Woodward Large Electric Sonic Valve II User manual

Product Manual 35076
(Rev C, 1/2019)
Original Instructions
Large Electric Sonic Valve II (LESV II)
2-inch, 3-inch, 4-inch, 6-inch
Installation and Operation Manual
Released

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 Out-of-date translations are marked with .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 35076
Copyright © Woodward, Inc. 2018 - 2019
All Rights Reserved
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Manual 35076 LESV II
Woodward 1
Contents
WARNINGS AND NOTICES ............................................................................................................... 4
ELECTROSTATIC DISCHARGE AWARENESS...................................................................................... 5
REGULATORY COMPLIANCE ............................................................................................................ 6
CHAPTER 1. GENERAL INFORMATION .............................................................................................. 9
Introduction ................................................................................................................................................... 9
CHAPTER 2. DESCRIPTION ............................................................................................................ 23
Actuator: Woodward LELA (Large Electrical Linear Actuator).................................................................... 23
Brushless DC Motor .................................................................................................................................... 23
Resolver Position Feedback Sensors ......................................................................................................... 23
Soft Stop Spring .......................................................................................................................................... 24
Valve Portion: SonicFlo............................................................................................................................... 24
LESV II Pressure Ratio Operational Limitations ......................................................................................... 24
CHAPTER 3. INSTALLATION ........................................................................................................... 25
General........................................................................................................................................................ 25
Required Clearance for Lubrication Kit Syringes and Gun/Needle............................................................. 26
Lifting Procedures ....................................................................................................................................... 27
Piping Installation ........................................................................................................................................ 30
Fuel Overboard Vent Connection ............................................................................................................... 32
Valve Characteristic Data............................................................................................................................ 32
Calibration ................................................................................................................................................... 32
Valve/Actuator Configuration Settings ........................................................................................................ 33
Electrical Connections................................................................................................................................. 35
SIL2 Flow Sensor - Electrical Wiring........................................................................................................... 43
Installation and Application Pre-Start Checks............................................................................................. 44
CHAPTER 4. MAINTENANCE AND HARDWARE REPLACEMENT......................................................... 46
Maintenance................................................................................................................................................ 46
Hardware Replacement .............................................................................................................................. 46
SIL2 Flow Sensor Replacement ................................................................................................................. 46
Fuel Overboard Vent Port ........................................................................................................................... 47
CHAPTER 5. TROUBLESHOOTING .................................................................................................. 48
CHAPTER 6. SAFETY MANAGEMENT –SAFE POSITION FUEL SHUTOFF FUNCTION ......................... 50
Product Variations Certified ........................................................................................................................ 50
Covered LESV Versions ............................................................................................................................. 50
SFF for the LESV – Over Speed SIF (Safety Instrumented Function) ....................................................... 50
Response Time Data .................................................................................................................................. 51
Limitations ................................................................................................................................................... 51
Management of Functional Safety .............................................................................................................. 51
Restrictions ................................................................................................................................................. 51
Competence of Personnel........................................................................................................................... 51
Operation and Maintenance Practice.......................................................................................................... 51
Installation and Site Acceptance Testing .................................................................................................... 51
Functional Testing after Initial Installation................................................................................................... 52
Functional Testing after Changes ............................................................................................................... 52
Proof Test (Functional Test)........................................................................................................................ 52
Suggested Proof Test ................................................................................................................................. 52
Proof Test Coverage ................................................................................................................................... 52
CHAPTER 7. SAFETY MANAGEMENT –POSITION FEEDBACK LIGHT-OFF FUNCTION FLOW SENSOR 53
Product Variations Certified ........................................................................................................................ 53
Covered LESV Versions ............................................................................................................................. 53
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Response Time Data .................................................................................................................................. 54
Limitations ................................................................................................................................................... 54
Management of Functional Safety .............................................................................................................. 54
Restrictions ................................................................................................................................................. 54
Competence of Personnel........................................................................................................................... 54
Operation and Maintenance Practice.......................................................................................................... 54
Installation and Site Acceptance Testing .................................................................................................... 55
Functional Testing after Initial Installation................................................................................................... 55
Functional Testing after Changes ............................................................................................................... 55
Proof Test (Functional Test)........................................................................................................................ 55
Functional Verification (Proof) Test Procedure (Module Level) .................................................................. 55
CHAPTER 8. PRODUCT SUPPORT AND SERVICE OPTIONS .............................................................. 56
Product Support Options............................................................................................................................. 56
Product Service Options ............................................................................................................................. 56
Returning Equipment for Repair ................................................................................................................. 57
Replacement Parts...................................................................................................................................... 58
Engineering Services .................................................................................................................................. 58
Contacting Woodward’s Support Organization ........................................................................................... 58
Technical Assistance .................................................................................................................................. 59
REVISION HISTORY ....................................................................................................................... 60
DECLARATIONS ............................................................................................................................ 61
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Illustrations and Tables
Figure 1-1. Optional SIL2 Flow Sensor 3, 4, 6 inch LESV II....................................................................... 12
Figure 1-2a. Outline Drawing (2-Inch LESV II, UHR, SST, 600# Dual Resolver)....................................... 13
Figure 1-2b. Outline Drawing (2-Inch LESV II, UHR, SST, 600# Dual Resolver)....................................... 14
Figure 1-3a. Outline Drawing (3-Inch LESV II Class 600) .......................................................................... 15
Figure 1-3b. Outline Drawing (3-Inch LESV II Class 600) .......................................................................... 16
Figure 1-4a. Outline Drawing (4-Inch LESV II Class 600) .......................................................................... 17
Figure 1-4b. Outline Drawing (4-Inch LESV II Class 600) .......................................................................... 18
Figure 1-5a. Outline Drawing (6-Inch LESV II Class 600) .......................................................................... 19
Figure 1-5b. Outline Drawing (6-Inch LESV II Class 600) .......................................................................... 20
Figure 1-6. Connector Pin-outs – DVP5K with 2-Inch LESV II ................................................................... 21
Figure 1-7. Connector Pin-outs – DVP12K with 3, 4, and 6-Inch LESV II .................................................. 22
Figure 2-1. 6-Inch LESV II Operating Envelope.......................................................................................... 24
Figure 3-1. Grease Port Locations 2-Inch LESV II ..................................................................................... 26
Figure 3-2. Port Locations 3, 4, and 6-Inch LESV II ................................................................................... 27
Figure 3-3. Vertical Lifting ........................................................................................................................... 28
Figure 3-4. Horizontal Lifting....................................................................................................................... 29
Figure 3-5. Representative Outline of LESV II............................................................................................ 29
Figure 3-6. Support Flange Bolted to Outlet Flange ................................................................................... 30
Figure 3-7. Valve Insulation ........................................................................................................................ 32
Figure 3-8. Power Connector...................................................................................................................... 36
Figure 3-9. Motor Resolver Connectors...................................................................................................... 36
Figure 3-10. ID Module/Shaft Resolver Actuator Connector ...................................................................... 37
Figure 3-11. Cable, Motor Resolver 1, Feedback Signal............................................................................ 38
Figure 3-12. Cable, Stem Shaft Resolver/LVDT, Feedback Signal ............................................................ 39
Figure 3-13. Cable, Motor Resolver 2, Feedback Signal............................................................................ 40
Figure 3-14. Cable, Motor Power – 2-Inch LESV II (LELA1 with DVP5k) .................................................. 41
Figure 3-15. Cable, Motor Power – 3, 4, and 6-Inch LESV II (LELA2 with DVP12k) ................................. 42
Table 1-1. LESV II Large Electric Sonic Valve Specifications ...................................................................... 9
Table 1-2. SIL2 Sensor Wiring Connections............................................................................................... 22
Table 3-1. Piping Loads According to Valve Size ....................................................................................... 31
Table 3-2. Valve Part Number Specific Parameters ................................................................................... 33
Table 3-3. Valve Serial Number Specific Parameters ................................................................................ 35
Table 3-4. Commissioning Procedure......................................................................................................... 44
Table 5-1. Troubleshooting Symptom, Cause, and Remedy...................................................................... 48
Table 6-1. Failure Rates according to IEC61508 in FIT ............................................................................. 50
Table 6-2. Suggested Proof Test ................................................................................................................ 52
Table 6-3. Proof Test Coverage.................................................................................................................. 52
Table 7-1. SIL Certified LESVs ................................................................................................................... 53
Table 7-2. Failure Rates according to IEC61508 in FIT ............................................................................. 54
Table 7-3. Suggested Proof Test ................................................................................................................ 55
Released
for 30% H2
Main A 4" valve
Pilot B 2" valve
Main B 6" valve
TopHat 4" valve
Pilot A 2" valve
******************
For 100% H2
F1-2 3" valve
F1-1 2" valve
F2-2 3" valve
F2-1 2" valve
F3-2 3" valve
F3-1 2" valve
F4 2" valve
******************
Sizes are as of Oct
21, 2020
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Manual 35076 LESV II
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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.
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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.
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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.
EMC Directive (Actuator): Declared to Directive 2014/30/EU of the European Parliament and of
the Council of 26 February 2014 on the harmonization of the laws of
the Member States relating to electromagnetic compatibility (EMC)
ATEX Directive (Actuator): Directive 2014/34/EU on the harmonization of the laws of the
Member States relating to equipment and protective systems
intended for use in potentially explosive atmospheres.
LELA: Zone 2, Category 3, Group II G, Ex nA IIC T3 Gc X
LELA 2 without external position sensor: Zone 2, Category 3, Group
II G, Ex ec IIC T3 X Gc
LELA 2 with external position sensor: Zone 2, Category 3, Group II
G, Ex db ec IIC T3 X Gc
Pressure Equipment
Directive (Valve):
Directive 2014/68/EU on the harmonization of the laws of the
Member States relating to the making available on the market of
pressure equipment.
2in, 3 in, 4 in: PED Category II
6 in: PED Category III
PED Module H – Full Quality Assurance,
CE-0041-PED-H-WDI 001-16-USA, Bureau Veritas UK Ltd (0041)
Other European Compliance:
Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
ATEX Directive: Exempt from the non-electrical portion of the ATEX Directive
2014/34/EU due to no potential ignition sources per
EN ISO 80079-36:2016 for Zone 2 installation.
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.
Other International Compliance
IECEx (LELA): Certified for use in explosive atmospheres per Certificate:
IECEx CSA 14.0013X
Without position sensor: Ex nA IIC T3 Gc
With position sensor: Ex db e nA IIC T3 Gc
IECEx (LELA2): Certified for use in explosive atmospheres per Certificate:
IECEx ETL 18.0002X
Without Position Sensor: Ex ec IIC T3 Gc
With Position Sensor: Ex db ec IIC T3 Gc
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North American Compliance
These listings are limited only to those units that bear the appropriate marking.
CSA (LELA):
CSA Certified for Class I, Div. 2, Groups A, B, C & D, T3 at 80°C
Ambient with Position Sensor, 93°C without Position Sensor; For use
in Canada and the United States, Certificate 1635932.
Actuator is certified for North America as on-systems engine
component connected to the certified Digital Valve Positioner. This
certificate does not cover the performance evaluation of the valves
attached to the actuator.
ETL (LELA 2): Intertek-ETL certified for Class I, Div. 2, Groups A, B, C & D, T3 at
80°C Ambient with Position Sensor, 93°C without Position Sensor;
For use in Canada and the United States.
Control Number 5012634
Conforms to UL STDS 121201 & 429
Certified to CSA STDS C22.2 No. 213 & 139
This certificate does not cover the performance evaluation of the
valves attached to the actuator.
SIL Compliance:
Large Electronic Sonic Valve (LESV II) – Certified SIL 3 Capable for
Shutoff Function in safety instrumented systems. Evaluated to IEC 61508
Parts 1-7. Refer to the instructions of this Installation and Operation
Manual, Chapter 6 Safety Management.
SIL Certificate Product Certificate Number: WOO 1707039 C001
Large Electronic Sonic Valve (LESV II) – Certified SIL 3 Capable for Flow
Sensor Function in safety instrumented systems. Evaluated to IEC 61508
Parts 1-7. Refer to the instructions of this Installation and Operation
Manual, Chapter 7 Safety Management.
SIL Certificate Product Certificate Number: WOO 1707039 C002
Special Conditions for Safe Use:
LESV II with LELA actuator is only suitable for use with the Woodward DVP1200 or DVP5000. LESV II
with LELA2 actuator is to be powered by the Woodward DVP12000, suitably certified for the intended
area of use.
Mating electrical connectors must be tightly installed on the actuator to maintain the IP55 rating.
Appropriate caps must be in place for any unused connectors.
LELA2: Use supply wires suitable for at least 125°C. LELA: Use supply wires suitable for 10°C above
surrounding ambient.
Maximum ambient temperature is 93°C for models without the optional SIL2 flow sensor, 80 °C for units
with the SIL2 flow sensor.
LELA valve-actuator interface temperature must not exceed 141 °C. LELA2 valve-actuator interface
temperature must not exceed 110 °C for models certified to 93 °C ambient, or 94 °C for models certified
to 80 °C ambient. Valves fitted to the actuator by Woodward meet these requirements when installed with
piping insulation as shown in the user manual.
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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.
EXPLOSION HAZARD – Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area is
non-hazardous.
Substitution of components may impair suitability for Class I, Division
2, or Zone 2.
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Chapter 1.
General Information
Introduction
The Large Electric Sonic Valve (LESV II) controls the flow of gas fuel to the combustion system of an
industrial or utility gas turbine. The LESV II is an extension of the HR-LESV product line, and provides
increased fuel pressure and temperature capabilities.
The integral electric actuator consists of a brushless dc motor and gear train which drives a precision lead
screw for precise linear positioning. Dual resolvers are provided for motor commutation and position
sensing. The actuators include a return spring for fail-closed operation, The LESV II includes a high
temperature memory device (ID Module) which contains all the configuration and calibration information
to be read by the Digital Valve Positioner (DVP) when the valve/actuator is connected and powered up. A
soft stop cushion within the actuator is provided to protect the gear train and lead screw from damage
when the actuator impacts the seat during trip events.
This valve is intended to operate only with specific models of the Woodward Digital Valve Positioner
(DVP). Refer to manual B26773 for specifications and additional information on the operation and
configuration of the DVP5000 and DVP12000 (DVP5K and DVP12K). Contact your sales person for part
numbers for your specific applications.
The LESV II is also available with an optional position feedback sensor for a SIL2 light-off flow function.
The purpose of the sensor is to provide an independent valve shaft position feedback to be used for fuel
flowrate verification during turbine light off. See information in the following chapters for additional details.
Table 1-1. LESV II Large Electric Sonic Valve Specifications
2-Inch using the LELA
Actuator
3, 4, & 6-Inch using the LELA2
Actuator
Description 2, 3, 4, & 6-Inch (51, 76, 102, 152 mm) electrically actuated natural
gas sonic metering valve.
Mean Time Between Failure
(MTBF):
100,000 hrs of operation
Combined metering valve/actuator/DVP/cable subsystem.
Service Interval: Contact Woodward for recommended service interval.
Ambient Temperature Range: -29 to +93 °C (-20 to +200 °F) for models without SIL2 Flow Sensor
-29 to +80 °C (-20 to +176 °F) for models with SIL2 Flow Sensor
Storage Temperature Range: -40 to +93 °C (-40 to +200 °F)
Approximate Weights: 2-Inch: 119 kg / 263 lb. 3-Inch: 259 kg / 571 lb.
4-Inch: 299 kg / 659 lb.
6-Inch: 375 kg / 827 lb.
ACTUATOR
Description: Brushless dc motor with dual position feedback sensors.
Motor Coil Insulation Rating: Class H
Failure Mode: Spring type to drive valve to safe position with loss of signal
(Fail Close).
Bandwidth: 2-Inch LESV II: 35 rad/s with
no more than 6 dB attenuation
and less than 180 degrees
phase loss at ±2% magnitude
and minimum supply voltage at
DVP.
3, ”, and 6-Inch LESV II: 30 rad/s
with no more than 6 dB attenuation
and less than 180 degrees phase
loss at ±2% magnitude and
minimum supply voltage at DVP.
Visual Position Indication: Yes
Ingress Protection: IP55
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Manual 35076 LESV II
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SIL2 Position Sensor: Available as an option
SIL2 Position Sensor
Input Voltage
20.4 - 28.8 V (dc)
SIL2 Position Sensor Output
Signal at 0 % Travel
(3.9 to 4.3) mA (not including thermal effects)
SIL2 Position Sensor Output
Signal at 100 % Travel
(9.5 to 9.85) mA
(not including thermal effects)
(19.0 to 19.7) mA
(not including thermal effects)
Actuator Response Time:
(Measured from 90%-10% on
a 100%-0% step)
2-Inch: 400 mSec maximum 3, 4, 6-Inch: 650 mSec maximum
DVP Model 2-Inch LESV II: DVP5000 3, 4, & 6-Inch LESV II: DVP12000
DVP Input Voltage
Typical:
Max:
Min (for full dynamic
performance):
220 Vdc
300 Vdc
112.5 Vdc
220 Vdc
300 Vdc
190 Vdc
DVP Input Current
Max Steady State1:
Max Transient2:
1.5 Amps
20 Amps for 1 Second
1.5 Amps
30 Amps for 1 Second
DVP Output Current
Max Steady State1:
Max Transient2:
12 Amps
40 Amps
25 Amps
40 Amps
1Assumes slow modulation as when following a base load. Does not consider additional power
required as seen in grid firming applications requiring continuous and fast ramping of power. If this is
expected in the application, please contact Woodward for additional information. Stated current
values are based on minimum DVP input voltage for full dynamic performance.
2Information provided for breaker and wire sizing. Current seen when performing a full 100% step
against load. Note: this value varies by actuator type. The values above are applicable only for the
products referenced in this manual. Stated current values are based on minimum DVP input voltage
for full dynamic performance.
VALVE
Operating Fluid: Natural Gas
Gas Filtration: 25 µm absolute at 75 beta requirement
Valve flange connection: Class 600 Flange per ANSI B16.5
Valve Materials: Per NACE MR0103
Min Fluid Temperature: –29 °C (–20 °F)
Max Fluid Temperature: 371 °C (700 °F)
Min Fluid Pressure: 0 kPa (0 psig)
Max Fluid Pressure: 6585 kPa at 38 °C (955 psig at 100 °F)
6585 kPa at 260 °C (955 psig at 500 °F) per ANSI B16.5 for
CF8M
5998 kPa at 371 °C (870 psig at 700 °F) per ANSI B16.5 for
CF8M
Proof Test Pressure/Production: 14996 kPa / 2175 psig
Burst Pressure: 5x maximum operating pressure.
Overboard Leakage: < 25 cm³/min as shipped (see Fuel Overboard Vent Port
section).
Trim Sizes: Contact Woodward for various Cg trim sizes.
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Recovery Capability: 1.06 P1/P2 Critical Choking Pressure Ratio *
* contact Woodward for additional details
Seat Leakage: Class IV per ANSI/FCI 70-2
Nominal Cg Curve, Cg Accuracy:
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Figure 1-1. Optional SIL2 Flow Sensor 3, 4, 6 inch LESV II
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Figure 1-2a. Outline Drawing (2-Inch LESV II, UHR, SST, 600# Dual Resolver)
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Figure 1-2b. Outline Drawing (2-Inch LESV II, UHR, SST, 600# Dual Resolver)
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Figure 1-3a. Outline Drawing (3-Inch LESV II Class 600)
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Figure 1-3b. Outline Drawing (3-Inch LESV II Class 600)
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Figure 1-4a. Outline Drawing (4-Inch LESV II Class 600)
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Figure 1-4b. Outline Drawing (4-Inch LESV II Class 600)
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