FIELD SERVICE

Installation, Operation Manual

SSV & ESD Control System

FSM16-155-01E Rev.01

CUSTOMER:
JOB NO.:XTXS16-155
PO NO.:
DATE: March, 2017

CHONGQING XINTAI MACHINERY LTD.

ADDRESS: No.9 Fenglin Road,YongChuan District,ChongQing,China
TEL:86-23-85375927 FAX:86-23-49832118 P.O.:402160
WEB:WWW.CQXTJXGS.COM E_MAIL:CQXTJSZX@163.COM
 Chongqing Xintai Machinery Ltd.

CONTENTS

1.Introduction of system…………………………………………………………3

2. Technical Parameter………………………………………………………….17

3. Installation of system…………………………………………………………18

4. Operation of system………………………………………………………….20

5. Maintenance of system………………………………………………………23

6. Trouble shooting………………………………………………………..……24

2 / 24
 Chongqing Xintai Machinery Ltd.

1.Introduction of system

SSV & ESD control system included three parts: SSV, ESD control system case, ESD

auxiliary system.

1.1 SSV:

Included gate valve and hydraulic actuator, the valve can be closed by release the

hydraulic pressure in actuator in emergency situation. Actuator included: actuator shell,

hydraulic cylinder, piston, cylinder bonnet and spring, while the hydraulic oil enter the

cylinder, it can push piston to overcome the force of spring and move down, valve be

opened; while the hydraulic pressure in actuator be released, the spring will push piston

move up to close gate valve.

3 / 24
Chongqing Xintai Machinery Ltd.

SSV & Skid

4 / 24
 Chongqing Xintai Machinery Ltd.

Part List of SSV & Skid

Assembly Dwg No.: 2016PJ094-00 Rev 1.0
Item Part Number Qty. Description
1 2015PJ043-01-00 1 Skid and support frame
2 2005PJ062-02 1 Hammer union wing 3”1502
3 2008PJ112-01-02 1 Stop snap ring
4 2016PJ094-01 1 Adapter flange with union 3-1/16”10M x 3”1502 Male
5 AQFY78-70F2-00 1 SSV with hydraulic actuator 3-1/16”10M
6 XS378-04 1 Adapter flange with union 3-1/16”10M x 3”1502 Female
7 2008PJ002-04 1 Union packing 3”1502
B1 GB894-115 1 Snap ring for shaft 115
B2 Q/XT38-LS-Y1-185 16 Stud bolt 1”-8UNCx185mm
B3 Q/XT38-LM-Y1 32 Nut 1”-8UNC
B4 Q/XT38-B154-S304 1 Ring gasket BX154

5 / 24
Chongqing Xintai Machinery Ltd.

SSV with hydraulic actuator, 3-1/16”10M

6 / 24
 Chongqing Xintai Machinery Ltd.

Part List of SSV with hydraulic actuator

Assembly Dwg No.: AQFY78-70F2-00 Rev 1.0
Item Part Number Qty. Description
1 QDQY20000A-00 1 SSV hydraulic actuator
2 PFF78-70B-02 1 stem
3 PFFA78-105P-04 1 stem packing
4 PFFA78-105P-06 1 stem packing gasket
5 PFF78-70B-02 1 connection flange for actuator
6 AQFY78-70F2-02 1 stem packing 35/55x30
7 AQFY78-70F-01 1 bonnet
8 ZZF1/2-00 1 grease fitting, 1/2”NPT
9 PFF65-70-09 1 grease injection tag
10 PFFA78-105P-09 1 bonnet ring gasket
11 AQFY78-70F2-01-00 2 seat with seal ring
12 AQFY78-70F-02 1 gate
13 PFFA78-70F1-01 1 body 3-1/16”10M
14 AQFY78-70F-03 1 name plate
15 PFFA78-105P-12 2 guide plate
B1 GB/T 827-36 6 rivet 3x6
B2 Q/XT38-LS-M33-165 8 stud bolt M33x3x165mm
B3 Q/XT38-LM-M33 8 nut M33x3
B4 GB/T 71 2 screw M8x12

7 / 24
 Chongqing Xintai Machinery Ltd.

1.2 ESD control system case：

Supply hydraulic pressure to actuator, and close SSV by release the supplied hydraulic

pressure in emergency situation. Pneumatic pump or hand pump can supply the pressure,

sensing line can release the pressure, if there is no pressure in this sensing line, control

system will release the pressure in actuator. The pressure in sensing line can be released

automatically by High/Low pilot sensor or released manually by button.

1.2.1 Control system case PI&D and part list：

8 / 24
 Chongqing Xintai Machinery Ltd.

Part List of ESD control system case

Item Part Number Qty. Description Manufacturer
A AC3010-03 1 Pneumatic two link Liandong
B NV1-F6-06-316 7 Needle valve CIR LOK
C CV2-F6-V-1-316 2 Check valve CIR LOK
D YNF60ZT 40MPA 4 Pressure gauge Baoji
E 3A310-10NC 2 Relay valve AirTAC
F AR3000-03 1 Pressure reducing valve Liandong
G BV-030D 2 Ball valve MASTERLOK
H 8100-20000 1 Interface valve RUELCO
I RV1-F6-F4-03V-W-316 1 Relief valve CIR LOK
J SS-XSS6 1 Restrictor valve SWAGELOK
K 11801-38800 1 Quick exhaust valve RUELCO
L NPT1/2-5 1 Combination block XINTAI
M GDH-2 1 ESD station XINTAI
N 4202-2S3RS 2 High pressure pilot RUELCO
O 4202-2B2RS 2 Low pressure pilot RUELCO
P NXQA10/31.5-L-Y 1 Accumulator CAORI
Q L3C-45-HP 1 Air/manual driven hyd. pump IVS
R EF2-32 1 Air filter YiBo
S BV3W-030D 2 Three-way ball valve MASTERLOK

9 / 24
 Chongqing Xintai Machinery Ltd.

1.2.2 Control system case arrangment：

ESD control system case arrangement

Item Description Item Description
1 Case 2 Pressure gauge
3 Pressure regulating valve 4 Cover
5 Accumulator 6 Air driven pump
7 Tank 8 Working manifold
9 Control manifold 10 Lifting lug
11 Operating valve

10 / 24
 Chongqing Xintai Machinery Ltd.

ESD control panel arrangement

Item Description Item Description
1 Air source pressure 2 Pump driven pressure
3 Start switch 4 System pressure
5 Working pressure 6 Switch of SSV
7 Pump driven pressure regulating valve 8 Switch of PSH/PSL

1.2.2 working principle

1) set pneumatic pump

Open source switch, with air pressure regulating valve, adjust the pressure to the

required upper limit pressure range of system, maintain. Start / run switch is in the "start"

position, the pressure switch is adjusted to enough pressure value by the pump driving on

the panel. Set the upper and lower limits of the oil pump in accordance with the specified

11 / 24
 Chongqing Xintai Machinery Ltd.

working oil pressure range so that it can automatically stop when it is higher than the upper

limit and be start when lower than the lower limit. The relief valve should be adjusted

higher 1- 2Mpa of the upper limit.

2) Start oil pump

Now, the safety valve switch should be in the "off" state, and the gas supply pressure is

normal and stable. Open and adjust the pump to drive pressure switch until the oil pump

work properly. The cut-off valve of accumulator is opened, and the hydraulic oil enters the

accumulator until system pressure is normal and stable.

3) Open SSV

According to the technological requirements, the safety valve switch is respectively in

the "on" (the oil pressure gauge on the panel will display working pressure of safety

valve).Hydraulic oil of pump enters into the safety valve to compress spring in the safety

valve and push forward the ejector pin, thereby the safety valve is opened and into normal

work to achieve open wells. The upper and lower limits of the automatic switch set by the

oil pump and power accumulators are used to maintain the working pressure of the oil

circuit. If it needs to observe work pressure change of safety valve or circuit leakage, the

safety valve switch will be in the "keep" position. After that , timely let it be in“open”

position to ensure that emergency shut- down can be completed in one step.

4) In service

After normal opening, open the sensors switch and then start / run switch is switched

to the "running" position, the ground safety valve received the signal control state of

sensor.
12 / 24
 Chongqing Xintai Machinery Ltd.

If cutting off the sensor switch, to make the production line pressure not to affect

operation of the device, the start / run switch should be on "start" position, and then the

system is in the local bypass state. In this state, whether the production line pressure is

normal, the safety valve can be turned on and off. However, this state can only be used in

the case of temporary maintenance. In order to return in the "run" state, the sensor switch

must be turned on, and the safety valve switch will be reset and restarted in sequence.

5) Close SSV manually

System shutting wells: In accordance with the order and time interval provided by the

process requirements, the wing valve switch is in the "off”. The hydraulic oil returns back to

the tank through the pipeline, and the pressure is removed. The spring reset in the safety

valve, safety valves are all closed, completing shut well. The start / run handle arrow is up,

and the pneumatic pump stop working. Turn off the gas source switch, and open the

pressure relief valve in the box, the system pressure can be removed and shut down and

the system returns back the state of non stress.

The emergency nearest shut: When person is far from control box and near the shut

box, in an emergency situation, then broke the nearest shut box, Unscrew the cut-off valve

in the box to realize emergency shut.

6) Close SSV automatically

Fire protection function: when a fire occurs at the wellhead, the hose is burned off, and

the ground safety valve is closed. The flow valve in the tank cuts off the hydraulic oil.

Overvoltage and pressure loss protection function: with two sets of high and low

pressure sensor, when any set of pipeline pressure is higher than the high pressure set
13 / 24
 Chongqing Xintai Machinery Ltd.

point or lower than the low pressure set point, the ground relief valve can be automatically

(ESD) closed. The set point of the pressure sensor can be adjusted by the user in the

range of 4 ~ 40MPa (operating pressure according to the actual operating mode).

After closing the well, it is necessary to ensure the safety to the manual opening.

1.3 ESD 辅助系统 ESD Auxiliary System：

The ESD auxiliary system be used to connect the ESD control system, included: ESD

station, High/Low pressure pilot, quick exhaust valve etc.

ESD Station

14 / 24
Chongqing Xintai Machinery Ltd.

High/Low pressure pilot

15 / 24
Chongqing Xintai Machinery Ltd.

Quick Exhaust Valve

16 / 24
 Chongqing Xintai Machinery Ltd.

2. Technical Parameter

SSV with hydraulic actuator

Internal Diameter 3-1/16” (78mm)
Working pressure 10000Psi
Service H2S
Temperature class P.U (-29 to 121 ℃)
Material class EE-NL
Product Specification Level 2
Performance Requirement 2
Connection ends 3-1/16”10000Psi BX154 flange
Inlet 3”Fig 1502 F
Outlet 3”Fig 1502 M
Actuator port for control line 1/2”NPT Box
Actuator Max. W.P. 3000Psi
Cylinder capacity 1.5L approximate

ESD control system case

Ambient temperature -20 to 55℃
Control circuit 1x to SSV
Maximum output pressure 5000PSi
Set output pressure(Max.) 3000PSi
Set pressure of relief valve 3190PSi
Air supply pressure 70 to 150PSi
Pilot operating pressure 80 to 150psi
Oil tank capacity 26L
Hydraulic oil 10# aviation hydraulic oil

auxiliary system
High/Low Pressure Pilot Adjustable range of pressure
High pressure pilot of group 1 2000 to 5000Psi, set @3000Psi
Low pressure pilot of group 1 1000 to 3000Psi, set @2000Psi
High pressure pilot of group 1 500 to 1500Psi, set @1000Psi
Low pressure pilot of group 1 200 to 750Psi, set @500Psi

17 / 24
 Chongqing Xintai Machinery Ltd.

3. Installation of system

control system connection diagram

18 / 24
 Chongqing Xintai Machinery Ltd.

3.1 Installation of ESD control system case：

3.1.1. Set the ESD control system case on appropriate place as requirement of

specification.

3.1.2. Connect related hoses as per diagram。

3.2 Installation of SSV：

3.2.1. Connect the 1/2”NP M x M connector to the ports of quick exhaust valve, and

then install the connector into the needle valve on the actuator.

3.2.2. Connect related hoses as per diagram.

3.3 Installation of ESD station：

3.3.1.Set the ESD station on appropriate place as requirement of specification.

3.3.2.Connect related hoses as per diagram.

3.4 Installation of High/Low pressure pilot：

3.4.1. Set the High/Low pressure pilot on appropriate place as requirement of

specification, it’s better to install a isolation needle valve between the pilot and monitoring

port to repair or calibration.

3.4.2. Connect related hoses as per diagram.

19 / 24
 Chongqing Xintai Machinery Ltd.

4.Operation of system

4.1 Calibration of pneumatic pressure

Close air supply, operate the air pressure regulating valve to get the air source

pressure at upper limit of system, then open air supply, rotate the pump drive pressure

regulation valve can get the proper out pressure for actuator.

4.2 Calibration of hydraulic control system

4.2.1Calibration of pressure relief valve: close the related outlet of pressure, start the

pump to supply system pressure, then adjust the relief valve, if the system pressure reach

a settle pressure and it can not rise any more, after set the pressure lock the adjustment

cap.

4.2.2 Calibration of High/Low pressure pilot：

1) open SSV and verify on gauge Connect the hose and pump to PSHL manifold to

simulate the process pressure.

2) Simulate flowline pressure above the low pressure pilot set point using the hand pump

with the hose and calibrated gauge.

3) To check the Low Pressure Pilot setting, slowly back off on the test pump, which is

simulating the flowline pressure drop down.

4) When the pressure reaches the Low pilot setting, the pressure on the “Actuator

Pressure” gauge should go to zero and SSV should be shutdown.

5) To adjust the Low Pressure Pilot setting, back off on the lock ring that is locked on the

adjustment cap.

6) To increase the setting, crank in on the adjustment cap located on the top of the Low
20 / 24
 Chongqing Xintai Machinery Ltd.

Pressure Pilot. To decrease the setting by back off on the adjustment cap.

7) Repeat until the pilot is set to the correct set point.

8) Simulate flowline pressure below the high pilot set point using the same hand pump with

the hose and calibrated gauge.

9) Open SSV and verify on gauge, to check the High Pressure Pilot setting, slowly stroke

the test pump above the High pilot set point. When the pressure reaches the High pilot

setting, the SSV will close and the pressure on the actuator pressure gauge will go to

zero.

10) To adjust the High Pressure Pilot setting, back off on the lock ring that is locked on the

adjustment cap.

11) To increase the setting, crank in on the adjustment cap located on the top of the Low

Pressure Pilot. To decrease the setting by back off on the adjustment cap.

12) Repeat until the pilot is set to the correct set point.

13) Once the pilot is set, remove the pump and ready for in service.

4.2.3 Main operation procedure

Open SSV
Procedure Operation Response
pneumatic loop open air source, operate pneumatic switch, air supply pressure gauge show
running compressed air go into air loop the pressure
hydraulic loop Operate the pump drive pressure valve on The pressure gauge show the
running the panel, open the needle valve before current system pressure
accumulator, till the system pressure reach
to 21MPa
start operate safety valve switch to “open”, start Pressure gauge show the current
and run switch to “start”, hold on more than 5 working pressure of SSV
minutes
In service operate sensor switch to “turn on”, after 5 Service in automatic model
seconds, operate the start and run switch to
21 / 24
 Chongqing Xintai Machinery Ltd.
“run”
Open SSV without air rotate the handle of interface valve
supply clockwisely, close the needle valve before
accumulator, pressure with hand pump

Close SSV
Procedure Operation Response
Close SSV on panel operate safety valve switch to working pressure of SSV go to zero
“close”
ESD station Open the cover of ESD station and working pressure of SSV go to zero
rotate handle of needle valve
anti-clockwisely

22 / 24
 Chongqing Xintai Machinery Ltd.

5. Maintenance of system

5.1 Check the pipeline leakage or not inside and outside of the control box at any time. If

there is leakage, air source should be close immediately, and release the pressure, repair

in time.

5.2 Check the nitrogen pressure of accumulator once every six months. When the

pressure is lower than 8MPa, nitrogen must be added.

5.3 Check the liquid level of the oil tank once a week, the amount of oil should be added

when it is lower than the height of 1/2.

23 / 24
 Chongqing Xintai Machinery Ltd.

6. Trouble shooting

Item Problem Description Cause Analysis Take Action

SSV
1 Leakage on the ends Union packing sealing failure Replace new union packing
of connection
2 Leakage between 1. bonnet stud bolt loosen 1. re-tighten stud bolt
bonnet and body 2. bonnet ring gasket failure 2. replace new bonnet ring gasket
3 leakage between 1. stem packing failure 1. replace new stem packing
actuator and bonnet 2. damage on the sealing 2. repair or replace stem
connection surface of stem
4 oil leakage from Relevant seal ring failure replace seal ring
actuator
ESD control system
1 pneumatic pump does 1. air source pressure anomaly 1.check air path loop
not work 2. pump blocking or jam 2.check air source pressure
3.Repair or replace pump
2 SSV control pressure 1. system leakage 1.find the leakage location and repair
drop too fast 2. pressure relief valve damage 2. repair or replace pressure relief valvee
3 1. Nitrogen in accumulator not 1.add Nitrogen
enough 2.repair or replace inflation valve
accumulator
2. inflation valve leak 3.Replace accumulator
3. Accumulator capsule damage

24 / 24