s
                Motion time for full stroke (controlled) Typically 0.5 s
                Effective forces Up to 500 kN [112,000 lbf]
                MTBF (Mean Time Between Failure) 35 years (estimated, theoretical value)
                Supply voltage for the SelCon electronics 24 VDC
                Current consumption for the SelCon electronics 5 A
                Supply voltage for the control unit 3 x 207 – 528 VAC, 50/60 Hz
                Current consumption for the control unit 17 A, max. 32 A
                when balanced < 1 A
                Input signal

                4 – 20 mA

                Communication (optional):
                • EtherCAT
                • CANopen
                • CANsync
                • Sercos
                • PROFIBUS-DP
                • Others upon request
                Fail-safe function Internal return spring
                Ambient temperature 0 to +60°C (standard version, not rated for use in potentially explosive areas)
                Explosion protection (optional)
                • ATEX (II 2G ck IIB T3, Ta = 0 to +60°C)
                • Others upon request
                Protection class IP 65
                Safety integrity level

                SIL 2 (upon request)

                Optional

                Design as a trip actuator with no control function (switch actuator)

                 

                Typical applications

                • Control valve actuation in:
                  • Steam turbines
                  • Gas turbines
                  • Compressors
                • Retrofit of mechanical-hydraulic valve controls
                • Retrofit of hydraulic, electro­mechanical and pneumatic actuators
                • Linear actuator for process valves with fail-safe function
                • Upgrade of systems with the Voith DSG I/H converters, WSR way valves and SMR control servo motors
                • Upgrade of systems with Woodward actuators:
                  • Varistroke linear, electro­hydraulic actuator
                  • EHPC electrohydraulic power cylinder
                  • EHPS electrohydraulic power servo
                  • PGPL hydraulic powered electric actuator
                  • EG 3P hydraulic amplifier
                  • TM 25LP or TM 200LP linear proportional actuators
                  • CPC or CPC II current to pressure converters

                Advantages and benefits

                Features

                Advantages

                Benefits

                • Self-contained closed hydraulic system
                • The linear actuator works without an external oil supply
                • You save procure­ment and main­tenance costs. Usually up to 35% of the procure­ment costs can be saved compared to a conventional system. Normally an external hydraulic power pack will require an oil tank and additional pipe­work
                • System integration is simple and economical
                • Your entire system has a higher operational reliability. External hydraulic dis­turb­ances such as pressure fluctuations, mismatched line diameters or negative pressure in the tank line are precluded
                • Increased safety due to the lower fire hazardwhich can potentially reduce your insurance premiums
                • The linear actuator is an optimal solution for new systems and for retrofits
                It is impossible for dirt or water to enter the hydraulic system
                • You save up to 5 days during commissioning because it is not necessary to flush and vent any piping
                • Operation is wear-resistant and main­tenance costs are low
                • Safety function is provided by a durable return spring and a reliable seat type trip valve
                • The fail-safe function is achieved simply and safely
                • The trip speed is exceptionally fast. Typically the trip time is < 300 ms
                • Your system has a high degree of operational reliability

                 

                • A reliable trip of the control valve reduces the danger of immediate and con­se­quen­tial damage
                • The safety function (tripping) and the operating function (control mode) are decoupled
                • Tripping is initiated by means of a separate safety control circuit
                • Position control of the hydraulic cylinder using a servo pump (displacement principle).
                • No classic control valves
                  (throttle principle).
                • The linear actuator has a high energy efficiency rating
                • A low level of heat is intro­duced into the integrated hydraulic system
                • You reduce energy costs for operating the actuator by up to 50% compared to an actuator using con­ven­tional valves and a hydraulic power pack
                • Environmentally sensitive with lower CO2 emissions
                • Modular design with few components – Compatible with existing hydraulic, electro­mechanical and pneumatic actuators
                • The application has high flexibility
                • Integration into your system is simple and the planning effort minimal
                • The actuator matches price and function in your application
                   
                • The SelCon is a high-quality cost-effective actuator solution for new systems, retrofits or modernization projects
                • Low-maintenance design using reliable system components
                • Very small amounts of operating fluid in the system
                • The time and money spent on maintenance are minimal
                • Your costs for maintenance and oil management are considerably less compared to conventional solutions
                • Environmentally sensitive in regards to the significantly reduced oil capacity
                • Continuous control using an internal gear pump that operates constantly (no intermittent duty)
                • The control system of the linear actuator operates with no response delay
                • The actuator is ready to operate immediately, especially even after a trip
                • You have high system availability leading to higher productivity
                • The valve actuator operates with virtually no hysteresis
                • The control system is precise and highly dynamic
                • Your processes are stable and product quality is high

                 

                Technical information

                Design

                Function

                SelCon Self-contained Linear Actuator - Function
                The control system activates the SelCon using a 4 – 20 mA standard signal. The stroke of the piston rod is proportional to this standard signal w (setpoint). In the event of a fast-acting trip, the trip solenoid valve opens and connects the two cylinder chambers. The return spring moves the piston rod to its safety position within 300 ms. During this action, the hydraulic fluid flows from one cylinder chamber into the other.

                The SelCon has two functions, namely providing a control function and a safety function (trip). In the control mode, the SelCon regulates the position of the piston rod using the setpoint signal w from the control system. The piston rod is connected to the control valve that controls the mass flow and changes its opening cross-section. If the setpoint signal is switched off, the trip solenoid valve opens. The piston rod is moved to its safety position by the energy stored in the return spring. This is carried out in an uncontrolled manner and at high speed. Furthermore, an auxiliary electrical power supply is required for operating the SelCon. All electrical components are protected against environmental influences and the electronic position detection system is integrated inside the actuator. The control loop parameters for position control and the parameters for scaling the piston rod position are set using the application software implemented in the control unit.

                Control schematic

                EMA electromechanical linear actuator

                EMA electromechanical linear actuator

                  EMA electromechanical valve actuator with fail-safe function, linear servo electric valve actuator and linear actuator for governor valve control with trip function is typically used in gas turbine and steam turbine applications

                  The EMA is an electromechanical linear actuator with trip function. It operates, for example, a valve that regulates the mass flow in a prime mover or a driven machine. Typical machine applications include gas turbines, steam turbines or compressors.

                  Providing a highly dynamic and precise control of the mass flow, this innovative linear actuator with fail-safe function has only electrical and mechanical interfaces. Importantly, it is oil-free which eliminates all oil management expenses and at 80% lower energy consumption, operational costs are significantly lower.

                  Furthermore, an oil-free actuator reduces the fire load of the entire system and insurance companies usually reward this with lower premiums. Lastly, there is nothing hindering the use of the actuator in places where environmental restrictions are stringent.

                  This operationally safe and reliable plug-and-play solution has an estimated mean time between failure (MTBF) of 35 years. As a result, your machine is very robust and the productivity of your plant is enhanced.

                  Technical data

                  Closing time for full stroke (trip) Typically < 0.3 s
                  Motion time for full stroke (controlled) Typically 0.5 s
                  Spring force Up to 30 kN
                  Actuating force

                  Up to 40 kN

                  MTBF (Mean Time Between Failure) 35 years
                  Supply voltage for the EMA electronics 24 VDC
                  Current consumption for the EMA electronics 3.4 A
                  Supply voltage for the control unit 3 x 207 – 528 VAC, 50/60 Hz
                  Current consumption for the control unit 17 A, max. 32 A,
                  when balanced < 1 A
                  Input signal

                  4 - 20 mA

                  Communication (optional):
                  • EtherCAT
                  • CANopen
                  • CANsync
                  • Sercos
                  • PROFIBUS DP
                  • Others upon request
                  Fail Safe Operation Piston rod retracted or extended, depending on the design
                  Ambient temperature -20 to +80°C (standard version, not rated for use in potentially explosive areas)
                  Degree of protection

                  IP 65

                  Safety integrity level SIL 2 (optional)
                  Optional Design as a trip actuator with no control function (switch actuator)

                   

                  Typical applications

                  • Control valve actuation for:
                    • Steam turbines
                    • Gas turbines
                    • Compressors
                  • Retrofit of mechanical-hydraulic valve controls
                  • Retrofit of hydraulic, electromechanical and pneumatic actuators
                  • Linear actuator for process valves with fail-safe function
                  • Upgrading systems with the Voith DSG I/H converters,
                    WSR way valves and SMR control servo motors
                  • Upgrading systems with Woodward actuators:
                    • PGPL hydraulic powered electric actuator
                    • TM 25LP or TM 200LP linear proportional actuators
                    • CPC or CPC II current to pressure converters

                  Advantages and benefits

                  Features Advantages Benefits
                  • Electromechanical design with synchronous

                  motor and screw drive

                  • The linear actuator is oil-free
                  • The actuator has only electrical and mechanical interfaces
                  • You save the procurement and maintenance costs required for an external hydraulic power pack with an oil tank and the pipework. Up to 35% of the procurement costs can be saved compared to a conventional system.
                  • System integration is simple and economical
                  • High operation safety of the entire system. Malfunctions such as those caused by contaminated pilot oil or by an oil leak aren't possible
                  • Increased safety with due to a ower fire load - This often reduces your insurance premiums
                  • The actuator is an optimal solution for new systems and for retrofits
                  • Commissioning is considerably simpler and is much faster than for hydraulic linear actuators. You save up to 5 days during commissioning because it is not necessary to flush and vent any pipes
                  • No hydraulics knowledge  is required for installation and commissioning
                  • The EMA is the ideal linear actuator for areas with stricter environmental regulations
                  • Low-wear and low-maintenance design
                  • Lower maintenance costs
                  • Safety function is provided by a high-strength return spring and magnetic coupling
                  • Simple and safe fail-safe function 
                  • Fast trip speed with a trip time of typically < 300 ms
                  • Your system has a high degree of operational reliability
                  • A reliable trip of the control valve reduces the danger of immediate and consequential damage
                  • The safety function (trip) and the operating function (control mode) are decoupled
                  • Trip is initiated by means of a separate safety control circuit
                  • Electromechanical position control with synchronous motor and threaded spindle
                  • No valves
                  • The linear actuator has a high level of energy efficiency
                  • Reduced actuator energy costs by up to 80% if compared to an actuator using conventional valves and a hydraulic power pack
                  • Environmentally sensitive  - With lower CO2 emissions
                  • Modular design with few components – Compatible with existing hydraulic, electromechanical and pneumatic actuators
                  • The application flexibility is high
                  • Easy system integration and minimal planning effort
                  • The actuator suits your application in terms of price and function
                  • The EMA is a high-quality, cost-effective actuator solution for new systems, retrofits or modernization projects
                  • Constant control with the permanently excited synchronous motor
                  • The linear actuator control system operates with no response delay
                  • The actuator is ready to operate immediately, especially after a trip
                  • High system availability leading to higher productivity
                  • Virtually no hysteresis during valve actuator operation
                  • Precise and highly dynamic control system
                  • Stable processes and high product quality

                   

                  Technical information

                  Design

                  Function

                  EMA Electromechanical Drive – Function

                  Control schematic

                  EMA Electromechanical Drive – Control Schematic

                  How it works

                  The control system activates the EMA using a 4 – 20 mA standard signal. The stroke of the piston rod is proportional to the standard signal w. In the event of a trip, when the valve closes quickly, an electromagnetic coupling opens and decouples the motor mass. The return spring moves the piston rod into the safety position within 300 ms, either fully retracted or fully extended.

                  The EMA has two functions, namely providing a control mode and ensuring safety. In the control mode, the EMA regulates the position of the piston rod using the setpoint w from the control system. The piston rod is connected to the control valve that controls the mass flow and changes its opening cross-section. If the setpoint signal is switched off (< 3.2 mA), the electromagnetic coupling opens. The piston rod is moved to the safety position by the energy stored in the return spring, this is carried out in an uncontrolled manner and at high speed. Whilst the piston rod is held in the safety position, the power section of the VFD (variable frequency drive) in the control unit is switched off. This ensures that the piston rod moves to its safety position even in the event of an electromagnetic coupling malfunction. An auxiliary electrical power supply is required for operating the EMA. All electrical components are protected against environmental influences. Electrical position detection is integrated in the drive whilst the controller,  with circuitry for setpoint limitation and minimum value switch-off, are integrated into the control unit. The control loop param­eters and the parameters for scaling the piston rod position are set on the control unit using the relevant software.

                  TripCon trip block

                  TripCon trip block

                    This electro‐hydraulic trip block is a fast acting, quick trip, actuator turbine trip control system

                     

                    The trip block is an extremely flexible electro-hydraulic safety control unit which is used for releasing the trip valves (quick trip) on steam turbines, gas turbines and in process engineering. The TripCon has a modular design and the components can be combined in a variety of ways. As a result, optional trip block functions can be provided which offers the best fit for your application, both technically and financially.

                    All variants of the trip block have a triple-redundant design with a 2oo3 selection (2 out of 3 voting), this means that turbine trips don't take place until at least two channels have been deactivated. An integrated 1oo1 partial stroke test enables a simple check of the function of the trip valve, even during operation. The partial stroke test is available with optional 2oo2 redundancy. An expansion module is also available, which allows the replacement of all solenoid valves during operation.

                    Particular attention to large dis­charge volumes and a dirt-resistant design enables TripCon to quickly and safely shutdown the turbine. Furthermore the TripCon is certified with the SIL 3 safety integrity level and has a Mean Time Between Failure (MTBF) of over 100,000 years.

                    Technical data

                    Operating pressure 2 to 180 bar [30 to 2,600 psi]
                    Flow rate Max. 320 l/min [85 gpm] at 5 bar [72 psi] differential pressure
                    Trip function 2oo3 (2-out-of-3)
                    Valve partial stroke test
                    • 1oo1 (1-out-of-1)
                    • Optional 2oo2 (2-out-of-2)
                    MTBF (Mean Time Between Failure) 100,000 years (calculated in accordance to MIL‑HDBK‑217 and Siemens SN 29500,
                    actual MTBF evaluations from installed products show even higher values)
                    Ambient temperature

                    -20 to +80°C [-4 to +176°F]

                    Oil temperature +10 to +70°C [50 to +158°F]
                    Supply voltage 24 VDC
                    Current consumption 0.8 A per solenoid
                    Fail Safe Operation Internal return spring on each solenoid valve
                    Protection class

                    IP 65

                    Explosion protection (optional) ATEX/IECEx (II 2G IIC T4, Ta = -20°C to +60°C)
                    Safety integrity level SIL 3

                     

                    Typical applications

                    • Safety control for steam turbines
                    • Safety control for gas turbines
                    • Control of process safety valves
                    • Retrofit of non-redundant trip systems

                    Advantages and benefits

                    Features Advantages

                    Benefits

                    Modularity    
                    • Modular and compact trip block with a 2oo3 configuration
                    • The TripCon has a great degree of functional flexibility
                    • A range of TripCon models are avail­able for different levels of turbine control system safety re­quirements
                    • The TripCon model you select will be suited to your system, both financially and functionally
                    • The competitiveness of the turbine is increased in terms of price, per­form­ance, and quality
                    • Integrated solenoid valves for the partial stroke test
                    • No additional valves, sensors and pipe­lines for an external partial stroke test system are required
                    • A cost-effective and compact partial stroke test system for the trip valve
                    • A partial stroke test is easy to perform
                    • Enhanced system safety 
                    • Extended trip valve maintenance intervals result in reduced maintenance costs and outage costs 
                    Safety    
                    • Solenoid valves with large magnetic forces
                    • The valves are extremely dirt-resistant
                    • In the event of a trip, the turbines are safely shut off
                    • Avoidance of  secondary damage re­sulting from turbine overspeed
                    • Turbine lubricating oil is suitable as an operating medium
                    • One oil supply system for both lu­bri­cating and pilot oil suffices. This keeps maintenance simple, which helps you lower operating costs
                    • Large discharge volumes (320 l/min [85 gpm] at Δp = 6 bar [87 psi]) using the integrated NG16 valve
                    • The flow volumes are very high without an additional shutoff valve
                    • Short trip time
                    • The TripCon provides you with a safe, simple, and cost effective trip system
                    • Solenoid valves with position feedback
                    • Every solenoid valve can be tested individually during operation be­cause of the 2oo3 selection logic
                    • Automatic test routines for regular testing of the solenoid valves, possible
                    • Minimal effort required in order to improve turbine control system safety
                    • Automatic switching from the 2oo3 selection to the 1oo2 selection, when replacing a solenoid valve
                    • Replacement of the solenoid valve improves safety
                    • Enhanced turbine control system  safety
                    Cost effective    
                    • All the solenoid valves can be
                      de­coupled from the hydraulic system
                    • It is possible to replace a solenoid valve during operation
                    • Achieve uninterupted production
                    • Manually adjustable orifice at the pressure connection P
                    • Adjustable closing time of the connected trip valve 
                    • The TripCon can be optimized to your turbine control system
                    • Hydraulic connection via pipe or flange connection
                    • The TripCon is suitable both for standalone mount­ing and for mounting on the cylinder of the trip valve
                    • Integration into your turbine control system is flexible and can be im­ple­mented economically

                     

                    Technical Information

                    Control schematic

                    Elektro-hydraulic Safety Control Unit TripCon Control Schematic

                    TripCon – Superior

                    Feautures:

                    • Trip function: 2oo3
                    • Partial stroke test: 2oo2 during operation
                    • Replacement of the MV1 – MV5 solenoids during operation
                    • Replacement of the MV1 – MV5 solenoid valves during operation
                    • Optional Atex

                    Elektro-hydraulic Safety Control Unit TripCon Superior

                    TripCon – Advanced

                    Features:

                    • Trip function: 2oo3
                    • Partial stroke test: 1oo1 during operation
                    • Replacement of the MV1 – MV4 solenoids during operation
                    • Replacement of the MV1 – MV4 solenoid valves during operation
                    • Optional Atex

                    Elektro-hydraulic Safety Control Unit TripCon Advanced

                    TripCon – Special

                    Features:

                    • Trip function: 2oo3
                    • Partial stroke test: 2oo2 during operation
                    • Replacement of the MV1 – MV5 solenoids during operation
                    • Replacement of the MV4 – MV5 solenoid valves during operation
                    • Optional Atex

                    Elektro-hydraulic Safety Control Unit TripCon Special

                    TripCon – Basic

                    Features:

                    • Trip function: 2oo3
                    • Partial stroke test: 1oo1 during operation
                    • Replacement of the MV1 – MV4 solenoids during operation
                    • Replacement of the MV4 solenoid valve during operation
                    • Optional Atex

                    Elektro-hydraulic Safety Control Unit TripCon Basic

                    CTo overspeed protection

                    CTo overspeed protection

                      The Voith CTo overspeed protection system consists of an electronic signal pro­cessing unit that detects overspeed and an electrohydraulic assembly that actuates a hydraulic positioning cylinder directly. This positioning cylinder opens or closes a trip valve that releases or blocks the mass flow needed to drive machinery.

                      The CTo is a compact unit and is intended for direct mounting to the trip valve actuator, this keeps the signal paths short, making the unit immune to inter­ference. Simple in design with reliable operation, the Mean Time Between Failure (MTBF) for the Voith CTo is over 200 years.

                      Technical data

                      Flow rate (A to T) 330 l/min [87gpm] at  Δp = 4 bar [58 psi]
                      Input pressure Up to 25 bar [362 psi]
                      MTBF (Mean Time Between Failure) 200 years (calculated in accordance to MIL‑HDBK‑217 and Siemens SN 29500,
                      actual MTBF evaluations from installed products show even higher values)
                      Supply voltage 24 VDC
                      Current consumption

                      0.5 A (2.5 A for t < 1 s)

                      Fail-safe operation Internal return spring
                      Trigger frequency 4,000 to 10,000 Hz adjustable
                      Ambient temperature -20 to +80°C [-4 to +176°F] (standard version, not rated for use in potentially explosive areas)
                      Explosion proof rating (optional)
                      • ATEX (II 2G IIC T4, Ta = -30 to +60°C)
                      • IECEx (Ex db llC T4, Ta = -30 to +60°C)
                      • Others on request
                      Protection class

                      IP 65

                      Safety integrity level

                      SIL 2

                       

                      Advantages and benefits

                      • The Mean Time Between Failure (MTBF) is over 200 years. Your equipment operates very reliably. Productivity increases and the costs associated with lost production remain low
                      • The Voith CTo isn't sensitive to contaminated pilot oil. Turbine lubricating oil is suitable as the operating fluid. One oil supply system for both lubricating and pilot oil suffices.
                        Maintenance is simple, which helps you lower operating costs
                      • The CTo features a simple design. Overspeed detection and tripping are de­cen­tralized.
                        This is a cost-effective solution – for both new equipment and when retrofit to existing equipment
                      • A partial stroke test ("Trip-Sim") permits testing of the trip valve during turbine operation.
                        This eliminates the need for additional hardware and keeps the system uncomplicated
                      • A separate speed feedback signal in the form of a 4 – 20 mA signal is available.
                        This makes installation of an additional speed measuring device unnecessary

                      Typical fields of use

                      • Actuation of trip valves for:
                        • Steam turbines
                        • Gas turbines
                        • Compressors

                      Technical information

                      Design

                      Overspeed Protection Type CTo - Design
                      A        Load connection (output)

                      T        Tank connection

                      P       Oil supply connection (input)

                      1       Control magnet housing

                      2       Plunger

                      3       Electrical connection

                      4       Hydraulic section

                      5       Control piston

                      Functionality

                      Overspeed Protection Type CTo - Function

                      The CTo consists of a 3/2 way hydraulic unit, a current-controlled electromagnet and the signal processing and control electronics. If there are no trip criteria, the control magnet generates the force FMag. This magnetic force presses the control piston of the hydraulic unit against a return spring. In this position, the hydraulic unit connects the pressure supply to the actuator of the trip valve, causing it to open. If there is a trip criterion (e.g. overspeed), the control magnet exciter current is interrupted immediately. The spring force FF exerted by the return spring shifts the control piston back to its original position, draining the actuator of the trip valve and causing it to close.

                      TurCon DTc steam turbine controller

                      TurCon DTc steam turbine controller

                        Turbine governor for steam turbines with a max. of 6 control valves used in applications requiring digital steam turbine control

                        The TurCon DTc is a compact, cost-effective steam turbine controller which can be used in mechanical driven machines or generator applications.

                        Supplied with pre-engineered standard software; the TurCon DTc software is based on proven and reliable turbomachinery control algorithms. The control mode parameters can be setup quickly and easily which is particularly beneficial when controlling speed, demanding frequency control or complex extraction pressure control.

                        The controller consists of two robust units of outstanding industrial quality.The first is a touchscreen control panel with integrated CPU and the other a remote I/O unit. In addition, a PC or an optional 15" control panel can be easily connected via LAN. This is especially practical, for example, during commissioning or for remote monitoring. Communication with a higher-level control system (DCS) uses Ethernet with Modbus TCP or OPC.

                        The TurCon DTc is, in principle, a steam turbine controller for everyone. If you are an OEM, you have a controller solution that economically fits into your overall system. Should you be a contractor or retrofitter, you can offer your clients an easy-to-use solution, whilst you benefit from our consulting expertise. Not forgetting our steam turbine operators will benefit from a reliable product with proven control algorithms that ensures high process quality and productivity.

                        Technical data

                        Control panel  
                        Operating voltage 9.6 – 28.8 VDC
                        Operating temperature 0 °C to +55 °C
                        Degree of protection

                        IP 54

                        Dimensions (W x H x D) 179 x 119 x 42 mm
                        Assembly Panel flush mounting
                        HMI 7" WVGA color TFT touchscreen with 800 x 480 pixels
                        Remote I/O  
                        Operating voltage 20.4 – 28.8 VDC
                        Operating temperature 0 °C to +55 °C
                        Degree of protection

                        IP 20

                        Dimensions (W x H x D) 390 x 130 x 52 mm
                        Fastening 35 mm DIN rails
                        Inputs
                        • 15 x digital/discrete (physical, LOW: -3 – 0.5 VDC, HIGH: 13 – 28.8 VDC)
                        • 32 x digital/discrete (virtual, via bus)
                        • 8 x analog (physical, 0 – 20 mA, input impedance: 200 Ω, measuring range:
                          0 – 20.475 mA, resolution: 12 bits)
                        • 16 x analog (virtual, via bus)
                        • 3 x frequency (for speed pickups, active or passive speed sensors, measuring range:
                          0.5 – 20 kHz, short circuit and open circuit detection)
                        Outputs
                        • 6 x digital/discrete (high-side switch, 0.5 A @ 24 VDC)
                        • 8 x digital/discrete (relays, 2 A @ 24 VDC, max. 12 A @ 250 VAC)
                        • 32 x digital/discrete (virtual, via bus)
                        • 8 x analog (physical, 0 – 20 mA, load resistance: < 500 Ω, resolution:
                          12 bits, AO0…3 and AO4…7 electrically isolated to the system)
                        • 16 x analog (virtual, via bus)
                        Communication  
                        Interface
                        • Ethernet (Modbus TCP or OPC)
                        • Others upon request
                        RemoteView & Control
                        • Standard PC with specified browser via LAN
                        • Voith 15" touch panel via LAN
                        Configurable functions  
                        Control modes for pumps, compressors, fans, etc.
                        • Speed control
                        • Extraction pressure control
                        Control modes for generators
                        • Speed control
                        • Frequency control
                        • Power control
                        • Live steam pressure control
                        • Back pressure control/exhaust steam pressure control
                        • Extraction pressure control
                        Control options Turbines with a maximum of 4 HP control valves and a maximum of 2 LP control valves
                        Other
                        • Cold/warm startup mode
                        • Start-up ramp with a maximum of 12 sampling points (Critical Speed Avoidance)
                        • Max. 8 configurable limiters:
                          • Min. back pressure limiter
                          • Max. back pressure limiter
                          • Min. load limiter
                          • Max. load limiter
                          • Min. live steam pressure limiter
                          • Max. live steam pressure limiter
                          • Max. speed limiter
                          • Max. wheel chamber pressure limiter
                        • External analog setpoint
                        • Simulation mode

                         

                        Typical applications

                        • Control of steam turbines that drive compressors, pumps, fans and other driven machines
                        • Control of steam turbines that drive generators
                        • Upgrade/retrofit of mechanical steam turbine controllers
                        • Upgrade/retrofit of analog steam turbine controllers, in particular
                          • Voith TurCon A
                          • Siemens / KKK SC800
                          • MAN / GHH Turbolog EKU
                          • Dresser Nadrowski / M+M / AEG
                          • Kanis / ABB CTn, CTp and CTf
                        • Upgrade of Woodward 505 and Woodward 505E steam turbine controllers

                        Advantages and benefits

                        Features Advantages Benefits
                        • Easy to configure controller parameters for virtually every steam turbine
                        • Simple to save and upload the configuration and parameters
                        • The turbine controller has a high degree of flexibility and is suitable for all standard steam turbine applications
                        • STandard software is pre-engineered in the supplied controller 
                        • The configuration and parameter data sets can be reused
                        • Integration of the controller into your system is quick, easy and economical
                        • The controller is suited both for new systems and for the modernization of existing equipment
                        • This keeps your commissioning effort and costs low
                        • A maximum of 4 HP and a maximum of 2 LP control valves can be controlled directly
                        • Individual valve control variables can be set to linearize the flow characteristic curve
                        • For turbines with more than one HP or LP control valve, there is no need to adjust the valves mechanically using a camshaft
                        • Fewer mechanical components mean lower maintenance and repair costs 
                        • For turbines with more than one HP or
                          LP control valve, no separate electronic valve coordinator (split range) is required
                        • Having fewer electronic components reduces system complexity and improves reliability
                        • The commissioning effort is lower facilitating considerable cost savings
                        • The turbine control valves can be controlled in a flexible manner
                        • Easy process control optimization
                        • 7-inch TFT LCD control panel with intuitive touchscreen operator interface
                        • The HMI is both user-friendly and modern
                        • All parameters can be changed on-site and the relevant process values can be visualized
                        • Quick initial training of operating personnel
                        • On-site you have quick, very informative process visualization and monitoring capabilities
                        • Remote view & control via LAN using a standard PC with specified browser or via an optional 15" touch panel
                        • A similiar interface to the standard control panel, all operating, setting and monitoring functions can be executed in the same manner
                        • An additional inexpensive HMI is located at another facility
                        • A large-area visualization system, for example when commissioning or for monitoring purposes, can be set up quickly and simply
                        • Compact design 
                        • Industry-proven standard hardware utilized
                        • The TurCon DTc is a plug-and-play solution, which is ready to operate after connection and configuration
                        • The components of the control system are optimally designed to compliment each other
                        • Your control system is operationally reliable and easy to service
                        • Up to 3 speed sensors can be connected, 2oo3 voting (2 out of 3 selection) possible
                        • The speed measuring equipment is fault-tolerant, whilst providing high reliability and availability
                        • Increased sysrem reliability and minimized risk of downtimes and secondary damage
                        • Integrated speed sensor monitoring
                        • Faults in the speed measuring system can be detected in real time
                        • The current controller and sensor information are displayed using informative graphics
                        • Archiving of the last 1,000 status, warning and alarm messages with time stamps
                        • Process flows and process faults are easy to trace
                        • Quick and targeted process optimization
                           
                        • System availability, product quality and, last but not least, productivity improves
                        • Integrated tool for optimizing the controller during operation without any related process faults
                        • Control loops and control loop performance can be quickly optimized
                        • Shorter commissioning time saves money
                        • HIgh process quality 
                        • An integrated simulation mode is available
                        • The validity of the configuration and the parameters of the turbine controller can be effectively checked, and optimized if needed, prior to actual commissioning
                        • Pre-simulation enables easier commissioning and reduces commissioning time
                        • Minimized damage as a result of incorrect parameters, is removed
                        • Multilevel password protection
                        • Optimal security for controller operation
                        • Your turbine control system is secure and protected against unauthorized access

                        Technical Information

                        Control schematic

                        Steam Turbine Control System with TurCon DTc - Schematic

                        Maximum configuration

                        Steam Turbine Control System with TurCon DTc - Maximum Configuration

                        Panel images

                        TurCon DTc steam turbine controller in quality control

                        TurCon DTm steam turbine controller

                        TurCon DTm steam turbine controller

                          Single-valve or two-valve steam turbine governor with steam turbine control

                          The TurCon DTm is a configurable digital controller which can be used on a wide range of steam turbines. It supports all established control modes – from speed control and high-performance frequency control to complicated extraction pressure control. The controller is pre-engineered which means that it is ready for operation after connecting and setting the parameters.

                          The controller is modular in design, using standard hardware that is industry-proven. Standard software and a consistent, intuitive operating concept makes the TurCon DTm one of the most modern turbine controllers. As a user, you get a re­li­able plug-and-play solution featuring components that are optimally matched to each other. In addition, the TurCon DTm has an outstanding price/performance ratio.

                          Using Profibus DP the integration into a central control system is simple. Be­sides this, the TurCon DTm, with its TFT LCD control panel, provides a user-friendly and modern HMI with a touchscreen operator interface. The configuration and parameterization of the controller are performed via the control panel or optionally with a PC.

                          The TurCon DTm is available in three versions:

                          1. Standard:
                            All hardware components wired in a cabinet incl. software.
                          2. OEM version:
                            CPU, memory card and LCD control panel, unwired incl. software.
                          3. Retrofitter version:
                            All hardware components without cabinet, unwired incl. software.

                          Technical data

                          Operating voltage 21 – 28 VDC
                          Ambient temperature 0 to +40°C [+32 to +104°F]
                          Dimensions 500 x 500 x 210 mm
                          HMI 7" TFT LCD control panel with touchscreen operator interface
                          Protection class IP 65
                          Communication
                          • Profibus DP

                          Optional:

                          • Ethernet (Modbus TCP or OPC)
                          • CAN
                          Configuration and parameterization
                          • Using the control panel
                          • Using the PC configurator as an option
                          Inputs
                          • 8 x digital (physical, LOW: 0 – 5 VDC,
                          • HIGH: 13 – 28 VDC)
                          • 32 x digital (virtual via Profibus)
                          • 6 x analog (physical, 4 – 20 mA, input impedance 50 Ohm, via 3-way isolating amplifier,
                            measuring range 0 – 20.5 mA, resolution 14 Bit, wire-break detection at current < 1.185 mA)
                          • 16 x analog (virtual via Profibus)
                          • 2 x frequency (for speed pickups, only active speed sensors, measuring range 0.05 – 20 kHz,
                            short circuit and wire-break monitoring)
                          Outputs
                          • 8 x digital (relays, 6 A @ 24 V)
                          • 32 x digital (virtual via Profibus)
                          • 4 x analog (physical, 4 – 20 mA,
                          • load resistance < 500 Ohm, resolution 16 Bit, each channel electrically isolated)
                          • 16 x analog (virtual via Profibus)
                          Driven machines
                          • Pumps, compressors, fans etc.
                          • Generators
                          Control modes for pumps, compressors, fans etc.
                          • Speed control
                          • Extraction pressure control
                          Control modes for generators
                          • Speed control
                          • Frequency control
                          • Power control
                          • Live steam pressure control
                          • Back pressure control/exhaust steam pressure control
                          • Extraction pressure control
                          Other
                          • Cold/warm startup mode
                          • Start-up ramp with a maximum of 12 sampling points (Critical Speed Avoidance)
                            • Max. 8 configurable limiters:
                            • Min. back pressure limiter
                            • Max. back pressure limiter
                            • Min. load limiter
                            • Max. load limiter
                            • Min. live steam pressure limiter
                            • Max. live steam pressure limiter
                            • Max. speed limiter
                            • Max. wheel chamber pressure limiter
                          • External analog setpoint
                          • Simulation mode
                          • Optional software package for optimizing control parameters

                           

                          Typical applications

                          • Control of steam turbines that drive compressors, pumps, fans and other driven machines
                          • Control of steam turbines that drive generators
                          • Upgrade/retrofit of mechanical steam turbine governors/controllers
                          • Upgrade/retrofit of analog steam turbine governors/controllers, especially:
                            • Voith TurCon A
                            • Siemens / KKK SC800
                            • MAN / GHH Turbolog EKU
                            • Dresser Nadrowski / M+M / AEG Kanis / ABB CTn, CTp and CTf
                          • Upgrade of steam turbine controllers Woodward 505 and Woodward 505E

                          Advantages and benefits

                          Features Advantages

                          Benefits

                          • Free configuration and parameteriza­tion of the controller for steam turbines with one or two control valves
                          • Easy saving and loading of configura­tion and parameters
                          • The turbine controller has a high degree of flexibility and is suitable for all standard industrial steam turbine applications
                             
                          • A pre-engineered controller with standard software
                             
                          • Reusable configuration and parameter data sets 
                          • Controller integration into your system is quick, easy and econom­ical
                             
                          • The controller is suited both for new systems and for the modernization of existing equipment
                             
                          • Low commissioning costs and effort
                          • 7-inch TFT LCD control panel with intuitive touchscreen operator interface
                          • Convenient and modern HMI interface
                             
                          • Relevant parameters can be con­figured and visualized on site
                          • Quick initial operational personnel training 
                             
                          • Quick informa­tive process visualization and moni­toring
                          • Modular industry-proven hardware
                          • All electronic components are integrated into a cabinet
                          • The TurCon DTm is a plug-and-play solution which is ready to operate after connecting and setting the parameters
                             
                          • Optimally matched control system components 
                          • An operationally reliable control system that is easy to service
                          • Optional connection of 2 speed sensors
                          • The speed measuring equipment is fault-tolerant, whilst providing good reliability and availability
                          • Enhanced system reliability with minimal risk of downtime and secondary damage
                          • Integrated speed sensor monitor 
                          • Faults in the speed measuring sys­tem can be detected in real time
                          • The current controller and sensor status are displayed using informative graphics
                          • Archiving of the last 1,000 status, warning and alarm messages with time stamps
                          • It is easy to trace process flows and process faults
                          • Quick and targeted process optimization
                             
                          • System availability, product quality and,
                            last but not least, productivity improves
                          • Configuration and parameterization are accomplished using the control panel or with a PC available as an option
                          • Flexible controller operation
                          • You save time and money during commissioning
                             
                          • Individual parameters can be ad­justed quickly and easily during operation
                          • Simulation mode
                          • The configuration and parameterization of the turbine controller can be easily checked (ensuring no errors)
                          • Pre-simulation enables easier commissioning and reduces commissioning time
                             
                          • Incorrect controller operation and the resulting damage is less likely
                          • Multilevel password protection
                          • Optimal security for controller operation
                          • Your turbine control system is safe and incorrect operations are prevented
                          • Optional software package available for optimizing control parameters
                          • The control loops and the control loop performance can be quickly optimized using the tool
                          • Quick commissioning time saves and money
                             
                          • The process quality is high

                           

                          Technical information

                          Control schematic

                          TurCon DTm Control Schematic

                          Maximum configuration

                          TurCon DTm Maximum Configuration

                          Panel images

                          Applications

                          TurCon DTe

                          TurCon DTe

                            Custom engineered turbomachinery controller


                            Tailored to your turbomachinery requirements this controller is supplied with engineered software and standard hardware, that has been tested extensively in the field. 

                            The hardware is fault-tolerant with a scalable redundancy covering a wide range. Software supplied is based on proven turbomachinery control algorithms with the possibility to scale it as desired. Optional remote servicing includes remote maintenance, data analysis and system optimization.

                            Typical turbomachinery applications include:

                            •  Turbines
                            •  Fans
                            •  Pumps
                            •  Compressors
                               

                            Technical data

                            Operating voltage

                            20.4 - 28.8 VDC
                            *Other options are available on request

                            Ambient temperature 0°C to 40°C
                            *Optional: -20°C to 60°C
                            Dimensions 800 x 2000 x 600 mm
                            *Other options are available on request
                            HMI 15" color TFT touch screen operating panel
                            Protection class IP 20
                            *Other options are available on request
                            Communication

                            Ethernet (Modbus TCP or OPC)

                            Optional:

                            • Profibus
                            • Profinet
                            • EtherCAT
                            • Modbus RTU
                            • CANopen
                            • DeviceNet
                            • Powerlink
                            Inputs
                            • Number of analog and digital inputs are adapted to the project
                            • 3 frequencies are available for speed acceleration, active or passive speed control, measuring range of up to 20kHz, short-circuit detection and wire break monitoring integrated
                            Outputs
                            • Number of analog and digital outputs are customized according to the project
                            General control modes for turbines
                            • Speed control
                              • Cold/warm start-up mode
                              • Start-up ramp with a maximum of 24 sampling points
                              • Critical speed avoidance
                            • Live steam pressure control
                              • Min. live steam pressure limiter
                              • Max. live steam pressure limiter
                            • Up to 2 x extraction pressure control
                              • Up to 2 x min. extraction pressure limiter
                              • Up to 2 x max. extraction pressure limiter
                            • Back pressure control/exhaust steam pressure control
                              • Min. back pressure limiter
                              • Max. back pressure limiter
                            • Gland steam pressure control
                            • Max. wheel chamber pressure limiter
                            • Other control/limiter functions on request
                            Control modes for generators
                            • Frequency control/frequency support
                            • Island modes
                            • Power control
                              • Min. load limiter
                              • Max. load limiter
                            • Other control/limiter functions on request
                            Control modes for pumps compressors, fans etc.
                            • External analog set-point for speed control
                            • Suction/discharge pressure control
                              • Min. suction/discharge pressure limiter
                              • Max. suction/discharge pressure limiter
                            • Anti-surge control with an unlimited no. of valves
                            • Surge protection
                            • Other control/limiter functions on request

                             

                            Typical applications

                            • Control of steam turbines that drive compressors, pumps, fans and other driven machines
                            • Control of steam turbines that drive generators
                            • Upgrade/retrofit of mechanical steam turbine governors/controllers
                            • Upgrade/retrofit of analog steam turbine governors/controllers, especially:
                              • Voith TurCon A
                              • Siemens/ KKK SC 800
                              • MAN/ GHH Turbolog EKU
                              • Dresser Nadrowski / M+M / AEG Kanis / ABB CTn, CTp and CTf
                            • Upgrade of steam turbine controllers Woodward 505 and Woodward 505E
                            • Non-redundant steam turbine controller upgrades

                            Advantages and benefits

                            Features Advantages Benefits
                            • Planning consulting expertise including use and cost-optimization for the entire control system
                            • More than 30 years expertize in DCS, controller, actuators and turbine/compressor interactions
                            • Cost-effective actuator and control solution regarding investment and operating costs (TCO)
                            • The control solution is designed to be suitable for all types of steam turbines and compressors, this includes manufacturer and power applications
                            • One control system for a variety of turbines and compressors
                            • Simple and cost-effective spare parts management
                            • Operating personnel use one control system
                            • One reliable contractor for several turbines and compressors
                            • Upgradeable for additional future functions, e.g. new control modes or additional limiting functions
                            • Controller software and number of inputs and outputs can be adjusted within the existing control system
                            • Upgrades can be realized easily and at a low costs. Furthermore, there is no necessity to exchange the whole control system
                            • IoT ready control system
                            • Provision off all relevant data from the controller via multiple communication interfaces
                            • Optional data recorder, on request
                            • Future-proof control system
                            • 15-inch TFT LCD control panel with intuitive touchscreen operator interface
                            • User-friendly and modern HMI
                            • All parameters can be adjusted onsite and relevant process values visualized
                            • Quick and brief operational staff training
                            • Onsite you can enjoy quick, informative process visualization and monitoring
                            • Web visualization via Ethernet and specified web browsers
                            • Complete visualization access with standard components
                            • Several units can simultaneously access the TurCon visualization
                            • Access to TurCon visualization requires no additional license costs
                            • Quick and easy access without special software installations
                            • Watchdog monitoring
                            • I/O malfunctions can be detected in real time
                            • System failure avoidance and the consequences thereof caused by the incorrect an input/output status

                             

                            Applications

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