Woodward SonicFlo Manuel utilisateur

Product Manual 35022

(Revision A, 2/2017)

Original Instructions

SonicFlo™

High Temperature Gas Fuel Control Valves

High Recovery and Ultra High Recovery Designs

(Dual Core LVDT with No-trip and Enhanced Dynamics

Package)

Installation and Operation Manual

General

Precautions

Read this entire manual and all other publications pertaining to the work to be

performed before installing, operating, or servicing this equipment.

Practice all plant and safety instructions and precautions.

Failure to follow instructions can cause personal injury and/or property damage.

Revisions

This publication may have been revised or updated since this copy was produced.

To verify that you have the latest revision, check manual

26455

, Customer

Publication Cross Reference and Revision Status & Distribution Restrictions, on

the publications page of the Woodward website:

www.woodward.com/publications

The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative

to get the latest copy.

Proper Use

Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or

property damage, including damage to the equipment. Any such unauthorized

modifications: (i) constitute "misuse" and/or "negligence" within the meaning of

the product warranty thereby excluding warranty coverage for any resulting

damage, and (ii) invalidate product certifications or listings.

Translated

Publications

If the cover of this publication states "Translation of the Original Instructions"

please note:

The original source of this publication may have been updated since this

translation was made. Be sure to check manual

26455

, Customer Publication

Cross Reference and Revision Status & Distribution Restrictions, to verify whether

this translation is up to date. Out-of-date translations are marked with . Always

compare with the original for technical specifications and for proper and safe

installation and operation procedures.

Revisions— A bold, black line alongside the text identifies changes in this publication since the

last revision.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is

believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly

undertaken.

Manual 35022

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 1

Contents

WARNINGS AND NOTICES ...............................................................................................................3

ELECTROSTATIC DISCHARGE AWARENESS......................................................................................4

REGULATORY COMPLIANCE............................................................................................................5

CHAPTER 1. GENERAL INFORMATION..............................................................................................7

Introduction ...................................................................................................................................................7

CHAPTER 2. DESCRIPTION............................................................................................................15

Triple Coil Electrohydraulic Servo Valve Assembly....................................................................................15

Hydraulic Filter Assembly............................................................................................................................16

LVDT Position Feedback Sensors..............................................................................................................16

CHAPTER 3. INSTALLATION...........................................................................................................17

General........................................................................................................................................................17

Unpacking ...................................................................................................................................................18

Piping Installation........................................................................................................................................18

Electrical Connections.................................................................................................................................19

CHAPTER 4. MAINTENANCE AND HARDWARE REPLACEMENT.........................................................22

Maintenance................................................................................................................................................22

Hardware Replacement ..............................................................................................................................22

Inspections..................................................................................................................................................26

Troubleshooting ..........................................................................................................................................28

CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS ..............................................................31

Product Support Options.............................................................................................................................31

Product Service Options .............................................................................................................................31

Returning Equipment for Repair .................................................................................................................32

Replacement Parts......................................................................................................................................33

Engineering Services..................................................................................................................................33

Contacting Woodward’s Support Organization...........................................................................................33

Technical Assistance ..................................................................................................................................34

REVISION HISTORY.......................................................................................................................35

DECLARATIONS ............................................................................................................................36

The following are trademarks of Woodward, Inc.:

ProTech

Woodward

The following are trademarks of their respective companies:

Modbus (Schneider Automation Inc.)

Pentium (Intel Corporation)

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 2

Illustrations and Tables

Figure 1-1. High Recovery SonicFlo Gas Fuel Control Valves.....................................................................7

Figure 1-2a. SonicFlo Outline Drawing (2-inch, Class 300, no Trip) ............................................................9

Figure 1-2b. SonicFlo Outline Drawing (2-inch, Class 300, no Trip)..........................................................10

Figure 1-3a. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip)........................11

Figure 1-3b. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip)........................12

Figure 1-4. Hydraulic Schematic Circuit......................................................................................................13

Figure 1-5. Wiring Diagram.........................................................................................................................14

Figure 2-1. Servo Valve Cutaway...............................................................................................................15

Figure 3-1. Gas Fuel Control Valve Block Diagram....................................................................................20

Figure 3-2. Structures for PID Control ........................................................................................................20

Figure 4-1. Inspection Areas for 2 Inch Valves...........................................................................................27

Figure 4-2. Location of Hydraulic Interseal Drain and Cap for 2 Inch Valves.............................................27

Table 3-1. Class 300 Flange and Bolt Specifications.................................................................................18

Table 3-2. Recommended Control Gain Values for Different Control Types..............................................21

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 3

Warnings and Notices

Important Definitions

This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all

safety messages that follow this symbol to avoid possible injury or death.

DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.

WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious

injury.

CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate

injury.

NOTICE - Indicates a hazard that could result in property damage only (including damage to the

control).

IMPORTANT - Designates an operating tip or maintenance suggestion.

Overspeed /

Overtemperature /

Overpressure

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against

runaway or damage to the prime mover with possible personal injury,

loss of life, or property damage.

The overspeed shutdown device must be totally independent of the

prime mover control system. An overtemperature or overpressure

shutdown device may also be needed for safety, as appropriate.

Personal Protective

Equipment

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage.

Always wear the appropriate personal protective equipment (PPE) for

the job at hand. Equipment that should be considered includes but is

not limited to:

Eye Protection

Hearing Protection

Hard Hat

Gloves

Safety Boots

Respirator

Always read the proper Material Safety Data Sheet (MSDS) for any

working fluid(s) and comply with recommended safety equipment.

Start-up

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against

runaway or overspeed with possible personal injury, loss of life, or

property damage.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 4

Electrostatic Discharge Awareness

Electrostatic

Precautions

Electronic controls contain static-sensitive parts. Observe the

following precautions to prevent damage to these parts:

Discharge body static before handling the control (with power to

the control turned off, contact a grounded surface and maintain

contact while handling the control).

Avoid all plastic, vinyl, and Styrofoam (except antistatic

versions) around printed circuit boards.

Do not touch the components or conductors on a printed circuit

board with your hands or with conductive devices.

To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual

82715

, Guide for Handling and Protection of Electronic Controls,

Printed Circuit Boards, and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic

materials. Wear cotton or cotton-blend materials as much as possible because these do not store

static electric charges as much as synthetics.

2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.

If you must remove the PCB from the control cabinet, follow these precautions:

Do not touch any part of the PCB except the edges.

Do not touch the electrical conductors, the connectors, or the components with conductive

devices or with your hands.

When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in

until you are ready to install it. Immediately after removing the old PCB from the control cabinet,

place it in the antistatic protective bag.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 5

Regulatory Compliance

European Compliance for CE Marking:

These listings are limited only to those units bearing the CE marking

EMC Directive Declared to Directive 2014/30/EU of the European Parliament and of the

Council of 26 February 2014 on the harmonisation of the laws of the

Member States relating to electromagnetic compatibility, EMC. 2014/30/EU

is met by evaluation of the physical nature to the EMC protection

requirement. Electromagnetically passive or “benign” devices are excluded

from the scope of the Directive 2014/30/EU, however, they also meet the

protection requirement and intent of the directive.

Pressure Equipment

Directive (Valve

Assembly):

Directive 2014/68/EU on the harmonisation of the laws of the Member

States relating to the making available on the market of pressure

equipment.

Product Type/Size: PED Category II and III

PED Module H – Full Quality Assurance,

CE-0041-PED-H-WDI 001-16-USA, Bureau Veritas UK Ltd (0041)

ATEX – Potentially

Explosive

Atmospheres

Directive:

Directive 2014/34/EU on the harmonisation of the laws of the Member

States relating to equipment and protective systems intended for use in

potentially explosive atmospheres

Zone 2, Category 3, Group II G, Ex nA IIC T3X, IP54

See below for special conditions for safe use.

Other European Compliance

Compliance with the following European Directives or standards does not qualify this product for the

application of the CE Marking:

Machinery Directive: Compliant as partly completed machinery with Directive 2006/42/EC of the

European Parliament and the Council of 17 May 2006 on machinery.

ATEX: Exempt from the non-electrical portion of the ATEX Directive 2014/34/EU

due to no potential ignition sources per EN 13463-1.

North American Compliance:

Suitability for use in North American Hazardous Locations is the result of compliance of the individual

components: LVDT: CSA Certified for Class I, Divisions 1 and 2, Groups A, B, C, D, T4, for use

in the United States and Canada per CSA 151336-1090811.

Servo Valve: FM Certified for Class I, Division 2, Groups A, B, C, D per 1H1A8.AX for use

in the United States.

CSA Certified for Class I, Division 2, Groups A, B, C, D for use in Canada

per CSA 1072373.

Junction Box: UL Listed for Class I, Zone 1: AEx e II, Ex e II, T6 for use in the United

States and Canada per UL E203312.

Special Conditions for Safe Use—All Valves

Wiring must be in accordance with North American Class I, Division 2 or European Zone 2, Category 3

wiring methods as applicable, except for valves requiring intrinsically safe wiring as stated above.

Field wiring must be suitable for at least 100 °C.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 6

The wiring junction box provides earth ground terminals if needed for a separate earth ground to meet

wiring requirements.

T3 reflects conditions without process fluid. The surface temperature of this valve approaches the

maximum temperature of the applied process media. It is the responsibility of the user to ensure that the

external environment contains no hazardous gases capable of ignition in the range of the process media

temperatures.

Compliance with the Machinery Directive 2006/42/EC noise measurement and mitigation requirements is

the responsibility of the manufacturer of the machinery into which this product is incorporated.

The risk of electrostatic discharge is reduced by permanent installation of the valve, proper connection to

the protective earth (PE) terminals, and care when cleaning. The valve should not be cleaned unless the

area is known to be

non-hazardous.

EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.

Substitution of components may impair suitability for Class I,

Division 2 or Zone 2 applications.

RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas

l’ambiance est décidément non dangereuse.

La substitution de composants peut rendre ce matériel

inacceptable pour des applications de Classe I, Division 2

ou Zone 2.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 7

Chapter 1.

General Information

Introduction

The SonicFlo™ valve controls the flow of gas fuel to the combustion system of an industrial or utility gas

turbine.

This unique high recovery design yields a flow characteristic unaffected by discharge pressure at very low

pressure ratios (P1/P2) [contact Woodward for specific recovery information]. The high recovery design

has an approximate equal percentage flow characteristic from 0% to 15% stroke and a linear flow

characteristic from 15% to 100% stroke. The design integrates the valve and actuator into a compact

assembly.

The integral actuator is a single-acting spring-loaded design for failsafe operation. The actuator includes

an onboard hydraulic filter for last chance filtration of the fluid to ensure reliability of the servo valve and

actuator. The servo valve is electrically redundant with triple coil design. Feedback for the actuator is

provided by a dual coil LVDT (linear variable differential transformer) directly coupled to the hydraulic

piston.

Figure 1-1. High Recovery SonicFlo Gas Fuel Control Valves

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves

Woodward 8

Control Valve Functional Characteristics

Valve Type Two Way–Right Angle

Fluid Ports ASME B16.5-2003 Class 300 flanges

Size 2 inch (50 mm)

Flowing Media Natural gas

Valve Proof Pressure Level 300 lb Flanges: 1125 psig/7757 kPa

Minimum Valve Burst Pressure 300 lb Flange: 3700 psig/25 511 kPa

Gas Filtration 25 µm absolute at 75 beta requirement

Ambient Temperature –20 to +180 °F (–29 to +82 °C)

Shut-off Classification Class IV per ASME B16.104/FCI 70-2

(0.01% of rated valve capacity at full travel measured with air at 50

psid/345 kPa)

External Leakage T2

Fuel Vent Leakage Max 1 cc/min (or 50 cc/min dependent on seal material)

Position Accuracy ±1% of full scale (Over ±25 °F/±14 °C deviation from calibration)

Position Repeatability ±0.5% of point over range of 10% to 100%

Hydraulic Fluid Type Petroleum based hydraulic fluids

Hydraulic Supply Pressure

(High Recovery models) 1300 to 1800 psig/8964 to 12 411 kPa

Hydraulic Supply Pressure

(Ultra High Recovery models) 1450 to 1800 psig/9997 to 12 411 kPa

Hydraulic Proof Test Fluid Pressure

Level Per SAE J214

Minimum Hydraulic Burst Fluid Pressure Per SAE J214

Fluid Filtration Required 10–15 µm absolute

Trip Time No Trip

Slew Time 0.490 ±0.098 seconds (open, 5% to 95%); 0.430 ±0.086 seconds

(closed, 95% to 5%)

Design Availability Objective Better than 99.5% over an 8760 hour period

Hydraulic Fluid Connections Supply pressure—0.750-14 UNF straight thread port (–8)

Drain pressure—1.312-20 UNF straight thread port (–16)

Sound Level <110 dB at max flow conditions

Vibration Test Level 0.5 gp 5–100 Hz sine wave

Random 0.01500 gr²/Hz from 10 to 40 Hz ramping down to 0.00015

gr²/Hz at 500 Hz

Shock Limited to 30 g by servo valve

Servo Input Current Rating –7.2 to +8.8 mA (null bias 0.8 ± 0.32 mA)

Hydraulic Fluid Contamination Level Per ISO 4406 code 18/16/13 max

Code 16/14/11 preferred

Trim Configuration Exponential 0% to 15%

Linear 15% to 100%

Materials Woodward certifies that our SonicFlo line of Gas Fuel Control Valves is

designed and manufactured such that all wetted materials that

experience a tensile stress are compliant with the thermo-mechanical

requirements of MR0103.

Allowable Operating Gas Pressure 300 lb Flanges: 1724 to 3103 kPa (250 to 450 psig)

Max & Min Gas Temperature –18 to +260 °C (0 to 500 °F)

Max Valve Discharge Flange

Temperature 530 °F (277 °C)

Valve Port Sizes 2" (50mm)--Cg=300, 900, 1200

Flow Characteristics ±3.0% Cg deviation of point from 15% to 100% stroke

Hydraulic Fluid Temperature 10 to 66 °C (50 to 150 °F)

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