A COURSE

ON

PNEUMATIC CONTROL SYSTEMS

Organized by

School of Maintenance Practices

BARODA

Prepared by

Suresh Madhavan,
ONGC

1
 MAJOR SECTIONS
Section Topic Page
1 Pneumatic & Hydraulic 05 - 27
Components
2 Pneumatic Circuits 28 – 46
3 Pneumatic Control Panel 47 - 61

2
 Section: 1

PNEUMATIC & HYDRAULIC COMPONENTS

3
 CONTENTS

S No Section Topic Page

No

1 1.1 Directional Control Valves 5

2 1.1.1 Two Way Valves 5

3 1.1.2 Three Way Valves 6
4 1.1.2.1 Manually operated 3 way valve 7
5 1.1.2.2 Pilot operated 3 way valve 7
6 1.1.2.3 Pilot operated pilot return 3 way valve 8
7 1.1.2.4 Solenoid operated 3 way valve 8
8 1.1.2.5 Solenoid operated solenoid return 3 way valve 9
9 1.1.2.6 Manual reset valve 9
10 1.1.2.7 Manual reset valve with indicator 10
11 1.2 Pneumatic Indicators 11

12 1.2.1 Amot Indicators 11

13 1.2.2 Versa Status Indicators 13
14 1.3 Check Valves 14
15 1.4 Relief Valves 15
16 1.5 Shuttle Valve 16
17 1.6 Quick Exhaust Valve 17
18 1.7 Flow Control Valve 17
18 1.8 Panic Valves 18
19 1.9 Fusible Plugs 19
20 1.10 Hydraulic Dump Valve 20
21 1.11 Sigma Master Reset Valve 21
22 1.12 High / Low Pilots 22
23 1.13 Hydraulic Accumulator 22
24 1.14 Hydraulic Pumps 24

25 1.14.1 Haskel Pumps – Principle of operation 24

26 1.14.2 Operation of Haskel Pump 25
27 1.14.3 Haskel Pump Features 26

4
 PNEUMATIC & HYDRAULIC COMPONENTS

1.1. DIRECTIONAL CONTROL VALVES

These are the functional valves used in control logics. The different
ports of the valve are connected through internal passages. They may either
allow air to pass through or block the passage depending on the plunger
movement inside.

One method of classifying directional control valve is based on the

internal flow passages or the different ways of flow, the number of ports and
the possible positions of the plunger movement. Thus we can classify the
directional valves as two - way two- port two- position valve or three- way
three- port two-position valves.

1.1.1. TWO- WAY VALVES

A two way directional valve has two ports which are either open to
each other or closed. In one position of the plunger the IN port is connected
to the OUT port and air is allowed to pass through. In the other extreme of

5
the plunger, the IN port is blocked from the OUT port and no air passage is
allowed. The change of position is achieved manually, electrically by using
solenoids or through pneumatic pilots.

Based on the construction and application, the valve can be either NC

(Normally Closed) or NO (Normally Open). The position of the valve
without applying any external force is its Normal position. In the above
manually operated Two - Way valve, if the ports are closed without
manually operating it, then it is Normally Closed.

Other variety of two-way valve includes block & bleed type. Here the
out put pressure is vented to the atmosphere in ‘Closed’ position.

1.1.2. THREE WAY VALVES

Three Way valves are the most preferred valves in logical applications.
They are the electronic equivalent of transistors. Unlike in electronic circuits
where cutting of inlet supply to the output is sufficient for logical results, in
pneumatics the out put pressure has to be vented off in addition to isolating
inlet.

In a Normally Closed 3 way valve, the IN port is blocked and the

OUT port connected to the Exhaust in its normal position. In an actuated
position, the port configuration changes, connecting IN and OUT ports. Here
the Exhaust port is blocked. In a typical application if the OUT port is
connected to a Shutdown valve actuator, the air supply flows from IN to the

6
actuator and the valve opens. If deactivated, the valve moves to its normal
position. Here the supply to the actuator is blocked and the stored pressure
of the actuator is connected to the Exhaust and bled off making the
shutdown valve closed.

1.1.2.1. Manually Operated 3 Way Valve

This is manually operated spring return type 3 ports, 2 position 3 way

valve. The valve can be either normally open or Normally Close type. In a
normally open valve, the IN port gets isolated and the OUT port is exhausted
when manually pressed. In a normally closed valve, the IN and OUT gets
connected and the exhaust port is blocked on manual actuation.

1.1.2.2. Pilot operated 3 Way Valve

This is a pilot activated 3 way valve. Here too there are 3 ports and 2
plunger positions. The pilot is opposed by a spring tension, which returns the

7
valve to its normal position on pilot removal. The pilot is a pneumatic signal
of 50 PSI. In the Normally open pilot valve shown above, presence of pilot
blocks IN port and connects OUT port with Exhaust port.

1.1.2.3. Pilot Operated Pilot Return 3 Way Valve

Here there is no spring to return the valve back to its original position
when the pilot is lost. A second pilot is required for this purpose. In this type
the port configuration is stay put even on removal of the pilot. The second
pilot pulse takes the valve to the opposite position.

1.1.2.4. Solenoid Operated 3 Way Valve

8
 In this 3 way valve, the piloting is done by a solenoid. The solenoid
coil gets magnetized on applying a voltage source. Different varieties of
solenoids capable of working with AC and DC sources are available. Most
of the solenoids used in offshore applications are 24V DC based. On
applying 24V DC, because of the magnetic action, the plunger is pushed
against the spring. Connection of valve ports depends on the construction
type.
1.1.2.5. Solenoid operated solenoid return 3 way valve

Here the return position is achieved through another solenoid

valve. This type of valve can be used where an electrical pulse is preferred
for valve operation rather than continuous energizing. This is most suitable
for unmanned platform operations where power availability is limited.
Electrical pulse is safer than continuous power supply in an explosive
environment. One pulse will operate the valve and leaves the valve in its
operated position. The valve is reset to its original position on application of
another pulse to the second solenoid.

A different variety of solenoid with a single housing performing the

above function is also available. This three wire solenoid is used extensively
in well control panels for remote SSV operations.

1.1.2.6. Manual Reset Valves

Here the valve will not shift to open position when pilot is resumed
until it is manually reset. The Manual Reset valves can function as master
relay valves and are generally pilot operated-spring return, 2-position valves
that are provided additionally with a means of manual operation. The pilot is
pressurized when the system is running normally, but when a problem is

9
sensed, the pilot is depressurized and the valve shuts off the pressure to the
main system or that portion of the main system that the valve controls.
These valves can be actuated (open to flow) by a pilot signal or
manually by pulling the knob when there is no pilot signal. When the pilot
signal is removed or drops below 7 psi (0.5 bar), or the knob is released
when there is no pilot pressure, the valve will spring return to close the flow.

The manual portion of the reset can also be latching or non-latching.

The figure above depicts a valve without latching facility and the one below
is of with latching facility.

Valves provided with the manual pin latch feature can be latched in
the actuated position (open to flow) when there is no pilot pressure, by
pushing the manual latch pin and holding it in while the knob is pulled out
and released. To release the manual pin latch, pull the knob or apply a pilot
signal.

1.1.2.7. Manual Reset Valve with Indicator

Reset valves can also be equipped with an integral visual indicator

that indicates when pressure is present in the pilot chamber. They have two
functions generally. First, to indicate visually on a panel that circuits
malfunction has occurred. Secondly, to quickly exhaust operating pressure
from the system through the Reset valve. An Indicating reset Valves with
latching facility is shown below;

10
 Valves provided with a pressure indicator will appear red when there
is no pressure in the pilot chamber or the pilot pressure drops below 7 psi
(0.5 bar), at which point the spring will return the valve to close the flow.
The pressure indicator will appear green when there is pilot pressure present
in the pilot chamber.

1.2. PNEUMATIC INDICATORS

1.2.1. AMOT INDICATORS

They are designed to assist personnel operating pneumatic panels with

an indication of the presence of control pressures and status in various legs
of the pneumatic circuitry. It is intended to be placed in those circuits where
there will be an instant indication of loss of pressure.

11
 They pin point’s trouble and instantly provides easily visible trip
indication. The first-out indication is held indefinitely. This simplifies
trouble shooting to save time and reduce maintenance costs.

Usually one indicator Relay is connected to each condition sensing

device as shown in Figure above. The sensing devices are normally closed 2
or 3 way valves which detect undesirable pressures or liquid levels, etc.
Sensing valves are connected to the TRIP Port in each relay, and pressure is
introduced at the IN Port. If the particular parameter is in a healthy or
satisfied condition pressure will feed through the internal orifice to the large
end of the piston and force it into the "Green" or safe position. Pressure is
also directed through to the OUT Port which is normally piped to the IN Port
of the next relay as shown below.

When a fault condition arises, the valve sensing that condition opens,
causing a loss of pressure at the large end of the piston and allowing
pressure on the small end to move the piston to the "Red" or tripped position.
The OUT Port connects with the VENT Port through specially formed vent
grooves and all pressure down stream is released to the VENT Port as the IN

12
Port is closed off from the OUT Port. Any indications existing at the
moment will be held indefinitely. The unique Red and White "Trip" tape,
selected by optical specialists, can be clearly seen at a distance even in poor
light or by those with impaired color vision.

In most cases, only one Relay will show "Red" on a shutdown in a

properly designed system indicating the ‘first out’ signal.

Spring return types of indicators are also available having an

automatic return to "Red" on loss of pressure. It has a return spring and no
orifice, thus the TRIP Port is isolated from the other ports.

There are other varieties of indicators available in the market. Amot

make indicators have a field proven credential with ONGC.

1.2.2. VERSA STATUS INDICATORS

Versa’s Status Indicator provides visual indication of pressure in a

system. The standard product displays a green field when a minimum of 8
psi (0.55 bar) to a maximum of 200 psi (14 bar) is present. Complete loss of
pressure causes the indicator to display a red field, marked with the
recognition character “R”.

13
1.3. CHECK VALVES

These valves are also called as non-return valve or NRV. They allow
free flow in one direction while blocks reverse flow. These check valves seal
bubble tight even without back pressure and provide a smooth, minimum
resistance flow path when open. The poppet is spring loaded for operation in
any position. The spring load is borne by a metal stop in high pressure
hydraulic applications ensuring long seal life and minimum maintenance.
Operation is smooth and chatter-free. Below is a typical specification;

Sizes 1/4" and 3/8" FNPT

1/4" and 1/2" MNPT
Maximum operating 10,000 PSIG
pressure
Operating temperature -40° to 450°F
Seals Buna N or Viton

14
1.4. RELIEF VALVE

Relief valves are used in well control panel in the hydraulic circuits.
They are installed on the hydraulic pump discharges and individual SSSV
control lines to bleed of excess pressures. The released hydraulic oil is
routed back to the storage tank. These right angle relief valves are pressure
balanced internally and pressure referenced to atmosphere. This yields
insensitivity to downstream pressure and permits the valve to be used as an
accurate back-pressure regulator. Below is a typical specification;

Proof pressure 20,000 PSIG

Minimum burst pressure 40,000 PSIG
Design standard 316 SS
Operating temperature
ranges
Buna N seals -40° to 250°F
Viton seals -20° to 450°F
Inlet port ¼" MNPT
Vent port ¼" MNPT or FNPT
Relief pressure ranges 100 to 10,000 PSIG

15
1.5. SHUTTLE VALVE

Shuttle valves are the pneumatic equivalent of OR gate in electronics.

Presence of either of the two inputs will yield an output. The shuttle valve
utilizes a stainless steel ball sealing against an o-ring. The technique of
"“contact seal" is often applied in the design. The ball offers "frictionless"
response to pressure from either inlet and closes the opposite inlet with a
bubble-tight seal. Below is a typical specification;

Service Hydraulic or pneumatic

Maximum operating
250 PSIG
pressure
Proof pressure 357 PSIG
Burst pressure 500 PSIG
Temperature -40° to 450°F
Design standard 316 SS
O-rings Buna N or Viton

16
1.6. QUICK EXHAUST VALVE

The quick exhaust valve is a two position high flow control valve
assembly. It establishes flow (from the inlet to outlet or Supply-to-Valve
connections) to open a Safety Valve (SSV or any pneumatic Actuator),
automatically with each application of operating pressure. A loss or
significant decrease of operating pressure will quickly establish high
volume, reverse or Exhaust flow. Rapid closure of an Actuator valve is
assured with the use of a Quick Exhaust Valve.

A Quick Exhaust Valve is a three-way valve with extra large exhaust

orifice. When pressure decreases at the inlet of the Quick Exhaust Valve, the
outlet is automatically opened to the exhaust and the cylinder is quickly
depressurized.

1.7. FLOW CONTROL VALVE

These valves are used in restricting air flow for achieving delayed
responses. Note that the valve offers free flow in one direction while in the
reverse direction, flow is restricted. The rate of restricted flow can be

17
adjusted by using the knob. It is also provided with a lock nut so as to
prevent any unwanted changes.

1.8. PANIC VALVES

As the name indicates these valves are handy during an emergency or

panic situation. They are installed on all escape routes in offshore
installations for easy accessibility during emergencies. The ESD valve or the
panic valve is a two position, two-way normally closed, high flow capacity
manually operated ESD control valve. In the shelf or normal placement, the
valve has the Supply port blocked or isolated from the Exhaust port. Pulling
outward on the ESD Valve's handle will establish a Supply-to-Exhaust flow
path, rapidly depressurizing the ESD control circuit.

Two-way normally closed ESD Valves of this type are used in

Emergency Shutdown (ESD) control circuits to immediately initiate
shutdown activities. These controls are most commonly found in parallel
ESD control circuits on offshore platforms. These valves are selected rugged
enough to help prevent accidental activation of safety system.

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1.9. FUSIBLE PLUGS

Fusible Plugs are commonly known as Temperature Safety Elements

(TSE) within the safety system industry. All Fusible Plugs have a solid core
that melts due to intense heat of a fire. They maintain operating pressure
within the control circuit until the maximum operating temperature of the
Fusible Plug is exceeded. Once the eutectic material melts, the FSD control
circuit experiences a loss of operating pressure, which initiates an
Emergency Shutdown sequence, Fire water pump starts and deluge valve
opening. Fusible Plugs are an integral part of most pneumatic FSD control
circuits.
Below are the of table fusible plug colour code and their
corresponding melting point;

S No Colour Code Melting Point

1 Red 158 deg F
2 Brown 184 deg F
3 Green 203 deg F
4 Pink 255 deg F
5 Orange 281 deg F

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1.10. HYDRAULIC DUMP VALVE

This valve is also called as hydraulic interface valve. This valve

interfaces the logical pneumatic signal with the hydraulic pressure essential
for SSSV operation.

The dump valve is a two position, three-way normally closed, Pilot

operated, hydraulic flow control valve assembly. It is designed to establish
high-pressure hydraulic fluid output, automatically with each application of
relatively low Pilot Supply pressure. In a well control panel the hydraulic
supply at the inlet of the valve is about 250 – 300 KG/Cm2 while the
pneumatic pilot pressure is 7 KG/Cm2.

A loss of Pilot Supply pressure will block the hydraulic Supply (inlet)
port and exhaust the SSSV control pressure back into the hydraulic storage
tank. The valve has an optional manual Override Handle to establish
hydraulic Supply to SSSV, without the application of Pilot Supply pressure.
This feature allows the SSSV to be opened for testing purpose.

20
1.11. SIGMA MASTER RESET VALVE

Valves of the above type are used in opening and closing of shutdown
valves. These valves are often installed near the shutdown valve and are
rarely used inside panels. These valves are handy for the field operator to
operate a safety valve if the panel system fails to perform.

This is a two position, three-way normally closed block and bleed,

Pilot supply pressure actuated valve. It is designed to establish Supply-to-
Valve, output pressure with manual Pull & hold of the handle. Once the
valve handle is pulled and Pilot Supply pressure is applied, the Relay's
normal in-service placement will be maintained. A loss of Pilot Supply
pressure will block the Supply (inlet) port and exhaust the accumulated
operating pressure within the receiving control circuit. To close the valve,
Push on the valve handle to release downstream pressure.

This type of relay valve is generally referred to as a Two Phase Relay.

It is capable of using a lower Pilot supply pressure (30-50 PSI) to maintain
the receiving control circuit (generally 50-150 PSI).

Most of these valves also have a special feature that will block the
Supply (Inlet) port, whenever master supply pressure decreases below 40
PSI. Manual reset is required after operating instrument supply pressure is
restored.

21
1.12. HIGH LOW PILOTS

Popularly known as PSHL, these pressure Hi-Lo pilots are designed to

protect equipment and installations against abnormal pressures. It is
available in pressure ranges up to 15,000 PSI and can operate as a normally
open block-and-bleed high pressure or closed block-and-bleed low pressure
device for pneumatic or hydraulic service. Each of the switches functions as
a 3 way valve - one as Normally Closed valve and the other as normally
open valve. Standard supply and output pressure is 50 PSI.

These valves give an output if the sensed pressure is within the set
pressure band. For instance, if the pressure false below 7 KG/Cm2 or if it
goes above 55 KG/Cm2 for a flow arm pressure switch, the out put to the
well control panel is dropped and thus shutdown of well surface safety valve
is initiated.

1.13. HYDRAULIC ACCUMULATOR

A hydraulic accumulator is an energy storage device. It is a pressure

storage reservoir in which the hydraulic oil is held under pressure by
compressed gas. Compressed gas accumulators are often called hydro-
pneumatic accumulators. A hydro-pneumatic accumulator is a vessel which
is capable of storing a large amount of energy in a small volume.

22
 These accumulators are used in the primary hydraulic header of the
well control panel. The main reason that an accumulator is used in a
hydraulic system are so that the supply circuit can respond more quickly to
any temporary demand, even when the pump is offline.

A compressed gas accumulator consists of a cylinder with two

chambers that are separated by an elastic diaphragm, a totally enclosed
bladder, or a floating piston. One chamber contains hydraulic fluid and is
connected to the hydraulic line. The other chamber contains an inert gas
under pressure that provides the compressive force on the hydraulic fluid.

When the fluid travels through the accumulator, and the pressure of
that fluid is greater than the pre-charge pressure of the accumulator, then the
gas compresses and the accumulator can take in the corresponding volume
of fluid. Any pressure drop in the hydraulic circuit causes the accumulator to
return fluid to the circuit. An accumulator can maintain the pressure in a
system for periods when there are slight leaks without the pump. When
temperature changes cause pressure excursions the accumulator helps absorb
them.

Nitrogen gas is used in most applications for charging the accumulator.

In general, hydraulic accumulators are pre-charged to half of the normal
operating hydraulic pressure. For instance, if the SSSV operating pressure is
300 KG/Cm2, the accumulator should be pre-charged to 150 KG/Cm2.

23
1.14. HYDRAULIC PUMPS

Hydraulic pumps are used in the well control panel for developing the
pressure required for SSSV operation. There are two pumps generally
installed inside the panel – the start up pump and the primary pump. Both
pumps are generally similar and are of Haskel make.

(Fig 1.14.1) (Fig 1.14.2)

1.14.1. Haskel pumps: Principle of operation

Haskel air driven liquid pumps work on an automatic reciprocating

differential area principle that uses a large area air drive piston connected to
a smaller area hydraulic piston/plunger to convert compressed air power into
hydraulic power.

The nominal ratio between the area of the air drive piston and the
hydraulic piston is indicated by the dash number in the model description
and approximates the maximum pressure the pump is capable of generating.
For example an AW-35 has a nominal pump ratio of 35:1.

24
If air drive piston area = 25.9 sq. in. and liquid piston area = 0.65 sq. in.
then actual pump ratio = 40:1
and nominal pump ratio = 35:1
If air drive pressure = 75 psi (5.2 bar)
then the maximum outlet stall pressure will be close to 40 x 75 = 3000 psi

When compressed air is applied to the pump it will cycle filling the
pressure receiver with liquid. The pump stops (stalls) when a balance of
forces is reached. i.e. when air drive pressure x air drive piston area = stall
pressure x driven hydraulic piston area.

1.14.2. OPERATION OF HASKEL PUMP

1. Air Drive Section

This consists of a light weight inertia reducing piston

complete with o-ring seal inside an epoxy filled wound
fiberglass or hard coated aluminum barrel. The diameter of
the air piston is constant for any series of air driven pumps.
When compressed air is fed into the air drive it forces the
piston down on the compression stroke. The air then drives
the piston back on the suction stroke (except in the case of
the M series pumps (Fig 1.14.2) which have a spring return).

25
 2. Hydraulic Section

The hydraulic piston/plunger is directly linked to the air piston and its
lower portion is housed inside the hydraulic body. Its diameter determines
the ratio of the pump (for any particular series) which in turn
determines the output flow and maximum pressure capability.
Its function is to induce liquid into the hydraulic body
through the inlet check valve and force it out through the
outlet check valve at a higher pressure.

These are spring loaded non-return valves that control

the passage of liquid into and out of the pump. When the
hydraulic piston/plunger is on the suction stroke the inlet
check valve opens to the maximum, the liquid is induced into
the pump while the outlet check valve is held closed by its
spring. On the pressure stroke the inlet check valve is closed as the hydraulic
piston/plunger force the liquid out through the outlet check valve.

3. Air Cycling Valve

This consists of an unbalanced, pilot operated, light

weight spool that channels the compressed air to either side
of the air piston, depending on position. The air piston
actuates pilot valves at the top and bottom of its stroke,
alternately pressurizing and venting the large area of the
spool, causing it to reciprocate and control the air flow to the
air piston to maintain automatic cycling. The air is
exhausted from the pump through an exhaust muffler.

1.14.3. HASKEL PUMP FEATURES

A wide range of pumps with different capabilities are available. Fig

1.14. 2 is the M series pump which are mostly used in well-head control
panels. They are 1/3 hp miniature pumps with 1 inch stroke. They can pump
liquid at the rate of 3 gpm or 12 L / M.

All hydraulic fluids, plain water, solvents, mild chemicals and

liquefied gases can be pumped by using Haskel pumps. SAE 30 or Enclo-
32 or equivalent is the preferred hydraulic oil for use in well control panels.

26
References

1. Web site, Catalog, Datasheets & Bulletins of VERSA Products Co.

2. Web site, Catalog, Datasheets & Bulletins of SIGMA valves.
3. Catalog of AMOT Indicators.
4. Catalog of HASKEL Liquid Pump
5. Flow control valve catalog of Pneu –Trol.
6. Web site of e-Production Solutions.
7. Wikipedia, the free encyclopedia
8. Operations Manual of IP platform, ONGC
9. Halliburton – Subsurface Safety Equipments
10. Hydro Leduc – Technical Datasheet for accumulators
11. Engineers Edge – Hydraulic Accumulator Sizing Calculations.

27
 Section: 2

PNEUMATIC CIRCUITS

28
 CONTENTS

S No Section Topic Page

No

1 2.1 Introduction 30
2 2.2 Symbols 32
3 2.2.1 Basic Symbols 32
4 2.2.2 Air Service Equipments 33
5 2.2.3 Pneumatic Accessories 33
6 2.2.4 Valve Operators 34
7 2.2.5 Directional Valve 35
8 2.2.6 Alternate Symbols 36
9 2.3 Pneumatic Circuit Drawings 38
10 2.3.1 ESD loop charging Circuit 38
11 2.3.2 Converting Pulse Input into a permanent Signal 40
12 2.3.3 Circuit for First-Out Indication 41
13 2.3.4 Timer Circuit and SSSV control logic 43
14 2.3.5 SSV control Logic 45

29
 PNEUMATIC CIRCUITS

2.1. INTRODUCTION

A pneumatic circuit is a set of components interconnected logically

to achieve a pre conceived interrelation.

When drawing component interconnections it is customary to use

symbols. At first some of the pneumatic circuit symbols may look very
complicated, but if the concept is understood it is much easier and simpler.

As an example let us look at the three way valve discussed earlier

under directional control valves.

Two positions of the 3 way valve is shown above. Remember it is a

spring return type 3 port normally closed valve. It is ‘normally closed’
because without application of external force (manual push/pull or pilot), the
IN port is blocked. Now refer to the symbol for this valve. Since this is a two

30
position valve, it is represented in two blocks. The bottom square block
represents the normal position of the block.

When the valve is pressed or actuated, the port configuration

changes and is represented in the top half of the symbol. While reading
pneumatic circuits imagine that when the valve is operated, the top half of
the symbol slides over the bottom half.

Another way of representing pneumatic components is through

triangles.

Each triangle represents a port of the valve. The triangle with the line
denotes a normally closed port and the one with the circle inside denotes a
normally open port. Only the normal position of the ports is represented in
this type of drawing and not the actuated position. On operating the valve,
the open and close ports interchange their position. The triangle without any
notation inside represents the OUT port or the common port. Hence in
normal position of the 3 way valve discussed above, the out is symbolically
shown connected to the exhaust, blocking IN. In the operated position it is
assumed that the IN gets connected to OUT and the EX port blocked.

31
2.2. SYMBOLS
2.2.1. BASIC SYMBOLS

S No Symbol Explanation
1 Control component
2 Filter / lubricator / separator
3 Pressurized reservoir / accumulator / tank
4 Reservoir / tank
5 Direction / nature of fluid (Pneumatic)
6 Direction / nature of fluid (Hydraulic)
7 Path of fluid through valve
8 Closed path or port
9 variability
10 Spring

11 Restrictor

12 Air bleed (continuous)

13 Air bleed (temporary)

14 Junction
15 Flexible
16
Pressure gauge

17 Ball valve
18 Needle valve
19
Accumulator (gas charged)

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2.2.2 AIR SERVICE EQUIPMENTS

S No Symbol Explanation

1
Air pressure regulator

2 Air filter

3
Coalescing filter

4 Air Lubricator

5 Air dryer

6 Air cooler

2.2.3. PNEUMATIC ACCESSORIES

S No Symbol Explanation

1
One way adjustable restrictor
2 Silencer

3 Non-return valve
4 Adjustable pressure switch

5 Adjustable restrictor bi-directional

6 Quick exhaust valve

7 Shuttle valve

8 Volume bottle

33
2.2.4 VALVE OPERATORS

S No Symbol Explanation

1
Solenoid operated

2
Air pilot operated
3
Hydraulic pilot operated
4
Spring return
5
Air operated and spring return
6 Double pulse coil

7 Manual override

8 Push to operate
9 Pull to operate

10 Push / pull operation

11 Pilot operated with manual override

12 Manual override on solenoid

34
2.2.5 DIRECTIONAL VALVES

S No Symbol Explanation

1
2 way, 2 position normally open valve

2
2 way, 2 position normally closed valve
3
3 way, 2 position normally open valve
4
3 way, 2 position normally closed valve

5 3 way, manually operated, spring return, NO

valve
6 3 way, solenoid operated, spring return, NC
valve
7 3 way, air operated, spring return, NO valve
8 3 way, air operated, air return, NC valve

All the above symbols are based on ISO standard. Other forms of
Symbols based on the German standard DIN, are also followed widely. The
following is a table of such symbols of mostly used directional valves and
components in wellhead shutdown panel.

35
2.2.6. ALTERNATE SYMBOLS
S No Symbol Explanation

1 2 way NC spring return manually operated

2 2 way NC pilot operated

3 3way NC spring return manually operated

4 3 way NC pilot operated

5 3 way NC solenoid operated, single coil

6
3 way NC solenoid operated, duel coil

7
3 way NC pilot operated hydraulic interface
valve ( dump valve)

8
3 way selector valve

36
9 3 way NC pressure switch (low)

10
3 way NC pilot operated, Pull to open, push to
close

11 3 way NC pilot operated, pilot return

12 Relief valve

13 Pressure regulator ( downstream)

14 Pressure regulator ( upstream)

15 Down stream Pressure regulator with filter, auto

drain

37
2.3. PNEUMATIC CIRCUIT DRAWINGS

2.3.1. ESD / FSD LOOP CHARGING CIRCUIT

Components used;

1. 2 Way NC, spring return, push to operate (C1) - 1 No.

2. 2 Way NC, spring return, air pilot operated (C2) - 1 No.
3. Adjustable restrictor (C3) - 1 No.
4. Panic (ESD) Valve (C4) - 1 No.
5. Pressure Gauge (C5) - 1 No.

Operation:

When the push to charge component C1 is pressed manually, supply

pressure is fed into the ESD loop. The valve C1 is held pushed until the loop

38
is charged to 50 PSI. Since pilot to the valve C2 is directly taken from ESD
loop, the valve gets sufficient pilot pressure to cause a change of state. This
will connect the supply pressure to the ESD loop through an adjustable
orifice (C3). The ESD loop is thus continuously charged to compensate for
minor leakages. If the restrictor opening is too low, it may lead to
unnecessary shutdown due to pertinent minor tube leakages. On the contrary
if the restrictor opening is too high, the pressure may not bleed sufficiently
to cause a plant shutdown.

On pulling the panic valve, the air pressure in the circuit bleed of to
the atmosphere. The rate of such discharge should be much higher than the
rate of charging through the restrictor, so as to cause a rapid shutdown.
When the ESD loop pressure falls, valve C2 goes into its close position,
preventing further charging of the loop. Charging of the loop again is
possible only by manually pushing the valve C1.

39
 2.3.2. CONVERTING A PULSE INPUT TO A PERMANENT SIGNAL

Components used:

1. 3 way NC, Spring return, manually operated (C1) - 1 No.

2. Shuttle Valve (C2) - 1 No.
3. 3 Way NC, Spring return, pilot operated - 1 No.

Operation:

The circuit is for converting a momentary signal to a permanent signal.

One manual pulse is sufficient to keep the actuator supplied continuously.
On pushing the valve C1 once, valve C3 gets its pilot through the shuttle
valve C2. The other input port of the shuttle valve is connected to the OUT
port of C3. Hence once the valve C3 is actuated, it gets a permanent pilot
from its own OUT port.

40
 2.3.3. CIRCUIT FOR FIRST-OUT INDICATION

Components used:

1. 3 way NC, Spring return, manually operated (C1) - 1 No

2. 3 way NC, Spring return, pilot operated (C2) - 1 No
3. Amot indicators, orifice type without spring (C3) - 4 Nos
4. 2 Way NO, spring return, pilot operated (C4) - 4 Nos
5. Shuttle valve (C5) - 1 No.

Operation:

During a shutdown, it is most essential to get an indication for the

cause of shutdown. Pneumatic indicators are available in the market to serve
this purpose. Suppose a shutdown happens because of gas leakage detection.
The corresponding indicator turns ‘red’. It possible that ESD and FSD loop
pressure goes down due to non availability of panel supply pressure because
of the shutdown. Hence if the operator reaches an unmanned platform he
may find all three indications showing ‘Red’. It is here that the need for
identifying primary shutdown signal or the first-out arises.

41
 The drawing above explains how this function can be achieved. Let us
consider the system is healthy and all indicators showing ‘Green’. Now let
us assume 60% LEL detection. This makes loss of pilot to the valve C4-3,
making its inlet open to atmosphere. Pressure in the ‘Trip’ port of amot
indicator C3-3 bleeds off making it ‘Red’. The function of Amot indicator is
not only to turn the colour indication but also closes its inlet port and vents
off the outlet. Valve C2 thus loses its pilot and the whole Amot loop
pressure becomes zero. Now what if another signal, say ESD or FSD
actuates? Nothing happens to the indicators as they do not have the inlet
pressure to turn it ‘red’. Hence only the 3rd indicator shows ‘red’ and all
other indicator remains in ‘green’, clearly indicating the first-out.

When the signal becomes healthy and when the push to rest indicators
component C1 is pressed the indicators will return to their operating position.

42
2.3.4 TIMER CIRCUIT AND SSSV CONTROL

Components used:

1. 3 Way NC, pilot operated, spring return, push / pull(C1) - 1 No

2. Low hydraulic pressure switch, 3 Way NC (C2) - 1 No
3. 3 Way NC dump valve (C3) - 1 No
4. Unidirectional adjustable restrictor (C4) - 1 No
5. Volume bottle (C5) - 1 No
6. 3 Way Selector valve (C6) - 1 No
7. Pressure gauge (C7) - 1 No

Operation:

This is the circuit used in the SSSV control logic. The timer circuit is
introduced to have the 3 minute time delay between the closure of SSV and
SSSV. On any shutdown, closure of SSSV is always delayed by 3 min.

43
 The selector valve C7 is initially selected towards the start-up
hydraulic header and the SSSV control line pressurized. When the valve C1
is pulled and if C2 is reset from the start-up pressure, valve C3 gets its pilot.
Note that the component C4 allows restriction less path for the signal to
reach the pilot port of C3 through the inbuilt NRV. C3 now allows primary
pump to be selected. Valve C6 is now turned towards primary hydraulic
header.
When there is a SSSV shutdown condition or if the valve C1 is
pushed to close SSSV, the component C3 does not drops out immediately.
This is because of the presence of timer circuit. The volume bottle C5 hold
the pilot pressure required for C3 until it is bled off through the restrictor.
The pilot has to bleed off through the restricted path because of the presence
of NRV. This restrictor can be adjusted to get the desired time duration
before the closure of SSSV. Once it is ‘timed-out’, the dump valve dumps
SSSV operating hydraulic pressure back into the storage tank.

44
2.3.5. SSV CONTROL LOGIC

Components used:

1. 3 WNC, Spring return, pilot operated, Push / Pull(C1) - 1 No

2. 3 Way NC, Spring return, pilot operated (C2) - 3 Nos
3. 3 Way solenoid valve, double pulse coil (C3) - 1 No
4. Status indicators (C4) - 2 Nos
5. 3 Way Selector valve (C5) - 2 Nos
6. Needle valve (C6) - 2 Nos
7. Pressure gauge (C7) - 2 Nos

Operation:

In SSV control, it may be noted that SSV can only be operated after
opening of SSSV. Component C2-1 is used to check the SSSV permissive.
Pull to Open, Push to Close SSSV valve C1 can now be operated to open the
SSV. SSV gauge C7-1 will sense pressure only if C2-2 and C2-3 conditions
are favorable. Valve C2-2 checks the remote SOV C3 status and valve C2-3
checks the flow arm PSHL status. C3 is a duel pulse coil type solenoid valve.

45
Here one pulse sets the solenoid and allows air to reach its outlet. The status
remains the same until another pulse is applied on the second coil to reset it.
Both PSHL and remote SOV can be bypassed through the 3 way selector C5.
Status indicators C4 provides the current status of PSHL and SOV. The
valve C2-3 has two functions – one is to check the total SSV control header
status and the other is the PSHL Status.

References:

1. Roymech : Symbols used in Pneumatic and Hydraulic Circuit

drawings
2. Industrial pneumatic Control by Z J Zansky & L F Schrader
3. Pneumatic Systems : Principles and Maintenance by S R Majumdar
4. Pneumatic Circuits – Wikipedia, the Free Encyclopedia
5. Petrotech Panel drawings

46
 Section: 3

PNEUMATIC CONTROL PANEL

47
 CONTENTS

S No Section Topic Page

No

1 3.1 Introduction 49
2 3.2 Control Panel Requirements 49
3 3.3 Shutdown Panel Philosophy 49
4 3.4 Well Control Overview 50
5 3.5 Well Control Panel Features 51
6 3.6 Multi Signal Functionality 52
7 3.7 Control Panel Sections 52
8 3.8 Panel Operation 54
9 3.8.1 Start-up logic gas system 54
10 3.8.2 Opening the Sub Surface Safety valve 54
11 3.8.3 Opening Surface Safety Valve & GLV 55
12 3.9 Control System Functional Description 55
13 3.9.1 ESD Loop 55
14 3.9.2 Fire Loop 56
15 3.9.3 Gas Detection 56
16 3.9.4 Major High / Low Pilots 57
17 3.9.5 High Level in KOD 57
18 3.9.6 Main Oil Line PSHL 58
19 3.9.7 Main GI Line PSHL 58
20 3.9.8 Flow arm PSHL 58
21 3.9.9 GI Line PSHL 58
22 3.10 Trouble Shooting SDP-100 59
23 3.10.1 Hydraulic Pump Did not Pump 59
24 3.10.2 Hydraulic Pump Pumps but pressure did not buildup 59
25 3.10.3 All SSSV did not OPEN 59
26 3.10.4 All SSV did not OPEN 60
27 3.10.5 All GI XSDV did not OPEN 60
28 3.10.6 Individual SSSV did not OPEN 60
29 3.10.7 Individual SSV did not OPEN 60
30 3.10.8 Individual GI XSDV did not OPEN 60
31 3.11 Maintenance Instructions 61

48
 PNEUMATIC CONTROL PANEL

3.1. INTRODUCTION

Pneumatic control panels are designed to monitor crucial wellhead

safety parameters. They provide sequential start up and safe shutdown of
production wells.
In remote unmanned well-head platforms produced gas is used as the
medium inside the control panel. Easy availability of pneumatic power
source makes pneumatic controls a desirable choice.

3.2. CONTROL PANEL REQUIREMENTS

Pneumatic supply : Air or natural gas

Pressure : 100- to 200-PSIG (6.9- to 13.8-BARG)
Service Standard : H2S-CO2 (NACE)
Consumption : 15 SCFM (max.) when pumping 5
YHHHHHHHHHHSCFD (normal)
Hydraulic outputs : 250 to 350 KG/Cm2
Pneumatic outputs ESD loop : 50 PSIG (3.4 BARG)
Pilot supply : 50 PSIG (3.4 BARG)
SSV supply : 100 PSIG (6.9 BARG)

3.3. SHUTDOWN PANEL PHILOSOPHY

The pneumatic shutdown panel is designed as a central protection unit

for overall protection of the installation. Three levels of protection for
personnel, production wells and surface facilities are envisaged. Thus a
panel consists of;

a) Fire and gas leakage protection system: Any gas leakage is

automatically detected and appropriate shutdown action initiated to
prevent formation of combustible mixture. All sources of ignition
are also shutdown. Any eruption of fire is detected and appropriate
shutdown and suppression action initiated.

49
 b) Surface Facility Protection: A safety analysis or hazardous
operability (HAZOP) analysis of surface facilities including rotary
and process equipments is carried out. All possible hazards,
interrelation between various parameters are identified and listed.
The functional chart thus evolved is the SAFE (Safety Analysis
and Function Evaluation) chart. The SAFE chart forms the basis
for design of panel in surface safety protection.

c) Well control & Protection: A major function of the wellhead

shutdown panel is to control the well through the surface and sub
surface safety valves. The interrelations between various valves are
well defined and their sequential operation established.

3.4. WELL CONTROL OVERVIEW

(A well-head control schematic)

There are two safety valves attached with the protection of producing
wells- the sub surface safety valve or the SSSV and the surface safety valve

50
or the SSV. In an offshore well-head platform, the sub surface safety valve
(SSSV pronounced triple SV) is situated below the sea level, under the sea
bed and the surface safety valve (SSV pronounced double SV) is situated on
the platform at surface level.

Various emergency conditions can be envisaged on the well-head

platform. These emergencies include rupture of flowing pipe lines, gas
leakages, abnormally high or low pressure conditions, emergency condition
at remote receiving process platforms etc. The wells are to be shut on
detecting such dangerous conditions automatically. SDP-100 or the
pneumatic well control panel does this critical function of safe shutting
down of wells and other well head facilities. SDP-100 provides the
necessary protection for the gas injection facilities too. Sequential start-up
and shutdown of producing wells are provided through fool proof interlocks.

3.5. WELL CONTROL PANEL FEATURES

Designed to comply with the guidelines of API RP 14B / 14C, the

pneumatic well control panel provides the following facilities;

• Generate visual and audio alarms locally

• First-Out Facility
• Provide alarm to remote stations through RTU
• Fire Safety shutdown
• Emergency shutdown
• Shut down surface and sub surface valves of producing wells
• Shut down oil dispatch facility
• Shut down gas lift facility
• Shut down water injection facility.
• Shutdown separator
• Manual Reset / Shutdown facilities
• Initiate fire water pump / spray system
• Provide necessary interlocks during well start-up
• Provide interlocks during well closure
• Remote telemetry control

51
3.6. MULTI SIGNAL FUNCTIONALITY

The SDP-100 control panel handles all verities of signals. Electrical,

hydraulic and pneumatic controls are processed in this central panel.

The logical activities of the panel are achieved through pneumatics.

The produced gases from the wells are conditioned and are used as the
media for panel operation. Pneumatic components used inside this panel can
perform all logical functions a PLC or an electronic relay circuit can do.
They provide visual alarm indications, timed audible annunciations,
complex control logics etc.

Though the SSVs and GI XSDVs are pneumatically operated, the

SSSVs require hydraulic pressures to the level of 300 KG/Cm2. There are
two hydraulic pumps normally present inside the panel. The ‘start-up pump’
and ‘primary pump’ are pneumatically driven to generate up to the required
hydraulic pressure of 250 KG/Cm2 and 300 KG/Cm2 respectively.

Electronic signals from remote centers are processed for total or

individual well shutdowns. Solenoid valves used inside the panel helps to
achieve these functions.

3.7. CONTROL PANEL SECTIONS

The panel is widely divided into two sections;

1. The main section and

2. The individual well control section.

The panel consists of a main section and many individual sections.

The main section handles signals which are common for all wells. Thus this
section consists of signals such as ESD loop, FSD loop, remote ESD, 60%
LEL, Low hydraulic pressure, Low pneumatic pressure, abnormal main oil
line pressure, abnormal main lift gas pressure, instrument gas header
pressure, scrubber level etc.

Emergency Shut Down (ESD) stations are installed through out

the well-head platforms. Each such station carries what is popularly known
as Panic Valves. These valves are to be manually pulled to cause ESD of the

52
plant. API RP 14C specifies the following locations as a minimum for
installation of ESD valves in offshore installations;
• Helicopter decks
• Exit stairway landings at each deck level
• At the center or each end of a bridge connecting two platforms
• Emergency evacuation stations
• Near the drillers console during drilling and work over
operations
• Near the main exit of living area

The Fire Shut Down stations too carries the panic valves. In addition
to pulling of panic valves FSD are automatically created by the use of
fusible plugs. The fusible plugs installed on the FSD loops melts at about 85
deg C and causes shutdown when a fire erupts.

Both ESD and FSD loops are kept pressurized up to 50 PSI. Any
considerable loss in pressure is detected as an emergency. To prevent false
shutdowns due to minor impulse tube leakages, the control panel keeps these
tubes continually charged. The charging rate is so controlled that it causes a
shutdown on real conditions while it prevents shutdown on minor leakages.
API RP14C recommends rapid shutdown on actuation of ESD loops.
Section C2.1 (d) of API RP 14C specifies 45 seconds as the maximum time
duration between actuation of ESD/FSD from the farthest point and actual
plant shutdown.

Gas detectors installed around the plant detects gas leakages. Methane
detectors are the normally employed detectors. H2S detectors are installed
wherever essential. The electronic gas detectors installed separately on the
plant detects the density of gas leakage in terms of LEL. 5% is the minimum
level of methane gas required, volume by volume, in air for it to get ignited.
Hence for methane gas, 5% is called its ‘Lower Explosive Limit’ or LEL. A
plant shutdown is initiated much before this minimum gas level required for
combustion. Normally plant goes into safe shutdown at 3% (= 60 % LEL) of
methane gas presence.

The individual sections are specific to individual wells. This section

has the controls for the wells SSSV, SSV and Gas injection shutdown valve
(GI XSDV). Individual flow arm and GI line pressure switches are sensed in
this section for appropriate actions.

53
3.8. PANEL OPERATION

3.8.1 Start-Up Logic Gas System

The SDP-100 control system is designed to receive an instrument gas

supply at a nominal 7.0 kg/cm2, with a tolerance of +2.0/-1.5 kg/cm2. Once
the supply has been filtered it is then pressure regulated through one of two
regulators which are set at 3.5 kg/cm2.With these pressures established the
input/output logic controls can be initialized prior to allowing the system to
operate under its own logic.

Ensure both the ESD and FSD valves are reset and that the above gas
pressures are indicated. Push to charge the FSD loop and hold until 3.5
kg/cm2 is indicated on the FSD Loop Pressure gauge. Similarly push to
charge the ESD loop and hold until the ESD Loop Pressure gauge shows 3.5
kg/cm2. Push to reset the panel and hold for a few seconds. Pull-and-pin to
reset ‘All SSSV’ and ‘All SSV’ header, depending on the panel. Pull-and-
pin to reset all XSDV output signals, if available.

During the control system start-up the gas supply to the primary
circuit hydraulic pump will be opened up allowing the primary system to
become charged to its operating pressure.

3.8.2. Opening the Sub-Surface Safety Valves (SSSV)

The plant ready condition is verified by checking the status of ESD /

FSD loops, instrument gas pressure conditions, remote ESD status and 60%
LEL detection etc. On resetting these signals, the hydraulic pumps are armed
to produce hydraulic pressure. The optimum pressure conditions are 250
KG/Cm2 for start-up pump and 300 KG/Cm2 for primary pump

With the main control system active the SSSV, SSV and GLV
control headers will be permissive. Therefore the well safety valve opening
sequence may start with the SSSV. Turn the hydraulic supply selector to the
start-up position for opening a SSSV. Gradually increase the start-up
hydraulic supply pressure until the hydraulic pump set limit is reached. Pull
to open SSSV valve. This will set the dump valve in the primary hydraulic
header. In some panel models, the pull to set SSSV is pulled and pined for
start-up header to get connected.

54
On charging the SSSV line from start-up header, selection can now be
shifted to the primary header.

3.8.3. Opening Surface Safety Valves and GLVs

The surface safety valve, and on a production well, the gas lift valve
(GL V) may now be opened. Pull and Pin to open the SSV and then GLV.
Reset the flow line pilot and GI pilot signals. At this point if the remote
signal is permissive then the SSV can be opened. In the case of a
production module the gas lift valve is supplied from downstream of the
SSV control valve. Therefore the GL V signal cannot remain permissive if
the SSV signal has been vented.

In the event of the SSSV being closed, the SSV and GL V will be
closed first. This is to protect the SSSV. An adjustable delay mounted on
the back of each well control module, keeps the SSSV open for 3 minute
from the loss of signal pressure, to allow the SSV to close first.

3.9. CONTROL SYSTEM FUNCTIONAL DESCRIPTION

The system may be considered as consisting of a series of independent

loops whose inter-relationships are defined in the SAFE charts. Each of the
independent loops is considered further in the following sections;

3.9.1. ESD loop

A signal pressurized 'ring main is used to provide a pneumatic signal

to the shutdown system. The ring main is routed throughout the platform and
is normally pressurized to 3.5 kg/cm2 (obtained from pressure regulator
within shutdown panel) which can be vented by the following means:

1. By remote control via the telemetry system which operates a solenoid

valve
2. ESD valve located on the shutdown panel
3. By operation of anyone of the ESD valves located at strategic points
throughout the platform.

Venting of the ESD signal will cause the following actions:

• Alarm - Visual and Audible

55
 • Stop Generator Engines
• Shutdown Separator (Via Separator Shutdown Panel)
• Shutdown Gas Lift Facilities
• Shutdown Water Injection Facilities (if available)
• Shutdown Oil Receiving Facilities (if available)
• Close all Surface Safety Valves
• Close all Sub Surface Safety Valves (After time delay interlock from
S.S.V. 's)
• Shut-in flow to Sump Caisson & Chemical Injection Pump ( If
available)
• Shutdown Sub sea Well (if available)

3.9.2. Fire Loop

A separate pressurized ring main is used to provide a pneumatic signal

to the shutdown system. The ring main is normally pressurized to 3.5
kg/cm2 (obtained from pressure regulator within shutdown panel). The ring
main is routed throughout the platform with particular attention being paid to
ensure that all process plant and equipment are reached. The ring main can
be depressurized by anyone of fusible plugs - designed to melt at 85 °C - or
anyone of the manually operated Fire Shutdown Valves located at strategic
points.
Venting of the Fire signal will result in the following actions:

• Alarm - Visual and Audible

• Start Fire Water Pump ( if available)
• Activate deluge system ( if available)
• All other shutdown actions equivalent to ESD loop actuation.

3.9.3. Gas Detection

Gas detection systems are installed separately on the platform. The

combustible gas detectors are of electronic type and are connected to an
electronic gas detection panel.
On detection of 60 % LEL, the gas panel generates a 24V DC output signal.
This signal is used to control a solenoid valve within the shutdown system
which generates a pneumatic signal for the logic.
Venting of either of these signals will result in the actions similar to that
of FSD loop depressurization.

56
 3.9.4. Major High / Low Pilots

The following High / Low pilots are considered major;

1. PSHL – 252 of Instrument gas finned pipe cooler inlet

2. PSHL – 321 of Volume bottle
3. PSHL – 314 of Instrument gas header

Venting of any of the above signals will result in the following actions:
• Alarm - Visual and Audible
• Alarm at RTU
• Shutdown Gas Lift Facilities
• Shutdown Water Injection Facilities (if available)
• Shutdown Oil Receiving Facilities (if available)
• Close all Surface Safety Valves
• Shut-in flow to Sump Caisson & Chemical Injection Pump ( If
available)
• Shutdown Sub sea Well (if available)

3.9.5. High Level in KOD

The following actions take place on venting of the level switch high
(LSH 190) of knock out drum;

• Alarm - Visual and Audible

• Shutdown Separator (Via Separator Shutdown Panel)
• Shutdown Gas Lift Facilities
• Shutdown Water Injection Facilities (if available)
• Shutdown Oil Receiving Facilities (if available)
• Close all Surface Safety Valves
• Close all Sub Surface Safety Valves (After time delay
interlock from S.S.V. 's)
• Shut-in flow to Sump Caisson & Chemical Injection Pump
( If available)
• Shutdown Sub sea Well (if available)

57
 3.9.6. Main oil line PSHL

Actuation of Main Oil line PSHL -243 will initiate the following
actions;

• Alarm - Visual and Audible

• Shutdown Separator (Via Separator Shutdown Panel)
• Shutdown Gas Lift Facilities
• Shutdown Oil Receiving Facilities (if available)
• Close all Surface Safety Valves
• Shut-in flow to Sump Caisson & Chemical Injection Pump ( If
available)
• Shutdown Sub sea Well (if available)

3.9.7. Main Gas injection line PSHL

Actuation of Main gas injection line PSHL will initiate the following actions;

• Alarm - Visual and Audible

• Shutdown all Gas Lift Facilities

3.9.8. Flow arm PSHL

Each wellhead is provided with a high / low pressure pilot which

gives a 3.5 Kg/cm2 pneumatic signal under normal conditions. If high or
low pressure conditions exist this pressure signal is vented which causes the
associated Surface Safety Valve to be closed with local visual and audible
alarms. The associated gas lift shutdown valve also closes.

3.9.9. GI line PSHL

Individual gas injection line is provided with a high / low pressure

pilot which gives a 3.5 Kg/cm2 pneumatic signal under normal conditions. If
high or low pressure conditions exist this pressure signal is vented which
causes the associated gas lift shutdown valve to close. SSV of the well is
unaffected and the well flows without gas lift.

58
3.10. TROUBLE SHOOTING SDP-100

3.10.1. Hydraulic Pump did not pump

Any one of the following signal can prevent air supply to the pumps;

1. ESD loop pressure low

2. Remote ESD activated
3. FSD loop Pressure low
4. 60 % LEL detected
5. Low Hydraulic pilot actuated ( Start-up bypass available )
6. Low Pneumatic Supply
7. High Level in KOD
8. Instrument header PSHL actuated ( PSHL 441 in some panels)
9. Panel indicators not reset.

3.10.2. Hydraulic Pump pumps but pressure did not build up

1. Air lock in hydraulic circuit

2. Pump discharge Relief valve not holding
3. Zero hydraulic Accumulator pre-charge pressure (applicable to
primary pump. Pump takes more time to fill the accumulator
before developing pressure)

3.10.3. ALL SSSV did not OPEN

Any one of the following signal can cause shutdown of all SSSV;

1. Pull to Reset all SSSV knob not pulled.

2. ESD loop pressure low
3. Remote ESD activated
4. FSD loop Pressure low
5. 60 % LEL detected
6. Low Hydraulic pilot actuated ( Start-up bypass available )
7. Low Pneumatic Supply
8. High Level in KOD
9. Instrument header PSHL actuated ( PSHL 441 in some panels)
10. Panel indicators not reset.

59
All SSV did not OPEN.

1. Pull to Reset All SSV knob not pulled

2. Main Oil line PSHL actuated (PSHL 243)
3. Instrument gas cooler inlet PSHL actuated (PSHL 252)
4. Volume bottle PSHL actuated (PSHL 321)
5. Instrument header PSHL actuated (PSHL 314)
6. Alarm Indicators not reset.

3.10.5 All GI XSDV did not OPEN

1. All SSV open Knob not set.

2. Main Gas Injection PSHL actuated.

3.10.6. Individual SSSV did not OPEN

1. Pull to open SSSV not pulled

2. Individual low Hydraulic pilot not set
3. Header Selector Valve not selected properly

(There is no direct signal which can close an individual SSSV)

3.10.7. Individual SSV did not OPEN

1. Flow arm PSHL actuated.

2. No permissive from individual SSSV circuit. (Circuit
allows opening of SSV only after opening of SSSV)
3. Pull to Open SSV not pulled.
4. Remote SSV close solenoid valve actuated.

3.10.8. Individual GI XSDV did not OPEN

1. Individual SSV not opened

2. Individual GI PSHL actuated
3. Pull to Open GI XSDV not Pulled.

60
3.11. MAINTENANCE INSTRUCTIONS

Contamination of the hydraulic fluid or air system is a major factor

causing breakdowns and internal leaks in this type of equipment. The
manufacturer’s instruction manual and company’s maintenance policy shall
be adhered to. However a few of the general checks are listed below:

• Observe general levels of fluid and investigate any excessive

losses.
• Check all pressure gauge readings for conformance to system
pressure requirements and for any loss of glycerin.
• Periodic check of Accumulator pre-charge pressure.
• A regular servicing routine should be established in line with
approved platform practices.
• Relief valves are to be tested and re-set at intervals of forty-
eight months maximum.

References:

1. Operation manual of IP platform

2. Operation manual of SP / SM / SR/ SF platforms
3. Wellhead Control Systems: Boustead controls & Electrics Pte Ltd.
4. Weather ford : Well Controlled Solutions.
5. ‘Industrial Pneumatic Control’ by Z J Zansky, L F Schrader.
6. ‘Pneumatic well control panel’ by Suresh Madhavan.
7. Recommended Practices (14C) of American Petroleum Institute.

61