Axiom XH5D, XH5D-HE User Manual

Axiom Technologies LLC

Telephone: [phone]
255 Pennbright Dr., Suite 220 Fax: [phone]
Houston, Texas 77090 www.axiomsafety.com

XH5D/XH5D-HE

USER’S MANUAL

SELF-CONTAINED, DUAL PUMP

WELLHEAD CONTROL PANEL

Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

GENERAL

The XH5D self-contained system is a device designed and built for protecting oil and gas
production wells. It includes a switch-gage to detect high and low pressures as well as hydraulic
interface for fire detection and manual ESD.

The XH5D is self-sufficient and doesn’t need external sources of energy or supply pressure for
keeping a wellhead open and protected. It uses hydraulic fluid for driving the surface and sub­surface valves and it has two separate hand pumps and dump valves for independent control of
the SSV and SCSSV

The detection of High and Low pressures is done by a switch-gage with adjustable contacts for
detecting when the monitored pressure is out of acceptable limits. The switch-gage connects to
an electronic module that indicates High and Low pressure conditions as well as initiates the
shutdown when a pressure alarm is detected. The electronic circuits are fed by a battery module
capable of keeping the system operating for five (5) years.

The XH5D is built to operate exposed to the elements as all hydraulic components are enclosed
in a stainless steel box while the electronic circuits and battery module are enclosed in a separate
compartment inside the stainless steel box. The front of the panel includes the gages and
controls as shown in Fig.1 while the inside components are shown in Fig. 2. The –HE version
also includes additional sealing and a chemical seal to protect the sensing gauge from process
fluids.

“Reset” – “Test”
Switch

Flow Pressure w/
High and Low
Pressure Alarm

LED Indicators:

-High Press. Alarm

-Low Press. Alarm

-Low Battery Alarm

-Auxiliary Alarm

-Telemetry Stdn

-“Heart Beat”
(System OK)

Hydraulic Pump
SCSSV

Hydraulic Pump
“SSV – Pilot”

Fig. 1 XH5 Interface & Controls

“Pilot” Pressure

SSV Actuator
Pressure.

SCSSSV Pressure

“SSV – Pilot”
Pumping Selector

“In Service – ESD”
Selector Valve
(Manual Shutdown)

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

Electronic Compartment

Flow Control Valve (SCSSV Closing Delay Adjustment)

Diaphragm Accumulator
(Pilot Pressure)

Solenoid Valve

Piston Accumulator (SSV)

SSV Dump Valve (SCSSV
Dump Valve directly behind)

Hydraulic Reservoir

Dual Hydraulic Hand Pump

Hydraulic Level Indicator

Pilot Pressure Relief Valve

Hydraulic Filter

Fig. 2 – XH5D-HE Enclosure’s Interior

INSTALLATION – PRELIMINARY STEPS AND TESTS

The XH5D is typically sent with the battery module mounted backwards or in a separate package
for preventing the system from operating while in transit. Also, as needed for meeting shipping
regulations, the device is typically shipped without hydraulic fluid in the reservoir and without
Nitrogen pre-charge in the SSV hydraulic piston accumulator. (The pilot pressure accumulator
uses only 60 psi of Nitrogen pre-charge and considered safe for air transport.)

Before installing, the system is to be inspected to confirm that there is no external damage or
indication of rough handling during shipment.

In case of overseas shipments it is recommended that the XH5D-HE is tested in a work shop near
the final destination to facilitate the commissioning and allow the operators to become familiar
with the unit.

NOTE
It is recommended that the operator becomes familiar with the Hydraulic Schematic
(Appendix “B”) and have a copy handy during the tests described below to better
understand the system’s behavior.

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

To commission the system follow with the steps listed below:

i. Pre-charge 16 CU IN piston accumulator with about 1,000 psi of Nitrogen

ii. Confirm the pre-charge of about with 60 psi of Nitrogen on the 20 CU IN

diaphragm accumulator.

iii. Add hydraulic fluid to the reservoir. Filling is to exceed over 75% full using the

high level mark on the level indicator as 100% reference. (In factory the units are
tested with “Megaflow” ™ AW Hydraulic Oil 32, however, any quality hydraulic
fluid with an AW32 viscocity will operate well.)

iv. Open Electronic Compartment inside the stainless steel box and install battery

module as shown in Appendix “A”. By doing this the electronic circuit becomes
energized and the green LED blinks every second (Heartbeat) to indicate the
electronic circuit is operating without problem.

v. Before pressurizing the hydraulic circuits is recommended that hydraulic fluid is

circulated throughout the system to flush any particle and contaminants that could
be present within the hydraulic lines. With this purpose proceed as follows:

a) Set valve “In Service – ESD” to “ESD”.
b) Set valve “SSV - Pilot” to “Pilot”
c) Pump “Pilot/ SSV” (right side pump) in a fast mode for approximately one

minute while observing the “Pilot” pressure gage (right side of the panel).
This gauge should display “0” psi but the needle oscillates with each pump
strike.

d) Set valve “SSV – Pilot” to “SSV”
e) Again, pump “Pilot/ SSV” (right side pump) in a fast mode for

approximately one minute while observing the “SSV” pressure gauge
(center of the panel). This gauge should stay in “0” psi

f) Pump “SCSSV” (left side pump) in a fast mode for approximately one

minute while observing the “SCSSV” pressure gage (left side of the
panel). This gauge should stay in “0” psi.

vi. Confirm that the plugs on the bulkhead connectors are tight before proceeding

with the following steps.

vii. Set valve “In Service – ESD” to “In Service”.

viii. Set valve “SSV - Pilot” to “Pilot”

ix. Press “Reset” on switch “Test – Reset”.

x. Pump “Pilot/ SSV” (right side pump) while observing the “Pilot” pressure gauge.

Pump until reaching 100 psi. Inspect hydraulic lines to confirm that there is no
leakage.

xi. Pump “SCSSV” pump (left side pump) while observing the “SCSSV” pressure

gauge. Pump until reaching about 10,000 psi. Inspect hydraulic lines to confirm
that there is no leakage. As this test is being done with the SCSSV output
blocked the pressure will rise quickly and the pressure will decrease in about 20 to
30% in a few seconds after the pumping stops. However, after the initial pressure
decrease the pressure should remain stable except for the effects of temperature
changes.

xii. Set valve “SSV - Pilot” into “SSV”

xiii. Pump “SSV - Pilot” pump (right side pump) while observing the “SSV” pressure

gauge. Pump until reaching 3,000 psi. Inspect hydraulic lines to confirm that

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

there is no leakage. It is normal for the pressure to fall about 15% after finishing
the pumping.

xiv. Set valve “In Service – ESD” to “ESD” to return all pressures to zero before

moving the XH5D to the field for installation.

FIELD INSTALLATION

Typically the XH5D is mounted on one or two poles made of 3” pipe. Using two poles is
preferred as it would insure safe mounting even if one of the pipe brackets used for fastening the
panel to the poles would fail. The two poles should have a separation of 10” to 15” (25cm to
38cm) center to center. The pipe brackets connect to the strut channel mounted on the left side
of the panel

Pipe Brackets

Strut Channel

Fig. 3 – XH5D Mounting

With the panel firmly mounted, proceed to connect the field devices as shown on Fig. 4.

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

-1-

Flow-line Sensing

Pressure

(3/8” Tubing)

-2-

Hydraulic pressure to

SSV

(3/8” Tubing)

-3-

Hydraulic pressure to

SCSSV

(1/4” Tubing)

-4-

Hydraulic pressure to

Manual ESD/Fire

Sensor (1/4” Tubing)

-5-

Hydraulic return

from Manual ESD

(3/8” Tubing)

Fig. 4 – Rear view, hydraulic lines connections.

The connection to the ESD station (Connection No. 4) can be also connected to a fire plug
(Included). If the fire plug used does not have a return line, some means are to be used to
prevent hydraulic fluid from reaching the ground. A small amount of hydraulic fluid
(approximately 10 CU IN or 164 CC) will be released in the event of a fire.

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

OPERATION AND ADJUSTMENTS

The operation of the installed panel is as follows:

Starting Production:

1- Set valve “In Service – ESD” to “In Service”
2- Set valve “SSV - Pilot” to “Pilot”.
3- Press “Reset” on switch “Test – Reset”.
4- Pump “Pilot/ SSV” (right side pump) while observing the “Pilot” pressure gauge until

reaching 90 to 100 psi.

5- Pump “SCSSV” (left side pump) while observing the “SCSSV” pressure gauge. Pump

until reaching the pressure necessary to open SCSSV. Do not exceed 12,000 psi.

6- Set valve “SSV - Pilot” into “SSV”.
7- Pump “SSV - Pilot” pump (right side pump) while observing the “SSV” pressure

gauge. Pump until SSV is fully opened plus about 500psi but no less than 1,500psi.
Do not exceed actuator’s pressure rating. It is normal for the pressure to fall about 10%
after finishing the pumping.

8- Check all hydraulic connections (internal and external to the panel) to confirm that

there is no leakage.

9- Adjust High and Low Alarm set point on switch-gage.

Closing SSV:

10- Move High or Low Alarm Set-Point until it touches the gage’s needle. The system

responds closing the SSV. The corresponding LED (High or Low Pressure Alarm)
blinks and the green LED stops blinking. There is no change on pilot pressure but the
SSV pressure goes to cero.

Re-opening the SSV:

11- Press “Reset”. The Alarm LED stops blinking while the green LED (Heartbeat) blinks

for a few seconds and then returns to one flash per second. The pilot pressure goes
down a couple of psi.

12- Pump “Pilot/ SSV” (right side pump) while observing the “Pilot” pressure gauge until

reaching 100 psi.

13- Set valve “SSV - Pilot” into “SSV”.
14- Pump “SSV - Pilot” pump (right side pump) while observing the “SSV” pressure

gauge. Pump until reaching 1,500 psi. It is normal for the pressure to fall about 10%
after finishing the pumping. Do not exceed 3,000 psi.

Initiating ESD (Clothing of the SSV and then SCSSV):

15- Set valve “In Service – ESD” to “ESD”.

Shutdown Delay adjustment for SCSSV:

16- The SCSSV closes only in case of manual ESD and/or by the activation of the fusible

plug.

17- Wh en an ESD is initiated, the “Pilot Pressure” and “SSV Pressure” shown on the front

of the panel go to zero psi in the first one or two seconds. Then after some time delay,
the SCSSV pressure slowly goes down to zero.

18- The time lapsing between the activation of the manual ESD can be adjusted by

adjusting the “Flow Control Valve” (shown on Fig.2, page 3 of this manual).

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

19- Turn knob of “Flow Control Valve” a fraction of a turn in the direction of the clock

pointers to increase time delay and in the opposite direction to reduce it.

20- For initial setting close the “Flow Control Valve“ by turning knob clockwise all the

way and then turning it back four turns.

Re-opening the well after ESD:

21- Repeat steps 1 through 9 of this list. When re-opening the well after ESD, it is

critical the pumping is done in the correct order of PILOT – SCSSV – SSV. The
SCSSV is to be always opened before the SSV

Adjusting High and Low Pressure Alarms:

22- Turn red knob to adjust High pressure Alarm to the desired High Pressure Alarm.

Repeat the same with the black knob to set the Low Pressure Alarm.

HYDRAULIC CIRCUITS

The hydraulic circuits are shown on appendix “B”.

ELECTRONIC SYSTEM

WARNING – EXPLOSION HAZARD

 SUBSTITUTION OF COMPONENTS MAY IMPAIRE

SUITABILITY FOR CLASS 1, DIVISION 2

 DO NOT DISCONNECT EQUIPMENT OR REPLACE

COMPONENTS UNLESS POWER HAS BEEN SWITCHED OFF OR
THE AREA IS KNOWN TO BE NON-HAZARDOUS

By replacing most of the hydraulic logic with electronic circuits, the most failure prone
components are removed and the hydraulic circuit greatly simplified to a few reliable
components. In this way, by having self-diagnostic in the electronics and a simplified hydraulic
system, the XH5D-HE offers a reliability level not seen on any of the typical self-contained
wellhead control panel. Furthermore, if a failure would occur, the diagnostic and correction of
the problem is much simpler because of the simplicity of the hydraulics.

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Axiom Technologies LLC

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

XH5D User’s Manual

Common

Telemetry
Shutdown
Command
from RTU

Shutdown alarm to RTU

End of line ZENER

Fig. 4 – External Alarm Termination Box

When operating under normal conditions (no alarms) the electronic system flashes the green
LED every second (heartbeat) to indicate that the electronic system is “alive” operating without
problems.

If any alarm is detected the green LED stops flashing and the solenoid valve is tripped to
initiate shutdown of the SSV only. The red LED corresponding to the detected alarm starts

flashing and it is latched in such way that even if the alarm condition would go away or a new
alarm would be detected; the first detected alarm only will flash, holding the information for the
operator to see the actual cause of the shutdown. For example, if a High Pressure Alarm would
occur, the corresponding High Pressure Alarm LED will flash and keep on flashing even if the
high pressure alarm goes away and now the needle is touching the Low Pressure contact. The
first detected alarm will keep displaying until the operator presses “Reset”.

A total shutdown or “ESD” (closing of the SSV and SCSSV) would be executed only in the case
of Fire Alarm (fusible plug) and/or Manual Shutdown. The Manual ESD and Fire alarms are
executed bypassing the electronics to maximize reliability.

Once the operator presses “Reset” while the alarm still present, the system resets the solenoid
valve to allow the re-opening of the well and alternatively flashes the green LED and
corresponding alarm red LED, if the alarm still present. The system tolerates the existing alarm
for 30 minutes before re-initiating the shutdown and prevents the system from being left in

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

production while operating in an abnormal condition. Once the pressure alarm clears, only the
green LED remain flashing.

The “Test” function allows the operator to see the last alarm and also confirm that all the
indicator LEDs are working properly. This is, when pressing “Test”, the system respond by
flashing the last detected alarm for about two seconds and then flashes the red LEDs in sequence.

The Telemetry and Auxiliary alarm signals are monitored by the XH5D-HE which is continually
verifying that the End Of Line Zeners (EOL) are connected. If the EOL is no longer connected,
either in the junction box itself or at the end of the cable connecting it to the external alarm, then
the XH5D-HE initiates shutdown and the corresponding LED shows a double blink to indicate
the alarm was caused by a wiring failure and not by an actual alarm. See Appendix “C” for field
wiring detail.

The battery module provides two separate voltages, 3.6 VDC to feed the microcontroller circuits
and 14.4 VDC to operate the solenoid valve. Both voltages are periodically monitored to
confirm the system has the proper battery supply to operate reliably.

If the system detects a low voltage, the green LED and the “Low Battery” red LED alternates
flashing but the system remains in operation. However, if a voltage falls too far down to insure
reliable operation, a shutdown is executed and only the “Low Battery” red LED flashes.

Given the low power consumption of the system it is expected that the operator will be able to
detect the warning signs of low battery and should be able to replace the battery module before it
gets to the point where the system causes shutdown because low battery.

The battery module is to be replaced as soon as the system shows signs of low voltage to insure
the system continues operating reliably. The battery module has an expected life of five years

WARNING!

Do not attempt to recharge the batteries on the battery

module as this may cause an instable condition that may

result in a violent explosion.

Return the spent battery modules to Axiom Technologies or

to any lithium battery recycling facility.

See the instructions shown on Appendix “A” for replacing the battery module.

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

WIRING INTEGRITY

Given the safety requirements associated with the XH5, enhanced self-diagnostics have been
added to insure the integrity of the system and the reliability of the operation.

To this effect, the XH5 monitors the wiring integrity of all alarms circuits including the
High/Low Pressure alarm gauge and the loop integrity to the remote alarms located external to
the XH5 enclosure.

As shown on Fig. 4, the XH5 is shipped with the End of Line Zener connected at the external
alarms input points. When connecting the XH5 to an external alarm device, the End of Line
Zener is to be removed from the Operator Interface Module and connected in parallel with the
external alarm device.

Please note that, when connecting the End of Line Zener, polarity is important for proper
operation. If the End of Line Zener is connected backwards it will cause the corresponding
alarm channel to go into and remain on alarm condition.

If the End of Line Zener is disconnected or the wiring to the external alarm signal would fail,
then the XH5 will read a “wiring failure” where the corresponding alarm LED would double
flash and XH5 shutdown is initiated.

TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES:

Do not open this enclosure unless the area is known free of ignitable mixture of

Battery Module is to be replaced only with Axiom Part No. AT00000001 (Former

Keep tightly closed when in operation.

AT-LBP-36144) battery module

CAUTION!

gases.

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Axiom Technologies LLC XH5D User’s Manual

255 Pennbright Dr., Suite 220, Houston, Texas 77090 Phone [phone]

XH5 - ENVIRONMENTAL SPECIFICATIONS

Temperature range : -40 to +85C
Humidity range : 0 To 95% max., non-condensing
Altitude : 2,000 m. max.
Hazardous Area Classification : Suitable for Class I, Division 2, Groups C & D, Hazardous Locations.

Temp. Code T3C

XH5D - PRESSURE RATINGS

Sensing Pressure : Ranges of up to 20,000 psi max
Solenoid Valve Pressure : 100 psi max. (standard)

XH5D - ELECTRICAL RATINGS

Electrical Source : Dual voltage lithium battery module3.6 & 14.4 VDC
Current consumption : 20 mA max. on 3.6VDC Circuits

0.5 mA (3 A max. pul se) on 14.4VDC Circuits

THIS APPARATUS IS SUITABLE FOR USE IN A CLASS 1,

DIVISION 2, GROUP C, D OR UNCLASSIFIED LOCATIONS

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Rev. Date Description

HYDRAULIC SELF CONTAINED - XH5D

WELLHEAD CONTROL PANEL

BATTERY MODULE INSTALLATION

Date

01

Appendix A - Battery Module Installation

Confirm the area is free of ignitable mixture
of gases and remove cover of electronic
compartment

Sheet

A

lign battery module

with the four mounting

bolts and insert pushing

gently. Confirm the

battery module is

positioned with the

resistors to the left as

shown in the picture.

Tighten spacers by

hand only.

Axiom Technologies

1-May-18

255 Pennbright Dr., Ste 220 - Houston TX 77090 - Ph. 281 931 0907

01 of 01

Rev.

NylonSpacers

Fill / Vent Cap

Sight
Glass

Remote

Shutdown/
Hi Hydr. Accumulator Fusible Plug
Press.
0-5000 N2 Relief

Valve

100 PSI
Dump
Valve

Solenoid

Valve In Service Lo Hydr.

To Surface (Closed) Press.
Actuato

r

ESD Valve 0-160

(Panel-mount)

Reservoir ESD

(Open)

"Pilot" Pressure

Hydraulic

A

ctuato

r

Accumulator

3,000 PSI N2
Max. Pilot SCSSSV

Time Delay
Adjustment

Hi Hydr. Dump
Press. Valve
0-15000
(0-20k Opt.

)

To Sub-Surface
Actuato

r

20,000 PSI Max.

Rev. Dat

e

Descriptio

n

HYDRAULIC SELF CONTAINED - DP

C

WELLHEAD CONTROL PANE

L

SCHEMATI

C

Reference Dwg. No. Sheet Rev. Date

01 of 01 01

APPENDIX "B" - HYDRAULIC SCHEMATIC XH5D

AXIOM TECHNOLOGIES

11-Feb-15

15711 W. Hardy Rd. - Houston TX 77060 - Ph. 281 931 0907

AT-XH5D

1- 4-

5-

2-

6-

3-

WARNING - ELECTRICAL INSTALLATION REQUIREMENTS

XH5D

1 This apparatus is suitable for use in a Class 1, Division 2, Groups C & D or unclassified locations.

Junction Box

2 Electrical parameters to permit selection of appratus for interconnection:

Vmax = 16.8 Volts DC Imax = 20mA on 3.6Volts DC Circuits
La = 100.0 mH (maximum value of inductance that can be connected to the apparatus

intrinisically safe input circuit.)

Ca = 12.6 uF (maximum value of capacitance that can be connected to the apparatus

intrinisically safe input circuit.)

3 Use the following formulas to calculate the allowed capacitance (Ca') and inductance values (La')

for field wiring used in the non-incendive field wiring circuit (Belden 8451 use for Example*):
Note: symbol " < " means less than (3 < 7)

Ca' = C pF/ft X length of wiring loop (ft) < Ca
Example*: Ca' = 33.45 pF/ft X 800 ft = 0.0268 uF < 12.6 uF
La' = L uH/ft X length of wiring loop (ft) < La
Example*: La' = 0.17uH/ft X 800 ft = 136.0 uH < 100.0 mH

4 The associated non-incendive field wiring apparatus shall not be connected in parallel unless

this is permitted by the the associated non-incendive field wiring apparatus approval.

5 This apparatus is approved for connection to simple apparatus, two wire applications such as

"dry" contacts, transistor open collector that would "pull signal to ground", etc.

Polarity requirements: TB2-1 and TB2-2 are positive voltage (3.6 VDC); TB2-3 and TB2-4

are return or ground connection.

"Trouble" Signal to RTU
"Common" to RTU

Field Wiring

"Shutdown" Signal to RTU

Polarity IS
Im

p

ortant!

Blue Wire goes to "Signal"

blue blue

White Wire

g

oes to "Common"

white white

End-Of-line Zener

(

EOZ) on each input

T

y

pical of 2 supplied with XH5

EOZ must be removed and installed

Remote Shutdown Sand Probe

with remote alarm switch as shown

Switch

on channels 1 and 2 of this sheet
MUST BE CONNECTED FOR WIRING
FAILURE ALARM TO GO AWAY!

(

TELEMETRY

)

(

SAND PROBE

)

Reference: Sheet: Rev: Date:

A

pp

endix "C" - XH5D Installation Notes

Axiom Technologies

The XH5 operates with normally open contact and contact closure indicates that an alarm is

p

resent.

Each input sends a pulse of 1 4 V DC t o the alarm switch. If the EOZ is connect e d ( a s it
should), then the voltage is cut down to 7.4VDC (+/- 0.3VDC) and the XH5 accepts this
voltage as a normal c ondition. If the EOZ would be missing or the wiring to the alarm
switch disconnected, then the voltage may ri s e up to about 14VDC which is considered a
"Wiring Failure" and cause shutdown.

The alarm switch ma

y

be located at 3,000 FT or more from the XH5

For supervising field wiri ng, each input channel is provided with a 7.5V "End Of line Zener "
(EOZ) at the XH5's input t e rminals. At the time of installat ion, the EOZ is to be move d t o t he
end of the loop and connected in parallel with t he a larm switch. I f m ore than one switch are
daisy-chained, then the EOZ is to be installed at the very last switch. The EOZ at the end of
the alarm wiring allows the XP7 to confirm the wiring's integrity.

The EOZ must be connected in the c orrect polarity, Blue wire to "Signal" and White wire to
"Common". Connecting the EOZ on a reverse polarity will cause the corresponding channel
to stay on alarm.

Multiple XH5s may share a single alarm switch such as a tank level, ESD station or any "dry
contact" alarm switch.

Telemetry

Interface

AT-XH5D

1 of 1 0

5/1/2018

XH5D Wiring Diagram

Monitored Inputs for

Safety Shutdown System