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WOODWARD | INDUSTRIAL TURBOMACHINERY SYSTEMS

PRODUCT FEATURES

Æ Dirt-tolerant design (25lb rotary chip shear force)

Æ Self-cleaning valve design (rotary solenoids)

Æ Fast trip times (< 50 ms solenoid action)

Æ Increased reliability (2-out-of-3 voting design)

Æ Repairable online

Æ Testable on-line

Æ Safety certified for use in IEC61508 SIL-3 systems

Æ API-670 Compliant

Æ Local & remote position indications

Æ Compact size

Æ Certified for hazardous locations

The QuickTrip trip block assembly is designed for use in steam, gas, and hydro

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 steam turbines that use low pressure (5–25 bar / 73–363 psi)

hydraulic trip oil headers.

The QuickTrip’s fault tolerant design makes it ideal for critical 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.

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.

Manually Stroking QuickTrip (powered)

Manually Stroking Valve Procedure:

1. To manually stroke the QuickTrip valve, the actuators must be powered with 24 VDC. Make sure the

power supply is connected and operating while performing this procedure. This can be verified by

viewing the LED status through the sight window on top of the valve. One or two blue LED’s indicate

that the power supply is connected and is turned on.

2. If QuickTrip is in a run state, as indicated by a green LED as viewed through the sight glass,

QuickTrip may be manually tripped either by de-energizing the logic solver interposing relay to initiate

a trip state or by tripping the breaker to the Control In discrete input terminals on the QuickTrip

electronics module (terminals 5 and 6 of TB2).

3. If QuickTrip is in a trip state, as indicated by a red as LED viewed through the sight glass, QuickTrip

may be energized to close either by activating the logic solver interposing relay to initiate a run state

or by supplying a separate 24 VDC input to the Control In terminals on the QuickTrip electronics

module (terminals 5 and 6 of TB2).

Manually Stroking QuickTrip Using ProTechTPS (powered)

Manually stroking valve using ProTechTPS procedure:

1. If QuickTrip is in a run state, as indicated by a green LED as viewed through the sight glass,

QuickTrip may be manually tripped by de-energizing the ProTechTPS interposing relay to initiate a

trip. This may be done by using the Temporary Overspeed Setpoint Test (see ProTechTPS product

manual for more detailed instructions on this function).

2. If QuickTrip is in a trip state, as indicated by a red LED as viewed through the sight glass, QuickTrip

may be energized to close by activating the ProTechTPS interposing relay to initiate a run state. This

may be done by pressing the RESET button on the front panel of the ProTechTPS (see the

ProTechTPS product manual if module does not reset when the RESET button is pressed).

Hardware Replacement

The user is permitted to replace some components of the QuickTrip in turbine shutdown conditions. The

user is also permitted to replace some components of the QuickTrip during normal turbine operation

conditions. The replacement components must be Woodward recommended products. Only this

guarantees full component compatibility and functionality. All safety instructions and detailed procedures

from this manual must be followed.

Service and Replacement Parts:

• Service Manual (26842) – Consult Woodward distributor for part number

• Solenoid – On-line replaceable. Consult local Woodward distributor or service manual for part number

• Electronics module (PCBA) – On-line replaceable. Consult local Woodward distributor or service manual

for part number

• Return Spring – Consult local Woodward distributor or service manual for part number

• Sight Window – On-line replaceable. Consult local Woodward distributor or service manual for

part number

• Top Cover – On-Line replaceable. Consult local Woodward distributor or service manual for part number

• Bottom Cover – Consult local Woodward distributor or service manual for part number

• Interface Seals Kit(s) – Consult local Woodward distributor or service manual for part number

• Woodward Field Repair Tools Kit – Consult Woodward distributor for part number.

Special Ambient Temperature Considerations

Cold Start Procedure:

If performing a cold-start of QuickTrip in very cold ambient environment conditions 

(temperatures between -40 °C to +15 °C), both the hydraulic oil within the QuickTrip manifold and the QuickTrip manifold itself

must undergo a warmup procedure prior to starting the turbine to ensure the QuickTrip will operate within

specified performance limits. In particular, slew open times increase at lower hydraulic fluid temperatures

due to the higher viscosity (lower fluidity) of the hydraulic oil.
General

Woodward products covered under Woodward Product and Service Warranty (5-09-0690) are warranted

to be free from defects in materials and workmanship, when installed and used in the manner for which

they are intended, for a period of 18 months from the date of shipment from Woodward, defined in

Woodward’s Terms and Conditions.

Repairs and servicing of the QuickTrip must be performed by Woodward or its authorized service facilities

Use of a cable gland or stopping plug that does not meet the hazardous area certification requirements or

thread form or thread size will invalidate the suitability for hazardous locations.

Never remove or alter the nameplate as it bears important information which may be necessary to service

or repair the unit.

QuickTrip Cover Replacement Kit

Servo cover replacement kit may be ordered from Woodward.

Refer to Figure 5-1a which displays the part number. The location and assembly orientation of each kit

component must be installed as depicted in Figure 5-1b using a spanner wrench or Woodward tool

#1013-6603. For additional information see QuickTrip Field Repair Procedure Manual 26842.

Wiring Requirements:

• Keep this and all other low level signal cables separated from input power cables to avoid

unnecessary coupling (noise) between them.

• Wire gauge range: (0.8 to 1.3) mm² / (16 to 18) AWG

• Shielding: These outputs are unshielded, however the wires should be kept in a twisted configuration

for noise immunity.

Wiring

The QuickTrip has three, 3/4 inch (19 mm) NPT wiring entries.

When using cable and cable glands, the gland fitting must meet the same hazardous locations criteria as

the QuickTrip. Follow all installation recommendations and special conditions for safe use that are

supplied with the cable gland. The cable insulation must have a temperature rating of at least

85 °C and 10 °C above the maximum ambient and fluid temperature.

Strip the cable insulation (not the wire insulation) to expose 12 mm (1/2 inch) of the conductors. Strip the

wire insulation 5 mm from each conductor. Mark wires according to their designation and install

connectors, if required.

Remove the top access cover(s). Pass the wires through the cable gland (not provided) or conduit fitting

and attach wires to the printed circuit board terminal blocks in accordance with the wiring diagram.

Secure each wire into connector terminal using a 2.5 mm flat screwdriver blade, applying a torque of

0.2-0.25 Nm (1.75-2.25 in-lbf). Snap the terminal blocks into the header terminal blocks on the PCB.

Tighten the terminal block flange screws to 0.5 Nm (4.4 in-lbf). Replace the top access cover and torque

it using a 1 meter bar or wrench; tightening until the O-ring seal is compressed and the cover is fully

seated against the housing.

Tighten the cable gland fitting per manufacturer’s instructions or pour the conduit seal to provide strain

relief for the cable and to seal the interface between the wiring cable and the QuickTrip modules.

In order to preserve the QuickTrip’s online reparability, each of the three electrical actuator cavities must

be kept isolated from each other. This allows any individual actuator requiring repair to be electrically de

energized, repaired and placed back online while maintaining safe operation of QuickTrip in potentially

explosive environments.

Control Input

The QuickTrip valves are controlled with the independent trip relay outputs from a trip system logic solver

such as the Woodward ProTechTPS.

Note: When used with the ProTechTPS, external power is not necessary for these inputs. All voltage

and isolation is provided within the ProTechTPS (24 VDC, 0.5 A).

Trip Points:

• If the input voltage drops below14 VDC, then the input will detect a Trip state.

• If the input voltage rises above 15 VDC, then the input will detect a Run state.

Control Input Isolation: 500 VAC from input to chassis.

Wiring Requirements

• Keep this and all other low level signal cables separated from input power cables to avoid

unnecessary coupling (noise) between them.

• Wire Gauge Range: 0.8 to 1.3 mm² / 16 to 28 AWG stranded wire.

• Shielding: The control inputs are unshielded; however, the wires should be kept in a twisted

configuration for noise immunity.

Position Feedback

There are two outputs for valve position feedback on each of the QuickTrip’s three valve modules (12

outputs total). Each of the two outputs features redundant connections. Both TRIP outputs and both RUN

outputs operate as normally open. The outputs can be wired to either switch load from positive supply or

switch load to ground. The user must supply the external 24 V supply for the output to function properly. If

using the Woodward ProTech TPS logic solver, the voltage may be supplied using the on-board discrete

power terminals (24 VDC, 0.050 A).

Wiring Strain Relief

Tie down points and ratcheting tie wraps are provided to secure the wiring to the PCB mounting plate.

This helps prevent wire strain from being transmitted to the connection at the terminal block and to keep

the wiring from chafing on the cover when tightening and under vibration. Failure to secure the wiring

could result in intermittent connections resulting in intermittent operation or shutdown conditions. Allow for

additional wire service length between the tie down points and the connectors to reduce strain on the wire

at the connector interface and to allow the black pluggable connector to be removed.

Shield Installation Notes

• Wires exposed beyond the shield should be as short as possible, not exceeding 50 mm (2 inches).

• The shield termination wire (or drain wire) should be kept as short as possible, not exceeding 50 mm

(2 inches), and the diameter should be maximized where possible.

• Installations with severe electromagnetic interference (EMI) may require additional shielding

precautions. Contact Woodward for more information.

• Do not ground shield on both ends, except where permitted by the control wiring diagram.

Failure to provide shielding can produce future conditions that are difficult to diagnose. Proper shielding at

the time of installation is required to ensure satisfactory operation of the product.

Wire Cross-Sectional Area Voltage Drop

A standard wire cross-sectional area voltage drop at maximum ambient temperature is provided in Table

3-6 and Table 3-7 to assist with cable selection.

Example of Voltage Drop Calculation Using Wire Cross-Sectional Area

0.067

Example #1. one power supply per module (3x power supplies): A 2.5mm2 wire will drop 0.044 V/m at 2.6 A at

maximum ambient temperature. Using 30m between the QuickTrip and the power supply would provide a

voltage drop of 30 x 0.044 = 1.32V.

Example #2. one power supply for all three modules (1x power supply): A 2.5mm2 wires will drop 0.132 V/m

at 7.8 A at maximum ambient temperature. Using 30m between the QuickTrip and the power supply would

provide a voltage drop of 30 x 0.132 = 3.96V.

It is very important to ensure the voltage at the QuickTrip’s input terminal is within the product power input

specification to achieve the maximum performance.

A guideline for allowable voltage drop is to size the wire for <10% of the nominal voltage under maximum

transient conditions.

Voltage Drop Calculation Using American Wire Gauge

Example #1. one power supply per module (3x power supplies): A 18 AWG wire will drop 0.042 V/ft at 2.6

A at maximum ambient temperature. Using 100 feet between the QuickTrip and the power supply would

provide a voltage drop of 100×0.042 = 4.2V.

Example #2. one power supply for all three modules (1x power supply): A 18 AWG wire will drop 0.125

V/ft at 7.8 A at maximum ambient temperature. Using 100 feet between the QuickTrip and the power

supply would provide a voltage drop of 100×0.125 = 12.5V.

It is very important to ensure the voltage at the QuickTrip’s input terminal is within the product power

input specification to achieve maximum performance.

Extended Power Input

The Power Wiring Requirements section above specifies the maximum length of 30 meters between the

power source and the QuickTrip. Installations that require a longer power cable run also require a much

larger wire gauge to account for voltage drop. Figure 3-6 below gives a possible solution for installations

required to run at longer distances.