BANGLADESH RESEARCH PUBLICATIONS JOURNAL

ISSN: 1998-2003, Volume: 5, Issue: 4, Page: 381-386, July -August, 2011

WOODWARD GOVERNOR’S TROUBLESHOOTING AND

RECTIFICATION: A CASE ON JAMUNA FERTILIZER COMPANY
PERSPECTIVE
*Md Mamunur Rashid1 and Md. Abdul Mannaf2

Md Mamunur Rashid and Md. Abdul Mannaf (2011). Woodward Governor’s

Troubleshooting and Rectification: A Case on Jamuna Fertilizer Company Perspective.
Bangladesh Res. Pub. J. 5(4): 381-386. Retrieve from
http://www.bdresearchpublications.com/admin/journal/upload/09246/09246.pdf

Abstract
Woodward governor is a mechanical sophisticated device. Normally
this governor is not maintenance in Bangladesh. Generally, if governor
falls in trouble then we replaced it by new one simply. Woodward
governor manufacturer does not permit to the users for maintenance
works of governor. This governor generally is used in heavy-duty turbine
and engine. The maintenance of the Woodward governor is successfully
done in Jamuna Fertilizer Company. In this perspective, a Woodward
governor’s trouble shooting and rectification related study is presented
in this article.
Key Words: Jamuna Fertilizer Company Limited, Woodward Governor,
Rectification, Turbine.
Introduction
Governor is a device, which maintains the constant speed of an engine or
turbine, regardless of load, that is, if the load changes of an engine, the speed of
the engine will also change but the governor will control the fuel flow
instantaneously to maintain the constant speed of the engine. A turbine is also
considered an engine. Thus, in this paper is discussed regarding steam turbine
generator (STG), which is operated by steam turbine, to obtain steady voltage
and frequency. Moreover, Jamuna Fertilizer Company (JFCL) related some
papers are published [Rashid, (2011), Manaf. and Rashid, (2002, 2004), Rashid and
Islam, (2004)]. The generator speed must be constant. On running condition, the
generator load may be changed. Suppose, the generator is loaded suddenly,
then the speed of the generator instantaneously decreased, at once the
governor will increase the fuel flow or steam flow to obtain the generator speed
constant as before. On the other hand, due to sudden unloading the speed of
the generator will be increased instantaneously, then the governor will decrease
the fuel flow or steam flow until the generator speed becomes previous set
speed. In this way, governor maintains the constant speed during running
condition. Old model governor has no internal oil pump, control oil is supplied to
the governor by external arrangement, but modern governor has internal oil
pump (gear pump), which is used for better and safe operation. WOOD WARD
GOVERNOR CO. LTD, USA is only modern governor manufacturer in the world.
They do not suggest repairing the governor locally like JFCL [Rashid, (2011),

*Corresponding Author’s email: mamun87245@gmail.com

1 Bangladesh Institute of Management, 4, Sobhanbag, Mirpur Road, Dhaka-1207.
2 Jamuna Fertilizer Company Limited, Tarakandi, Jamalpur-2055, Bangladesh.
Rashid and Mannaf 382

Manaf. and Rashid, (2002),] of Bangladesh, although already some governors

have rectified, which are running in the plant. To test and to calibrate the
governor by the governor test bench only in Chittagong Urea Fertilizer Limited
(CUFL) in Bangladesh. Now a day, electronics governor, which is most modern
and sophisticated equipment, is used in turbine or engine control system. In JFCL,
only electronics governor is used at GTG. Only WOOD WARD GOVERNOR CO.
LTD. USA, [8] in the world manufactures the governor and they advice the users
not to do maintenance works. Although the governor trouble and rectification
works have been done at JFCL. This paper is focused on this maintenance works
and divided the following sections:
¾ Description of Woodward governor
¾ Remarkable Maintenance works in JFCL
¾ Discussion
¾ Recommendation
¾ Conclusion
Description of Woodward governor
Governor maintains the constant speed of an engine or turbine irrespective of
load by sequence of action and operation. Governor drive shaft is connected
directly to the turbine shaft by reduction gearbox to sense the speed from the
turbine. Simple explanation of input-output signal to the governor as below:
Speed Setting Input

Governor Output Shaft C.W/C.C.W

As Output

Speed Input

Figure 1. Input-output signal of Governor

This drive shaft mainly operates two elements: One lube oil pump (gear
pump) another ball head mechanism. Lube oil pump generates control oil and
the ball head mechanism regulates this control oil to actuate the governor output
shaft. The ball head mechanism consists of two flyweights, speeder spring and
pilot valve plunger. Flyweight movements inward or out ward direction depend
upon the speeder spring pressure and speed of the turbine. If the governor speed
is more, then the flyweight becomes outward position, which pushes the pilot
valve plunger upward, direction, regulating the control oil to the power piston as
the governor shaft decreases fuel position. In reverse matter, if the governor
speed is suddenly decreased, then the flyweight becomes inward position, which
allows the pilot valve plunger downward, direction, regulating the control oil to
the power piston as the governor output shaft increases fuel position. Speed
setting system is nothing but the pressure of the speeder spring, which is operated
manually or by servomotor remotely. Governor output shaft moves clockwise or
counter clockwise i.e. fuel increase or decrease position, which depends upon
the speed setting and input speed. The conditions of the speed setting and input
speed are following:
™ If the input speed is greater than the setting speed, the governor
output shaft will decrease fuel position.

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Woodward Governor’s Troubleshooting and Rectification 383

™ If the input speed is less than the setting speed, the governor output
shaft will increase fuel position.
™ If the input speed is equal than the setting speed, the governor
output will become stationary that is governor will remain steady
state condition.
Speed control system
A Speed control system of a turbine is shown in the following block diagram
figure. Assume the speed 1500 rpm of the generator have to maintain. Initially, the
governor setting speed 1500 rpm have to set.
Speed Setting Signal

Output
Governor Pilot Mech. Power
Shaft System move Cylinder Mech.
move move

Steam in

Governor
Speed Valve
Turbine Speed Reducer Generator
Speed

High pressure Steam (control)

Steam out

High Pressure Steam Header

Figure 2. Speed control diagram

Now, if the governor is suddenly loaded, the speeds of the generator will
little less than 1500 rpm, instantaneously. Then the governor will actuate that is
governor output shaft moves clockwise direction (increase fuel). Consequently
the pilot valve moves downward by linkage arrangement then the pressure oil
enter to the power cylinder which moves the governing valve up, the more steam
flows to the turbine to maintain the speed of the generator through 1500 rpm.
Reversibly, if the generator is suddenly unloaded, the speed of the generator will
little higher than 1500 rpm, instantaneously. Then the governor output shaft moves
counter clockwise direction (decrease fuel). Subsequently, that the pilot valve
moves upward by linkage arrangement, pressure oil cut the flow to the power
cylinder, which moves the governing valve down, then steam flow decreases to
the turbine as a result generator speed, will become 1500 rpm again.
Additional items of governor
The following items of governor, which are to adjust to the governor during
operation:
Compensation: Compensation system is to give stability to the governor and
obtains steady state speed control by adjusting the needle valve orifice, which
control the oil flow between both compensation piston and oil sump.
Droop Mode: Drop is the decrease in speed taking place when the governor
output shaft moves from minimum to maximum fuel position in response to a load
increase.
Droop= [(No load speed –Full load speed)/ Full load speed] X 100=3.5%; Reducing
droop to zero allows the unit to change the load without changing speed, which
is called ISO-mode. Only JFCL, Gas turbine Generator (GTG) runs ISO –mode.
Load limit: The purpose of the load limit control is to hydraulically and
mechanically limit, the load that can be placed on the turbine by restricting the
travel of the governor output shaft in the increase fuel direction. The load limit
control may also be used for shutting down the turbine by turning it to zero.

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Rashid and Mannaf 384

Governor components for speed setting

A brief description of the governor components will facilitate understanding the
speed setting and operation of the governor.
Oil pump: The oil pump (gear pump) is driven by governor driven shaft, which is
driven by the prime mover (turbine). Oil flow is directed into the accumulator
system.
2.3.2 Accumulator: The purpose of the accumulator is to store oil under pressure
for operation of the governor.
Power piston: The power piston is to rotate the governor output shaft to the
increase or decrease fuel position.
Pilot valve system
The pilot valve plunger and bushing is to control the oil flow to or from the bottom
of the power piston.
Ball head system
The ball head system is to sense speed changes of the prime mover (turbine) as
compared to the speed setting reference given by the speeder spring and to
give position the pilot valve plunger.
Remarkable Maintenance works in JFCL
Only WOOD WARD GOVERNOR CO. LTD. USA, in the world manufactures
the governor and they advice the users not to do maintenance works. Although
the following examples of governor trouble and rectification works have been
done at JFCL:
Case 1
In JFCL, Carbon-di-oxide compressor’s minimum governor speed was
comparatively high. It was near about rated speed, which was observed during
start up period since erection December 1991. For this reason steam turbine
speed becomes sudden high and turbine was being hunting for long time. This
adjustment especially in high speed and high power turbine was so risky on
running condition. Any mistakes during adjustment may cause severe damage.
This situation was conquered by adjusting pilot valve system.
Case 2
Gear operated manual speed setting Knob of Induced draft fan (IDF)
turbine was broken and the minimum governor speed of IDF turbine was become
undefined. The trial and error method at startup period and defined the minimum
governor speed successfully.
Case 3
NG compressor seal oil turbine governor (SG governor) was hunting for
long time. For this reasons, this problem has been rectified to replace the new ball
bearing in drive end side of the turbine, to fabricate new coupling bush with
governor. Hence, control has been dismantled for inspection, but the hunting of
the turbine was existed. Later adjusted the droop of the governor by opening
governor head, subsequently the hunting was stopped.
Case 4
Due to fire in natural gas (NG) compressor, PG-PL governor was completely
damaged. This governor was stored under open sky for long time. Later on this
governor dismantled and checked each and every parts of the governor. Some
parts replaced by another rejected governor. Then it made fully in service
condition. This type of governor from WOOD WARD CO.LTD, USA can be

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Woodward Governor’s Troubleshooting and Rectification 385

purchased, then need around BDT. 1 (one) million. Consequently, that money was
saving of JFCL.
Case 5
Lean turbine governor speed sensing device was broken completely. It
was made in by own JFCL design and it was set successfully for operation. Now
this is running with good condition.
Discussion
A maintenance platform may introduce unprecedented levels of
transparency and efficiency into the entire industry producing an integration of
business process that significantly contributes to the acceleration of total
processes, to an easier design (lean processes) and to synchronize maintenance
with production, maximizing process throughout and minimizing downtime cost
[Hausladen and Bechheim, 2004]. Data and information flows into the decision
making and planning process at all levels can be improved [Ucar and Qiu, 2005].
The maintenance analysis of Woodward governor of JFCL has done based on
different situations has been discussed on the five cases. By minimizing the
maintenance cost allocation to various subsystems with any governor, the
optimum repair policy can be determined through details study. Maintenance is
linked with safety and quality maintenance; moreover preventive, remote,
predictive, collaborative maintenance can save plant damage and also save
foreign currency. For this purpose, Inspection, monitoring, modification,
improvement, knowledge capitalization and management can be considered
also for Woodward governor maintenance, and also for overall plant
maintenance.
Recommendations
The following recommendations are for maintenance work or
management purpose:
¾ E-manufacturing, e-business and e-maintenance can be
considered for plant operation.
¾ Fault/ Failure analysis can be done properly.
¾ Maintenance documentation can be kept properly.
¾ Predictive, preventive maintenance can be functional in plant
operation.
¾ Business process integration may be consideration.
Conclusion
This paper presents an overview of Woodward governor maintenance
capabilities and challenges in Bangladesh perspective. According to finding, any
adjustment, calibration, setting and troubleshooting regarding turbine control
system can be solved in Bangladesh with foreign expert. Any trouble of specific
Wood ward governor’s rectification, trouble shooting and modification can be
done in Bangladesh. Hence it is saving foreign currency.
References
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business process integration. In: Proceedings of INDIN04, 2nd IEEE
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Manaf, M. &. Rashid, M.M. (2004). A process upgrading of urea synthesis and
high pressure recovery section by reducing pressure from high pressure
loop, Proceedings of the national paper meeting on fertilizer sector, IEB,

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Rashid and Mannaf 386

Rangadia, Chittagong, Bangladesh, July 09, 2004, Paper No 1B, pp. 68-72
Manaf, M. &. Rashid, M.M. (2002). Technical Challenge about Woodward
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