BLA POWER PVT.

LTD
WOODWARD 505 GOVERNOR VALVE / ACTUATOR
CALIBRATION &TEST
LALIT SINGH
Sr. Engineer
C&I Dept.
WHY CALI BRATI ON/STROKE
CHECKI NG REQUI RED
Before initial operation or after a turbine overhaul where any actuator or valve
travel may have been affected, the below Valve Calibration procedure should be
followed to insure that the 505 is correctly calibrated to the turbine control
valve(s). When calibration is complete, 0 to 100% actuator position as displayed
by the 505 must equal 0 to 100% actual valve travel.
BEFORE START PROCEDURE
Before calibrating or testing, the unit must be tripped and the steam
supply removed. This is to ensure that opening the control valve (s)
will not allow steam into the turbine. Overspeed sensing and its
relay are disabled during this process. Overspeeding the turbine
may cause damage to turbine and can cause severe injury or death
to personnel. STEAM TO THE TURBINE MUST BE SHUT OFF BY
OTHER MEANS DURING THIS PROCESS.

505 KEY PAD AND DISPLAY

IN WOODWARD STEP-1
The 505s Emergency shutdown contact input must be closed or
jumpered throughout this procedure (All Turbine Trip Interlock From DCS Side will by pass after that
setting jumper as mention below TBs after that DCS will not be able to turbine trip)
J UMPERE DETAI L I N TSP PANEL
Jumper J1:- In TSP Panel DIT-1 & DIT-2 .
Jumper J2:- In TSP Panel DIT-5 & DIT-6
Jumper J3:- In TSP Panel DIT-7 & DIT-8
Jumper J4:- In TSP Panel DIT-11 & DIT-12
Jumper J5:- In TSP Panel DIT-13 & DIT-14
Jumper J6:- In TSP Panel DIT-17 & DIT-18

IN WOODWARD STEP-2
Execute a system RESET command (Press the 505 Reset key)
Press the 505s front panel Emergency Shutdown button.
Press the ACT key then the SCROLL DOWN key until the
Stroke Actuators - Dsbled, Steam Must be Off message
appears. (Verify that the turbines steam supply has been shutoff
before by an external Trip and Throttle valve.)
IN WOODWARD STEP-3
Press the YES key (This will cause the screen to display a
Stroke to Min - Enabled, Min Curr Adjust *XX.XX message).
Press the YES key to enable this mode or the Scroll Down
Arrow to step to the mode desired
IN WOODWARD STEP-4
Stroke to Min - Enabld, Min Curr Adjust * XXX.XX Press YES to force
the actuator output to the minimum stop. The message will display At Min and the
actuator output current will move to its minimum setting. The minimum current
value can be adjusted only when the at sign (@) is on the bottom line of the
display. Press the SELECT key to move the @ symbol between the top and bottom
lines. Press the ADJ UP or DOWN keys to change the 0% actuator current level.
Press the SCROLL DOWN ARROW to step the next desired mode, or the
CLEAR key twice to save changes, and exit Calibration mode.
IN WOODWARD STEP-5
Stroke to Max - Enabld, Max Curr Adjust * XXX.XX Press YES to force
the actuator output to the maximum stop. The message will display At Max and the
actuator output current will move to its maximum setting. The maximum current
value can be adjusted only when the at sign (@) is on the bottom line of the
display. Press the SELECT key to move the @ symbol between the top and bottom
lines. Press the ADJ UP or DOWN keys to change the 100% actuator current
DOWN ARROW to step the next desired mode, or the CLEAR key twice to save
changes and exit Calibration mode.
IN WOODWARD STEP-6
Manually Adjust - Enabld, Stroke Valve XXX.XX Press the ADJ UP, ADJ DOWN keys from this
screen to move the valves output current between 0-100% at a 5%/second rate. This allows both the
actuator and valve to be tested for binding, play, resolution, linearity, and repeatability.
Press the YES key at any time to allow a setting to be directly Entered. The message will display
Manual when the ENTER mode is allowed. When in the Manual mode, press the ENTER key, enter
the setting desired, then press the ENTER key again. This will step the actuator output to a specific
position instantly. Press the ADJ UP/DOWN or No keys at any time to switch back to the Enabld
mode.
When calibration is complete, 0 to 100% valve position as displayed by the 505 must equal 0 to
100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the
CLEAR key twice to save changes and exit Calibration mode.
INFORMATION
Press the CLEAR key twice to permanently save any
minimum or maximum actuator settings into the 505. If
variables are tuned or changed but not stored in EEPROM by
pressing the CLEAR key twice, then those changes will be lost
if power is removed from the control or if the control receives a
CPU reset.
FLOW CHART

SCREEN DETAIL
Screen 3 show only when the unit is shut down. Screen 4,5 and 6 show
only when stroke actuator is set to yes .
The asterisk (*) denotes a tunable parameter . To adjust this parameter
, the @ symbol must be on the display line containing the asterisk .
The @ symbol is moved with the selection key .
Note :- If change are made to min or max current values they can be
recoded on the program mode worksheet under the Driver
Configuration header .
STROKE ACTUATOR MESSAGES
MESSAGE MEANING
Dsbld Stroke actuators function is disabled
Enabld Stroke actuators function is enabled
At Min Actuator output is set to the minimum
value ( 0% )
At Max Actuator output is set to the maximum value ( 100% )
Manual Actuator output is in manual mode
VOI TH I / H CONVERTER OR CPC
Voith electro hydraulic I/H converters 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 ensure very precise and highly 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 with respect to 2- 4 Kg/Cm2 O/P Hydraulic Pressure . The major
components of the I/H converter are a hydraulic unit and a force-controlled electromagnet.



WORKING PRINCIPAL
A set signal w = 4...20 mA generates a magnetic force FMag in the VRM, the limits of which can be adjusted
by means of the X0 and X1 potentiometers and which is then transmitted onto the control piston via tappet. The
hydraulic force FHyd being proportional to the output signal pressure PA acts against this force. In the case of
the two forces being equal, the control piston is positioned in the hydraulic center as shown in fig. and the
output signal pressure PA corresponds to the set signal. In the hydraulic center position the control piston
performs minimum oscillating movements in the area of the guiding edges PPA and PAT, in order to keep
the output pressure PA on the value set by FMag. When increasing the set signal and thus FMag from this
condition, the control piston position changes and thus connects the output pressure PA to the feed pressure P
and blocks PA towards the tank return line T1and T2. Now pressure PA will increase until the same has returned
the control piston to the hydraulic center and PA corresponds to the new set signal. The spring force FFed of
the control spring generates a force-offset in order to guarantee the I/H converter function for output pressures
of approx. 0 bar, too.

FUNCTION
Solenoid-force control generates a magnetic force of FMag in a 24V d.c. solenoid.
This magnetic force is proportional to the 0/4 20 mA input signal , the limits are
configured using the X0 and X1 parameters. The electronic control, magnetic flux
measurement, engineering design of the magnet and the hydraulic pilot control together
form a dynamic functional unit that is practically free of hysteresis.
The control magnet applies the force FMag to the control piston. This in turn
counteracts hydraulic force FHydr as generated by the pressure at output A over the
cross-sectional area of the control piston .
As a result of this regulation, the output line of the actuator always receives the exact
required pressure and the oil quantity for positioning the steam or fuel valves.
CALIBRATION
Due to unintentional maladjustment of the parameters or changed operating conditions,
new setting of one or both parameters may become necessary. We recommend to document
adjustment of the parameters as well as the set values. The parameters are adjusted by means
of potentiometers X0 and X1.
X0 - With help of potentiometer X0 the minimum output pressure PA min is adjusted at a
set point of 4 mA. Pressure increase by turning the potentiometer clockwise.
X1 - With help of potentiometer X1 the maximum output pressure PA max is adjusted at a
set point of 20 mA. Pressure increase by turning the potentiometer clockwise.
Note:-X1 should be adjusted before X0. The X1- adjustment influences the
adjustment of X0
I/P CURRENT V/S O/P PRESSURE
S.No.
I/P Comm.
(0-100% wrt 4-
20mA)
O/P Press. Kg/Cm2
Inc.
O/P Press. Kg/Cm2
Dec.
1
0 2 2
2
10 2.18 2.19
3
20 2.36 2.37
4
30 2.55 2.57
5
40 2.74 2.76
6
50 2.94 2.96
7
60 3.14 2.16
8
70 3.34 3.36
9
80 3.57 3.57
10
90 3.76 3.77
11
100 3.99 3.99