XH5D Manual - Axiom Technologies, LLC
Contents
1. 060 Phone 281 931 0907 19 Turn knob of Flow Control Valve a small fraction of a turn in the direction of the clock pointers to increase time delay and in the opposite direction to reduce it 20 For initial setting close the Flow Control Valve by turning knob clockwise all the way and then turning it back one half of a turn Re opening the well after ESD 21 Repeat steps through 9 of this list Adjusting High and Low Pressure Alarms 22 Turn red knob to adjust High pressure Alarm to the desired High Pressure Alarm Repeat the same with the black knob to set the Low Pressure Alarm HYDRAULIC CIRCUITS The hydraulic circuits are shown on appendix B ELECTRONIC SYSTEM By replacing most of the hydraulic logic with electronic circuits the most failure prone components are removed and the hydraulic circuit greatly simplified to a few reliable components In this way by having self diagnostic in the electronics and a simplified hydraulic system the XH5D HE offers a reliability level not seen on any of the typical self contained wellhead control panel Furthermore if a failure would occur the diagnostic and correction of the problem is much simpler because of the simplicity of the hydraulics See Appendix C for Auxiliary or Telemetry Shutdown Fig 4 External Alarm Termination Box XHSD ME R2 doc 5 11 2013 Page 8 of 10 Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 7702. 60 Phone 281 931 0907 When operating under normal conditions no alarms the electronic system flashes the green LED every second heartbeat to indicate that the electronic system is operating without problems If any alarm is detected the green LED stops flashing and the solenoid valve is tripped to initiate shutdown of the SSV only The red LED corresponding to the detected alarm starts flashing and it is latched in such way that even if the alarm condition would go away or a new alarm would be detected the first detected alarm only will flash holding the information for the operator to see the actual cause of the shutdown For example if a High Pressure Alarm would occur the corresponding High Pressure Alarm LED will flash and keep on flashing even if the high pressure alarm would go away and now the needle is touching the Low Pressure contact The first detected alarm will keep displaying until the operator presses Reset A total shutdown or ESD closing of the SSV and SCSSSV would be executed only in the case of Fire Alarm fusible plug and or Manual Shutdown Once the operator presses Reset while the alarm still present the system resets the solenoid valve to allow the re opening of the well and alternatively flashes the green LED and corresponding alarm red LED if the alarm still present The system tolerates the existing alarm for 30 minutes before re initiating the shutdown and prevents the system from being left in
3. Axiom Technologies LLC Telephone 281 931 0907 15711 W Hardy Road Suite 1 Fax 281 231 6562 Houston Texas 77060 www axiomsafety com XHSD HE USER S MANUAL SELF CONTAINED DUAL PUMP WELLHEAD CONTROL PANEL FOR HARSH ENVIRONMENTS Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77060 Phone 281 931 0907 GENERAL The XH5D HE self contained system is a device designed and built for protecting oil and gas production wells It includes a switch gage to detect high and low pressures as well as hydraulic interface for fire detection and manual ESD The XH5D HE is self sufficient and doesn t need external sources of energy or supply pressure for keeping a wellhead open and protected It uses hydraulic fluid for driving the surface and sub surface valves and it has two separate hand pumps and dump valves for independent control of the SSV and SCSSSV The detection of High and Low pressures is done by a switch gage with adjustable contacts for detecting when the monitored pressure is out of acceptable limits The switch gage connects to an electronic module that indicates High and Low pressure conditions as well as initiates the shutdown when a pressure alarm is detected The electronic circuits are fed by a battery module capable of keeping the system operating for five 5 years The XH5D HE is built to operate exposed to the elements as all hydraulic components are enclosed in a stainless ste
4. change on pilot pressure but the SSV pressure goes to cero Re opening the SSV 11 Press Reset The Alarm LED stops blinking while the green LED Heartbeat blinks every second Also as the solenoid trips the pilot pressure goes momentarily to cero and slowly returns to approximately 80 PSI 12 Pump Pilot SSV right side pump while observing the Pilot pressure gauge until reaching 80 to 90 psi 13 Set valve SSV Pilot into SS V 14 Pump SS V Pilot pump right side pump while observing the SSV pressure gauge Pump until reaching 3 000 PSI It is normal for the pressure to fall about 10 after finishing the pumping Do not exceed 3 000 PSI Initiating ESD Clothing of the SSV and then SCSSSV 15 Set valve In Service ESD to ESD Shutdown Delay adjustment for SCSSSV 16 The SCSSSV closes only in case of manual ESD and or by the activation of the fusible plug 17 When an ESD is initiated the Pilot Pressure and SSV Pressure shown on the front of the panel go to zero psi in the first one or two seconds Then after some time delay the SCSSSV pressure slowly goes down to zero 18 The time lapsing between the activation of the ESD can be adjusted by adjusting the Flow Control Valve shown on Fig 2 page 3 of this manual XHSD ME R2 doc 5 11 2013 Page 7 of 10 Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77
5. e with care not to exceed about 2 3 of capacity In factory the units are tested with Megaflow AW Hydraulic Oil 32 however any quality hydraulic fluid with a AW32 will operate well Open Explosion Proof Box mounted inside the stainless steel box and install battery module as indicated in Appendix A By doing this the electronic circuit becomes energized and the green LED blinks every second Heartbeat to indicate the electronic circuit is operating without problem Before pressurizing panel it is recommended that hydraulic fluid is circulated throughout the system to flush any particle and contaminants that could be present within the hydraulic lines With this purpose proceed as follows a Set valve In Service ESD to ESD b Set valve SSV Pilot to Pilot c Pump Pilot SSV right side pump in a fast mode for approximately one minute while observing the Pilot pressure gage right side of the panel This gauge should display 0 PSI but the needle oscillates with each pump strike d Set valve SSV Pilot to SSV e Again pump Pilot SSV right side pump in a fast mode for approximately one minute while observing the SSV pressure gauge center of the panel This gauge should stay in 0 PSI f Pump SCSSSV left side pump in a fast mode for approximately one minute while observing the SCSSSV pressure gage left side of the panel Thi
6. el box while the electronic circuits and battery module are enclosed in a explosion proof box inside the stainless steel box The front of the panel includes the gages and controls as shown in Fig 1 while the inside components are shown in Fig 2 Flow Pressure w High and Low Pressure Alarm Reset Test Switch LED Indicators High Press Alarm 4 i Pilot Pressure Low Press Alarm PE A Low Battery Alarm A gt 7 SSV Actuator Auxiliary Alarm ES A EA Telemetry Stdn Heart Beat System OK Pressure SCSSSV Pressure SSV Pilot Hydraulic Pump SCSSSV Hydraulic Pump SSV Pilot Fig 1 XH5D HE Front Panel XHSD ME R2 doc Pumping Selector Valve In Service ESD Selector Valve Manual Shutdown Page 2 of 10 Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77060 Phone 281 931 0907 Electronic Enclosure Solenoid Valve Piston Accumulator Diaphragm Accum Directly behind Flow Control Valve SCSSSV Closing Delay Adjustment SSV Dump Valve SCSSSV Dump Valve directly behind Hydraulic Reservoir Pilot Pressure Relief Valve Dual Hydraulic Hand Hydraulic Filter mamam Level Pump Indicator Fig 2 XH5D HE Enclosure s Interior INSTALLATION PRELIMINARY STEPS AND TESTS The XH5D HE is typically sent with the battery module mounted backwards or in a separate package for
7. eleased in the event of a fire XHSD ME R2 doc 5 11 2013 Page 6 of 10 Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77060 Phone 281 931 0907 OPERATION AND ADJUSTMENTS The operation of the installed panel is as follows Starting Production 1 Set valve In Service ESD to In Service 2 Set valve SSV Pilot to Pilot 3 Press Reset on switch Test Reset 4 Pump Pilot SSV right side pump while observing the Pilot pressure gauge until reaching 80 to 90 PSI 5 Pump SCSSSV pump left side pump while observing the SCSSSV pressure gauge Pump until reaching the pressure necessary to open SCSSSV Do not exceed 12 000 PSI 6 Set valve SSV Pilot into SSV 7 Pump SSV Pilot pump right side pump while observing the SSV pressure gauge Pump until SSV is fully opened plus about 500psi reaching Do not exceed actuator s pressure rating It is normal for the pressure to fall about 15 after finishing the pumping 8 Check all hydraulic connections internal and external to the panel to confirm that there is no leakage 9 Adjust High and Low Alarm set point on switch gage Closing SSV 10 Move High or Low Alarm Set Point until it touches the gage s needle The system responds closing the SSV The corresponding LED High or Low Pressure Alarm blinks and the green LED stops blinking There is no
8. es LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77060 Phone 281 931 0907 WARNING Do not attempt to recharge the batteries on the battery module as this may cause an instable condition that may resultin a violent explosion Return the spent battery modules to Axiom Technologies or to any lithium battery recycling facility See the instructions shown on Appendix A for replacing the battery module XH5D ME R2 doc 5 11 2013 Page 10 of 10
9. preventing the system from operating while in transit Also as needed to meet shipping regulations the device is typically shipped without hydraulic fluid in the reservoir and without Nitrogen pre charge in the SSV hydraulic accumulator the larger of the two accumulators The pilot pressure accumulator uses only 50 psi of Nitrogen pre charge and considered safe for air transport Before installing the system is to be inspected to confirm that there is no external damage or indication of rough handling during shipment In case of overseas shipments it is recommended that the XH5D HE is tested in a work shop near the final destination to facilitate the commissioning and allow the operators to become familiar with the unit NOTE It is recommended that the operator becomes familiar with the Hydraulic Schematic Appendix B and have a copy handy during the tests described below to better understand the system s behavior XHSD ME R2 doc 5 11 2013 Page 3 of 10 Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77060 Phone 281 931 0907 To commission the system follow with the steps listed below 1 il ii iv vi vii viii IX X1 xii Pre charge 16 CU IN piston accumulator with about 1 000 PSI of Nitrogen Confirm pre charge of the 6 CU IN diaphragm accumulator with 50 PSI of Nitrogen Add hydraulic fluid to the reservoir approximately one gallon Filling is to be don
10. production while operating in an abnormal condition Once the pressure alarm clears only the green LED remain flashing The Test function allows the operator to see the last alarm and also confirm that all the indicator LEDs are working properly This is when pressing Test the system respond by flashing the last detected alarm for about two seconds and then flashes the red LEDs in sequence The battery module provides two separate voltages 3 6 VDC to feed the microcontroller circuits and 14 4 VDC to operate the solenoid valve Both voltages are periodically monitored to confirm the system has the proper battery supply to operate reliably If the system detects a low voltage the green LED and the Low Battery red LED alternates flashing but the system remains in operation However if a voltage falls too far down for insuring reliable operation then a shutdown is executed and only the Low Battery red LED flashes Given the low power consumption of the system it is expected that the operator will be able to detect the warning signs of low battery and should be able to replace the battery module before it gets to the point where the system causes shutdown because low battery The battery module is to be replaced as soon as the system shows signs of low voltage to insure the system continues operating reliably The battery module has an expected life of five years XHSD ME R2 doc 5 11 2013 Page 9 of 10 Axiom Technologi
11. s gauge should stay in 0 PSI Confirm that the plugs on the bulkhead connectors are tight before proceeding with the following steps Set valve In Service ESD to In Service Set valve SSV Pilot to Pilot Press Reset on switch Test Reset Pump Pilot SSV right side pump while observing the Pilot pressure gauge Pump until reaching between 80 and 90 PSI Inspect hydraulic lines to confirm that there is no leakage Pump SCSSSV pump left side pump while observing the SCSSSV pressure gauge Pump until reaching about 10 000 PSI Inspect hydraulic lines to confirm that there is no leakage As this test is being done with the SCSSSV output blocked the pressure will rise quickly and the pressure will decrease in about 20 to 30 in a few seconds after the pumping stops This is normal however after the initial pressure decrease the pressure should remain stable except for the effects of temperature changes Set valve SSV Pilot into SSV XHSD ME R2 doc 5 11 2013 Page 4 of 10 Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77060 Phone 281 931 0907 xiii Pump SSV Pilot pump right side pump while observing the SSV pressure gauge Pump until reaching 3 000 PSI Inspect hydraulic lines to confirm that there is no leakage It is normal for the pressure to fall about 15 after finishing the pumping xiv Set
12. valve In Service ESD to ESD to return all pressures to cero before moving the XH5D HE to the field for installation FIELD INSTALLATION Typically the XH5D HE is mounted on one or two poles made of 3 pipe Using two poles is preferred as it would insure safe mounting even if one of the pipe brackets used for fastening the panel to the poles would fail The two poles should have a separation of 10 to 15 25cm to 38cm center to center The pipe brackets connect to the unistrut channel mounted on the left side of the panel Fig 3 XH3 Mounting With the panel firmly mounted proceed to connect the field devices as shown on Fig 4 XHSD ME R2 doc 5 11 2013 Page 5 of 10 Axiom Technologies LLC XH5D HE User s Manual 15711 W Hardy Rd Suite 1 Houston Texas 77060 Phone 281 931 0907 1 Flow line Sensing Pressure 2 Hydraulic pressure PRESSURE TO bp to SSV SSV Z 3 Hydraulic pressure a 4 Hydraulic pressure v to Manual ESD Fire TO ESD FIRE Sensor 5 g Hydraulic return a from Manual RETURN ESD ESD Fire Sensor Fig 4 Rear view hydraulic lines connections The connection to the ESD station Connection No 4 can be also connected to a fire plug Included If the fire plug used does not have a return line some means are to be used to prevent hydraulic fluid from reaching the ground A small amount of hydraulic fluid approximately 3 CU IN or 50 CC will be r
Download Pdf Manuals
Related Search