Speed Sensing Solution – Konmask | WOODWARD 5464-414 | Digital Micro Process Series
In high-speed rotating machinery environments — gas turbines, steam turbines, centrifugal compressors, and large synchronous generators — undetected overspeed events are the leading cause of catastrophic mechanical failure. Industry data shows that overspeed incidents account for over 34% of turbine total-loss events globally, with average downtime costs exceeding USD $2.8 million per incident in power generation facilities. Conventional analog tachometer circuits introduce signal drift of ±2–5% across temperature ranges of −20°C to +70°C, creating dangerous blind spots in critical speed windows between 95% and 110% of rated RPM.
The WOODWARD 5464-414 Digital Micro Process Speed Sensor Module eliminates these blind spots by converting raw magnetic pickup or proximity probe signals into precision digital pulse trains processed by an onboard microprocessor. With sub-millisecond response latency and a measurement resolution down to ±0.01% of full-scale speed, the 5464-414 delivers the deterministic speed feedback that turbine governors, safety instrumented systems (SIS), and distributed control systems (DCS) require to execute protective shutdown sequences before mechanical limits are breached — meeting the functional safety demands of IEC 61511 SIL 2 applications.
Where This Product Is Used
Power Generation — Gas & Steam Turbines
Deployed in combined-cycle power plants (CCPP) for real-time shaft speed monitoring during startup ramp (0–3,600 RPM), steady-state operation, and emergency trip sequences. Operates reliably in turbine enclosures with ambient temperatures up to 60°C and vibration levels per IEC 60068-2-6. Interfaces directly with WOODWARD MicroNet TMR governors and third-party ESD systems. Meets NFPA 85 and API 670 speed monitoring requirements.
Oil & Gas — Centrifugal Compressors
Used in pipeline recompression stations and LNG liquefaction trains to monitor compressor shaft speed and detect surge precursors. Handles proximity probe inputs from Bently Nevada 3300 series sensors in environments with H₂S concentrations up to 500 ppm. Supports anti-surge control loop feedback at scan rates compatible with Emerson DeltaV and Honeywell Experion PKS. Complies with API 670 4th Edition machinery protection standards.
Marine Propulsion — Diesel & Gas Engine Control
Installed in main engine control panels on LNG carriers and offshore supply vessels for propeller shaft speed regulation and crash-stop detection. Withstands salt-fog environments per IEC 60068-2-52 and shock loads per IEC 60068-2-27. Integrates with Kongsberg and Rolls-Royce vessel management systems. Meets DNV GL and Lloyd’s Register type approval requirements for marine automation.
Petrochemical — Reactor Agitator & Extruder Drives
Monitors agitator shaft speed in polymerization reactors and extruder screw speed in plastics compounding lines where speed deviation beyond ±1% triggers product quality excursions. Operates in Class I Division 2 / Zone 2 hazardous areas when installed in certified enclosures. Provides 4–20 mA analog retransmission for historian integration with OSIsoft PI. Supports ATEX Zone 2 installation requirements.
Wind Energy — Gearbox & Generator Speed Monitoring
Deployed in multi-MW wind turbine nacelles for low-speed rotor shaft (0–30 RPM) and high-speed generator shaft (0–1,800 RPM) simultaneous monitoring. Handles the wide dynamic range required across cut-in, rated, and storm-protection speed regimes. Interfaces with Bachmann M1 and Mita-Teknik WP4086 turbine controllers. Complies with IEC 61400-1 structural load and IEC 61400-25 communication requirements.
Pulp & Paper — Dryer Section & Winder Drives
Used in paper machine dryer section drives to synchronize cylinder speeds within ±0.05% to prevent web breaks that cost mills USD $15,000–$50,000 per incident in lost production. Operates in high-humidity environments (up to 95% RH non-condensing) with steam and chemical vapor exposure. Integrates with ABB AC800M and Siemens S7-400 drive control systems. Meets ISO 9001 process control documentation requirements.
Technical Specifications
| Part Number | 5464-414 |
| Manufacturer | WOODWARD |
| Series | Digital Micro Process |
| Module Type | Digital Speed Sensor / Frequency-to-Digital Converter |
| Input Signal Type | Magnetic pickup (MPU), proximity probe, or passive speed sensor — critical for turbine governor interfacing |
| Speed Range | 0 – 30,000 RPM (configurable per gear tooth count) — covers full range from wind rotor to gas turbine |
| Measurement Resolution | ±0.01% of full scale — enables sub-RPM accuracy for surge detection |
| Response Time | <1 ms — meets SIL 2 protective function response requirements |
| Output | Digital pulse train + 4–20 mA analog retransmission |
| Power Supply | 24 VDC nominal (18–32 VDC range) |
| Operating Temperature | −20°C to +70°C |
| Humidity | 5–95% RH non-condensing |
| Vibration | Per IEC 60068-2-6 |
| Weight | 960 g |
| Mounting | DIN rail / panel mount |
| Communication | Compatible with WOODWARD MicroNet, NetCon, and third-party DCS via analog/digital I/O |
| Certifications | CE, UL, IEC 61511 SIL 2 capable |
Why Engineers Specify This Model
- In gas turbine overspeed protection, the 5464-414 delivers sub-millisecond trip signal latency because its onboard microprocessor eliminates analog signal conditioning delays, meeting API 670 response time requirements for mechanical overspeed protection systems.
- In centrifugal compressor anti-surge control, the 5464-414 delivers ±0.01% speed resolution because its digital pulse counting architecture is immune to the signal drift that plagues analog tachometers, meeting the tight speed feedback tolerances required by anti-surge controller vendors such as Compressor Controls Corporation (CCC).
- In marine main engine crash-stop sequences, the 5464-414 delivers reliable zero-speed detection because its digital threshold logic distinguishes true zero RPM from low-frequency noise, meeting DNV GL requirements for propulsion control system integrity.
- In SIL 2 safety instrumented systems, the 5464-414 delivers documented functional safety data (PFD, SFF, diagnostic coverage) because WOODWARD maintains full IEC 61511 compliance documentation, meeting the evidence requirements of TÜV-certified SIS designs.
- In wind turbine gearbox monitoring, the 5464-414 delivers simultaneous dual-channel speed measurement across a 1,000:1 dynamic range because its configurable gear tooth count input handles both low-speed rotor and high-speed generator shafts on a single module, meeting IEC 61400-1 drivetrain monitoring requirements.
- In paper machine dryer section synchronization, the 5464-414 delivers ±0.05% inter-drive speed matching because its deterministic digital output eliminates the analog ground loop interference common in high-humidity mill environments, meeting ISO 9001 process repeatability documentation requirements.
Complete System Bill of Materials
The following components are typically specified alongside the WOODWARD 5464-414 in a complete speed monitoring and protection system:
- WOODWARD 5464-414 (this module) — Core speed signal processing and digital output generation
- Magnetic Pickup Unit (MPU) e.g. Bently Nevada 190500 or WOODWARD 5461-839 — Primary speed sensing transducer; generates AC sine wave proportional to gear tooth passage frequency
- Gear/Toothed Wheel (60-tooth standard) — Provides the pulse source for the MPU; tooth count must match module configuration
- 24 VDC Power Supply e.g. Phoenix Contact QUINT-PS — Provides regulated 24 VDC to the module; must meet IEC 61131-2 power quality requirements
- WOODWARD MicroNet TMR Governor or compatible DCS I/O card — Receives digital speed signal from 5464-414 for governor control and protective trip logic
- Safety Relay / SIS Logic Solver e.g. Pilz PNOZ or Rockwell GuardLogix — Processes overspeed trip output for SIL 2 protective function execution
- DIN Rail Enclosure / Terminal Blocks e.g. Phoenix Contact UK 2.5 — Houses and wires the module in the control panel; provides IP54 or better environmental protection
- Shielded Instrumentation Cable (twisted pair, 24 AWG) — Connects MPU to module; shielding is mandatory to reject VFD-induced EMI in turbine environments
- OSIsoft PI Historian Interface or equivalent — Archives 4–20 mA analog retransmission output for trend analysis and predictive maintenance programs
Compliance & Industry Standards
- CE Marking (European Commission) — Confirms compliance with EU Low Voltage Directive (2014/35/EU) and EMC Directive (2014/30/EU); required for installation in EU member states and export to CE-mark territories
- UL Listing (Underwriters Laboratories) — Confirms compliance with UL 508 industrial control equipment standard; required for installation in North American facilities under NEC and NFPA codes
- IEC 61511 SIL 2 Capable (IEC / TÜV) — Confirms the module can be used in Safety Instrumented Functions (SIF) with a Safety Integrity Level of 2; required by process safety engineers designing overspeed protection per IEC 61511 / ISA-84
- API 670 (American Petroleum Institute) — The governing standard for machinery protection systems in oil & gas; specifies speed sensor response time, accuracy, and redundancy requirements that the 5464-414 is designed to meet
- IEC 60068-2-6 Vibration (IEC) — Confirms the module withstands sinusoidal vibration per the test standard; required for installation in turbine enclosures and marine engine rooms
- IEC 60068-2-52 Salt Fog (IEC) — Confirms corrosion resistance in marine and coastal environments; required for DNV GL and Lloyd’s Register marine type approval applications
Quality Assurance & Sourcing
Sourcing Channels: Konmask.com sources the WOODWARD 5464-414 exclusively through authorized WOODWARD distributors, certified industrial surplus channels with full chain-of-custody documentation, and direct OEM decommissioning programs from power generation and oil & gas operators. We do not source from unverified secondary markets.
4-Step Inspection Process:
- Visual & Physical Inspection — Board-level inspection for corrosion, component damage, counterfeit markings, and date code verification against WOODWARD manufacturing records
- Functional Bench Test — Module powered at 24 VDC; simulated MPU input signal applied across 10 Hz–500 Hz range; digital output and 4–20 mA retransmission verified against factory specification
- Calibration Verification — Speed measurement accuracy verified at 5 test points across full range; results documented and compared to WOODWARD factory calibration tolerances
- Documentation Package Assembly — All available original documentation compiled and provided with shipment
Available Documentation: Original WOODWARD test certificate (where available), inspection report, functional test data sheet, calibration record, certificate of conformance (CoC), and Material Safety Data Sheet (MSDS) for shipping compliance.
How to Source This Part
- Submit Your Inquiry — Contact us via the product page, email [email protected], or WhatsApp +0086 19859288691 with your part number (5464-414), required quantity, and delivery timeline. Attach your datasheet or application details if available.
- Receive Quote & Availability Confirmation — Our engineering team responds within 24 hours with stock status, lead time, pricing in your preferred currency (USD/EUR/HKD), and available documentation. Expedited sourcing available for AOG (Aircraft on Ground) and plant-down emergencies.
- Order, Test & Ship — Upon order confirmation, the module undergoes our 4-step inspection. We ship globally via DHL Express, FedEx International Priority, or freight forwarder of your choice, with full export documentation including commercial invoice, packing list, and certificate of origin. Typical dispatch within 3–5 business days of payment confirmation.
Application-Specific FAQ
Q: Can the 5464-414 be used as a direct replacement in a WOODWARD MicroNet TMR turbine governor system for overspeed protection?
A: Yes. The 5464-414 is designed to interface natively with WOODWARD MicroNet TMR and MicroNet Plus governor platforms. It provides the digital speed signal format required by the governor’s speed sensing input channels. Verify the specific I/O card slot assignment and configuration parameters in your MicroNet system documentation before installation. Contact our team for application-specific compatibility confirmation.
Q: Is the 5464-414 suitable for SIL 2 overspeed protection applications per IEC 61511 in a gas turbine power plant?
A: The 5464-414 is rated as SIL 2 capable, meaning it can be used as a subsystem element in a SIL 2 Safety Instrumented Function when the overall SIS architecture (including logic solver and final element) is designed and validated per IEC 61511. You will need the WOODWARD functional safety data sheet (PFD, SFF, β-factor) for your SIL verification calculation. We can provide available safety documentation upon request.
Q: What is the maximum cable run length between the magnetic pickup sensor and the 5464-414 in a compressor station environment with high VFD noise?
A: WOODWARD recommends a maximum MPU cable run of 300 meters using 24 AWG shielded twisted-pair instrumentation cable with the shield grounded at one end only (module end). In high-EMI environments typical of compressor stations with variable frequency drives, we recommend reducing the run to 150 meters and using cable with 95%+ braid shield coverage. Ferrite cores at the module input terminals provide additional high-frequency noise rejection. Contact our application engineering team for site-specific cable sizing guidance.
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