Woodward SonicFlo Installation And Operation Manual
High temperature gas fuel control valves
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Summary of Contents for Woodward SonicFlo
- Page 1 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...
- Page 2 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.
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Page 3: Table Of Contents
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Contents ....................... 3 ARNINGS AND OTICES ..................4 LECTROSTATIC ISCHARGE WARENESS ......................5 EGULATORY OMPLIANCE 1. G ....................7 HAPTER ENERAL NFORMATION Introduction ..............................7 2. D ......................15 HAPTER ESCRIPTION ... - Page 4 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 ...
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Page 5: Warnings And Notices
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves 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. -
Page 6: Electrostatic Discharge Awareness
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. -
Page 7: Regulatory Compliance
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves 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. - Page 8 Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves 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.
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Page 9: Chapter 1. General Information
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]. - Page 10 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.
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Page 11: Figure 1-2A. Sonicflo Outline Drawing (2-Inch, Class 300, No Trip)
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-2a. SonicFlo Outline Drawing (2-inch, Class 300, no Trip) Woodward... -
Page 12: Figure 1-2B. Sonicflo Outline Drawing (2-Inch, Class 300, No Trip)
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-2b. SonicFlo Outline Drawing (2-inch, Class 300, no Trip) Woodward... -
Page 13: Figure 1-3A. Sonicflo Outline Drawing (2-Inch, Class 300, Ultra High Recovery, No Trip)
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-3a. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip) Woodward... -
Page 14: Figure 1-3B. Sonicflo Outline Drawing (2-Inch, Class 300, Ultra High Recovery, No Trip)
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-3b. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip) Woodward... -
Page 15: Figure 1-4. Hydraulic Schematic Circuit
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-4. Hydraulic Schematic Circuit Woodward... -
Page 16: Figure 1-5. Wiring Diagram
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-5. Wiring Diagram Woodward... -
Page 17: Chapter 2. Description
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Chapter 2. Description Triple Coil Electrohydraulic Servo Valve Assembly The hydraulic actuator assembly uses a two-stage hydraulic servo valve to modulate the position of the actuator output shaft and thereby control the gas fuel valves. The first stage torque motor utilizes a triple- wound coil, which controls the position of the first and second stage valves in proportion to the total electric current applied to the three coils. -
Page 18: Hydraulic Filter Assembly
LVDT Position Feedback Sensors The SonicFlo high recovery control valves use a dual-coil LVDT for position feedback. The LVDT is factory set to give 0.7 Vrms feedback at minimum position and 3.5 Vrms feedback at maximum position, when supplied with 7 Vrms excitation at 3000 Hz. -
Page 19: Chapter 3. Installation
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Chapter 3. Installation General See the outline drawings (Figure 1-2) for: Overall dimensions Process piping flange locations Hydraulic fitting sizes Electrical connections Lift points and center of gravity ... -
Page 20: Unpacking
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Unpacking The valve is shipped in an airtight bag with desiccant to ensure a non-corrosive environment. We recommend that the valve be kept in its shipping container until installation. If the valve is to be stored for extended periods of time, encase the valve in an airtight container with desiccant. -
Page 21: Electrical Connections
Fuel Vent Port There is a fuel vent port that must be vented to a safe location. In normal operation, this vent should have zero leakage. However, if excessive leakage is detected from this vent port, contact a Woodward representative for assistance. -
Page 22: Figure 3-1. Gas Fuel Control Valve Block Diagram
Every valve shipped contains documentation that gives the actual Null Current as measured by Woodward. It is imperative that the control system null current match the as-measured current for each valve in the system. Incorrect null current setting, with proportional control only, will result in position error. - Page 23 Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Table 3-2. Recommended Control Gain Values for Different Control Types Proportional Control Proportional Proportional Integral Gain Settings Control Integral Derivative Kp=5; Kp=3; Ki=5; Kp=3; Ki=5; Kd=0.01 or Tau Lead = 0.01 Rigging Procedure There are generally two possible rigging procedures for the high recovery gas fuel control valves.
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Page 24: Chapter 4. Maintenance And Hardware Replacement
The SonicFlo™ valve requires no maintenance or adjustment for operation. Woodward recommends routine checks of the DP gauge on the filter assembly to verify that the filter is not partially clogged. If the DP indicator shows red, the filter element needs to be replaced. - Page 25 SonicFlo High Temperature Gas Fuel Control Valves To facilitate field replacement of items, spare parts should be kept on-site. See the outline drawing (Figure 1-2) for the locations of items. Contact Woodward for a complete list of field-replaceable parts and additional instructions for their replacement.
- Page 26 Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves 9. Place the replacement servo valve onto the hydraulic manifold. Be sure to orient the servo valve to match the original orientation. Be sure that all four O-rings remain in their proper location during assembly.
- Page 27 Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves 21. Install four 0.500-13 nuts, one onto each stud. Slowly compress the springs into their cavity by rotating each nut one turn at a time. This will keep the cover and LVDT square with the housing.
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Page 28: Inspections
Verify that the spacers are all tightly held between the actuator and valve bodies. Inspections Woodward recommends the following maintenance and inspection schedule for the SonicFlo valve: Routine Inspections Routinely check the DP gauge on the filter assembly to verify that the filter is not partially clogged. If the DP indicator shows red, the filter element needs to be replaced. -
Page 29: Figure 4-1. Inspection Areas For 2 Inch Valves
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Figure 4-1. Inspection Areas for 2 Inch Valves Remove the hydraulic interseal drain tube and cap the drain fitting. Figure 4-2. Location of Hydraulic Interseal Drain and Cap for 2 Inch Valves... -
Page 30: Troubleshooting
2. Remove the visual indicator. 3. Using two cap screws provided, attach tool 1010-4982 (available from Woodward) to the actuator. Be sure to place the pin of the sliding piece onto the top of the spring seat within the actuator housing. - Page 31 Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves When requesting information or service help from Woodward, it is important to include the part number and serial number of the valve assembly in your communication. Symptom Possible Causes Remedies External hydraulic...
- Page 32 Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Symptom Possible Causes Remedies Valve will not Hydraulic filter clogged Check the differential pressure indicator on the respond smoothly filter housing. Servo valve spool sticking Verify hydraulic contamination levels are within recommendations of Chapter 1.
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Page 33: Chapter 5. Product Support And Service Options
An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs, repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's primary mission. A Recognized Turbine Retrofitter (RTR) is an independent company that does both steam and gas turbine control retrofits and upgrades globally, and can provide the full line of Woodward systems and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc. -
Page 34: Returning Equipment For Repair
All repair work carries the standard Woodward service warranty (Woodward Product and Service Warranty 5-01-1205) on replaced parts and labor. -
Page 35: Replacement Parts
The unit serial number, which is also on the nameplate Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website. Technical Support ... -
Page 36: Technical Assistance
SonicFlo High Temperature Gas Fuel Control Valves Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General... -
Page 37: Revision History
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Revision History Changes in Revision A— Updated Certifications in Regulator and Compliance Section Modified and added Ultra High Specifications to Control Valve Functional Characteristics Table Added Figures 1-3a and 1-3b ... -
Page 38: Declarations
Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Declarations Woodward... - Page 39 Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves Woodward...
- Page 40 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.
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