Woodward QuickTrip User manual

Product Manual 26815
(Revision E, 4/2017)
Original Instructions
QuickTrip
Electro-Hydraulic Trip Block Assembly
Installation and Operation Manual
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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 publicati
on 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 Out-of-date translations are marked with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.
All persons involved in the installation and maintenance of the Quick
Trip unit must have appropriate training. The calibration and checkout
procedure should only be performed by authorized personnel
knowledgeable of the risks posed by live electrical equipment.
The power supply mains should be properly fused according to the
National Electrical Code. The recommended fuse is a European Type T
fuse.
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A switch or circuit breaker shall be included in the bui
lding
installation that is in close proximity to the equipment and within easy
reach of the operator and that is clearly marked as the disconnecting
device for the equipment. The switch or circuit breaker shall not
interrupt the protective earth conductor.
The external ground lugs shown on the installation drawing must be
properly connected to ensure equipotential bonding. This will reduce
the risk of electrostatic discharge in an explosive atmosphere.
Any cleaning by hand or with water spray must be performed while
the area is known to be non-hazardous to prevent an electrostatic
discharge in an explosive atmosphere.
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 26815
Copyright © Woodward, Inc. 2015 - 2019
All Rights Reserved
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Contents
W ARNINGS AND N OTICES ..............................................................................................................4
E LECTROSTATIC D ISCHARGE A WARENESS ....................................................................................5
R EGULATORY C OMPLIANCE ..........................................................................................................6
C HAPTER 1. G ENERAL I NFORMATION .............................................................................................9
Introduction....................................................................................................................................................9
Construction................................................................................................................................................11
C HAPTER 2. S PECIFICATIONS ......................................................................................................14
Physical and Performance Specifications...................................................................................................14
Environmental Specifications......................................................................................................................14
Electrical Specifications ..............................................................................................................................14
Hydraulic Specifications..............................................................................................................................14
Functional Block Diagram...........................................................................................................................17
Hydraulic Schematic ...................................................................................................................................18
Outline Dimensions and Installation Features ............................................................................................19
C HAPTER 3. I NSTALLATION .........................................................................................................23
Receiving Instructions.................................................................................................................................23
Unpacking Instructions................................................................................................................................23
Installation Instructions................................................................................................................................24
C HAPTER 4. O PERATION .............................................................................................................35
Operating QuickTrip....................................................................................................................................35
Valve Position Feedback.............................................................................................................................37
Special Ambient Temperature Considerations ...........................................................................................38
C HAPTER 5. R EPAIR AND T ROUBLESHOOTING ..............................................................................39
General........................................................................................................................................................39
Hardware Replacement ..............................................................................................................................40
Troubleshooting ..........................................................................................................................................42
C HAPTER 6. S AFETY M ANAGEMENT ............................................................................................47
Product Variations Certified ........................................................................................................................47
Safe State....................................................................................................................................................47
SIL Specifications........................................................................................................................................47
Failure Rate Data........................................................................................................................................48
Limitations...................................................................................................................................................49
Management of Functional Safety ..............................................................................................................49
Restrictions..................................................................................................................................................50
Competence of Personnel...........................................................................................................................50
Operation and Maintenance Practice..........................................................................................................50
Installation and Site Acceptance Testing....................................................................................................50
Functional Testing after Initial Installation...................................................................................................50
Functional Testing after Changes...............................................................................................................50
Proof Testing (Full Functional Test)............................................................................................................50
Diagnostic Testing (On-Line Test)..............................................................................................................52
C HAPTER 7. P RODUCT S UPPORT AND S ERVICE O PTIONS .............................................................53
Product Support Options.............................................................................................................................53
Product Service Options .............................................................................................................................53
Returning Equipment for Repair .................................................................................................................54
Replacement Parts......................................................................................................................................55
Engineering Services..................................................................................................................................55
Contacting Woodward’s Support Organization...........................................................................................55
Technical Assistance ..................................................................................................................................56
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C HAPTER 8. A SSET M ANAGEMENT AND R EFURBISHMENT S CHEDULING P ERIOD ............................57
C HAPTER 9. ...............................................................................................................................58
L ONG -T ERM S TORAGE R EQUIREMENTS .......................................................................................58
A PPENDIX ..................................................................................................................................59
C OMMISSIONING C HECKLIST .......................................................................................................59
R EVISION H ISTORY .....................................................................................................................61
D ECLARATIONS ..........................................................................................................................62
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Illustrations and Tables
Figure 1-1. QuickTrip, Key Features...........................................................................................................11
Figure 1-2. Application Example.................................................................................................................12
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. Hydraulic Schematic.................................................................................................................18
Figure 2-6a. QuickTrip Outline Dimensions................................................................................................19
Figure 2-6b. QuickTrip Outline Dimensions................................................................................................20
Figure 2-6c. QuickTrip Outline Dimensions................................................................................................21
Figure 3-1. QuickTrip Product Installation Interface—Bolting Pattern........................................................25
Figure 3-2. Electrical Wiring Diagram .........................................................................................................27
Figure 3-3. Power Supply Input Connections .............................................................................................28
Figure 3-4. Correct Wiring to Power Supply Input ......................................................................................29
Figure 3-5. Example of Incorrect Wiring to Power Supply Input.................................................................29
Figure 3-6. Recommended Wiring Strain Relief .........................................................................................30
Figure 3-7. Control Input Connections........................................................................................................31
Figure 3-8. Feedback Output Connections.................................................................................................32
Figure 3-9. Cover Clamps...........................................................................................................................33
Figure 4-1. Pressure Test Ports..................................................................................................................38
Figure 6-1. TUV Rheinland SIIL Certification Stamp ..................................................................................47
Figure 6-2. Response Time.........................................................................................................................49
Table 1-1. QuickTrip Part Numbers ............................................................................................................12
Table 1-2. Recommended QuickTrip Spare Part Kits.................................................................................13
Table 1-3. Optional QuickTrip Spare Part Kits............................................................................................13
Table 2-1. QuickTrip Cv in Trip Condition...................................................................................................15
Table 3-1. QuickTrip Product Installation Interface.....................................................................................24
Table 3-2. Recommended Circuit Breaker Fuse Ratings...........................................................................28
Table 3-3. Power Supply Input Terminals...................................................................................................28
Table 3-4. Control Input Terminals .............................................................................................................31
Table 3-5. Feedback Terminals ..................................................................................................................31
Table 4-1. Pressure Port Logic Table.........................................................................................................37
Table 7-1. QuickTrip Troubleshooting Guide..............................................................................................44
Table 6-1. De-Energize-to-Trip Functionality..............................................................................................47
Table 6-2. Calculation Types and SIL 3 Values..........................................................................................47
Table 6-3. QuickTrip SIL3 Certification values............................................................................................48
Table 6-4. Safe Failure Fraction (SFF) Value.............................................................................................48
Table 6-5. Diagnostic Coverage (DC) Value...............................................................................................48
Table 6-6. MTBF Value...............................................................................................................................48
Table 6-7. QuickTrip Response Time Value...............................................................................................48
Table 6-8. Environmental Specifications:....................................................................................................49
Table A-1. Installation and Commissioning Checklist.................................................................................59
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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 public
ation 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 st
arting 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 conta
in 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
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.
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking and the appropriate agency
certification marking.
EMC Directive
Declared to 2014/30/EU of the European Parliament and of the Council of
26 February on the harmonisation of the laws of the Member States
relating to electromagnetic compatibility (EMC).
Item Prefix(es): ALL
ATEX
Directive:
Declared to 2014/34/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 equipment and protective systems intended for use in
potentially explosive atmospheres.
Item Prefix(es): 1, 3 -
Zone 1, Category 2, Group II G, Ex db IIB T4 Gb X
SIRA 15ATEX1230X
Item Prefix(es): 1, 2, 3, 4 -
Zone 2, Category 3, Group II G, Ex nA nC IIC T4 Gc X
SIRA 15ATEX4231X
Other Europea
n and International 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 13463-1:2009 for Category 2.
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.
Pressure Equipment
Directive: Compliant as “SEP” per Article 4.3 to Pressure Equipment Directive
2014/68/EU on the harmonisation of the laws of the Member States
concerning pressure equipment.
EAC Customs Union
These listings are limited only to those units with labels, marking, and manuals in Russian language to
comply with their certificates and declaration.
EAC Customs Union
(Marked) Certified to Technical Regulation CU 012/2011 for use in potentially
explosive atmospheres per Certificate RU C-US.МЮ62.В.02276 as
Item Prefix(es): 3 -
1Ex d IIB T4 Gb X
Item Prefix(es): 3, 4 -
2Ex nA IIC T4 Gc X
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EAC Customs Union
Declared to Technical Regulation CU 020/2011 On Electromagnetic
Compatibility of Technical Equipment Declaration of Conformity
Registration No: RU Д-US.AЛ32.B.05234
Item Prefix(es): 3, 4
Other International Compliance
These listings are limited only to those units bearing the appropriate agency certification marking.
IECEx:
Certified for use in explosive atmospheres per Certificate:
IECEx CSA 15.0009X
Item Prefix(es): 1, 3 - Ex db IIB T4 Gb
Item Prefix(es): 1, 2, 3, 4 - Ex nA IIC T4 Gc
North American
Compliance
:
These listings are limited only to those units bearing the CSA identification
CSA:
(Item Prefix: 1) CSA Certified For Class I, Division 1, Groups C & D, Class I, Division 2,
Groups A, B, C, & D, T4 at 85 °C Ambient. For use in Canada and the
United States. Certificate 2757391
CSA:
(Item Prefix: 2) CSA Certified For Class I, Division 2, Groups A, B, C, & D, T4 at 85 °C
Ambient. For use in Canada and the United States. Certificate 2757391
SIL Compliance:
SIL
-
3:
Product has been evaluated to IEC 61508 Parts 1-2 and 4-7:2010 as well
as IEC 61511 Parts 1-3:2004 (in extracts) and has been found to be
suitable for use in a safety instrumented system up to SIL-3. The
instructions of the associated installation and Operating Manual shall be
considered and followed – reference “Safety Management” in Chapter 6
of this manual. See end of this manual for certificate and test results.
Certificate V 486.01./15
Special Conditions for Safe Use
Field wiring must be suitable for at least +85 °C and 10 °C above the maximum fluid and ambient
temperatures.
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
and hence are as detailed below:
Flamepath Max Gap, ic (mm)
Min. width of joint L (mm)
Sleeve to Spacer 0.08 12.852
Rotor to Spacer 0.08 13.46
Sleeve to Carrier 0.0483 14.757
Sleeve to Housing 0.178 14.097
Under certain extreme circumstances, the non-metallic parts incorporated in the enclosure of this
equipment may generate an ignition-capable level of electrostatic charge. Therefore the equipment shall
not be installed in a location where the external conditions are conducive to the build-up of electrostatic
charge on such surfaces. In addition, the equipment shall only be cleaned with a damp cloth.
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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.
Connect external safety ground terminal to earth ground.
For installation using Ex nA nC protection:
1. Transient protection of QuickTrip is to be provided externally by the end user. The transient protection
device is to be set at a level not exceeding 140% of the peak rated voltage.
2. The installation of QuickTrip shall only be within a Pollution Degree 2 environment as defined in IEC
60664-1.
3. Minimum ambient temperature shall not be lower than -20 °C
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.
Do not connect/disconnect/substitute components
WARNING - Explosion Hazard—Do not remove covers or
connect/disconnect electrical connectors unless power has
been switched off or the area is known to be non-hazardous.
Substitution of components may impair suitability for Class
I, Division 2 or Zone 2 applications.
AVERTISSEMENT - Risque d’explosion— Ne pas enlever les
couvercles, ni raccorder / débrancher les prises électriques,
sans vous en assurez auparavant que le système a bien été
mis hors tension; ou que vous situez bien dans une zone
non explosive.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I,
applications Division 2 ou Zone 2.
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Chapter 1.
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.
The QuickTrip’s fault tolerant design makes it ideal for critical gas or steam turbine applications, where
turbine up-time and availability are essential. This trip block assembly’s 2-out-of-3 voting design provides
users with a very high level of system reliability as well as compliance with industry standard API-670.
This trip block assembly is designed to allow turbine controls and/or turbine safety systems to quickly
dump (bleed off) hydraulic header pressure during emergency trip or normal trip conditions. When applied
in conjunction with Woodward’s ProTechTPS logic solver, the QuickTrip allows users to independently
test each trip leg to verify operation and trip time. API-670 5th edition requires that all components except
for the final element (trip valve) shall be routinely tested while the turbine is in operation.
With the use of trip solenoids which respond in less than 50 milliseconds, the QuickTrip is designed for
gas or steam turbine trip systems where it is imperative the entire trip system shut the system trip valve
as quickly as possible.
The QuickTrip’s robust design (corrosion resistant materials, three independent moving rotary valves, and
self-cleaning port design) makes it optimal for challenging applications where dirty or contaminated oil
may be present.
The QuickTrip is certified for use in IEC61508 based turbine safety systems, and when paired with the
Woodward ProTechTPS, can be applied into systems that require a “Safety Integrity Level – 3” rating or
below.
Designed for use in new or retrofit turbine packages, the QuickTrip’s compact package size allows it to be
located near the turbine and trip & throttle valve, minimizing trip header piping and related system delays.
Each trip leg includes bright position indication LEDs (run & trip) to allow turbine operators to quickly
verify system status locally near the turbine as well as integrated limit switches for safety system and
plant DCS status and health validation.
The QuickTrip is an IEC61508 safety certified electro-hydraulic trip block assembly designed for use in
gas or steam turbine shutdown systems for quick and reliable dumping of the turbine’s trip oil header.
This trip block assembly’s 2-out of-3 voting design provides users with a high level of system reliability as
well as compliance with industry standards like API-670, API-612, and API-611.
This trip block assembly is housed in a fully integrated package which includes three patented dirt-
tolerant rotary trip valves. These valves are connected to provide redundant two-out-of-three based voting
to ensure that a failure of any one component (electronics module, valve, wiring, connector, etc.) does not
result in a nuisance trip condition. The QuickTrip’s modular design also allows users to replace critical
components (electrical module, solenoid, wiring, etc.) while the turbine is operating on-line.
Designed to quickly and reliably bleed off trip oil header pressure, at least two of the QuickTrip's three
rotary solenoid valves must be de-energized to open a bleed path from the trip oil header to system drain.
The QuickTrip accepts one or two (redundant) 24 Vdc power sources to power each solenoid, and uses
three independent discrete input shutdown commands from a safety logic solver like the Woodward
ProTechTPS (independent voted models) to test and control each solenoid valve.
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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.
When packaged with a Woodward ProTechTPS safety logic solver, the ProTechTPS performs the
required routine safety system diagnostic tests to verify unit operation while the turbine is on-line, and the
proof test trip time response monitoring and logging ensures the total turbine safety system can respond
fast enough to safely shutdown the turbine.
The total installed cost for this fully integrated trip block assembly is low because it has been completely
assembled and tested at the factory. This greatly reduces OEM and end-user fabrication time, installation
time, and testing time.
Dirt Tolerance
The QuickTrip is specifically designed for gas and steam turbine applications where turbine lube oil is
also used to power the hydraulic turbine control valve actuator(s). Gas and steam turbine applications can
be extremely challenging for hydraulic trip block assemblies as dirt, metal shavings, water, and other
contaminants (Babbitt, ammonia, etc.) are common in such oil systems. Also due to the high
temperatures at which turbines operate, turbine oil breakdown is common, resulting in the creation of a
sludge-type substance and the varnishing of internal system components. However, the QuickTrip is
designed to operate reliably within such challenging applications. Its corrosion-resistant materials, rotary
valve design, and self-cleaning ports allow it to operate in such applications without experiencing
undesirable sticking or dragging.
In the past, older style trip block assemblies utilized internal orifices and pressure gauges to verify
solenoid valve operation, causing many maintenance problems when applied in turbine lube-oil-powered
trip systems. Since the QuickTrip does not utilize problematic orifices or pressure gauges, maintenance is
reduced and system reliability improved.
Valve Status (local & remote)
Each valve solenoid accepts power for one or two (redundant) power sources and has the following
status indications to assist operators with understanding the status and health of each valve.
•Valve Open—Local LED (red)
•Valve Open—Limit Switch
•Valve Closed—Local LED (green)
•Valve Closed—Limit Switch
•Power Supply #1 Healthy—Local LED (blue)
•Power Supply #2 Healthy—Local LED (blue)
Redundancy/Availability
Designed for use in critical gas and steam turbine applications where turbine up time is important, the
QuickTrip uses three isolated solenoid valves designed to be driven by a triple modular redundant 2-out-
of-3 voting based safety logic solver. Each isolated solenoid valve uses redundant power supply inputs to
increase both system reliability and availability. Note: Only one power source is required to
power/energize each of the isolated solenoid valves.
On-Line Repairable
The QuickTrip’s modular design allows independent repair/replacement of each valve’s solenoid,
electrical module, and associated power supplies and wiring to increase both system reliability and
availability. Note: Only one power source is required to power/energize each of the isolated solenoid
valves.
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Construction
The QuickTrip is made up of the following major components:
1. Hydraulic Manifold
2. Three Independently Actuated, Spring Return Rotary Trip Valves
3. Feedback Sensors: Limit Switches
4. Integrated Electric Actuators and Electronics Modules
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. As a valve rotates to the tripped position, the ports open and the trip header pressure
is connected to either the drain, or the inlet ports of another one of the valves. The combined action of the
three valves results in trip header pressure being connected to drain only when 2 or 3 valves are tripped.
If the unit detects any shutdown condition or loss of power occurs, the trip valve return springs will force
the valves to the fail-safe / tripped position.
Electric Valve Actuators
The QuickTrip uses a set of three unique rotary solenoids called limited angle torquers (LAT). The
permanent magnet rotor is directly coupled to the trip valve.
The position of the valves is sensed by two limit switches present on each of the electrical modules.
These limit switches are located on both the closed and tripped positions of the valves, allowing the user
to easily determine the position of each valve.
Electronic Driver Modules (PCB)
The printed circuit boards (PCB) are mounted on of the top of each valve module. The PCB(s) performs
the following tasks:
•Trip Demand Input
•Dual Redundant Power Inputs
•Valve Position Feedback Discrete Outputs
•Visual Valve Position Indication
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Discrete outputs are provided for position feedback indication of each valve module. Within each valve
module, there are also four LEDs that indicate the current condition of the module as well as power
supply health. These LEDs are viewable through the transparent sight window of the module covers.
Inlet Steam
Header
Redundant Speed Signals
Turbine Control
Control Valve
Actuator
Generator
or
Compressor
or
Pump
Turbine Safety System
TS
TS PS
Analog or Discrete Signals
Drain
Trip Oil Header
QuickTrip
Trip Block
LS
Governor Valve Trip Command
T&T Valve Trip
Commands & Solenoid
Position Indication
Valve Position & Trip
Commands
Drain
T&T Valve Trip Command
T&T Valve Closed Indication
T&T
Valve
Figure 1-2. Application Example
Table 1-1. QuickTrip Part Numbers
Item
Prefix
Item
Number
Description
Primary
Language
0 9907-1978 CE Mark for Ordinary Location English
1 9907-1978 North American Div 1 & 2, ATEX/IECEx Zone 1 & 2 English
2 9907-1978 North American Div 2, ATEX/IECEx Zone 2 English
3 9907-1978 North American Div 1 & 2, EAC CU/ATEX/IECEx Zone 1 & 2 Russian
4 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).
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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, & rotor)
Table 1-3. Optional QuickTrip Spare Part Kits
Part Number
Spare Kit Description
8923-2191 Rotor Replacement Kit
8923-2143 Sight Window Replacement Kit
8923-2144 Top Cover Replacement Kit
8923-2145 Bottom Cover Replacement Kit
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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly
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Chapter 2.
Specifications
Physical and Performance Specifications
Solenoid Response Time:
< 50 ms*
Failsafe Operation: Internal return spring on each solenoid valve
Weight: 110 kg (242 lb)
Mounting: Vertical Mounting
* Solenoid Response Time represents the valve trip time and is defined as the time from when the
solenoid is de-energized to the time when the valves are at full open position.
Environmental Specifications
Ambient Temperature:
(–40 to +85) °C / (–40 to +185) °F
Ex nA nC Minimum Ambient
Temperature:
-20 °C (-4 °F)
Vibration Resistance:
MIL-STD 810F, M514.5A, Cat. 4
(0.015 G²/Hz, 1.04 Grms)
Shock Resistance:
US MIL-STD-810C method 516.2, procedure 1
(10 G Peak, 11 ms duration, saw tooth)
Corrosion Resistance: Two part epoxy paint coating. Designed for outdoor conditions
Electrical Specifications
Supply Voltage:
24 Vdc nominal ± 10% (use cable at least 0.8mm² / 18 AWG)
Current Consumption:
8 A Max (2.6 A per channel Max) at steady state @ 24 V
10 A transient (100 ms maximum)
Control Input Voltage: 15-32 Vdc, 20 mA max
Feedback Output Signal:
Resistive: 2 A @ 28 Vdc, max 32 Vdc
Inductive: 0.5 A @ 28 Vdc (max. 0.2 Henry)
Supply Voltage Connections: Terminal suitable for 0.8 to 3.3 mm² or 18 to 12 AWG stranded wire
Control Input and Discrete
Connections:
Removable terminal suitable for 0.8 to 3.3 mm² or 18 to 12 AWG
stranded wire
Cable Entries:
3 X 0.750”-14 NPT
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).
Fluid Type:
Petroleum-based hydraulic fluids as well as fire-resistant hydraulic
fluids such as Fyrquel EHC
Maximum Trip Header Pressure: 34.5 bar (500 psi)
It is recommended to set
hydraulic system pressure regulator to
110% or less of normal operating pressure to prevent over-
pressure.
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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly
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Proof Pressure: 51.7 bar (750 psig)
Burst Pressure: 86.2 bar (1250 psig)
Fluid Temperature: 15 to 70 °C / 59 to 158 °F continuous
Fluid Cleanliness Level: ISO 4406 code 20/18/16 or cleaner
Fluid Filtration Level:
20 micron filter is recommended with a beta ratio of at least 200
(99.5% efficiency)
Hydraulic Connections:
Hydraulic Supply Port: 1.250 SAE Code 61 Flange
Hydraulic Drain Port: 1.250 SAE Code 61 Flange
Oil Flow / Cv Rating: Refer to following figures for Cv and Leakage Rates of the Valves
Figure 2-1. QuickTrip Cv vs Time Curve
The figure above shows the estimated, worse case Cv of the
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.
Table 2-1. QuickTrip Cv in Trip Condition
Trip Condition Cv
Trip A & B 10.3
Trip B & C 11.4
Trip A & C 11.9
Trip A, B & C 13.4
The figure above shows the typical Cv values for the QuickTrip
assembly. Actual values may vary by as much as ± 12% from the
values shown.
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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly
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Flow Coefficient (Cv):
The flow coefficient (Cv) of a valve is defined as the relationship between flow rate (Q), pressure drop
(∆P), and fluid specific gravity (SG). The equation for Cv is shown below. Note: the variables in the Cv
equation must be in the correct units (GPM, psi) for values to be correctly calculated.





!"#
$!%&#'(( 
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-(1#!)
.)*21113"%4/5!!#
 
6 .)*2 )*+,- .0-(
6 .27*8-).9
Steady State Leakage
The graphs below show the hydraulic steady-state leakage flow through QuickTrip with 50 °C and 70 °C
hydraulic fluid. Each graph shows the leakage with the Channel A valve open, Channel B valve open,
Channel C valve open and with all valves closed. The worst-case leakage flow through QuickTrip occurs
with the Channel A valve open. The trip system orifice should be sized for this maximum leakage so that
an auto sequence test that trips channel A to an open position will not cause the trip header pressure to
fall below the trip point for the system.
Figure 2-2. QuickTrip Steady State Leakage (50 °C hydraulic oil)
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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly
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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).
Functional Block Diagram
Trip Header
Drain
High Pressure
Supply
Supply
Orifice
Turbine Trip
Valve
QuickTrip
ProTechTPS
Trip Signal
Power Supply
24V, 9A
Redundant
Power
Supplies
Power Supply
24V, 9A
Position Feedback
Figure 2-4. Functional Block Diagram
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