Woodward 9904-257 User manual

Product Manual 40134
(Revision A)
Original Instructions
Liquid Fuel Shutoff Valve
9904-257 and 9907-198
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 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, 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 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, 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 Out-of-date translations are marked with .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—Changes in this publication since the last revision are indicated by a black line
alongside the text.
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. Copyright © Woodward 1989
All Rights Reserved

Manual 40134 Liquid Fuel Shutoff Valve
Woodward i
Contents
WARNINGS AND NOTICES............................................................................ II
ELECTROSTATIC DISCHARGE AWARENESS ..................................................III
CHAPTER 1. GENERAL INFORMATION...........................................................1
Safety Considerations ............................................................................................1
Shutoff Valve Description .......................................................................................1
CHAPTER 2. INSTALLATION..........................................................................3
Receiving................................................................................................................3
Mounting.................................................................................................................3
Electrical .................................................................................................................3
Maintenance ...........................................................................................................3
CHAPTER 3. PRINCIPLES OF OPERATION .....................................................5
CHAPTER 4. REPLACEMENT PARTS .............................................................8
CHAPTER 5. SERVICE OPTIONS .................................................................11
Product Service Options.......................................................................................11
Woodward Factory Servicing Options ..................................................................12
Returning Equipment for Repair...........................................................................12
Replacement Parts ...............................................................................................13
Engineering Services............................................................................................13
How to Contact Woodward...................................................................................14
Technical Assistance............................................................................................14
Illustrations and Tables
Figure 1-1. Liquid Fuel Shutoff Valve .................................................................... iv
Figure 2-1. Outline Drawing of Liquid Fuel Shutoff Valve ......................................4
Figure 3-1. Cross Section of Liquid Fuel Shutoff Valve .........................................6
Figure 3-2. Liquid Fuel Shutoff Valve Schematic ...................................................7
Figure 4-1. Liquid Fuel Shutoff Valve Exploded View ............................................9
Figure 4-2. Liquid Fuel Shutoff Valve Exploded View ..........................................10

Liquid Fuel Shutoff Valve Manual 40134
ii Woodward
Warnings and Notices
Important Definitions
This is the safety alert symbol. It is 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.
Automotive
Applications
On- and off-highway Mobile Applications: Unless Woodward's control
functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
control with possible personal injury, loss of life, or property damage.

Manual 40134 Liquid Fuel Shutoff Valve
Woodward iii
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
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.

Liquid Fuel Shutoff Valve Manual 40134
iv Woodward
Figure 1-1. Liquid Fuel Shutoff Valve

Manual 40134 Liquid Fuel Shutoff Valve
Woodward 1
Chapter 1.
General Information
Safety Considerations
The shutoff valve is a critical component for protection against
equipment failure and turbine overspeed. Routine inspection is
necessary for the protection of the turbine and/or the turbine
operators.
The shutoff valve is designed to protect the turbine should the
normal fuel control become inoperative for any reason. Critical
overspeed may occur should the valve fail to shut off fuel to the
turbine. Engine overspeed can cause serious mechanical damage as
well as personal injury or death.
Always use the shutoff valve to stop the turbine. This exercise provides proof of
the proper operation of the safety equipment.
Because of the critical function of the valve, it is mandatory that the operator
regularly monitor the valve whenever the turbine is shut down, as well as during
normal operation.
While the valve is closed, check for excessive leakage, either through the valve
or through the vent. Any leakage through the valve to the turbine should be
considered proof of wear and/or possible malfunction. The valve should be
immediately replaced and returned for factory service.
A minimal amount of leakage can be expected through the bypass connection of
the valve. Should the volume of leakage change appreciably, the valve should be
replaced and returned to a service facility.
Woodward recommends the installation of two shutoff valves per API-616.
Shutoff Valve Description
The Woodward High Speed Liquid Fuel Shutoff Valve is a three-way, two-stage
valve, designed to provide fuel bypass in 0.090 seconds or less after termination
of the solenoid current. Loss or termination of the electrical signal will result in all
fuel delivery to the valve being bypassed to the return system.
The valve is compatible with most liquid fuels, including diesel fuel, methanol,
ethanol, Jet "A", kerosene, #2 home heating oil, heated light crudes, and
residuals. The valve will accommodate contaminated fuels within prescribed
limits.
An inlet screen in the valve prevents contaminants in excess of 40 µm (nominal)
from damaging the pilot-valve section.
The shutoff valve housing is constructed of anodized aluminum. All moving
internal parts are hardened stainless steel.

Liquid Fuel Shutoff Valve Manual 40134
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Electrical Requirements
Voltage Nominal 24 Vdc, 125 Vdc,
115 Vac or 220 Vac
Power 15 W maximum
Resistance
to Ground 50 MΩminimum at 500 Vdc
General Specifications
Liquid Fuel Diesel fuel, methanol, ethanol,
Jet "A", kerosene, #2 home
heating oil, heated light crudes,
and residuals
Fuel
Temperature 0 to +250 °F (–18 to +121 °C)
Chemical All typical fuels. Call Woodward
Compatibility for special applications.
Rated Flow 30 000 lb/h (13 608 kg) of
MIL-C-7024 calibrating fluid at
70 °F (21 °C)
Cycle Life 10 000 cycles
Weight 21.5 lb (9.8 kg)
Construction Anodized aluminum housing;
hardened stainless steel
internal components
Fittings Fuel inlet, fuel outlet, and
bypass threaded for 1.625 (-20)
straight thread port
Electrical 0.500-14 NPTF conduit
connector with 10 ft (3 m) of
insulated conductor for field
wiring
Operating Specifications
Opening Time 0.4 seconds maximum after
admission of fuel and solenoid
current
Closing Time Within 0.09 seconds after the
solenoid is de-energized with
1200 psig (8274 kPa) fuel
applied to the inlet
Pressure Drop 53 psid (365 kPa) inlet to
discharge at 30 000 lb/h (13
608 kg)
90 psid (621 kPa) inlet to
bypass at 30 000 lb/h
(13 608 kg)
Internal Leakage:
Shutoff From inlet to discharge:
None
From inlet to bypass:
370 lb/h (168 kg) maximum at
800 psid (5516 kPa)
Reverse
Pressure
Condition 900 psig (6206 kPa)
Contaminants The shutoff valve will operate
satisfactorily when using fuel
contaminated with less than
0.01% by volume of salt-water
compound or 4% by weight of
NaCl and 96% water and solid
contamination of 10 grams per
1000 US gallons (2.6 g/1000 L)
composed of particle sizes up
to 40 µm.
Fluid Supply Normal: 1200 psig (8274 kPa)
Range Proof: 1800 psig (12 411 kPa)
Burst: 6000 psig (41 370 kPa)

Manual 40134 Liquid Fuel Shutoff Valve
Woodward 3
Chapter 2.
Installation
Receiving
The liquid fuel shutoff valve is tested with a non-corrosive liquid, drained and
packed in a foam-filled box for shipment. The unit may be stored for an extended
period in the original container.
Mounting
The valve is designed for installation in any attitude with two 3/8 inch or M10
bolts. (See the outline drawing, Figure 2-1, for location of the mounting holes and
of the valve.)
1.625 inch (-20) straight thread ports are provided for inlet, bypass and outlet
pipe connections. The bypass plumbing must be of equal size to the inlet and
unobstructed to assure positive shutoff by the valve.
Electrical
A 0.500 inch-14 NPTF conduit adapter and 10 ft (3 m) leads of shielded wire are
provided for the electrical connection. Connect the proper voltage to the two
wires extending from the conduit connector (see the outline drawing). Polarity is
not important.
Maintenance
Recommended: Disassembly for cleaning and inspection every 10 000 cycles or
3 years of operation, whichever occurs first. In case of contamination of the
interior passages, the valve may be disassembled and cleaned in the field by a
trained service technician.
Routinely check the shutdown switches or relays to be sure they are capable of
interrupting the electronic signal to the shutoff valve.
Always use the valve for routine shutdown as a check for continued
operation.

Liquid Fuel Shutoff Valve Manual 40134
4 Woodward
Figure 2-1. Outline Drawing of Liquid Fuel Shutoff Valve