Woodward SonicFlo Installation And Operation Manual
  1. Manuals
  2. Brands
  3. Woodward Manuals
  4. Control Unit
  5. SonicFlo
  6. Installation and operation manual
Woodward SonicFlo Installation And Operation Manual

Woodward SonicFlo Installation And Operation Manual

High temperature gas fuel control valves with electric trip and enhanced dynamics package
Hide thumbs Also See for SonicFlo:
Table of Contents

Advertisement

Quick Links

Download this manual
Released
Product Manual 26699
(Revision M, 6/2024)
Original Instructions
SonicFlo™
High Temperature Gas Fuel Control Valves
with Electric Trip and Enhanced Dynamics Package
Installation and Operation Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SonicFlo and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Woodward SonicFlo

Summary of Contents for Woodward SonicFlo

  • Page 1 Released Product Manual 26699 (Revision M, 6/2024) Original Instructions SonicFlo™ High Temperature Gas Fuel Control Valves with Electric 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.

  • Page 3: Table Of Contents

    UNCTION Safety Function ............................64 Product Variations Certified ........................64 SFF (Safe Failure Fraction) for the SonicFlo™ Gas Fuel Control Valve – Over Speed SIF ...... 64 Response Time Data ..........................65 Limitations ..............................65 Management of Functional Safety ......................65 Restrictions..............................
  • Page 4 Figure 1-5a. SonicFlo Outline Drawing (3-inch, Class 300) ................ 17 Figure 1-5b. SonicFlo Outline Drawing (3-inch, Class 300) ................ 18 Figure 1-5c. SonicFlo Outline Drawing (3-inch, Class 300, Relocated Junction Box) ........ 19 Figure 1-5d. SonicFlo Outline Drawing (3-inch, Class 300, Relocated Junction Box) ........ 20 Figure 1-6a.

  • Page 5: Warnings And Notices

    Released Manual 26699 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

    • 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

    Released Manual 26699 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 2014/30/EC COUNCIL DIRECTIVE of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and all applicable amendments.
  • Page 8 Groups A, B, C, D for use in Canada and the United States per CSA 1260548. SIL Compliance: SIL certification is available for specific Woodward item numbers. Please contact a Woodward representative for assistance. SonicFlo™ Gas Fuel Control Valve – Certified SIL 3 Capable for safe position fuel shutoff function in safety instrumented systems.
  • Page 9 Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves 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.

  • Page 10: 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 11 ±0.5% of point over range of 10% to 100% Hydraulic Fluid Type Petroleum based hydraulic fluids 1500 - 1800 psig (10342 - 12411 kPa) – Consult Woodward Hydraulic Supply Pressure for use of pressures down to 1300 psig (8963 kPa). Design...
  • Page 12 Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Woodward certifies that our SonicFlo line of standard 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 NACE Materials MR0175/ISO 15156 and MR0103.

  • Page 13: Figure 1-2A. Sonicflo Outline Drawing (2-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-2a. SonicFlo Outline Drawing (2-inch, Class 600) Woodward...

  • Page 14: Figure 1-2B. Sonicflo Outline Drawing (2-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-2b. SonicFlo Outline Drawing (2-inch, Class 600) Woodward...

  • Page 15: Figure 1-3A. Sonicflo Outline Drawing (2-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-3a. SonicFlo Outline Drawing (2-inch, Class 300) Woodward...

  • Page 16: Figure 1-3B. Sonicflo Outline Drawing (2-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-3b. SonicFlo Outline Drawing (2-inch, Class 300) Woodward...

  • Page 17: Figure 1-4A. Sonicflo Outline Drawing (3-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-4a. SonicFlo Outline Drawing (3-inch, Class 600) Woodward...

  • Page 18: Figure 1-4B. Sonicflo Outline Drawing (3-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-4b. SonicFlo Outline Drawing (3-inch, Class 600) Woodward...

  • Page 19: Figure 1-5A. Sonicflo Outline Drawing (3-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-5a. SonicFlo Outline Drawing (3-inch, Class 300) Woodward...

  • Page 20: Figure 1-5B. Sonicflo Outline Drawing (3-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-5b. SonicFlo Outline Drawing (3-inch, Class 300) Woodward...

  • Page 21: Figure 1-5C. Sonicflo Outline Drawing (3-Inch, Class 300, Relocated Junction Box)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-5c. SonicFlo Outline Drawing (3-inch, Class 300, Relocated Junction Box) Woodward...

  • Page 22: Figure 1-5D. Sonicflo Outline Drawing (3-Inch, Class 300, Relocated Junction Box)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-5d. SonicFlo Outline Drawing (3-inch, Class 300, Relocated Junction Box) Woodward...

  • Page 23: Figure 1-6A. Sonicflo Outline Drawing (4-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-6a. SonicFlo Outline Drawing (4-inch, Class 600) Woodward...

  • Page 24: Figure 1-6B. Sonicflo Outline Drawing (4-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-6b. SonicFlo Outline Drawing (4-inch, Class 600) Woodward...

  • Page 25: Figure 1-7A. Sonicflo Outline Drawing (4-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-7a. SonicFlo Outline Drawing (4-inch, Class 300) Woodward...

  • Page 26: Figure 1-7B. Sonicflo Outline Drawing (4-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-7b. SonicFlo Outline Drawing (4-inch, Class 300) Woodward...

  • Page 27: Figure 1-7C. Sonicflo Outline Drawing (4-Inch, Class 300, Relocated Junction Box)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-7c. SonicFlo Outline Drawing (4-inch, Class 300, Relocated Junction Box) Woodward...

  • Page 28: Figure 1-7D. Sonicflo Outline Drawing (4-Inch, Class 300, Relocated Junction Box)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-7d. SonicFlo Outline Drawing (4-inch, Class 300, Relocated Junction Box) Woodward...

  • Page 29: Figure 1-8A. Sonicflo Outline Drawing (6-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-8a. SonicFlo Outline Drawing (6-inch, Class 600) Woodward...

  • Page 30: Figure 1-8B. Sonicflo Outline Drawing (6-Inch, Class 600)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-8b. SonicFlo Outline Drawing (6-inch, Class 600) Woodward...

  • Page 31: Figure 1-9A. Sonicflo Outline Drawing (6-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-9a. SonicFlo Outline Drawing (6-inch, Class 300) Woodward...

  • Page 32: Figure 1-9B. Sonicflo Outline Drawing (6-Inch, Class 300)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-9b. SonicFlo Outline Drawing (6-inch, Class 300) Woodward...

  • Page 33: Figure 1-9C. Sonicflo Outline Drawing (6-Inch, Class 300, Relocated Junction Box)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-9c. SonicFlo Outline Drawing (6-inch, Class 300, Relocated Junction Box) Woodward...

  • Page 34: Figure 1-9D. Sonicflo Outline Drawing (6-Inch, Class 300, Relocated Junction Box)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-9d. SonicFlo Outline Drawing (6-inch, Class 300, Relocated Junction Box) Woodward...

  • Page 35: Figure 1-9E. Sonicflo Outline Drawing (6-Inch, Class 600, Hydrogen Compatible Model)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-9e. SonicFlo Outline Drawing (6-inch, Class 600, Hydrogen Compatible Model) Woodward...

  • Page 36: Figure 1-9F. Sonicflo Outline Drawing (6-Inch, Class 600, Hydrogen Compatible Model)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-9f. SonicFlo Outline Drawing (6-inch, Class 600, Hydrogen Compatible Model) Woodward...

  • Page 37: Figure 1-10A. Hydraulic Schematic Circuit (Hydraulic Trip)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-10a. Hydraulic Schematic Circuit (hydraulic trip) Woodward...

  • Page 38: Figure 1-10B. Hydraulic Schematic Circuit (Electric Trip)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves HYDROGEN MODEL Figure 1-10b. Hydraulic Schematic Circuit (electric trip) Woodward...

  • Page 39: Figure 1-11A. Wiring Diagram

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-11a. Wiring Diagram Woodward...

  • Page 40: Figure 1-11B. Wiring Diagram - Relocated Junction Box

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-11b. Wiring Diagram – Relocated Junction Box Woodward...

  • Page 41: Figure 1-11C. Wiring Diagram (Iecex Versions)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-11c. Wiring Diagram (IECEx Versions) Woodward...

  • Page 42: Figure 1-12A. Lvdt Barrier Wiring Diagram (Tiis Requirement, Japan)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-12a. LVDT Barrier Wiring Diagram (TIIS requirement, Japan) Woodward...

  • Page 43: Figure 1-12B. Servo Valve Barrier Wiring Diagram (Tiis Requirement, Japan)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 1-12b. Servo Valve Barrier Wiring Diagram (TIIS requirement, Japan) Woodward...

  • Page 44: Chapter 2. Description

    Released Manual 26699 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 45: Trip Relay Valve Assembly

    LVDT Position Feedback Sensors The SonicFlo high recovery control valves use a triple-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 46: Chapter 3. Installation

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Chapter 3. Installation General See the outline drawings (Figures 1-2 through 1-9) for: Overall dimensions • Process piping flange locations • Hydraulic fitting sizes • • Electrical connections • Lift points and center of gravity •...

  • Page 47: Figure 3-1. Illustration Of Diverging Sleeve Screws

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Do not operate the valve without proper support for the diverging sleeve. IF BENCH TESTING THE VALVE, ENSURE THAT ASME/ANSI RATED FLANGES ARE GASKETED AND INSTALLED OVER THE INLET AND DISCHARGE FLANGES WITH THE BOLTS PROPERLY TORQUED.

  • Page 48: Unpacking

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 3-3. Illustration of Extension Style Diverging Sleeve Extension style diverging sleeves should be secured with a threaded or weld neck style flange when bench testing Products ordered to the 102T8791 specification or referencing the 102T8791 or equivalent specification must coincide with control system gain updates in the Mark VI control system.

  • Page 49: Hydraulic Connections

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Table 3-1. Class 600 Flange Dimensions Nominal Number of Diameter of Machine Pipe Size Bolts Bolts Stud Length Bolt Length 1 inch/ 5/8 inch/ 3.50 inch/ 3.00 inch/ 25 mm 16 mm 88.9 mm...

  • Page 50: Electrical Connections

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Make provisions for proper filtration of the hydraulic fluid that will supply the actuator. The system filtration should be designed to assure a supply of hydraulic oil with a maximum ISO 4406 contamination level of 18/16/13 and a preferred level of 16/14/11.

  • Page 51: 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. Blocking or clogging the fuel vent port can lead to damage of the valve and potentially dangerous conditions.

  • Page 52: Figure 3-5. Structures For Pid Control

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Table 3-3. Electronic Specifications 2 Inch Valves Ksv nominal = 6.1 in³/sec/mA at 1600 psi supply; Ksv is proportional to square root of supply, and constant with position. Ksv = 8.1 in³/sec/mA in the opening direction...
  • Page 53 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 54: 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 55 To facilitate field replacement of items, spare parts should be kept on-site. See the outline drawing (Figures 1-2 through 1-9) for the locations of items. Contact Woodward for a complete list of field-replaceable parts and additional instructions for their replacement.
  • Page 56 On units with an intermediate orifice plate, verify that the four O-rings between the servo valve and plate are removed. 7. Obtain a replacement servo valve from Woodward and verify part number and revision with the existing unit. 8. Remove the protective plate from the replacement servo valve and verify that O-rings are on all four counter bores of the servo valve.
  • Page 57 Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves To prevent possible personal injury, do NOT completely remove the nuts in step 9 from the tie rods until you have verified that the preload has been removed from the springs.
  • Page 58 Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves 37. With the actuator at minimum position, the output of the LVDT (measured across terminals 9 & 10 and 13 & 14 [and 17 & 18 if triple coil LVDT]) should be 0.700 ±0.100 Vrms. If the readout is not within these specifications, adjust the LVDT in or out of the actuator by screwing the LVDT housing in or out of the top block.

  • Page 59: Clocking (Rotation) Of Actuator To Valve (For 2" Valves)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves 18. Install four 0.625-11 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 core rods square with the housing.

  • Page 60: Clocking (Rotation) Of Actuator To Valve (For 3", 4", And 6" Valves)

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves To prevent possible personal injury, do NOT completely remove the nuts in step 6 from the tie rods until you have verified that the preload has been removed from the springs.

  • Page 61: 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 62: Figure 4-1B. Inspection Areas For 3, 4, And 6 Inch Valves

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Figure 4-1b. Inspection Areas for 3, 4, and 6 Inch Valves 2 Inch Valves Only: 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 63: 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 64: Troubleshooting Charts

    Under unusual circumstances where disassembly becomes necessary, all work and adjustments should be made by personnel thoroughly trained in the proper procedures. 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.
  • Page 65 Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Symptom Possible Causes Remedies Valve will not close Servo valve command Trace and verify that all wiring is in accordance current incorrect. (The sum with the electrical schematic (Figures 1-11 & 1-12) of the current through the and the system wiring schematic(s).

  • Page 66: Chapter 5. Safety Management - Safe Position Fuel Shutoff Function

    Function Safety Function The SonicFlo™ Gas Fuel Control Valve will move to the closed position within the full stroke trip time listed in this manual. Note: the SIL ratings in this section only apply to standard models. Hydrogen models are not SIL rated or certified.

  • Page 67: Response Time Data

    PVST numbers. Response Time Data The SonicFlo™ Gas Fuel Control Valve full stroke trip time is as listed in this manual. Limitations When proper installation, maintenance, proof testing, and environmental limitations are observed, the design life of the SonicFlo™...
  • Page 68 SonicFlo High Temperature Gas Fuel Control Valves The SonicFlo™ Gas Fuel Control Valve is intended for use according to the requirements of a safety lifecycle management process such as IEC 61508 or IEC 61511. The safety performance numbers in this chapter can be used for the evaluation of the overall safety lifecycle.

  • Page 69: Restrictions

    Functional Testing after Initial Installation A functional test of the SonicFlo™ Gas Fuel Control Valve is required prior to use in 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 SonicFlo™...

  • Page 70: Suggested Proof Test

    Proof Test Coverage The Proof Test Coverage for the SonicFlo™ Gas Fuel Control Valve is given in the table below. Table 5-3. Proof Test Coverage Proof Test Coverage λ...

  • Page 71: Chapter 6. Product Support And Service Options

    Service Distributor or the OEM or Packager of the equipment system, based on the standard Woodward Product and Service Warranty (Woodward North American Terms and Conditions of Sale 5-09-0690) that is in effect at the time the product is originally shipped from Woodward or a service is performed: Replacement/Exchange (24-hour service) •...

  • Page 72: Returning Equipment For Repair

    All repair work carries the standard Woodward service warranty (Woodward North American Terms and Conditions of Sale 5-09-0690) on replaced parts and labor.

  • Page 73: 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 74: 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 75: Revision History

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Revision History Changes in Revision M— Added details for hydrogen model • Added content to Chapter 1 Introduction Revised Table 1-1 Added Figures 1-9e and 1-9f Re-titled Figures 1-10 to 1-10a...
  • Page 76 Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Changes in Revision B— Updated Regulatory Compliance information & certificates • Added warning to Chapter 3 about proper grounding of junction box • Added cleaning warning to Chapter 4 •...

  • Page 77: Declarations

    Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Declarations Woodward...
  • Page 78 Released Manual 26699 SonicFlo High Temperature Gas Fuel Control Valves Woodward...
  • Page 79 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.

Table of Contents