Woodward QuickTrip Installation And Operation Manual

Released

Product Manual 26815

(Revision E, 4/2017)

Original Instructions

Electro-Hydraulic Trip Block Assembly

QuickTrip

Installation and Operation Manual

Read this entire manual and all other publications pertaining to

the work to be

This publicati

on may have been revised or updated since this copy was

Any unauthorized modifications to or use of this equipment outside its

If the cover of this publication states "Translation of the Original Instructions"

All persons involved in the installation and maintenance of the Quick

The power supply mains should be properly fused according to the

Released

General

Precautions

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

Proper Use

Translated

Publications

produced. To verify that you have the latest revision, check manual

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.

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.

please note:
The original source of this publication may have been updated since this

translation was made. Be sure to check manual

Cross Reference and Revision Status & Distribution Restrictions, to verify

26455

, Customer Publication

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 Out-of-date translations are marked with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.

26455

,

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.

National Electrical Code. The recommended fuse is a European Type T
fuse.

A switch or circuit breaker shall be included in the bui

lding

The external ground lugs shown on the installation drawing must be

Released

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.

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

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Contents

W

ARNINGS AND NOTICES

E

LECTROSTATIC DISCHARGE AWARENESS

R

EGULATORY COMPLIANCE

C

HAPTER 1. GENERAL INFORMATION

Introduction.................................................................................................................................................... 9

Construction ................................................................................................................................................ 11

C

HAPTER 2. SPECIFICATIONS

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. INSTALLATION

Receiving Instructions ................................................................................................................................. 23

Unpacking Instructions ................................................................................................................................ 23

Installation Instructions ................................................................................................................................ 24

.............................................................................................................. 4

.................................................................................... 5

.......................................................................................................... 6

............................................................................................. 9

...................................................................................................... 14

......................................................................................................... 23

C

HAPTER 4. OPERATION

Operating QuickTrip .................................................................................................................................... 35

Valve Position Feedback ............................................................................................................................. 37

Special Ambient Temperature Considerations ........................................................................................... 38

C

HAPTER 5. REPAIR AND TROUBLESHOOTING

General ........................................................................................................................................................ 39

Hardware Replacement .............................................................................................................................. 40

Troubleshooting .......................................................................................................................................... 42

C

HAPTER 6. SAFETY MANAGEMENT

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. PRODUCT SUPPORT AND SERVICE OPTIONS

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

Woodward 1

............................................................................................................. 35

.............................................................................. 39

............................................................................................ 47

............................................................. 53

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

C

HAPTER 8. ASSET MANAGEMENT AND REFURBISHMENT SCHEDULING PERIOD

C

HAPTER

L

ONG-TERM STORAGE REQUIREMENTS

A

PPENDIX

C

OMMISSIONING CHECKLIST

R

EVISION HISTORY

D

ECLARATIONS

9. ............................................................................................................................... 58

....................................................................................... 58

.................................................................................................................................. 59

....................................................................................................... 59

..................................................................................................................... 61

.......................................................................................................................... 62

............................ 57

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

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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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

The engine, turbine, or other type of prime mover should be

The products described in this public

ation may present risks that

Be prepared to make an emergency shutdown when st

arting the

Released

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.

equipped with an overspeed shutdown device to protect against

Overspeed /

Overtemperature /

Overpressure

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.

could lead to personal injury, loss of life, or property damage.

Personal Protective

Equipment

Start-up

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.

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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Electronic controls conta

in static

-

sensitive parts. Observe the

Released

Electrostatic Discharge Awareness

following precautions to prevent damage to these parts:

Electrostatic

Precautions

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.

• 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.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

The certifications and regulatory information that are marked on each

European Compliance for CE Marking:

EMC Directive

ATEX

Directive:

Other Europea

n and International Compliance:

ATEX Directive:

Machinery Directive:

Pressure Equipment

EAC Customs Union

EAC Customs Union

Released

Regulatory Compliance

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.

These listings are limited only to those units bearing the CE Marking and the appropriate agency
certification marking.

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

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

Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:

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.

Compliant as partly completed machinery with Directive 2006/42/EC of
the European Parliament and the Council of 17 May 2006 on machinery.

Compliant as “SEP” per Article 4.3 to Pressure Equipment Directive

Directive:

2014/68/EU on the harmonisation of the laws of the Member States
concerning pressure equipment.

These listings are limited only to those units with labels, marking, and manuals in Russian language to
comply with their certificates and declaration.

Certified to Technical Regulation CU 012/2011 for use in potentially

(Marked)

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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

EAC Customs Union

Other International Compliance

IECEx:

North American

Compliance

:

CSA:

CSA:

SIL Compliance:

SIL-3:

Released

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

These listings are limited only to those units bearing the appropriate agency certification marking.

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

These listings are limited only to those units bearing the CSA identification

CSA Certified For Class I, Division 1, Groups C & D, Class I, Division 2,

(Item Prefix: 1)

Groups A, B, C, & D, T4 at 85 °C Ambient. For use in Canada and the
United States. Certificate 2757391

CSA Certified For Class I, Division 2, Groups A, B, C, & D, T4 at 85 °C

(Item Prefix: 2)

Ambient. For use in Canada and the United States. Certificate 2757391

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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Do not connect/disconnect/substitute components

Released

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.

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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

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 dirt­tolerant 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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

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-out­of-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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

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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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Item

Item

Description

Primary

Released

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.

Turbine Safety System

Governor Valve Trip Command

T&T Valve Closed Indication

T&T Valve Trip

Commands & Solenoid

Position Indication

T&T Valve Trip Command

Turbine Control

Valve Position & Trip

Commands

Trip Oil Header

QuickTrip
Trip Block

Drain

Redundant Speed Signals

Analog or Discrete Signals

Inlet Steam

Header

LS

T&T

Valve

TS

Drain

Control Valve

Actuator

Figure 1-2. Application Example

Table 1-1. QuickTrip Part Numbers

Prefix

Number

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

Generator

or

Compressor

or

Pump

TS PS

Figure 1-3. Ordering Example

Note: 9907-1978 is used as an example. Contact Woodward for latest item number(s).

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Part Number

Spare Kit Description

Part Number

Spare Kit Description

Released

Table 1-2. Recommended QuickTrip Spare Part Kits

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

8923-2191 Rotor Replacement Kit
8923-2143 Sight Window Replacement Kit
8923-2144 Top Cover Replacement Kit
8923-2145 Bottom Cover Replacement Kit

Woodward 13

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Make sure that the QuickTrip hydraulic connections are installed

It is recommended to set

hydraulic system pressure regulator to

Released

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:

Vibration Resistance:

Shock Resistance:

Corrosion Resistance: Two part epoxy paint coating. Designed for outdoor conditions

Supply Voltage: 24 Vdc nominal ± 10% (use cable at least 0.8mm² / 18 AWG)

Current Consumption:

Control Input Voltage: 15-32 Vdc, 20 mA max

Feedback Output Signal:

Supply Voltage Connections: Terminal suitable for 0.8 to 3.3 mm² or 18 to 12 AWG stranded wire

Control Input and Discrete

Connections:

Cable Entries:

-20 °C (-4 °F)
MIL-STD 810F, M514.5A, Cat. 4

(0.015 G²/Hz, 1.04 Grms)
US MIL-STD-810C method 516.2, procedure 1
(10 G Peak, 11 ms duration, saw tooth)

Electrical Specifications

8 A Max (2.6 A per channel Max) at steady state @ 24 V
10 A transient (100 ms maximum)

Resistive: 2 A @ 28 Vdc, max 32 Vdc
Inductive: 0.5 A @ 28 Vdc (max. 0.2 Henry)

Removable terminal suitable for 0.8 to 3.3 mm² or 18 to 12 AWG
stranded wire
3 X 0.750”-14 NPT
1 Ground

Hydraulic Specifications

correctly. Equipment damage is possible if the hydraulic
connections are attached incorrectly (backwards).

Fluid Type:

Maximum Trip Header Pressure: 34.5 bar (500 psi)

110% or less of normal operating pressure to prevent over­pressure.

Woodward 14

Petroleum-based hydraulic fluids as well as fire-resistant hydraulic
fluids such as Fyrquel EHC

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

The figure above shows the estimated, worse case Cv of the

The figure above shows the typical Cv values for the QuickTrip

Released

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:

Hydraulic Connections:

20 micron filter is recommended with a beta ratio of at least 200
(99.5% efficiency)
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

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

assembly. Actual values may vary by as much as ± 12% from the
values shown.

Woodward 15

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

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

)*+,-



6 .27*8-).9

.0-(

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)

Woodward 16

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

The figures above show the maximum expected steady

-

state leakage

Released

Figure 2-3. QuickTrip Steady State Leakage (70 °C hydraulic oil)

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

ProTechTPS

High Pressure

Supply

Turbine Trip

Valve

Supply

Orifice

Trip Signal

Position Feedback

Redundant

Power

Supplies

Power Supply

24V, 9A

Power Supply

24V, 9A

Trip Header

Figure 2-4. Functional Block Diagram

Woodward 17

QuickTrip

Drain

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Hydraulic Schematic

Figure 2-5. Hydraulic Schematic

Woodward 18

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Outline Dimensions and Installation Features

Figure 2-6a. QuickTrip Outline Dimensions

Woodward 19

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Figure 2-6b. QuickTrip Outline Dimensions

Woodward 20

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Figure 2-6c. QuickTrip Outline Dimensions

Woodward 21

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

NOTES

1. These general reference outline drawings apply to Woodward QuickTrip only. Consult Woodward for
the latest outline drawing.

2. Installation Orientation: Orientation vertical approximately as shown See elsewhere in this manual for
other installation recommendations.

3. Service Manual Replacement Parts:

• Product Manual – Consult Woodward distributor for part number

• Solenoid – Consult Woodward distributor for part number

• Electronics module (PCBA) – Consult Woodward distributor for part number

• Return Spring – Consult Woodward distributor for part number

• Sight Window – Consult Woodward distributor for part number

• Top Cover – Consult Woodward distributor for part number

• Bottom Cover – Consult Woodward distributor for part number

• Seals Kit(s) – Consult Woodward distributor for part number

• Woodward Special Tools Kit – Consult Woodward distributor for part number

Woodward 22

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

The external ground lug shown on the installation drawing must be

External fire protection is not provided in the scope of this product. It

Take care not to damage the electronics covers’ seals, the covers’

For Zone 1/2 products: Proper torque on all joints is required to

For lifting and transportation, use lifting straps fitted

through both

Due to typical noise levels in engine and turbine environments,

The surface of this product can become hot enough or cold enough to

Released

Chapter 3.

Installation

Receiving Instructions

The QuickTrip is carefully packed at the factory to protect it from damage during shipping; however,
careless handling during shipment can result in damage. If any damage to the QuickTrip is discovered,
immediately notify both the shipping agent and Woodward.

Unpacking Instructions

Carefully unpack the QuickTrip and remove it from the shipping container. Do not remove the hydraulic or
electric blanking covers until the unit is ready for mounting.

properly connected to ensure equipotential bonding. This will reduce
the risk of electrostatic discharge in an explosive atmosphere.

is the responsibility of the user to satisfy any applicable requirements
for their system.

surface, threads, or the QuickTrip housing mating surface while
removing or replacing the covers.

ensure that the unit is sealed properly.

lifting points on the product. Support the QuickTrip in a vertical
position during transportation.

hearing protection should be worn when working on or around the
QuickTrip.

be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.

Woodward 23

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Min Thread

Bolting

Released

Installation Instructions

General

See the outline drawings (Figure 2-8) and Specifications for:

• Outline dimensions

• Hydraulic connections and fitting sizes

• Electrical connections

• Weight of the QuickTrip

Note: QuickTrip must be mounted in a vertical position (sight windows facing upwards).

Allow space for removal of the top cover for access to the terminal blocks and to see the status LEDs on
the printed circuit board.

If the QuickTrip is to be installed in close proximity to un-insulated/un-shielded steam valves or piping,
radiation heat shields should be installed between the actuator and these hot surfaces

The QuickTrip is designed for support by one of the two mating surfaces shown in Figure 3-1. For the
mating surface bolt patterns, threads, and torques, the recommendations in Table 3-1 must be followed.

Table 3-1. QuickTrip Product Installation Interface

Thread Thread Size

Dim. A
[mm]

Dim. B
[mm]

”A” M12x1.75 203.2 195.58
“B” M12x1.75 203.2 76.2

Engagement

[mm]

(in)

[18]

(0.71)

[18]

(0.71)

Min. Bolt

Grade

8.8

8.8

Torque

[Nm]

(lbf-ft)

[47-54]
(35-40)
[47-54]
(35-40)

Bolt Tol.
Class

6g
6g

Woodward 24

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Minimum Bolt Grade, Bolting Torque and Thread Engagement

Released

Figure 3-1. QuickTrip Product Installation Interface—Bolting Pattern

Recommendation is valid for low carbon steel mounting surfaces to
which product is bolted. For different configurations please consult
Woodward for torque and bolt grade recommendations.

Woodward 25

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

The QuickTrip is designed for support by the two mounting surfaces

QuickTrip lifting is allowed ONLY by using two provided strap loops.

Ensure that the c

rane, cables, straps, and all other lifting equipment

Before installin

g the QuickTrip, all hydraulic lines must be

Released

and bolt holes shown. Additional supports are neither needed nor
recommended.

Any mounting deviation from the one recommended by Woodward
might cause assembly damage, improper performance or operator
injury risk.

Improper mounting might be considered as a violation of warranty
conditions.

During transportation, the QuickTrip may be supported in either the
vertical or horizontal orientation. Do not lift or handle the QuickTrip by
any conduit.

used for QuickTrip lifting is able to support the QuickTrip weight. See
outline drawings for QuickTrip weight.

Hydraulic Connections

The QuickTrip has two hydraulic connections that must be made to supply and drain.
The QuickTrip actuators uses:

• 1.250 SAE J518 Code 61 Flange for Hydraulic Supply Port

• 1.250 SAE J518 Code 61 Flange for Hydraulic Drain Port

(Note: SAE J518, JIS B 8363, ISO/DIS 6162 AND DIN 20066 are interchangeable, except for bolt sizes.
QuickTrip uses a metric bolt size.)

Hydraulic connection tightening torques:

• Hydraulic Supply:

4x M10x1.5 Screws Torque to 34 to 48 Nm, (25 to 35 lbf-ft)

• Hydraulic Drain:

4x M10x1.5 Screws Torque to 34 to 48 Nm, (25 to 35 lbf-ft)

thoroughly flushed.

Make provisions for proper filtration of the hydraulic fluid that will supply the QuickTrip. The system
filtration should be designed to assure a supply of hydraulic oil with a target cleanliness level of ISO 4406
code 20/18/16 or cleaner. A filter of size 20 micron or smaller is recommended with a beta ratio of at least
200 (95.5% efficiency) in order to prevent large particles (50 microns or larger) from entering the
QuickTrip valves.

The tubing connected to the actuator must be constructed to eliminate any transfer of vibration or other
forces to the actuator.

The hydraulic supply and drain to the QuickTrip are to be at least 25 mm (1 inch), or larger, tubing
capable of flowing up to 908 L/min (240 US gal/min) at 34.5 bar / 500 psig.

The drain pressure must not exceed 10% of trip header pressure or 3.4 bar (50 psig), whichever is less,
under any condition.

Woodward 26

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Do not remove any test port connection plugs when hydraulic

Released

Pipe diameters to both the Supply and Drain connections should be maximized, within reason, to ensure
that flow losses and restrictions are minimized. For the same reason, pipe lengths should be kept to a
minimum.

supply pressure is applied. All required hydraulic connections
must be made before hydraulic pressure is applied. Hydraulic
test ports provided for use by authorized service personnel
only.

Electrical Connections

An overall electrical wiring diagram is shown in Figure 3-3. Detailed wiring requirements for these
connections will follow in the remainder of the Electrical Connections section.

Figure 3-2. Electrical Wiring Diagram

Input Power

The QuickTrip requires a power source capable of a supplying the necessary output voltage and current
at full transient conditions. The maximum power in watts (W) of a DC source can be calculated by
multiplying the rated output voltage by the maximum output current capability. The calculated power
rating of the supply should be greater than or equal to QuickTrip requirements. The electrical power
supply should be able to provide 8 A (or 2.6 A per channel) at
24 Vdc continuously, with a peak of 10 A for 100 milliseconds.

Cable selection and sizing are very important to avoid power loss during operation. The power supply
input at the electronic module input terminal must always provide the required nominal voltage to operate
the valve.

Woodward 27

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

If redundancy option is not used, both (+) signals (Termi

nal #2 and

Released

The input power wires must comply with local code requirements and be of sufficient size such that the
power supply voltage minus the IR loss in the two lead wires to the QuickTrip valve electronics module
does not drop below the input minimum voltage requirement.

The QuickTrip is not equipped with an input power disconnect. A means of disconnecting input power to
the QuickTrip must be provided for safe installation and servicing.

The QuickTrip is not equipped with input power protection. A means of protecting input power to the
QuickTrip must be provided. Breakers or fuses are intended to protect installation wiring and power
sources from faults in the QuickTrip or wiring. A circuit breaker meeting the requirements from the table
below, or a separate protection with the appropriate ratings, may be used for this purpose.

Refer to the table below for recommended fuse ratings or circuit breakers.

Table 3-2. Recommended Circuit Breaker Fuse Ratings

Component Input Voltage

QuickTrip

(21.6-26.4) Vdc
24 Vdc nominal

Steady State

Input Current

(per module)

2.6 A @ 24
Vdc

Maximum

Transient
Input Current
(all modules)

10 A

Maximum

Power

280 W

(100 ms)

Maximum Slow

Blow Fuse / C.B.

Rating

20% above

Steady State

Current

Figure 3-3. Power Supply Input Connections

The QuickTrip is capable of connecting two redundant power supplies to each valve electronics module.
The following table presents terminal assignment for this option usage.

Table 3-3. Power Supply Input Terminals

Power Input (+) Power Input (-)
Power Supply #1 Terminal # 2 Terminal # 1
Power Supply #2 Terminal # 4 Terminal # 3

Terminal #4) should be connected together at the terminal.

Although the QuickTrip is protected against input voltage transients, good wiring practices must be
followed. The following drawings illustrate correct and incorrect wiring methods to the power supply.

Woodward 28

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

In cases where the EMC ground configuration also meets installation

Released

Figure 3-4. Correct Wiring to Power Supply Input

Figure 3-5. Example of Incorrect Wiring to Power Supply Input

Power Wiring Requirements:

• Keep these inputs separated from low level signals to reduce signal noise

• Wire Gauge minimum Requirements: 0.8 mm² / 18 AWG

• Maximum Wiring Distance: 30 m

Unit Grounding

The unit housing must be grounded using the designated PE ground connection point (see Figure 2-8a).
For the PE connection, use required type (typically green/yellow, 3.3 mm² / 12 AWG) as necessary to

meet the installation safety ground requirements. Torque the ground lug to 1.7-2.3 Nm (15-20 in-lbf).

safety ground requirements, no additional PE ground is required.

Woodward 29

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

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.
Additional wire service length should be allowed between the tie down points and the connectors to
reduce strain on the wire at the connector interface and to allow removal of the black pluggable
connector.

Figure 3-6. Recommended Wiring Strain Relief

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 where possible the diameter should be maximized.

• 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 which are difficult to diagnose. Proper
shielding, at the time of installation is required to ensure satisfactory operation of the product.

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.

Woodward 30

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

The following table presents terminal assignment for the control input.

Table 3-4. Control Input Terminals

Control In (+) Control In (-)
Control Input Terminal # 5 Terminal # 6

Figure 3-7. Control Input Connections

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).

External Power Supply Voltage Range: 0-28 V
Maximum Load Current: 2 A
Response Time: Less than 10 ms
On-state Voltage drop: Less than 100 mV @500 mA
Isolation: 500 Vac from digital ground to chassis

The following table presents terminal assignment for the control input.

Table 3-5. Feedback Terminals

Trip/Run (NO) Trip/Run (Com)
Trip # 1 Out Terminal # 7 Terminal # 8
Trip # 2 Out Terminal # 9 Terminal # 10
Run # 1 Out (optional) Terminal # 11 Terminal # 12
Run # 2 Out (optional) Terminal # 13 Terminal # 14

Woodward 31

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Figure 3-8. Feedback Output Connections

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 de­energized, repaired and placed back online while maintaining safe operation of QuickTrip in potentially
explosive environments.

Woodward 32

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Fai

lure to isolate each QuickTrip actuator cavity from the environment

Take care not to damage the electronics’ cover seal, the cover

Due to the hazardous location listings associated with this product,

Failure to install the cover clamps may allow the electronics covers

Do not connect any cable grounds to “instrument ground”, “control

Released

and from each other may result in an unintended explosion hazard.

Once all wiring is complete, carefully thread the top electronics cover onto each actuator cavity, being
careful not to cross-thread them. Thread the covers all the way down by hand, and then torque them to
136-190 Nm (100-140 ft-lbf). Woodward tool 1013-6603 can be used to torque the cover.

surface, the threads, or the QuickTrip housing mating surface while
installing the cover.

proper wire type and wiring practices are critical to operation.

Proper wiring

Once all covers are in place, install the two cover clamps to secure the covers in place. The clamps must
engage the lip of each cover to prevent the covers from unintentionally coming loose (ex. due to
vibration). Torque the two screws to 24-32 Nm (18-24 (in-lbf). See Figure 3-7 Below.

Figure 3-9. Cover Clamps

to unintentionally loosen, and may result in an unintended explosion
hazard.

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagrams.

Woodward 33

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

ELECTRIC SHOCK

—

To reduce the risk of electric shock, Protective

Released

Earth (PE) must be connected to the termination point on the top of

the unit next to the label with the symbol.
The conductor providing the connection must have a properly sized

ring lug and wire gauge larger than or equal to 4 mm² (12 AWG). The
ring lug should be placed between the nut and star washer.

The calibration and checkout procedure should only be performed by
authorized personnel. To be authorized personnel, personnel must
be knowledgeable of the risks posed by live electrical equipment.

Woodward 34

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Chapter 4.

Operation

Operating QuickTrip

Each QuickTrip consists of three independently operated modules referred to as A, B and C. Each
module accepts two redundant power inputs, one control signal input (to energize or de-energize the
actuator) and includes two trip feedback outputs (for de-energized/valve open state) and two run
feedback outputs (for energized/valve closed state). A logic solver, such as the Woodward ProTechTPS
or MicroNet Safety Module, is required to provide the control input signal and to monitor the feedback
outputs. The QuickTrip is a SIL-3 (according to IEC-61508) triple modular design that operates in a two­out-of-three voting logic method. This means the QuickTrip will continue to function normally even if one
module is not operating correctly. It also means any module can be repaired online while the turbine is
on-line and operating normally.

Operation with ProTechTPS

QuickTrip is designed for use with a logic solver such as the Woodward ProTechTPS or MicroNet Safety
Module. If another logic solver is used, consult that manufacturer’s user’s manual for instructions for
interface, configuration and operation with QuickTrip. This section provides an overview of operating the
QuickTrip with ProTechTPS. For more detailed information, please consult the ProTechTPS product
manual.

Energizing QuickTrip Modules

With no alarm conditions present, any QuickTrip module can be energized by pressing the “RESET”
button on the ProTechTPS front panel. This places QuickTrip into a run mode (valves closed).

Tripping QuickTrip modules

Any QuickTrip module can be individually tripped by performing a simulated speed test (manual or auto).
These tests can be accessed through the ProTechTPS front panel display by pressing “Test Menu”. Refer
to ProTechTPS manual 26501V2, Chapter 11 for additional information.

Performing Auto-Sequence Test (Periodic Overspeed Test)

Since QuickTrip is a critical part of the turbine overspeed safety system, it is important to perform a
regular Auto-Sequence Test in order to verify unit health and to take advantage of the diagnostic
coverage provided by this test. The Auto-Sequence Test initiates an automated and sequential test of
each individual module and can be performed without interrupting turbine operation. The test begins with
ProTech module A automatically ramping up the module’s internal frequency generator until it exceeds
the overspeed set point at which time the control signal is interrupted and the QuickTrip module trips.
Then, this module resets and the test is repeated, sequentially, on modules B and C. Refer to
ProTechTPS manual 26501V2, Chapter 11 for additional information.

The Auto-Sequence Test can be accessed through the ProTechTPS front panel display by pressing “Test
Menu”, then “Auto-Sequence Test”. This test should be configured to run automatically by enabling the
Periodic Test Timer (set to “YES”). The Periodic Test Timer Interval should also be set. This interval can
be configured for intervals ranging from 1 to 999 days. Woodward recommends this interval be set
between 1 and 7 days in order to continually ensure QuickTrip health and to maintain its reliability when
used with dirty hydraulic oil. Refer to ProTechTPS manual 26501V2, Chapters 10 and 11 for additional
information.

View Trip Log

The trip log displays a log of any trip events. The trip log can be accessed by pressing the “VIEW” button
directly underneath the “TRIPPED” LED indicator on the ProTechTPS front panel. Refer to ProTechTPS
manual 26501V2, Chapter 9 for additional information.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

View Alarms

The alarm log displays a log of any alarm events that may or may not have resulted in a trip event. The
alarm log can be accessed by pressing the “VIEW” button directly underneath the “ALARM” LED indicator
on the ProTechTPS front panel. Refer to ProTechTPS manual 26501V2, Chapter 9 for additional
information.

Manually Monitoring Trip Cycle Time Log

ProTech can be configured to monitor the trip time for each QuickTrip module (see below). This trip time
can be checked through the ProTechTPS front panel display by pressing “View Logs”, then “Trip Cycle
Time Log”. This log displays the last 20 trip events and the time from when the control signal was
dropped to the time the QuickTrip valve rotated to the open position and the trip position sensor
annunciated a trip signal back to ProTech. Refer to ProTechTPS manual 26501V2, Chapters 9 and 11 for
additional information.

Configuration Options

In order to detect certain failure modes and provide diagnostic coverage for the QuickTrip, the following
configuration recommendations are provided.

1. Trip Time Monitor

Since QuickTrip is a critical part of the turbine overspeed safety system and needs to perform its
safety function quickly, it is important to continuously monitor the trip time to ensure it remains below
a certain threshold. Woodward recommends a threshold of 100 ms, but the installation site should set
this value such that the entire safety system performs is function within a safe timeframe. The Trip
Cycle Time Monitor can be accessed through the ProTech “Monitor” Menu. Refer to ProTechTPS
manual 26501V2, Chapter 9 for additional information.

2. Trip Alarm

ProTech should be configured to annunciate an alarm when any QuickTrip module annunciates a
tripped state (through the trip feedback circuit). This will provide early warning for a QuickTrip module
that fails to remain in a run state (valve fails to remain closed) when the turbine is running. Refer to
ProTechTPS manual 26501V2, Chapters 9 and 11 for additional information.

3. Run Alarm (optional)

ProTech may be configured to detect an event where the ProTechTPS module is commanded to a
run state, but QuickTrip fails to annunciate a run state (through the run feedback circuit) within a
certain timeframe (Ex. 5 sec). This configuration is optional, but may provide early warning for a
QuickTrip module that fails to energize to a run state (valve fails to close) when commanded to do so.
Refer to ProTechTPS manual 26501V2, Chapters 9 and 11 for additional information.

4. Power Failure Alarm

With input power properly applied to any QuickTrip module, that module will normally annunciate
either a run or a trip signal since the valve for that module will either be in a run or trip state. If no run
or trip signal is annunciated, then the power supplies that power QuickTrip may not be functioning.
The run and trip position switches actuate normally open relays that are operated by the same power
supplies that power the QuickTrip module. Without these power supplies, both relays and both trip
and run position annunciation outputs revert to normally open (Refer to Figure 3-2). ProTechTPS may
be configured to detect the case where one (if only one PS is used) or both power supplies fail to
provide power to any QuickTrip module. In this case, the ProTechTPS would be configured to
annunciate an alarm if both the run and the trip feedback are inactive (open) for some amount of time
(Ex. 5 seconds). Note that when the valve changes position and travels from closed to open or from
open to closed, both feedbacks will be momentarily open since the valve is in motion from one state
to another and is not actuating the trip or the run position switch during the time the valve is moving.
Also note that, if the power supplies are not functioning, the two blue LED’s on the electronics module
(PCBA) will also not be lit (see Valve Position Feedback below). Reference ProTechTPS manual
26501V2, Chapter 11 for additional information.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Do not remove any tes

t port connection plugs when hydraulic supply

Released

Valve Position Feedback

There are three methods by which to determine the position of any QuickTrip module valve element:
The position feedback circuits, actuated through the valve position sensors (ref wiring diagram in Figure

3-2).

1. When any QuickTrip module is in a tripped state (de-energized, valve open), the trip position sensor

switch is actuated, energizing a relay that closes the trip feedback circuits*. At the same time, the red
trip LED is on (see LED lamps below)*.

o When any QuickTrip module is in a run state (energized, valve closed), the run position sensor

switch is actuated, energizing a relay that closes the run feedback circuits*. At the same time,
the green run LED is on (see LED lamps below)*.

2. The LED lamps on the electronics module (PCBA), visible through the sight window in the top of the

electronics cover.

o When any QuickTrip module is in a tripped state (de-energized, valve open), the red trip LED is

on*.

o When any QuickTrip module is in a run state (energized, valve closed), the green run LED is

on*.

Note: The QuickTrip module must also be connected to an active power source (reference Figure 3-

3).

3. The pressure ports on the front of the QuickTrip manifold.

o While the position feedback circuits and LED’s are the preferred method to determine module

valve position, three pressure ports are provided on the front of the QuickTrip unit. These
may be connected to pressure gages or pressure transducers and may be used to determine
the state of any module valve element. The image in Figure 4-1 below shows these pressure
ports. Note that Pressure Port B is not used. These ports are for standard dash-4 straight
thread port fittings (7/16-20 thread size).

pressure is applied. All required hydraulic connections must be
made before hydraulic pressure is applied. Hydraulic test ports
provided for use by authorized service personnel only.

o The following logic table shows the approximate pressure that can be expected at each

pressure port for any QuickTrip state where only one valve is open.

Table 4-1. Pressure Port Logic Table

All Valves Closed
Module A Valve Open
Module B Valve Open
Module C Valve Open

* P1 is equal to the Trip Header Pressure at the inlet to QuickTrip

Pressure Port A Pressure Port B Pressure Port C

≈45% P1* (not used) ≈50% P1*

=P1* (not used) =P1*

= drain pressure (not used) =P1*

≈50% P1* (not used) = drain pressure

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Figure 4-1. Pressure Test Ports

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.

Before starting the QuickTrip, follow the warm-up procedure below:

1. De-energize all QuickTrip modules (valves should be open)

2. Start flow of warm hydraulic fluid through QuickTrip such that the temperature of the oil flowing from

the drain side of QuickTrip is at or above +15 °C.

3. Allow the warm hydraulic fluid to flow through QuickTrip for at least 30 minutes, while maintaining the

temperature at the drain side of QuickTrip at or above +15 °C.

4. Energize all QuickTrip modules

5. Use the ProTechTPS to run an auto sequence test on QuickTrip (sequentially de-energizing and re-

energizing each channel individually)

6. After the auto sequence test is complete, check the trip time log and verify each QuickTrip module

tripped in less than 50 ms.

7. If QuickTrip is to be operated continuously in very cold ambient environment conditions, the hydraulic

oil temperature flowing from the drain side of QuickTrip must be continuously maintained above +15
°C.

8. Alternate methods of heating/insulating the QuickTrip and the hydraulic fluid lines upstream from

QuickTrip in very cold ambient environment conditions are recommended and might include the use
of heat tape, heat blankets and insulation.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

To prevent possible serious personal injury, or damage to equipment,

Due to typical noise levels in turbine env

ironments, hearing

Released

Chapter 5.

Repair and Troubleshooting

be sure all electric power and hydraulic pressure have been removed
from the QuickTrip before beginning any maintenance or repairs.

protection should be worn when working on or around the QuickTrip.

General

Woodward Products covered under Woodward Product and Service Warranty
(5-01-1205) 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.

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.

Return for Repair Instruction

Should the QuickTrip need to be returned for repair:

1. Attach a tag on the unit.

2. Include the following information on the tag:

• Customer's name and address

• The name and location where the equipment is installed

• Complete Woodward part number and serial number

• Description of the failure

• Instructions as to what type of repair is to be done

Protective Packing

The following procedures are used for protective packaging of the QuickTrip, when returning for repair:

1. Install shipping plates or plugs in all hydraulic connection ports or seal with tape.

2. Wrap the QuickTrip with packaging materials that will not damage the surface of the unit.

3. Place in a double-walled packing box.

4. Secure the unit inside of the box by removing all of its degrees of freedom using straps and belts, do
not damage the unit.

5. Place at least 100 mm (4 inches) of tightly packed, industry-approved, shock-absorbing material
around the unit.

6. Secure the box with strong metal straps around the outside of the box to increase the strength of the
box.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

EXPLOSION HAZARD

—

Do not remove covers or connect/disconnect

Released

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.

Manually Stroking QuickTrip (powered)
Manually stroking valve procedure:

1. In order 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.

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

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).

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

EXPLOSION HAZARD

—

Do not remove covers or connect/disconnect

EXPLOSION HAZARD

—

Do not remove covers or connect/disconnect

Take care not to damage the electronics’ cover seal, the cover

Released

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).

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

Manually Stroking QuickTrip (un-powered)
Manually stroking valve procedure:

1. If the QuickTrip valve is unable to rotate using the powered methods above, the valve element may

be manually rotated by use of a specially designed Woodward tool (tool # 1013-8807) which
interfaces with the top of the spool shaft.

2. Make sure all power is disconnected from QuickTrip so the solenoid coil is de-energized.

3. Remove the cover clamp by removing the M5 screw (4mm hex key).

4. Remove electronics module cover using a spanner wrench (or WW tool # 1013-6603).

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

surface, the threads, or the QuickTrip housing mating surface while
removing the cover.

4. Remove top silkscreen wiring diagram cover by removing the four Philips screws.

5. Disconnect the solenoid wiring connector (TB3) using a 2.5mm flat-bladed screwdriver.

6. Remove position lever by loosening the M4 screw using a 3mm hex key.

7. Place tool # 1013-8807 onto shaft, aligning the set screw with the flat part of the shaft.

8. Tighten the set screw using (3/16”) hex key.

9. Use a (1/2”) socket and socket wrench to manually rotate the shaft clockwise and counter-clockwise.

Note that there will be some resistance when rotating in the clockwise direction due to the failsafe
return spring. Also note that the total rotation between end-stops is only about 51 degrees. The shaft
will not rotate 360 degrees. If the shaft will not rotate with 50-100 lb-in of torque, do not force it to
move. Return the unit to Woodward for evaluation and repair.

10. If the above operation to manually rotate the shaft was successful, reassemble the unit by following

the below steps.

11. Remove tool # 1013-8807.

12. Re-install the position lever by placing it over the shaft, lining up the flat side of the lever with the flat

on the shaft. Make sure the lever is pushed all the way down onto the shaft and that the magnet is
facing up, away from the electronics module. Tighten the screw and torque to 1.4-1.7 Nm (12-15
in-lbf) using a 3 mm hex key.

13. Re-install the solenoid wiring connector (TB3). Snap the terminal block into the mating connector on

the electronics module (TB3). Tighten the terminal block flange screws to 0.5 Nm (4.4 in-lbf) using a

2.5mm flat-bladed screwdriver.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Make sure that there is no contamination anywhe

re on the electronics

Damage to sealing surfaces may result in moisture ingress, fire or

Released

module that could cause it to malfunction.

14. Re-install the silkscreen wiring diagram cover by placing it onto the hex standoffs, lining up the four

holes in the cover with the four standoffs. The rounded side of the cover should face towards the front
of the QuickTrip unit (away from the conduit port).

15. Secure the cover with the four Philips screws and torque these to 0.3-.5 Nm (2.5-4.5 in-lbf) using a

Philips screwdriver.

16. Re-install the electronics module cover by carefully threading it into the manifold. Thread it as far as

possible by hand. Torque the cover to 136-190 Nm (100-140 ft-lbf) using a spanner wrench (or WW
tool 1013-6603), tightening until the O-ring seal is compressed and the cover is fully seated against
the housing.

17. Re-install the cover clamp and the M5 screws using a 4mm hex key.

explosion. Take care not to damage the electronics’ cover seal, the
cover surface, the threads, or the QuickTrip housing mating surface
while installing the cover.

Cleaning/Flushing the QuickTrip Hydraulic Cavities
Cleaning/Flushing QuickTrip Hydraulic Cavities procedure:

If QuickTrip is not operating normally or if a contaminant is known to have entered the QuickTrip hydraulic
cavities, the QuickTrip cleaning/flushing procedure may be performed as follows.

1. Eliminate the source of the contamination either by polishing the hydraulic supply or by replacing the

hydraulic supply with clean hydraulic oil.

2. Flow clean hydraulic oil through the QuickTrip at a maximum pressure of 500 psi, while manually

stroking the valves using the Manual Stroking procedures above. Make sure to stroke all valves to an
open position in order to ensure maximum oil flow through QuickTrip, then close the valves and
repeat the process several times.

3. If the above procedure has been performed several times and QuickTrip still does not operate

normally or the contaminant has not been flushed from the system, the valve may require repair.
Consult the Troubleshooting and Service Options sections of this manual.

Troubleshooting

General

The following troubleshooting guide will help you isolate trouble with the QuickTrip valve electronics
modules, solenoids, wiring, and system problems. Troubleshooting beyond this level is recommended
ONLY when complete facility control testing is available.

Troubleshooting Procedure

This table is a general guide for isolating system problems. In general, most problems are a result of
incorrect wiring or installation practices. Make sure that the system wiring, input/output connections,
controls and contacts are correct and in good working order. Complete the checks in order. Each check
assumes that the preceding checks have been completed and any problems have been corrected.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Be prepared to make an emergency shutdown of the turbine, or other

EXPLOSION HAZARD

—

Do not remove covers or connect/disco

nnect

ELECTRICAL SHOCK HAZARD

—

Follow all local plant and safety

The ex

ternal ground lug shown on the installation drawing must be

Released

type of prime mover, to protect against runaway or overspeed with
possible personal injury, loss of life, or property damage.

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

instructions/precautions before proceeding with Troubleshooting the
QuickTrip.

properly connected to ensure equipotential bonding. This will reduce
the risk of electrostatic discharge in an explosive atmosphere.

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

General Faults

Problem

Cause

Remedy

Released

Table 7-1. QuickTrip Troubleshooting Guide

One or More Valves Fails

to Close (Reset)

One or More Valves Fails

to Open (Trip)

Input Power below specified limit
Speed sensor logic solver is in a

trip state

Malfunctioning electronics module

or solenoid

Valve seized / Excessive oil

contamination

Operating temperature too high

Speed sensor logic solver is in a

run state

Valve seized / Excessive oil

contamination

Supply hydraulic pressure exceeds

maximum

Check power source and connections

(Chapter 2: Electrical Specifications).
Ensure turbine is running and speed sensors
and logic solver are functioning correctly and

that all wiring connections are correct

Replace electronics module or solenoid (refer

to manual 26842 for hardware replacement

procedure).

Ensure hydraulic fluid meets recommended

filtration and ISO cleanliness levels specified

in Chapter 2: Hydraulic Specifications.

Ensure proof test is performed at an

appropriate interval as recommended in

Chapter 6: Safety Management. Replace and

filter oil and flush clean oil through the valve.

Check ambient operating temperature and

verify that it falls within the requirements
outlined in the Chapter 2: Environmental

Specifications.

Ensure all speed sensors and logic solver are

functioning correctly and that all wiring

connections are correct.

Ensure hydraulic fluid meets recommended

filtration and ISO cleanliness levels specified

in Chapter 2: Hydraulic Specifications.

Ensure proof test is performed at an

appropriate interval as recommended in

Chapter 6: Safety Management. Replace and

filter oil and flush clean oil through the valve.

Check hydraulic supply pressure and

regulator setting

Supply hydraulic pressure exceeds

Trip time too long (> 50

ms)

Power supply is not turned on or

Power supply voltage or current are

Power Supply #1 or #2

LED indicator is not on

LED damaged or malfunctioning Replace electronics module (refer to manual

Broken return spring

maximum

Valve seized / Excessive oil

contamination

wiring is not connected

below recommended ratings

Check/replace return spring (refer to manual
26842 for hardware replacement procedure)

Check hydraulic supply pressure and

regulator setting

Ensure hydraulic fluid meets recommended

filtration and ISO cleanliness levels specified

in Chapter 2: Hydraulic Specifications.

Ensure proof test is performed at an

appropriate interval as recommended in

Chapter 6: Safety Management. Replace and

filter oil and flush clean oil through the valve

Check power source and connections

(Chapter 2: Electrical Specifications).

26842 for hardware replacement procedure)

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Table 7-1. QuickTrip Troubleshooting Guide (continued)

Power supply is not turned on or

wiring is not connected

Check power source and connections

(Chapter 2: Electrical Specifications).

Verify that speed sensors and logic solver are

functioning correctly and that all wiring

connections are correct

Verify that the position lever is installed at the

top of the shaft and is seated all the way

down onto the shaft indexing surface. Also

ensure the position lever is correctly

positioned over the sensors on the

electronics module.

Run LED indicator is not

on

Power supply voltage or current are

below recommended ratings

Valve is in a tripped state

Position lever/magnet not correctly

positioned over sensor

LED damaged or malfunctioning

Power supply is not turned on or

Trip LED indicator is not

on

Position lever/magnet not correctly

LED damaged or malfunctioning

Trip Header Pressure

Fails to Decrease Below

Trip header orifice size is too large

Trip Pressure When

Valves are Open

Trip Header Pressure is

Too Low When Valves

Trip header orifice size is too small

are Closed

wiring is not connected

Valve is in a run state

positioned over sensor

Hydraulic ports blocked

Replace electronics module (refer to manual
26842 for hardware replacement procedure)

Check power source and connections

(Chapter 2: Electrical Specifications).

Ensure all speed sensors and logic solver are

functioning correctly and that all wiring

connections are correct.

Verify that the position lever is installed at the

top of the shaft and is seated all the way

down onto the shaft indexing surface. Also

ensure the position lever is correctly

positioned over the sensors on the

electronics module.

Replace electronics module (refer to manual
26842 for hardware replacement procedure)

Check orifice size and replace with a smaller

orifice

Disconnect and check hydraulic ports for

obstructions

Check orifice size and replace with a larger

orifice

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Released

Table 7-1. QuickTrip Troubleshooting Guide (continued)

Check all wiring between trip terminals on

electronics module and logic solver

Verify that all speed sensors and logic solver

are functioning correctly and that all wiring

connections are correct

Check power source and connections

(Chapter 2: Electrical Specifications).

Replace electronics module (refer to manual
26842 for hardware replacement procedure)

Check all wiring between trip terminals on

electronics module and logic solver

Verify that the turbine is in operation and that

the speed sensors and logic solver are
functioning correctly and that all wiring

connections are correct

Check power source and connections

Check power source and ensure ratings meet

the requirements in the Electrical

Specifications section of this manual

Replace electronics module and/or solenoid.

(refer to manual 26842 for hardware

replacement procedure)

Trip #1 or Trip #2

Discrete Outputs Not

Functioning

Run #1 or Run #2

Discrete Outputs Not

Functioning

Wiring not connected properly

Valve is in a run state

Power supply is not turned on or

wiring is not connected

Power supply voltage or current

are below recommended ratings

Malfunctioning electronics module

Wiring not connected properly

Valve is in a tripped state

Power supply is not turned on or

wiring is not connected

Power supply voltage or current

are below recommended ratings

Malfunctioning electronics module

or solenoid

Woodward 46

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

Module Power Loss

Module Power Up

Type

SIL 3 Value

Released

Chapter 6.

Safety Management

Product Variations Certified

The functional safety requirement in this manual applies to all QuickTrip variations.
These products are certified for use in applications up to SIL3 according to

IEC61508.

Figure 6-1. TUV Rheinland SIIL Certification Stamp

Safe State

The QuickTrip is designed so that the safe state is configured for de-energize to trip. De-energize to trip
will place the valves into their open state.

The de-energize-to-trip functionality is implemented such that a complete loss of power to the module
results in a trip of that module. When power is again supplied to the electrical modules, they will power up
in the tripped state when a trip condition is present or in the run state when a run condition is present.

Table 6-1. De-Energize-to-Trip Functionality

Configuration

De-energize to trip, trip

condition present

De-energize to trip, run

condition present

State

Tripped Tripped
Tripped Not Tripped

State

SIL Specifications

PFD and PFH calculations have been performed on the QuickTrip according
IEC61508. For SIL3, IEC states the following requirements.

Table 6-2. Calculation Types and SIL 3 Values

PFH ≥ 10-8 to < 10-7
PFD ≥ 10-4 to < 10-3
SFF ≥ 60% to < 90%

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Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

PFD

PFD Proof Test Interval*

Safe Failure Fraction

Diagnostic Coverage

MTBF

Response Time

Released

Table 6-3. QuickTrip SIL3 Certification values

2.97E-7 7 days

4.77E-6 6 months

9.44E-6 1 year

Note: In order to maintain the dirt tolerance and to verify correct function of the QuickTrip, it is
recommended that the proof test interval be set to between 1 and 7 days. If using the ProTechTPS,
refer to Auto-Sequence Test in Chapter 4. If using a different logic solver, refer to that manufacturer’s
product manual for instructions on conducting and automating the proof test.

Table 6-4. Safe Failure Fraction (SFF) Value

SFF > 93%

Table 6-5. Diagnostic Coverage (DC) Value

DC > 86%

Failure Rate Data

The Mean Time Between Failure (MTBF) is a measure of time between failures that cause a complete
process shutdown. In determining this number, IEC61508 evaluation takes into account safe failure and
dangerous detected failures that cause a module trip.

Table 6-6. MTBF Value

4.95E6 hrs

Because of the nature of the 2-o-o-3 voting structure, a single module trip does not shut down the
process.

Response time data

The response time for a safety system must be less than the process safety time.
The system integrator must determine the process safety time and the response time of all elements
(sensors, logic solver, QuickTrip, actuators, etc.) that make up the total process safety time. For this
purpose, the QuickTrip response time is given below.

Table 6-7. QuickTrip Response Time Value

QuickTrip Response Time < 50 ms

The response time of the QuickTrip is the time from when the control signal is removed from the
QuickTrip terminal block to the point where the valves have rotated to their full open position (ref Figure 6­1 below).

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Operating Temperature

Storage Temperature

(Non

-

operational)

Relative humidity

Vibration

Shock

IP rating

Altitude

Electromagnetic Compatibility

These limitations are critical to the SIL certification. See Ch. 2 for a

Released

Figure 6-2. Response Time

Limitations

When proper installation, maintenance, proof testing, and environmental limitations are observed, the
product life of the QuickTrip is 20 years.

Table 6-8. Environmental Specifications:

–40 to +85 °C
–40 to +85 °C

up to 95% non-condensing

2 h/axis, 1.04 Grms, 10–500 Hz, three axis
±3 pulses, 10 G, 11 ms sawtooth shock pulse, three axis

66
up to 3000 meters above sea level
Emissions: EN61000-6-4
Immunity: EN61000-6-2

complete list of specifications.

Management of Functional Safety

The QuickTrip is intended for use according the requirements of a safety lifecycle management process
such as IEC61508 or IEC61511. The safety performance numbers in this chapter can be used for the
evaluation of the overall safety lifecycle.

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Restrictions

The user must complete a full functional check of the QuickTrip after initial installation, and after any
modification of the programming of the logic solver or configuration of the device. This functional check
should include as much of the safety system as possible, such as sensors, transmitters, actuators and trip
blocks. When used with the Woodward ProTechTPS, the ProTechTPS has the capability to facilitate the
automatic checkout and periodic maintenance of the safety system. For help on programming, see the
chapters on functionality, configuration and the example applications in the ProTechTPS manual.

The QuickTrip must be used within the published specification in this manual.

Competence of Personnel

All persons involved in the installation and maintenance of the QuickTrip unit must have appropriate
training. In the event that QuickTrip is used with the Woodward ProTechTPS logic solver, all persons
involved in the initial design or modification of the programmable software, installation and maintenance
must have appropriate training. Training and guidance materials include this manual, the ProTechTPS
service tool, and any training programs available at Woodward. See Chapter 7 (Product Support and
Service Options) for more information.

Operation and Maintenance Practice

A periodic proof (functional) test of the QuickTrip is required to verify that no dangerous faults not
detected by external means remain undetected. More information is in the “Proof Testing” section of this
chapter. The frequency of the proof test is determined by the overall safety system design, of which the
QuickTrip is a part. The safety numbers are given in the following sections to help the system integrator
determine the appropriate test interval.

Installation and Site Acceptance Testing

Installation and use of the QuickTrip must conform to the guidelines and restrictions included in this
manual. No other information is needed for installation and maintenance.

Functional Testing after Initial Installation

A functional test of the QuickTrip is required prior to use as a safety system. This should be done as part
of the overall safety system installation check and should include all I/O interfaces to and from the
QuickTrip that are part of the safety system. For guidance on the functional test, see the proof test
procedure below.

Functional Testing after Changes

A functional test of the QuickTrip is required after making any changes that affect the safety system.

Proof Testing (Full Functional Test)

The QuickTrip must be periodically proof tested to ensure there are no dangerous faults present that are
not detected by external diagnostics. The test procedure will set the trip outputs on the module under test
into a trip state (de-energized for a de-energize-to-trip configuration). It is possible to automate several
steps of the proof test procedure shown below using the programmability and test mode configurability of
the ProTechTPS, but the intent of the steps below must be met. If using a different logic solver, consult
the manual for the unit to determine the steps required to implement a proof test for QuickTrip.

With the procedure below, the user can expect 99% test coverage of the dangerous failures that are not
tested by external diagnostics.

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Functional Verification (Proof) Test Procedure (module level):

1. The following procedure should be followed for each QuickTrip module (A, B and C)

2. Ensure power is connected to one or both power inputs on QuickTrip module (terminals 1 & 2 and 3 &

4)

3. Verify that one or both blue LED’s on the QuickTrip electronics module are lit indicating that either a
single power supply or two redundant power supplies are connected and turned on.

4. Measure voltage at the QuickTrip terminals and verify that it is within the range 24 Vdc ± 10%.

5. Verify that the red LED on the QuickTrip electronics module is lit indicating the valve is in the tripped
(open) position

6. Verify trip feedback outputs are active on the QuickTrip electronics module. This can be done by
using an ohmmeter to verify continuity between terminals 7 & 8 and terminals 9 & 10 on the QuickTrip
electronics module. Note that there should be no continuity on the run feedback terminals 11 & 12
and 13 & 14. The ProTechTPS or other logic solver can also be used to detect trip feedback.

7. Use ProTechTPS or other logic solver to start the module and energize QuickTrip by applying 24 Vdc
to the control terminals (5 & 6)

8. Verify that the green LED on the QuickTrip electronics module is lit indicating the valve is in the
energized (closed) position

9. Verify run feedback outputs are active on the QuickTrip electronics module. This can be done by
using an ohmmeter to verify continuity between terminals 11 & 12 and terminals 13 & 14 on the
QuickTrip electronics module.
Note: there should be no continuity on the trip feedback terminals 7 & 8 and 9 & 10. The ProTechTPS
or other logic solver can also be used to detect run feedback if configured to do so (refer to
ProTechTPS product manuals, Woodward numbers 26501V1 and 26501V2).

10. Use ProTech or other logic solver to trip the module and verify the red LED is lit indicating the valve is
once again in the tripped (open) position

11. Using the ProTechTPS or other logic solver, check Trip Log or Trip Cycle Time Log and verify the
most recent trip time is less than 50 ms.

12. Use ProTechTPS or other logic solver to start all modules and energize all QuickTrip modules by
applying 24 Vdc to the control terminals (5 & 6) for each module.

13. Apply hydraulic pressure to the QuickTrip inlet and verify the normal operating trip header pressure is
reached.

14. Confirm the ability of the QuickTrip to hold trip header pressure when any one QuickTrip module is
tripped (module A, Module B, or Module C). Confirm this for all modules individually. Note: When any
QuickTrip module is tripped, there will be a slight decrease in trip header pressure since steady-state
hydraulic leakage through the unit increases. This slight decrease in trip header pressure should
remain above the normal trip pressure for the turbine trip system.

15. Confirm the ability of the QuickTrip to dump trip header pressure when any two QuickTrip modules
are tripped (2oo3 voting operation). Trip QuickTrip modules A and B and confirm the trip header
pressure quickly drops below the normal trip pressure for the turbine trip system.

16. Repeat the above test for the following combinations of two and three modules:

17. Modules B and C

18. Modules A and C

19. Modules A, B and C

20. If there are any failures of the QuickTrip valve to operate correctly, consult the Repair and
Troubleshooting section of this manual (Chapter 5).

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Diagnostic Testing (On-Line Test)

Because of the 2-o-o-3 configuration of the QuickTrip, it is possible to perform a diagnostic test while the
QuickTrip is on-line and the turbine is running. The test procedure will set the trip outputs on the module
under test into a trip state (de-energized for a de-energize-to-trip configuration) and for only one module
at a time. It is possible to automate the procedure shown below by using a built-in function in the ProTech
TPS called “Auto-Sequence Test” or with the programmability and test mode configurability of the
ProTechTPS, but the intent of the steps below must be met. If using a different logic solver, consult the
manual for the unit to determine the steps required to implement a diagnostic test for QuickTrip.

With the procedure below, the user can expect 83% test coverage of the dangerous failures that are not
tested by external diagnostics.

Diagnostic Test Procedure:

1. Verify that each QuickTrip module is in a run state (valve closed). This can be done by verifying that a
green light is lit on each QuickTrip electronics module, or by verifying there are no trip alarms on the
ProTech TPS (or other logic solver).

2. If using a ProTech TPS logic solver, initiate the Auto-Sequence Test by accessing the “Test Menu”,
then “Auto-Sequence Test” on the front panel (refer to Chapter 4 “Operation” for additional
information).

3. The Auto-Sequence test will automatically ramp up the internal frequency generator for module A
until it exceeds the overspeed set point at which time the control signal is interrupted and the
QuickTrip module trips. A trip alarm is momentarily displayed. Then, this module resets and the test is
repeated, sequentially, on modules B and C.

4. Once the Auto-Sequence test has completed, both ProTech TPS and QuickTrip will return to a
normally operating state.

5. Upon completion of the Auto-Sequence Test, check for any trip alarms that are not cleared and, if
ProTech is configured to do so, verify there are no run alarms (failure to energize to a run state).

6. Verify the trip time for each module by checking the Trip Cycle Time Log. This trip time can be
checked through the ProTech TPS front panel display by pressing “View Logs”, then “Trip Cycle Time
Log”. This log displays the last 20 trip events and the time from when the control signal was dropped
to the time the QuickTrip valve rotated to the open position and the trip position sensor annunciated a
trip signal back to ProTech. This trip time should be less than 50ms.

7. If there are any failures of a QuickTrip module (valve) to rotate to an open or closed state when
commanded to do so or if the trip time is greater than 50ms, consult the Repair and Troubleshooting
section in this manual (Chapter 5) for assistance.

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Chapter 7.

Product Support and Service Options

Product Support Options

If you are experiencing problems with the installation, or unsatisfactory performance of a Woodward
product, the following options are available:

• Consult the troubleshooting guide in the manual.

• Contact the manufacturer or packager of your system.

• Contact the Woodward Full Service Distributor serving your area.

• Contact Woodward technical assistance (see “How to Contact Woodward” later in this chapter) and

discuss your problem. In many cases, your problem can be resolved over the phone. If not, you can
select which course of action to pursue based on the available services listed in this chapter.

OEM or Packager Support: Many Woodward controls and control devices are installed into the equipment
system and programmed by an Original Equipment Manufacturer (OEM) or Equipment Packager at their
factory. In some cases, the programming is password-protected by the OEM or packager, and they are the
best source for product service and support. Warranty service for Woodward products shipped with an
equipment system should also be handled through the OEM or Packager. Please review your equipment
system documentation for details.

Woodward Business Partner Support: Woodward works with and supports a global network of
independent business partners whose mission is to serve the users of Woodward controls, as described
here:

• A Full Service Distributor has the primary responsibility for sales, service, system integration

solutions, technical desk support, and aftermarket marketing of standard Woodward products within
a specific geographic area and market segment.

• An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs,

repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's
primary mission.

• A Recognized Turbine Retrofitter (RTR) is an independent company that does both steam and gas

turbine control retrofits and upgrades globally, and can provide the full line of Woodward systems
and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc.

A current list of Woodward Business Partners is available at www.woodward.com/directory.

Product Service Options

The following factory options for servicing Woodward products are available through your local Full­Service Distributor or the OEM or Packager of the equipment system, based on the standard Woodward
Product and Service Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:

• Replacement/Exchange (24-hour service)

• Flat Rate Repair

• Flat Rate Remanufacture

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Replacement/Exchange: Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new replacement unit in minimum
time (usually within 24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime. This is a flat-rate program and includes the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205).

This option allows you to call your Full-Service Distributor in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of
the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new
replacement and return the field unit to the Full-Service Distributor.

Charges for the Replacement/Exchange service are based on a flat rate plus shipping expenses. You are
invoiced the flat rate replacement/exchange charge plus a core charge at the time the replacement unit is
shipped. If the core (field unit) is returned within 60 days, a credit for the core charge will be issued.

Flat Rate Repair: Flat Rate Repair is available for the majority of standard products in the field. This
program offers you repair service for your products with the advantage of knowing in advance what the
cost will be. All repair work carries the standard Woodward service warranty (Woodward Product and
Service Warranty 5-01-1205) on replaced parts and labor.

Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with
the exception that the unit will be returned to you in “like-new” condition and carry with it the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is
applicable to mechanical products only.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair, please contact your Full­Service Distributor in advance to obtain Return Authorization and shipping instructions.

When shipping the item(s), attach a tag with the following information:

• Return authorization number

• Name and location where the control is installed

• Name and phone number of contact person

• Complete Woodward part number(s) and serial number(s)

• Description of the problem

• Instructions describing the desired type of repair

Packing a Control

Use the following materials when returning a complete control:

• Protective caps on any connectors

• Antistatic protective bags on all electronic modules

• Packing materials that will not damage the surface of the unit

• At least 100 mm (4 inches) of tightly packed, industry-approved packing material

• A packing carton with double walls

• A strong tape around the outside of the carton for increased strength

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

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Products Used in

Products Used in

Products Used in Industrial

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Replacement Parts

When ordering replacement parts for controls, include the following information:

• The part number(s) (XXXX-XXXX) that is on the enclosure nameplate

• The unit serial number, which is also on the nameplate

Engineering Services

Woodward offers various Engineering Services for our products. For these services, you can contact us by
telephone, by email, or through the Woodward website.

• Technical Support

• Product Training

• Field Service

Technical Support is available from your equipment system supplier, your local Full-Service Distributor, or
from many of Woodward’s worldwide locations, depending upon the product and application. This service can
assist you with technical questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business hours by phoning
Woodward and stating the urgency of your problem.

Product Training is available as standard classes at many of our worldwide locations. We also offer
customized classes, which can be tailored to your needs and can be held at one of our locations or at
your site. This training, conducted by experienced personnel, will assure that you will be able to maintain
system reliability and availability.

Field Service engineering on-site support is available, depending on the product and location, from many
of our worldwide locations or from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-Woodward equipment with which
our products interface.

For information on these services, please contact us via telephone, email us, or use our website:

www.woodward.com.

Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service facility, please consult our
worldwide directory at www.woodward.com/directory, which also contains the most current product
support and contact information.

You can also contact the Woodward Customer Service Department at one of the following Woodward
facilities to obtain the address and phone number of the nearest facility at which you can obtain
information and service.

Electrical Power Systems

Facility --------------- Phone Number

Brazil ------------- [phone]
China ----------- [phone]
Germany:
Kempen ---- [phone]
Stuttgart - [phone]
India --------------- [phone]
Japan --------------- [phone]
Korea --------------- [phone]
Poland -------------- [phone]
United States ----- [phone]

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Engine Systems

Facility --------------- Phone Number

Brazil ------------- [phone]
China ----------- [phone]
Germany ------ [phone]
India --------------- [phone]
Japan --------------- [phone]
Korea --------------- [phone]
The Netherlands-- [phone]
United States ----- [phone]

Turbomachinery Systems

Facility --------------- Phone Number

Brazil ------------- [phone]
China ----------- [phone]
India --------------- [phone]
Japan --------------- [phone]
Korea --------------- [phone]
The Netherlands-- [phone]
Poland -------------- [phone]
United States ----- [phone]

Manual 26815 QuickTrip Electro-Hydraulic Trip Block Assembly

General

Prime Mover Information

etc.)

Control/Governor

Information

Symptoms

Released

Technical Assistance

If you need to contact technical assistance, you will need to provide the following information. Please write
it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the
Woodward factory:

Your Name

Site Location

Phone Number

Fax Number

Manufacturer

Turbine Model Number

Type of Fuel (gas, steam, etc.)

Power Output Rating

Application (power generation, marine,

Control/Governor #1

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Woodward Part Number & Rev. Letter

Control Description or Governor Type

If you have an electronic or programmable control, please have the adjustment setting positions or the menu
settings written down and with you at the time of the call.

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Control/Governor #2

Serial Number

Control/Governor #3

Serial Number

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Chapter 8.

Asset Management and Refurbishment Scheduling

Period

The following recommendations regarding the Woodward designed and manufactured QuickTrip trip
block assembly are to assist in properly managing the reliability, availability and “safety of operation”
expectations established for turbines. While there are electronic control systems designed to monitor and
diagnose the operational performance of these components, control monitoring cannot replace normal
preventative maintenance practices. It is important to follow these recommendations in order to avoid
unnecessary and unscheduled shutdowns.

This product is designed for continuous operation under normal industrial operating conditions. There are
no components that require periodic service between scheduled major turnarounds (normally every five to
eight years depending on the site and application). During major outages, Woodward recommends the
QuickTrip be send back to Woodward or a Woodward Authorized Independent Service Facility (AISF) for
inspection, component servicing and to take advantage of any related hardware improvements.

Installations that do not meet “normal” industrial operating conditions may require customized
maintenance cycles to maximize reliability, performance, and asset life. Contact your local Woodward
Representative for a detailed evaluation of your site conditions to determine the right maintenance cycles
for your installation.

Woodward’s overhaul services will return the unit to “like new” condition, ready for another full operating
cycle, lasting until the next planned maintenance outage. Upon reaching the recommended maintenance
cycle of the auxiliary equipment, please contact either the site turbine OEM service representative, local
Woodward distributor or Woodward Authorized Independent Service Facility to initiate services. Refer to
Chapter 7 for Product Support and Services options.

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Chapter 9.

Long-Term Storage Requirements

Units that will not be put into service within twelve months should be packaged for long-term storage as
described in Woodward manual 25075, Commercial Preservation Packaging for Storage of Mechanical-
Hydraulic Controls. This product is designed for continuous storage in IP66 rated locations with an
ambient temperature of –40 °C to +85 °C.

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Category

Parameter

Specification

This Installation

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Appendix

Commissioning Checklist

When installing and commissioning the QuickTrip unit, the following checklist can be used as a guide to
ensure proper installation and successful commissioning.

Table A-1. Installation and Commissioning Checklist

Trip Header and Drain
Port connections
Metric Port connection
Hardware

Hydraulics

Torque Value
Trip Header Pressure
Drain Pressure

External Hydraulic Leaks None
Supply Voltage
(measured at QuickTrip
terminals)
Supply Current
(measured at QuickTrip
terminals)

Power Supply

Wiring: PS #1 – TB1, Terminal 1
Wiring: PS #1 + TB1, terminal 2
Wiring: PS #2 - TB1, Terminal 3
Wiring: PS #2 + TB1, Terminal 4

Terminal Torque
Breakers

Wiring: Control + TB2, terminal 5
Wiring: Control - TB2, Terminal 6

Terminal Torque

Control Input

Voltage 15-32 Vdc
Current 20 mA Min

Breakers

1.250 SAE J518 Code 61
Flange

M10 x 1.5 bolts
34 to 48 Nm

(25 to 35 ft-lbf)

34.5 bar
500 psi max

3.4
50 psi max

24 Vdc ± 10%

2.6 Amps Max
(per module)

0.2-0.25 Nm
(1.75-2.25 in-lbf)
Breakers used between
PS + output and QuickTrip

0.2-0.25 Nm
(1.75-2.25 in-lbf)

Breakers used between
Control + output and
QuickTrip

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Specification

This Installation

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Table A-1. Installation and Commissioning Checklist (Continued)

Wiring: Trip #1 NO TB2, Terminal 7
Wiring: Trip #1 COM TB2, Terminal 8
Wiring: Trip #2 NO TB2, Terminal 9
Wiring: Trip #2 COM TB2, Terminal 10

Terminal Torque

Breakers

0.2-0.25 Nm
(1.75-2.25 in-lbf)
Breakers used between
logic solver NO and

QuickTrip
Discrete
Outputs

Wiring: Run #1 NO TB2, Terminal 11
Wiring: Run #1 COM TB2, Terminal 12
Wiring: Run #2 NO TB2, Terminal 13
Wiring : Run #2 COM TB2, Terminal 14

Terminal Torque

Breakers

0.2-0.25 Nm

(1.75-2.25 in-lbf)

Breakers used between

logic solver NO and

QuickTrip

Connector Flange Screw
Torque
Power Supply #1 LED
Indicator

Power Supply #2 LED
Electronics
Module

Indicator

Run LED Indicator (green)

Trip LED Indicator (red)
Top cover Torque

Top Cover
Retaining
Clip

Torque

0.5 Nm (4.4 in-lbf)
ON

ON
(only if PS#2 is used)
ON when valve in run
(closed) state
ON when valve in trip
(open) state
136-190 Nm
(100-140 ft-lbf)

2-2.7 Nm

(18-25 in-lbf)
Screws
Actuation
Times

Proof Test Operation of Proof Test

Trip Time < 50 ms
Actuation (close) Time < 1 s

Initiate proof test and

ensure correct operation of

all three QuickTrip modules

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Revision History

Changes in Revision E—

• Changed Item number references in Table 1-1 and Figure 1-3

• Changed ground lug torque value in the Unit Grounding section in Chapter 3

Changes in Revision D—

• Updated ATEX Directive and added instructions to Regulatory Compliance section

• Added Ex nA nC Minimum Ambient Temperature to Environmental Specifications in Chapter 2

• Added IMPORTANT box to Limitations section in Chapter 6

• Updated EU DoC

Changes in Revision C—

• Replaced Figure 3-2 with a corrected chart

Changes in Revision B—

• Updated specifications in Chapter 1 first paragraph, in Hydraulic Connections section in Chapter 3,
and in the Commissioning Checklist in the Appendix

• Deleted Minimum Supply Pressure from Hydraulic Specifications

• Changed Maximum Trip Header Pressure in Hydraulic Specifications

• Changed content to clarify Oil Flow/Cv Rating in Hydraulic Specifications

• Added Table 2-1

• Removed Figures 2-2 and 2-3

• Added Flow Coefficient and Flow Rate Calculation formulas and variable definitions

• Updated former Figure 2-4 and 2-5 which were redesignated Figures 2-2 and 2-3

Revision A—

• Added new part number

• Reordered and updated Compliance section

• New DOC/DOI

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Declarations

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Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other

authorized service and sales facilities throughout the world.

Complete address / phone / fax / email information for all locations is available on our website.