Woodward SonicFlo User manual

Product Manual 35022
(Revision A, 2/2017)
Original Instructions
SonicFlo™
High Temperature Gas Fuel Control Valves
High Recovery and Ultra High Recovery Designs
(Dual Core LVDT with No-trip and Enhanced Dynamics
Package)
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
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 Out-of-date translations are marked with .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 35022
Copyright © Woodward, Inc. 2017
All Rights Reserved

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Contents
WARNINGS AND NOTICES ...............................................................................................................3
ELECTROSTATIC DISCHARGE AWARENESS......................................................................................4
REGULATORY COMPLIANCE............................................................................................................5
CHAPTER 1. GENERAL INFORMATION..............................................................................................7
Introduction ...................................................................................................................................................7
CHAPTER 2. DESCRIPTION............................................................................................................15
Triple Coil Electrohydraulic Servo Valve Assembly....................................................................................15
Hydraulic Filter Assembly............................................................................................................................16
LVDT Position Feedback Sensors..............................................................................................................16
CHAPTER 3. INSTALLATION...........................................................................................................17
General........................................................................................................................................................17
Unpacking ...................................................................................................................................................18
Piping Installation........................................................................................................................................18
Electrical Connections.................................................................................................................................19
CHAPTER 4. MAINTENANCE AND HARDWARE REPLACEMENT.........................................................22
Maintenance................................................................................................................................................22
Hardware Replacement ..............................................................................................................................22
Inspections..................................................................................................................................................26
Troubleshooting ..........................................................................................................................................28
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS ..............................................................31
Product Support Options.............................................................................................................................31
Product Service Options .............................................................................................................................31
Returning Equipment for Repair .................................................................................................................32
Replacement Parts......................................................................................................................................33
Engineering Services..................................................................................................................................33
Contacting Woodward’s Support Organization...........................................................................................33
Technical Assistance ..................................................................................................................................34
REVISION HISTORY.......................................................................................................................35
DECLARATIONS ............................................................................................................................36
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Illustrations and Tables
Figure 1-1. High Recovery SonicFlo Gas Fuel Control Valves.....................................................................7
Figure 1-2a. SonicFlo Outline Drawing (2-inch, Class 300, no Trip) ............................................................9
Figure 1-2b. SonicFlo Outline Drawing (2-inch, Class 300, no Trip)..........................................................10
Figure 1-3a. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip)........................11
Figure 1-3b. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip)........................12
Figure 1-4. Hydraulic Schematic Circuit......................................................................................................13
Figure 1-5. Wiring Diagram.........................................................................................................................14
Figure 2-1. Servo Valve Cutaway...............................................................................................................15
Figure 3-1. Gas Fuel Control Valve Block Diagram....................................................................................20
Figure 3-2. Structures for PID Control ........................................................................................................20
Figure 4-1. Inspection Areas for 2 Inch Valves...........................................................................................27
Figure 4-2. Location of Hydraulic Interseal Drain and Cap for 2 Inch Valves.............................................27
Table 3-1. Class 300 Flange and Bolt Specifications.................................................................................18
Table 3-2. Recommended Control Gain Values for Different Control Types..............................................21

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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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.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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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 Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonisation of the laws of the
Member States relating to electromagnetic compatibility, EMC. 2014/30/EU
is met by evaluation of the physical nature to the EMC protection
requirement. Electromagnetically passive or “benign” devices are excluded
from the scope of the Directive 2014/30/EU, however, they also meet the
protection requirement and intent of the directive.
Pressure Equipment
Directive (Valve
Assembly):
Directive 2014/68/EU on the harmonisation of the laws of the Member
States relating to the making available on the market of pressure
equipment.
Product Type/Size: PED Category II and III
PED Module H – Full Quality Assurance,
CE-0041-PED-H-WDI 001-16-USA, Bureau Veritas UK Ltd (0041)
ATEX – Potentially
Explosive
Atmospheres
Directive:
Directive 2014/34/EU on the harmonisation of the laws of the Member
States relating to equipment and protective systems intended for use in
potentially explosive atmospheres
Zone 2, Category 3, Group II G, Ex nA IIC T3X, IP54
See below for special conditions for safe use.
Other European Compliance
Compliance with the following European Directives or standards does not qualify this product for the
application of the CE Marking:
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.
ATEX: Exempt from the non-electrical portion of the ATEX Directive 2014/34/EU
due to no potential ignition sources per EN 13463-1.
North American Compliance:
Suitability for use in North American Hazardous Locations is the result of compliance of the individual
components: LVDT: CSA Certified for Class I, Divisions 1 and 2, Groups A, B, C, D, T4, for use
in the United States and Canada per CSA 151336-1090811.
Servo Valve: FM Certified for Class I, Division 2, Groups A, B, C, D per 1H1A8.AX for use
in the United States.
CSA Certified for Class I, Division 2, Groups A, B, C, D for use in Canada
per CSA 1072373.
Junction Box: UL Listed for Class I, Zone 1: AEx e II, Ex e II, T6 for use in the United
States and Canada per UL E203312.
Special Conditions for Safe Use—All Valves
Wiring must be in accordance with North American Class I, Division 2 or European Zone 2, Category 3
wiring methods as applicable, except for valves requiring intrinsically safe wiring as stated above.
Field wiring must be suitable for at least 100 °C.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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The wiring junction box provides earth ground terminals if needed for a separate earth ground to meet
wiring requirements.
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.
The risk of electrostatic discharge is reduced by permanent installation of the valve, proper connection to
the protective earth (PE) terminals, and care when cleaning. The valve should not be cleaned unless the
area is known to be
non-hazardous.
EXPLOSION HAZARD—Do not connect or disconnect while circuit is
live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2 or Zone 2 applications.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher
tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel
inacceptable pour des applications de Classe I, Division 2
ou Zone 2.

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Chapter 1.
General Information
Introduction
The SonicFlo™ valve controls the flow of gas fuel to the combustion system of an industrial or utility gas
turbine.
This unique high recovery design yields a flow characteristic unaffected by discharge pressure at very low
pressure ratios (P1/P2) [contact Woodward for specific recovery information]. The high recovery design
has an approximate equal percentage flow characteristic from 0% to 15% stroke and a linear flow
characteristic from 15% to 100% stroke. The design integrates the valve and actuator into a compact
assembly.
The integral actuator is a single-acting spring-loaded design for failsafe operation. The actuator includes
an onboard hydraulic filter for last chance filtration of the fluid to ensure reliability of the servo valve and
actuator. The servo valve is electrically redundant with triple coil design. Feedback for the actuator is
provided by a dual coil LVDT (linear variable differential transformer) directly coupled to the hydraulic
piston.
Figure 1-1. High Recovery SonicFlo Gas Fuel Control Valves

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Control Valve Functional Characteristics
Valve Type Two Way–Right Angle
Fluid Ports ASME B16.5-2003 Class 300 flanges
Size 2 inch (50 mm)
Flowing Media Natural gas
Valve Proof Pressure Level 300 lb Flanges: 1125 psig/7757 kPa
Minimum Valve Burst Pressure 300 lb Flange: 3700 psig/25 511 kPa
Gas Filtration 25 µm absolute at 75 beta requirement
Ambient Temperature –20 to +180 °F (–29 to +82 °C)
Shut-off Classification Class IV per ASME B16.104/FCI 70-2
(0.01% of rated valve capacity at full travel measured with air at 50
psid/345 kPa)
External Leakage T2
Fuel Vent Leakage Max 1 cc/min (or 50 cc/min dependent on seal material)
Position Accuracy ±1% of full scale (Over ±25 °F/±14 °C deviation from calibration)
Position Repeatability ±0.5% of point over range of 10% to 100%
Hydraulic Fluid Type Petroleum based hydraulic fluids
Hydraulic Supply Pressure
(High Recovery models) 1300 to 1800 psig/8964 to 12 411 kPa
Hydraulic Supply Pressure
(Ultra High Recovery models) 1450 to 1800 psig/9997 to 12 411 kPa
Hydraulic Proof Test Fluid Pressure
Level Per SAE J214
Minimum Hydraulic Burst Fluid Pressure Per SAE J214
Fluid Filtration Required 10–15 µm absolute
Trip Time No Trip
Slew Time 0.490 ±0.098 seconds (open, 5% to 95%); 0.430 ±0.086 seconds
(closed, 95% to 5%)
Design Availability Objective Better than 99.5% over an 8760 hour period
Hydraulic Fluid Connections Supply pressure—0.750-14 UNF straight thread port (–8)
Drain pressure—1.312-20 UNF straight thread port (–16)
Sound Level <110 dB at max flow conditions
Vibration Test Level 0.5 gp 5–100 Hz sine wave
Random 0.01500 gr²/Hz from 10 to 40 Hz ramping down to 0.00015
gr²/Hz at 500 Hz
Shock Limited to 30 g by servo valve
Servo Input Current Rating –7.2 to +8.8 mA (null bias 0.8 ± 0.32 mA)
Hydraulic Fluid Contamination Level Per ISO 4406 code 18/16/13 max
Code 16/14/11 preferred
Trim Configuration Exponential 0% to 15%
Linear 15% to 100%
Materials Woodward certifies that our SonicFlo line of Gas Fuel Control Valves is
designed and manufactured such that all wetted materials that
experience a tensile stress are compliant with the thermo-mechanical
requirements of MR0103.
Allowable Operating Gas Pressure 300 lb Flanges: 1724 to 3103 kPa (250 to 450 psig)
Max & Min Gas Temperature –18 to +260 °C (0 to 500 °F)
Max Valve Discharge Flange
Temperature 530 °F (277 °C)
Valve Port Sizes 2" (50mm)--Cg=300, 900, 1200
Flow Characteristics ±3.0% Cg deviation of point from 15% to 100% stroke
Hydraulic Fluid Temperature 10 to 66 °C (50 to 150 °F)

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Figure 1-2a. SonicFlo Outline Drawing (2-inch, Class 300, no Trip)

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Figure 1-2b. SonicFlo Outline Drawing (2-inch, Class 300, no Trip)

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Figure 1-3a. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip)

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Figure 1-3b. SonicFlo Outline Drawing (2‐inch, Class 300, Ultra High Recovery, no Trip)

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Figure 1-4. Hydraulic Schematic Circuit

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Figure 1-5. Wiring Diagram

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Chapter 2.
Description
Triple Coil Electrohydraulic Servo Valve Assembly
The hydraulic actuator assembly uses a two-stage hydraulic servo valve to modulate the position of the
actuator output shaft and thereby control the gas fuel valves. The first stage torque motor utilizes a triple-
wound coil, which controls the position of the first and second stage valves in proportion to the total
electric current applied to the three coils.
If the control system requires a rapid movement of the valve to send more fuel to the turbine, total current
is increased well above the null current. In such a condition, control port PC1 is connected to supply
pressure. The flow rate delivered to the piston cavity of the actuator is proportional to the total current
applied to the three coils. Thus, the opening velocity is also proportional to the current (above null)
supplied to the torque motor.
If the control system requires a rapid movement to close the gas fuel valve, the total current is reduced
well below the null current. In such a condition, port PC1 is connected to the hydraulic drain circuit. The
flow rate from the piston cavity to drain is proportional to the magnitude of the total current below the null
value. Thus, the closing velocity is also proportional to the current (below null) supplied to the torque
motor.
Near the null current, the four-landed valve isolates the control port from the hydraulic supply and drain,
balancing the piston pressure against the spring to maintain a constant position. The control system,
which regulates the amount of current delivered to the coils, modulates the current supplied to the coil to
obtain proper closed loop position of the valve.
Figure 2-1. Servo Valve Cutaway

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Hydraulic Filter Assembly
The valve is supplied with an integrated, high-capacity filter. The broad range filter protects the internal
hydraulic control components from large oil-borne contaminants that might cause the hydraulic
components to stick or operate erratically. The filter is supplied with a visual indicator which shows when
the recommended pressure differential has been exceeded and thus replacement of the element is
necessary.
LVDT Position Feedback Sensors
The SonicFlo high recovery control valves use a dual-coil LVDT for position feedback. The LVDT is
factory set to give 0.7 Vrms feedback at minimum position and 3.5 Vrms feedback at maximum position,
when supplied with 7 Vrms excitation at 3000 Hz.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Chapter 3.
Installation
General
See the outline drawings (Figure 1-2) for:
Overall dimensions
Process piping flange locations
Hydraulic fitting sizes
Electrical connections
Lift points and center of gravity
Weight of the valve
Installation attitude does not affect actuator or fuel valve performance, but a vertical position is generally
preferred to conserve floor space as well as ease of making electrical, fuel, and hydraulic connections
and changing the hydraulic filter element. The gas fuel control valve is designed for support by the piping
flanges alone; additional supports are neither needed nor recommended. Do not use this valve to provide
support to any component other than the piping to which it is directly connected.
The orientation of the visual position indicator may be changed to accommodate surrounding
obstructions, if any. See Chapter 4 for instructions to change the orientation.
External fire protection is not provided in the scope of this product. It
is the responsibility of the user to satisfy any applicable
requirements for their system.
Due to typical noise levels in turbine environments, hearing
protection should be worn when working on or around the
SonicFlo™ valve.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Do not lift or handle the valve by any conduit. Lift or handle the valve
only by using the eyebolts. Use a “Y” type lifting configuration to
prevent damage to the LVDT conduit.
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.
Do not operate the valve without proper support for the diverging
sleeve. If bench testing the valve, ensure that all screws are in place
and torqued properly to hold the diverging sleeve in place.

Manual 35022 SonicFlo High Temperature Gas Fuel Control Valves
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Unpacking
The valve is shipped in an airtight bag with desiccant to ensure a non-corrosive environment. We
recommend that the valve be kept in its shipping container until installation. If the valve is to be stored for
extended periods of time, encase the valve in an airtight container with desiccant.
Piping Installation
Refer to ASME B16.5 for details of flange, gasket, and bolt types and dimensions.
The gas fuel control valve is designed for support by the piping flanges alone; additional supports are
neither needed nor recommended.
This is a 90° angle valve. Verify that the process piping centerline-to-flange-face dimensions meet the
requirements of the outline drawings (Figure 1-2) within standard piping tolerances. The valve should
mount between the piping interfaces such that the flange bolts can be installed with only manual pressure
applied to align the flanges. Mechanical devices such as hydraulic or mechanical jacks, pulleys, chain-
falls, or similar should never be used to force the piping system to align with the valve flanges.
ASTM/ASME SA-449 grade or better bolts or studs should be used to install the valve into the process
piping.
The length and diameter for Class 300 flanges shall conform to the following table according to the valve
flange size.
Table 3-1. Class 300 Flange and Bolt Specifications
Nominal
Pipe Size Number of Bolts Diameter of Bolts Stud Length Machine Bolt Length
2 inch/
51 mm 8 5/8 inch/ 16 mm 3.50 inch/ 88.9 mm 3.00 inch/ 76.2 mm
Flange gasket materials should conform to ASME B16.20. The user should select a gasket material which
will withstand the expected bolt loading without injurious crushing, and which is suitable for the service
conditions.
When installing the valve into the process piping, it is important to properly torque the stud/bolts in the
appropriate sequence in order to keep the flanges of the mating hardware parallel to each other. A two-step
torque method is recommended. Once the studs/bolts are hand tightened, torque the studs/bolts in a crossing
pattern to half the required torque. Once all studs/bolts have been torqued to half the appropriate value, repeat
the pattern until the rated torque value is obtained.
Do not insulate the valve or actuator. Insulation may be used on the inlet horizontal leg of the pipe. There
should be no insulation around the outlet flange of the valve or the outlet riser pipe. If the outlet riser pipe
is longer than 6 diameters, insulation may be used below the 6-diameter mark. This is because the purge
temperature is extremely hot and may damage the valve seals.
The valve discharge flange must not exceed 277 °C (530 °F) when the valve is closed and the downstream
circuit is being purged.
Hydraulic Connections
There are two hydraulic connections that must be made to each valve: supply and return. The
connections to the valve are straight-thread O-ring style ports per SAE J514. The tubing up to the valve
must be constructed to eliminate any transfer of vibration or other forces into the valve.