Woodward QuickTrip Installation And Operation Manual
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Woodward QuickTrip Installation And Operation Manual

Electro-hydraulic trip block assembly
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Released
Product Manual 26815
(Revision E, 4/2017)
Original Instructions
QuickTrip
Electro-Hydraulic Trip Block Assembly
Installation and Operation Manual

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  • Page 1 Released Product Manual 26815 (Revision E, 4/2017) Original Instructions QuickTrip Electro-Hydraulic Trip Block Assembly Installation and Operation Manual...
  • Page 2 26455 produced. To verify that you have the latest revision, check manual Customer Publication Cross Reference and Revision Status & Distribution Restrictions, on the publications page of the Woodward website: Revisions 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.
  • Page 3 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.

  • Page 4: Table Of Contents

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Contents ......................4 ARNINGS AND OTICES ..................5 LECTROSTATIC ISCHARGE WARENESS ......................6 EGULATORY OMPLIANCE 1. G ..................... 9 HAPTER ENERAL NFORMATION Introduction..............................9 Construction ..............................11 2. S ...................... 14 HAPTER PECIFICATIONS Physical and Performance Specifications ....................
  • Page 5 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly 8. A ......57 HAPTER SSET ANAGEMENT AND EFURBISHMENT CHEDULING ERIOD 9..........................58 HAPTER ..................58 TORAGE EQUIREMENTS ..........................59 PPENDIX ....................... 59 OMMISSIONING HECKLIST ........................61 EVISION ISTORY .......................... 62...
  • Page 6 Figure 1-3. Ordering Example ........................12 Figure 2-1. QuickTrip Cv vs Time Curve ..................... 15 Figure 2-2. QuickTrip Steady State Leakage (50 °C hydraulic oil) ............. 16 Figure 2-3. QuickTrip Steady State Leakage (70 °C hydraulic oil) ............. 17 Figure 2-4. Functional Block Diagram ......................17 Figure 2-5.

  • Page 7: Warnings And Notices

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly 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 8: 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 9: Regulatory Compliance

    Regulatory Compliance The certifications and regulatory information that are marked on each QuickTrip valve are determined by the Item Prefix that appears before the Item Number (See Table 1-1). This Item Prefix appears on the product nameplate and sales documentation. This section has been indexed to show which certificates apply to which item prefix.
  • Page 10 The maximum hydraulic fluid temperature shall not exceed 70°C. Conduit stops must be installed within 45cm (18 inches) of the QuickTrip product in order to meet the Zone 1 classification. The following have a maximum constructional gap (ic) less than that required by Table 2 of EN 60079-1...
  • Page 11 QuickTrip Electro-Hydraulic Trip Block Assembly The Temperature Code T4 (135 °C) may be exceeded if QuickTrip is cycled on and off at a frequency exceeding 1 Hz. This is considered a rare malfunction and not part of the intended use of the device.

  • Page 12: Chapter 1. General Information

    General Information Introduction The QuickTrip trip block assembly is designed for use in gas or steam turbine shutdown systems for quick and reliable dumping of the turbine’s trip oil header. This integrated trip block assembly is intended for use on mechanical-drive or generator-drive gas or steam turbines that use low-pressure (up to 34.5 bar / 500 psi) hydraulic trip oil headers.
  • Page 13 Because gas and steam turbines are often used in hazardous locations where flammable gases may be present, the QuickTrip is designed to be mounted next to the turbine and is certified for use in Zone-1 or Zone-2 (Class 1 or Class 2) hazardous locations.

  • Page 14: Construction

    Figure 1-1. QuickTrip, Key Features Rotary Trip Valves All three of the QuickTrip’s trip valves are spring return, two position rotary valves. When any of the hydraulic valves is in its closed position, the ports in the valve are blocked preventing hydraulic flow through the valve.

  • Page 15: Figure 1-2. Application Example

    North American Div 1 & 2, EAC CU/ATEX/IECEx Zone 1 & 2 Russian 9907-1978 North American Div 2, EAC CU/ATEX/IECEx Zone 2 Russian Figure 1-3. Ordering Example Note: 9907-1978 is used as an example. Contact Woodward for latest item number(s). Woodward...
  • Page 16 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Table 1-2. Recommended QuickTrip Spare Part Kits Part Number Spare Kit Description 8923-2142 Solenoid Replacement Kit 8923-2146 Electrical Module Replacement Kit 8923-2147 Return Spring Replacement Kit 8923-2192 Field Repair Tool Kit - (Includes special tools to replace the solenoid, return spring, sight window, top cover, &...

  • Page 17: Chapter 2. Specifications

    3 X 0.750”-14 NPT Cable Entries: 1 Ground Hydraulic Specifications Make sure that the QuickTrip hydraulic connections are installed correctly. Equipment damage is possible if the hydraulic connections are attached incorrectly (backwards). Petroleum-based hydraulic fluids as well as fire-resistant hydraulic...

  • Page 18: Figure 2-1. Quicktrip Cv Vs Time Curve

    QuickTrip assembly with only 2 of the 3 three valves tripped. The table below shows the QuickTrip’s Cv in the various tripped conditions. Note: the actual Cv values may deviate by as much as ± 12% from the values shown.

  • Page 19: Figure 2-2. Quicktrip Steady State Leakage (50 °C Hydraulic Oil)

    ∗ ∆ " ∆ $ ! % & Flow Rate Calculation Example: Calculate minimum flow rate through the QuickTrip with typical, ISO VG32 fluid at 15degC and a trip header pressure of 10 Bar. 0.875 ∆ 10 / 145 1 # 10.3 1 1 1, " %&/ 5 !! #...

  • Page 20: Functional Block Diagram

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Figure 2-3. QuickTrip Steady State Leakage (70 °C hydraulic oil) The figures above show the maximum expected steady-state leakage flow through the QuickTrip assembly during normal operation. It is important to size the trip system orifice such that the trip header pressure does not fall below the system trip pressure when channel A is open (maximum leakage).

  • Page 21: Hydraulic Schematic

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Hydraulic Schematic Figure 2-5. Hydraulic Schematic Woodward...

  • Page 22: Outline Dimensions And Installation Features

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Outline Dimensions and Installation Features Figure 2-6a. QuickTrip Outline Dimensions Woodward...

  • Page 23: Figure 2-6B. Quicktrip Outline Dimensions

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Figure 2-6b. QuickTrip Outline Dimensions Woodward...

  • Page 24: Figure 2-6C. Quicktrip Outline Dimensions

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Figure 2-6c. QuickTrip Outline Dimensions Woodward...
  • Page 25 Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly NOTES These general reference outline drawings apply to Woodward QuickTrip only. Consult Woodward for the latest outline drawing. Installation Orientation: Orientation vertical approximately as shown See elsewhere in this manual for other installation recommendations.

  • Page 26: Chapter 3. Installation

    Woodward. Unpacking Instructions Carefully unpack the QuickTrip and remove it from the shipping container. Do not remove the hydraulic or electric blanking covers until the unit is ready for mounting. The external ground lug shown on the installation drawing must be properly connected to ensure equipotential bonding.

  • Page 27: Installation Instructions

    The QuickTrip is designed for support by one of the two mating surfaces shown in Figure 3-1. For the mating surface bolt patterns, threads, and torques, the recommendations in Table 3-1 must be followed.

  • Page 28: Figure 3-1. Quicktrip Product Installation Interface-Bolting Pattern

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Figure 3-1. QuickTrip Product Installation Interface—Bolting Pattern Minimum Bolt Grade, Bolting Torque and Thread Engagement Recommendation is valid for low carbon steel mounting surfaces to which product is bolted. For different configurations please consult Woodward for torque and bolt grade recommendations.
  • Page 29 The hydraulic supply and drain to the QuickTrip are to be at least 25 mm (1 inch), or larger, tubing capable of flowing up to 908 L/min (240 US gal/min) at 34.5 bar / 500 psig.

  • Page 30: Figure 3-2. Electrical Wiring Diagram

    Figure 3-2. Electrical Wiring Diagram Input Power The QuickTrip requires a power source capable of a supplying the necessary output voltage and current at full transient conditions. The maximum power in watts (W) of a DC source can be calculated by multiplying the rated output voltage by the maximum output current capability.

  • Page 31: Figure 3-3. Power Supply Input Connections

    The input power wires must comply with local code requirements and be of sufficient size such that the power supply voltage minus the IR loss in the two lead wires to the QuickTrip valve electronics module does not drop below the input minimum voltage requirement.

  • Page 32: Figure 3-4. Correct Wiring To Power Supply Input

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Figure 3-4. Correct Wiring to Power Supply Input Figure 3-5. Example of Incorrect Wiring to Power Supply Input Power Wiring Requirements: • Keep these inputs separated from low level signals to reduce signal noise •...

  • Page 33: Figure 3-6. Recommended Wiring Strain Relief

    Control Input The QuickTrip valves are controlled with the independent trip relay outputs from a trip system logic solver such as the Woodward ProTechTPS. Note: When used with the ProTechTPS, external power is not necessary for these inputs. All voltage and isolation is provided within the ProTechTPS (24 Vdc, 0.5 A).

  • Page 34: Figure 3-7. Control Input Connections

    Position Feedback There are two outputs for valve position feedback on each of the QuickTrip’s three valve modules (12 outputs total). Each of the two outputs features redundant connections. Both TRIP outputs and both RUN outputs operate as normally open. The outputs can be wired to either switch load from positive supply or switch load to ground.

  • Page 35: Figure 3-8. Feedback Output Connections

    Tighten the cable gland fitting per manufacturer’s instructions or pour the conduit seal to provide strain relief for the cable and to seal the interface between the wiring cable and the QuickTrip modules. In order to preserve the QuickTrip’s online reparability, each of the three electrical actuator cavities must be kept isolated from each other.

  • Page 36: Figure 3-9. Cover Clamps

    Thread the covers all the way down by hand, and then torque them to 136-190 N m (100-140 ft-lbf). Woodward tool 1013-6603 can be used to torque the cover. Take care not to damage the electronics’ cover seal, the cover surface, the threads, or the QuickTrip housing mating surface while installing the cover.
  • Page 37 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly ELECTRIC SHOCK—To reduce the risk of electric shock, Protective Earth (PE) must be connected to the termination point on the top of the unit next to the label with the symbol. The conductor providing the connection must have a properly sized ring lug and wire gauge larger than or equal to 4 mm²...

  • Page 38: Chapter 4. Operation

    Performing Auto-Sequence Test (Periodic Overspeed Test) Since QuickTrip is a critical part of the turbine overspeed safety system, it is important to perform a regular Auto-Sequence Test in order to verify unit health and to take advantage of the diagnostic coverage provided by this test.
  • Page 39 (Ex. 5 sec). This configuration is optional, but may provide early warning for a QuickTrip module that fails to energize to a run state (valve fails to close) when commanded to do so. Refer to ProTechTPS manual 26501V2, Chapters 9 and 11 for additional information.

  • Page 40: Valve Position Feedback

    2. The LED lamps on the electronics module (PCBA), visible through the sight window in the top of the electronics cover. o When any QuickTrip module is in a tripped state (de-energized, valve open), the red trip LED is on*.

  • Page 41: Special Ambient Temperature Considerations

    If performing a cold-start of QuickTrip in very cold ambient environment conditions (temperatures between -40 °C to +15 °C), both the hydraulic oil within the QuickTrip manifold and the QuickTrip manifold itself must undergo a warmup procedure prior to starting the turbine to ensure the QuickTrip will operate within specified performance limits.

  • Page 42: Chapter 5. Repair And Troubleshooting

    18 months from the date of shipment from Woodward. Repairs and servicing of the QuickTrip must be performed by Woodward or its authorized service facilities Use of a cable gland or stopping plug that does not meet the hazardous area certification requirements or thread form or thread size will invalidate the suitability for hazardous locations.

  • Page 43: Hardware Replacement

    (terminals 5 and 6 of TB2). 3. If QuickTrip is in a trip state, as indicated by a red as LED viewed through the sight glass, QuickTrip may be energized to close either by activating the logic solver interposing relay to initiate a run state...
  • Page 44 2. If QuickTrip is in a trip state, as indicated by a red LED as viewed through the sight glass, QuickTrip may be energized to close by activating the ProTechTPS interposing relay to initiate a run state. This may be done by pressing the RESET button on the front panel of the ProTechTPS (see the ProTechTPS product manual if module does not reset when the RESET button is pressed).

  • Page 45: Troubleshooting

    Cleaning/Flushing the QuickTrip Hydraulic Cavities Cleaning/Flushing QuickTrip Hydraulic Cavities procedure: If QuickTrip is not operating normally or if a contaminant is known to have entered the QuickTrip hydraulic cavities, the QuickTrip cleaning/flushing procedure may be performed as follows. 1. Eliminate the source of the contamination either by polishing the hydraulic supply or by replacing the hydraulic supply with clean hydraulic oil.
  • Page 46 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Be prepared to make an emergency shutdown of the turbine, or other type of prime mover, to protect against runaway or overspeed with possible personal injury, loss of life, or property damage.
  • Page 47 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Table 7-1. QuickTrip Troubleshooting Guide General Faults Problem Cause Remedy Check power source and connections Input Power below specified limit (Chapter 2: Electrical Specifications). Ensure turbine is running and speed sensors Speed sensor logic solver is in a...
  • Page 48 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Table 7-1. QuickTrip Troubleshooting Guide (continued) Power supply is not turned on or wiring is not connected Check power source and connections (Chapter 2: Electrical Specifications). Power supply voltage or current are...
  • Page 49 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Table 7-1. QuickTrip Troubleshooting Guide (continued) Check all wiring between trip terminals on Wiring not connected properly electronics module and logic solver Verify that all speed sensors and logic solver Valve is in a run state...

  • Page 50: Chapter 6. Safety Management

    Figure 6-1. TUV Rheinland SIIL Certification Stamp Safe State The QuickTrip is designed so that the safe state is configured for de-energize to trip. De-energize to trip will place the valves into their open state. The de-energize-to-trip functionality is implemented such that a complete loss of power to the module results in a trip of that module.

  • Page 51: Failure Rate Data

    < 50 ms The response time of the QuickTrip is the time from when the control signal is removed from the QuickTrip terminal block to the point where the valves have rotated to their full open position (ref Figure 6- 1 below).

  • Page 52: Limitations

    Management of Functional Safety The QuickTrip is intended for use according the requirements of a safety lifecycle management process such as IEC61508 or IEC61511. The safety performance numbers in this chapter can be used for the evaluation of the overall safety lifecycle.

  • Page 53: Restrictions

    Functional Testing after Initial Installation A functional test of the QuickTrip is required prior to use as a safety system. This should be done as part of the overall safety system installation check and should include all I/O interfaces to and from the QuickTrip that are part of the safety system.
  • Page 54 1. The following procedure should be followed for each QuickTrip module (A, B and C) 2. Ensure power is connected to one or both power inputs on QuickTrip module (terminals 1 & 2 and 3 & 3. Verify that one or both blue LED’s on the QuickTrip electronics module are lit indicating that either a single power supply or two redundant power supplies are connected and turned on.

  • Page 55: Diagnostic Testing (On-Line Test)

    Diagnostic Test Procedure: 1. Verify that each QuickTrip module is in a run state (valve closed). This can be done by verifying that a green light is lit on each QuickTrip electronics module, or by verifying there are no trip alarms on the ProTech TPS (or other logic solver).

  • Page 56: Chapter 7. 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 57: 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 58: 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 59: Technical Assistance

    QuickTrip Electro-Hydraulic Trip Block Assembly 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 60: Period

    During major outages, Woodward recommends the QuickTrip be send back to Woodward or a Woodward Authorized Independent Service Facility (AISF) for inspection, component servicing and to take advantage of any related hardware improvements.

  • Page 61: R Equirements

    Units that will not be put into service within twelve months should be packaged for long-term storage as described in Woodward manual 25075, Commercial Preservation Packaging for Storage of Mechanical- Hydraulic Controls. This product is designed for continuous storage in IP66 rated locations with an ambient temperature of –40 °C to +85 °C.

  • Page 62: Table A-1. Installation And Commissioning Checklist

    Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Appendix Commissioning Checklist When installing and commissioning the QuickTrip unit, the following checklist can be used as a guide to ensure proper installation and successful commissioning. Table A-1. Installation and Commissioning Checklist Category...
  • Page 63 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Table A-1. Installation and Commissioning Checklist (Continued) Category Parameter Specification This Installation Wiring: Trip #1 NO TB2, Terminal 7 Wiring: Trip #1 COM TB2, Terminal 8 Wiring: Trip #2 NO TB2, Terminal 9...
  • Page 64 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Revision History Changes in Revision E— • Changed Item number references in Table 1-1 and Figure 1-3 • Changed ground lug torque value in the Unit Grounding section in Chapter 3 Changes in Revision D—...

  • Page 65: D Eclarations

    Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Declarations Woodward...
  • Page 66 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Woodward...
  • Page 67 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Woodward...
  • Page 68 Released Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly Woodward...
  • Page 69 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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