LPO Detailed Description BOTNovember2003Rev5

Rev.
5a
Baker Oil Tools (Nov. 2003)
Detailed Description of a Line Pressure Operated system
Job No.: 4500972470 Aberdeen, United Kingdom
Baker Oil Tools

Line Pressure Operated (LPO)
Actuator Control System
Pipeline Protection
from
High and Low Pressures
Aberdeen AB2 0ES United Kingdom www.bakerhughes.com/bot

Phone: +44 (0) 1224 223 500 Telefax: +44 (0) 1224 771 400
Baker Oil Tools Rev. 5a
Detailed Description of a Line Pressure Operated system (Nov. 2003)
O PERATING AND MAINTENANCE MANUAL

for the
Baker Oil Tools

LPO Actuator Control System
Baker Oil Tools P.O. No.: 4500972470
TABLE OF CONTENTS
Index No. Document Title Page
1 Basis of Design 1
2 Local Control Functions and Operation of the System 3
3 Detailed Hook-up of the LPO System 5
4 Calibration of the System 6
5 Component Data 7
RHB Datasheet 7
Velocity Check Valve Datasheet 13
Oliver Manifold Needle Valve Datasheet 15
Oliver Needle Angle Valve Datasheet 15
6 Part Number Identification 16
7 Certification 17
RHB Pilot NACE Certification Blue Tab
Tattle Tale NACE Certification White Tab
Velocity Check Valve NACE Certification Orange Tab
Oliver Valve NACE Certification Yellow Tab
Tubing and Fittings Certification Green Tab
Hose Certification Blue Tab

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Job No.: 4500972470 Aberdeen, United Kingdom Page 1 of 17
1 Basis of design
Description
A Surface Safety Valve (SSV) is installed in a flowline or onto a Xmas tree to shut down in case of an
emergency and if the pressure in it is too high or too low. An SSV has several main components:
Control System:- The control system takes fluids from the flowline or Xmas tree or valve flange through
valves and pilots (pressure switches) to the actuator and controls all of the actions of the actuated valve
according to the conditions in the flowline or Xmas tree.
The system has been designed to operate one high-pressure actuator mounted on a reverse acting gate
valve with the control pressure coming from the flowline/pipeline. The maximum operating pressure will be
6000 psi gas of crude oil mixed with associated gas. The system has a high-pressure pilot installed to offer
protection to the line or downstream installations. The low-pressure pilot will give protection for a low-
pressure condition, which could indicate a broken line downstream of the system. Tattle tales are installed to
indicate which pilot - high or low, has been tripped. The system requires no electrical power or external
power source other than flowline/pipeline pressure.
Valve:- The valve is a full bore, through conduit, reverse acting gate valve, “RAGV”. The valve is called
Reverse Acting because the gate of the valve is pushed into the flow stream in the well-bore or flow-line to
open the valve. The through bore of the gate is at the same end as the stem. The stem passes through the
packing seal in the bonnet and is attached to an actuator.
Actuator:- The actuator is a high-pressure, hydraulic, fail safe, spring return type. The actuator uses flowline
fluids to push down the piston inside it, compress the spring, push the valve stem and open the valve. The
valve will close when the flowline fluids are exhausted from the actuator. The fluids in the flowline push the
against the valve stem, push up against the piston in the actuator and if the actuator is empty of fluids the
valve will close. The spring in the actuator will close the valve fully if the flowline fluid pressure is too low.
The flowline fluids are guided into or exhausted out of the actuator by the control system.
Method of Operation
The Control System is a set of components that include:
• An isolation valve, to isolate the wellbore or flowline fluids from the system.
• A high pressure sensing switch or pilot. The High Pilot bleeds the fluids from the actuator when the
wellbore or flowline pressure is greater than the spring force in the pilot.
• A low pressure sensing switch or pilot. The Low Pilot bleeds the fluids from the actuator when the
wellbore or flowline pressure is lower than the spring force in the pilot. The IN and OUT ports are
reversed on the low pressure sensing switch or pilot.
• A velocity check valve. The Velocity Check valve prevents fluids flowing into the actuator to replace
the fluids bleeding out of it when the High Pilot or Low Pilot is tripped. The velocity check valve is
overridden during valve opening to allow fluids to enter the actuator. The Velocity Check Valve is
overridden by pushing down on the manual button.
• A low-pressure pilot bypass valve. The Low Pilot Bypass Valve is closed to isolate the actuator
fluids from the Low Pilot to prevent the Low Pilot from bleeding fluids from the actuator before the
wellbore or flowline fluid pressure is stabilised. Once the wellbore or flowline fluids are stabilised the
Low Pilot must be placed in service by opening the bypass valve.
• Tattle tales. The Tattle Tales will show which pilot, High or Low, tripped and closed the valve. This
helps in trouble shooting after the valve has shut in.

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How does it work?

Wellbore or flow line fluids flow from the pipeline or valve flange through the isolation valve, enter the base of
each pilot, push on the pistons in the base of the pilots and compress the spring in each pilot.
The fluids push on the ball in the base of the velocity check valve. When the fluids pass the ball in the
velocity check valve (pushed open for start up), they pass to the switch part of the high pilot and the low pilot
bypass valve (closed for start up).
The fluids pass through the flexible hose and into the actuator where they push the piston and compress the
spring, which opens the SSV.
When pressure in the system is stabilized the velocity check valve button is released and the low pilot
bypass valve is opened allowing fluids to pass to the switch part of the low pilot. The system is now stable
and in control of itself.
If the pilots sense a High or Low pressure above or below the trip set points of the respective pilots, they will
trip, bleed the fluids from the actuator through the switch part of the pilots and shut in the SSV.
Caution warning
When servicing the LPO system, make sure that the needle valve is closed before you start

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2 Local control functions and operation of the system

To open a SSV follow this procedure:-
CLOSE the Low Pressure Pilot Bypass Valve and PUSH IN the Tattle Tail
PUSH and HOLD DOWN the button to bypass the velocity check valve and allow the fluids to pass into the
system. When the SSV is open and the system stabilized, RELEASE the button. The position of the
actuator rising stem is a good indication of the status of the valve opening.

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When the SSV is fully open and the pressure in the system is higher than the setting of the Low Pilot, OPEN
the Low Pressure Pilot Bypass Valve.
It is possible to adjust the settings of the High Pilot and the Low Pilot by adjusting the bolt that is at the end
of each pilot.
A manual shut down function is not installed in the standard LPO system, this is an option however the
connections are provided on both pilots, the plug has to be removed and a additional control line must be
installed to an ESD station mounted on a 2” pipe stand near the entrance gate.
To get the system operational OPEN the Low Pressure Pilot Bypass Valve

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3 Detailed hookup of the LPO system
Connection for the

Velocity Check flexible hose to the
Valve Low Pilot actuator and/or to the
bypass valve calibration source
High pilot Low pilot

adjustment High Pilot Low Pilot adjustment
bolt Trip Tattle Trip Tattle bolt
Tale Tale
Indicator Indicator
Pilot vent to Pilot vent to

safe area safe area
Process
Flow line isolation
connection ½“ valve
NPT-male thread

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4 Calibration of the system

4.1 Field calibration of the LPO without disconnecting the system from the flowline.
Close the isolation valve (L) to prevent process pressure from entering the pilot manifold block, check that
the actuator is fully closed. If the actuator is open, it contains pressure and process fluid/gas, this must be
vented off through the pilot.
To vent off the pressure in the actuator, the high pressure pilot adjustment bolt must be turned counter
clockwise until the pilot trips and closes the actuator. It is advisable to put some tape over the threads of the
pilot adjustment bolt so that after tripping, the pilot adjustment bolt can be returned to it’s original position.
Note:- if the actuator is fully closed, disconnect the flexible hose.
Connect the hose connection (A) from the LPO system to a calibration source (A hand pump with clean
hydraulic fluid, or a nitrogen test unit, the connection has to be a male 3/8” tubing connector) with a certified
pressure gauge. Make sure the tattle tails are pushed in.
4.1.1 To calibrate the high pilot:

Close the low-pressure pilot isolation valve (B). Apply pressure to the system with the calibration source
(hand pump or nitrogen test unit). Stop when the pilot starts to vent through (C). The tattle tail (D) will give an
indication of the pilot trip.
If the set point is not correct, adjust the pilot set point;
To increase the set point, turn the pilot adjustment bolt (E) clockwise.
To decrease the set point, turn the pilot adjustment bolt (E) counter clockwise.
If the set point is correct:
Tighten the locknut (F) and register the calibration on your calibration records.
4.1.2 To calibrate the low pilot:

Lower the pressure of the calibration source (hand pump or nitrogen test unit) until the required set point is
reached and watch the tattle tail (H) pop up and the vent port (I) starts venting. Ensure that the velocity
check valve button (G) is pushed down, and open the low pilot bypass valve (B).
If the set point is not correct, adjust the pilot set point:
To increase the set point, turn the pilot adjustment bolt (J) clockwise.
To decrease the set point turn the pilot adjustment bolt (J) counter clockwise.
If the set point is correct: tighten the locknut (K) and register the calibration on your calibration records.
After calibration, vent off the pressure of the calibration source (hand pump or nitrogen test unit) and re-
connect the actuator hose.
To put the system back into service:- Close the low pressure bypass valve (B) hold the velocity check button
(G) down by hand and slowly open the process isolation valve (L) to allow process fluids through the system
to open the actuator/valve, the process isolation valve will control the opening speed. Open valve (L)
completely. Open the low pressure pilot bypass valve (B) to put the low pilot in service..
4.2 Calibration of the LPO in workshop

Close both valves of the LPO system (B and L). Connect the hose connection (A) from the LPO system to a
certified pressure gauge (3/8” OD).
Connect the connection (M) from the LPO system to a calibration source (A hydraulic test unit with clean
hydraulic fluid, or a nitrogen test unit) with a calibrated pressure gauge. Apply simulated flow line pressure to
the isolation valve (L). Make sure the tattle tails are pushed in.

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4.2.1 To calibrate the high pilot:

Close the low-pressure pilot isolation valve (B). Hold down the velocity check valve (G) and check if there is
pressure on point (A). Completely screw in the High Pilot adjustment bolt (E).
Apply the required trip pressure to the valve connection (M) with the calibration source (hydraulic or nitrogen
test unit). Slowly turn the pilot adjustment bolt (E) counter clockwise to decrease the setting point. Stop when
the pilot starts to vent through (C). The tattle tail (D) will give an indication of the pilot trip. Make a final check
to ensure that the set point is correct.
To increase the set point, turn the pilot adjustment bolt (E) clockwise.
To decrease the set point, turn the pilot adjustment bolt (E) counter clockwise.
If the set point is correct; tighten the locknut (F) and register the calibration on your calibration records.
4.1.2 To calibrate the low pilot:

Close valve (B). Adjust (J) counter clockwise until the adjustment bolt is almost out (watch out that you do
not take the pilot apart). Set the pressure at connection (M) to the required set point. Open valve (B) and
hold down the velocity check valve (G). Turn the adjustment bolt clockwise until the set point is reached and
watch the tattle tail (H) pop up and the vent port (I) starts venting. This indicates that the set point has been
reached. Make a final check to ensure that the set point is correct.
To increase the set point, turn the pilot adjustment bolt (J) clockwise.
To decrease the set point, turn the pilot adjustment bolt (J) counter clockwise.
If the set point is correct; tighten the locknut (K) and register the calibration on your calibration records.
After calibration vent off the pressure at connections (A) and (M) (hydraulic or nitrogen test unit)
Hose
B A
G
Actuator
E F D K J
High Pilot Low Pilot
L
C I

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5 Component Data
RHB Datasheet
Connections
Connection: 1/4” NPTF, Control
Process connection ½” NPTM
Process Panel Mount: 1- 3/8” Diameter Hole
Port A PSH - Supply Inlet PSL - Exhaust (30-6000 PSI) Orifice .125
Port B PSL – Supply Inlet PSH - Exhaust (30-6000 PSI) .125”
Port D Sensing Pressure Inlet (0.5-10000 PSI) .312”
Method of operation
The Model RHB Pressure Sensing Pilot is a two way, normally open or normally closed
automatic, hydraulic pressure sensing device.
Choose the appropriate inlet and the sensor can react to pressure above/higher (PSH) or
below/lower (PSL) any desired pressure setting.
Select the correct piston assembly and spring combination (see pressure chart) and by
screwing the adjustment bolt in or out, the sensor may be set between 20 and 10,000 PSI.
The sensor/pilot is normally installed on a process vessel, process flowline, or in a control

panel. The sensor receives sensing pressure at Port D from the component which it is
monitoring and hydraulic supply pressure at either Port A or Port B from the safety system
which it will shutdown.
During normal operation, the sensing pressure, Port D, should remain either above or
below the desired setting. This will allow supply pressure at either Port A or Port B to be
blocked and the exhaust either Port A or Port B to be open to the reservoir.
When the sensing pressure at Port D rises above or falls below the set pressure, the
sensor will bleed the supply pressure either at Port A or Port B through the exhaust either
Port A or Port B) and either allow the actuator to close or vent the system.
When the sensing pressure at Port D returns to normal operating limits, the sensor will automatically reset.
Features
• All Viton O-Rings and Teflon Seals
• All 316 Stainless Steel Construction
• Available in exotic metals for special service and applications
• Spring can be removed with sensing pressure present
• Sensing pressure will exhaust through vent if body is loosened from base
• Operation and reset within 10% of set pressure (above 700 PSI)
• Sensor can be used in pneumatic circuits
Options
R-Pilot base can be utilized for 1/2” NPTM or 1/4“NPTF sensing connections
Weight
5.75 Pounds

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Phone: +44 (0) 1224 223 500 Telefax: +44 (0) 1224 771 400

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Pilot base and Spring information
Operational Configurations
NO. 1/2
PISTON ASSEMBLY
NO. 1 CONFIGURATION NO. 2 CONFIGURATION
NO. 2/3
PISTON ASSEMBLY
NO. 2 CONFIGURATION NO. 3 CONFIGURATION
NO. 4/5
PISTON ASSEMBLY
NO. 4 CONFIGURATION NO. 5 CONFIGRATION
PISTON ASSEMBLIES #1 - #5
The BWB “R-Pilot” utilizes 5 different assemblies and 4 different springs, for a combined sensing range of 0,5-10.000
PSI. The pressure ranges are determined by the use of an appropriate assembly and spring combination – See Pressure
Chart for more detail.
PISTON NUMBER PISTON DIAMETER

1 1 3/8”
2 7/8”
3 1/2”
4 3/8”
5 1/4”

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Conversion details
Piston assemblies #1 through #5 are designed with 2 available diameters, which provide expanded adjustable
ranges using the same assembly.
No. 1/2 Piston Assembly To convert from No. 1 (1 3/8”) to No. 2 (7/8”)
Reserve Piston
To convert from No. 1 (7/8”) to No. 1 (1 3/8”)

Reserve Piston
No. 2/3 Piston Assembly To convert from No. 2 (7/8”) to No. 3 (1/2”)
Remove 018-90D O-Ring & Back-up Ring and
Install 012-90D O-Ring & Back-up Ring
To convert from No. 3 (1/2”) to No. 2 (7/8”)

No. 4/5 Piston Assembly To convert from No. 4 (3/8”) to No. 5 (1/4”)
Install 006-90D O-Ring & Back-up Ring.
To convert from No. 5 (1/4”) to No. 4 (3/8”)


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Pressure Chart
SENSING PISTON RANGE CAPABILITY

Diaphragm Assembly 0,5 – 3 PSI
Low Pressure Assembly 3 – 7 PSI
No. 1/2 Piston Assembly 5 – 700 PSI
No. 2/3 Piston Assembly 250 - 2000 PSI
No. 4/5 Piston Assembly 1000 – 10.000 PSI
Piston / Diameter / Spring / Adjustment range
SENSING ASSEMBLY DIAMETER SPRING ADJUSTABLE
Diaphragm
2 11/16” Plain 0,5 – 3 PSI
Low Pressure
1 5/8” Plain 3 – 7 PSI
No. 1/2 Piston
1 3/8” Plain 5 – 15 PSI
1 3/8” Red 15 – 50 PSI
1 3/8” White 50 – 150 PSI
1 3/8” Blue 150 – 250 PSI
7/8” White 150 – 250 PSI
7/8” Blue 250 – 800 PSI
No. 2/3 Piston
7/8” Blue 250 – 800 PSI
1/2” Blue 800 – 2000 PSI
No. 4/5 Piston
3/8” White 1000 – 2500 PSI
3/8” Blue 2000 – 4000 PSI
1/4" Blue 4000 – 10.000 PSI

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Velocity Check Valve Datasheet

A Velocity Check Valve (“VCV”) enables process pressure to be safely transmitted through instrumentation
tubing from an input source to a receiving item of equipment. If a component downstream of a VCV
ruptures, due to over pressuring, the high flow through the VCV will cause the VCV to shut. This will prevent
the continuous flow to the receiving item.
In the case of the LPO system, when an RHB pilot trips, because it has seen higher or lower than it’s preset
service conditions, and the systems starts to bleed fluids to shut in the SSV, the VCV blocks the flow.
The VCV valve is a two position, two way Normally Closed, flow control safety valve that is field mounted.
This model is normally selected for control applications that have operating pressures above 100 PSI
(6,9 Bar)
Special features: The Velocity Check Valve requires manual reset after a “Blocked-To-Flow” condition
occurs. The valve’s manual reset feature provides the necessary failsafe, lockout status. When the reason
for shutdown has been corrected, the operator manually depresses the knob to re-establish normal operating
status.
Characteristics:
1. Working Pressure: Up to 10,000 PSI (max.)
2. Connections: Control – 1/4” –18 NPTF (Outlet)
Process – 1/2” – 14 NPTM (Inlet)
3. Material: 316 Stainless Steel

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Oliver Manifold Needle Valve datasheet
Oliver Needle Angle Valve Datasheet

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6 Part number Identification

BOT part number is located on the back of the Process Isolation Valve
LPO serial number is located on the front of the Process Isolation Valve
PCE part and serial number identification
Velocity Check Valve serial number

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7 Certification (Please select the required chapter)
7.1 RHB pilot NACE certification.
7.2 Tattle Tale NACE certification
7.3 Velocity Check Valve NACE certification
7.4 Oliver Valve NACE certification.
7.5 Tubing and Fitting certification
7.6 Hose Certification

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Rev. 5a
7.1 Certificates
RHB Pilot
Baker Oil Tools P.O. No: 4500972470
PART NUMBER DESCRIPTION

RHB 6 Lockring
RHB 11 Sleeve
RHB 22 Inner Seat
RHB 26 Upper Inner Piston
RHB 27 Adjustment Bolt
RHB 28 Adjustment Bolt Lockring
RHB 30 Spring Guide
RHB 33 Lower Inner Piston
RHB 35 Lower Sleeve
RHB 39 Inner Cap
RHB 40 Upper Body
RHBV 41 Lower Body

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Rev. 5a
7.2 Certificates
Tattle Tail

VPIS BODY Tattle Tale
VPIS PISTON Tattle Tale

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Rev. 5a
7.3 Certificates
Velocity Check Valve

4 5 7
3 9 11

VC 03 VCV Pin
VC 04 VCV Body
VC 05 VCV Sleeve
VC 07 VCV Knob
VC 09 VCV Piston
VC 11 VCV Retainer

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Rev. 5a
7.4 Certificates
Oliver Valves

GM1S – 3’’ EXT / NA Gauge manifold
AM25S / NA Needle Valve

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Rev. 5a
7.5 Certificates
Tubing & Fitting

TUBING QA – Tube THT - 3R60 - 9.53 - 1.65 (9.53 x 1.65)
6MSEL4N – 316 3/8’’ OD x 1/4’’ NPT MALE 90 ELBOW IN 316 ST/ST
6MRT4N – 316 3/8’’ OD x 1/4’’ NPT MALE RUN TEE IN 316 ST/ST
6MBT4N – 316 3/8’’ OD x 1/4’’ NPT MALE BRANCH TEE IN 316 ST/ST

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Rev. 5a
7.6 Certificates
Flame Resistant Hose

GOLDENSPIR / 4SP FLAME RESISTANT HYDRAULIC HOSE

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Job No.: 4500972470 Aberdeen, United Kingdom

Baker Oil Tools

 Aberdeen AB2 0ES  United Kingdom  www.bakerhughes.com/bot

Job No.: 4500972470 Aberdeen, United Kingdom

O PERATING AND MAINTENANCE MANUAL

Baker Oil Tools

2 Local Control Functions and Operation of the System 3

3 Detailed Hook-up of the LPO System 5

4 Calibration of the System 6

6 Part Number Identification 16

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How does it work?

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2 Local control functions and operation of the system

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3 Detailed hookup of the LPO system

Connection for the

High pilot Low pilot

Pilot vent to Pilot vent to

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4 Calibration of the system

4.1.1 To calibrate the high pilot:

4.1.2 To calibrate the low pilot:

4.2 Calibration of the LPO in workshop

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Job No.: 4500972470 Aberdeen, United Kingdom Page 7 of 17

4.2.1 To calibrate the high pilot:

4.1.2 To calibrate the low pilot:

High Pilot Low Pilot

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The sensor/pilot is normally installed on a process vessel, process flowline, or in a control

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Pilot base and Spring information

PISTON NUMBER PISTON DIAMETER

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Job No.: 4500972470 Aberdeen, United Kingdom Page 12 of 17

To convert from No. 1 (7/8”) to No. 1 (1 3/8”)

To convert from No. 3 (1/2”) to No. 2 (7/8”)

To convert from No. 5 (1/4”) to No. 4 (3/8”)

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Job No.: 4500972470 Aberdeen, United Kingdom Page 13 of 17

SENSING PISTON RANGE CAPABILITY

Piston / Diameter / Spring / Adjustment range

SENSING ASSEMBLY DIAMETER SPRING ADJUSTABLE

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Velocity Check Valve Datasheet

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