Replacing two pressure switches with just one!

Case study:

One series 1XSWLL solves the problem of overhead pressure control in the hydraulic power unit of a solar-powered wellhead control panel.

?This section of the wellhead control panel includes the hydraulic power generation needed to operate the valves of the WH for flowing the crude out.

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A hydraulic reservoir provides a sufficient quantity of oil to operate a wellhead. The hydraulic pump is followed by a non-returning valve, to drive the flow to a single direction. There is an accumulator to ensure the hydraulic demand from the valves is achievable and to lead the pump supply quickly. The Pump is developing the pressure of Max. 6000 psi (as required by the customer). This hydraulic pressure operates the valves of the wellhead.

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The old solution used by the customer:

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The customer, a renowned OEM of WHCP, was using two (PSH & PSL) pressure switches to maintain the head pressure between 343-413 bar, per the guidelines by the end user. The pressure switches with a set point of 413 rising pressure would cut off the pump. As the pressure falls to 343 bar, the PSL pressure switch starts the pump. The two pressure switches were used to meet the exact start-stop of the hydraulic pump.

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As the OEM won a big order from their customer for around 162 WHCP, in a very competitive pricing due to stiff competition, they were looking for cost savings without compromising on the quality of the instrumentation.

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UE came forward with the solution by offering One series model 1XSWLL-P20-M201 with a set point programmed to 413 bar on rising pressure and reset when the pressure reached to exactly at 343 bar. This set-reset of the switch was achieved by programming the desired dead band of 70 bar. The 1XSWLL was hooked with a digital input card of Schneider Electric SIL-certified PLC. Refer. ?

The OEM chose to place a trial order of 2 units first to test it with the digital input of the PLC. After finding satisfactory performance, an additional order of 12 units was placed, followed by a large order of 148 units.

The cost savings with 1XSWLL :

-???????? The OEM saved on extra installation costs by using only one pressure switch instead of two.

-???????? The customer saved on extra process connection, related hardware, hydro-testing, test and radiography, related documents, and compliance procedures.

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More benefits:

-???????? The customer was able to get a large LCD indication from the 1XSWLL, more accurate than a mechanical pressure gauge.

-???????? With an unmanned wellhead, their need for routine maintenance and calibration checks also came down with the solid state design of the 1XSWLL.

-???????? The 1XSWLL parameters are protected with password protection, which adds extra security in the unmanned remote location.

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