OBS RPL-X Series User manual

Regulator Pressure Liquid
RPL-X-Series
Installation, operation, and
maintenance manual
Regulators in this series are also commonly known as XHPR-
regulators (engraved on housing)
Ver
Document
Issue date
Made by
Approved by
04
RPL-X-P04-MA-IOM
25.01.2022
Even Høifødt
Bente Ottestad

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
2 av 15
REVISIONS
Rev. Case Id/date Changes
00 25.02.2015 First issue 25th of February 2015
01 20.05.2017 Updated, new product designation
02 19.01.2019 Updated service instruction
03 OBS-P12-220110 Implemented RPL-X21 and Rep Kits
04 OBS-P12-220125 Referred to the engraved product name XHPR on front of this document to ensure
customers this is the same product
TABLE OF CONTENTS
1Introduction ......................................................................................................................................................3
1.1 RPL-X-Series ...........................................................................................................................................3
1.1.1 RPL-X08 ..........................................................................................................................................3
1.1.2 RPL-X14 ..........................................................................................................................................4
1.1.3 RPL-X21 ..........................................................................................................................................5
1.1.4 RPL-X-Fixed ....................................................................................................................................6
2Installation........................................................................................................................................................7
3Start-up ............................................................................................................................................................8
4Operation .........................................................................................................................................................9
5Trouble shooting ............................................................................................................................................10
6Periodic maintenance ....................................................................................................................................10
7Service RPL-X-Series....................................................................................................................................11
7.1 Procedure for change of Inlet Valve ......................................................................................................12
7.2 Procedure for change of Dump Valve ...................................................................................................12
7.3 Spare part list.........................................................................................................................................13
7.3.1 RPL-X14 / RPL-X21 / RPL-X-Fixed ...............................................................................................13
7.3.2 RPL-X08 ........................................................................................................................................15

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
3 av 15
1 INTRODUCTION
Figure 1: RPL-X08/14 Figure 2: RPL-X-Fixed Figure 3: RPL-X21
RPL-X-Series
OBS Technology’s RPL-X (XHPR) series are high performance pressure regulators for controlling pressure up
to 863 bar with AISI 316 and 1035 bar with duplex housing. Depending on internal springs and pressure
sensors the regulators reduce the inlet pressure down to meet required output pressure like 345, 690 and 900
bar. Within the designed flow range, the outlet pressure is kept close to adjusted value. The regulators can
handle a differential pressure up to 300 bar. A variable geared adjustment mechanism incorporated in the
regulator reduces the required operating torque over the operating range.
All regulators in the RPL-X-Series are based on the same principal, the main difference between the regulators
is that they are built for different working pressure ranges.
1.1 RPL-X-SERIES
1.1.1 RPL-X08
The RPL-X08 is a high flow regulator developed for fluid operations. The regulator is designed for 863 to 345 barg
(12.500 to 5000 psi) inlet pressure, and a range from 50 to 690 barg (725 to 10.000 psi) regulated output pressure.

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
4 av 15
Extreme pressure drops across regulators must be controlled to avoid critical flow conditions. Operator should be
fully conversant with this document before attempting to operate regulator.
The valve has an internal bleed valve which offloads pressure if downstream pressure increases due to thermal
expansion or similar. The bleed valve has been set during manufacturing and the actual offload pressure is
recorded in the test certificate for each regulator. The offloading pressure will be approximately 30 barg above set
pressure for HP regulators. For LP regulators the offloading pressure will be approx 20 barg above.
The valve is designed for flow ranges up to 10 lpm during normal operation and intermittent flow up to 30 lpm.
Flow ranges above these values are not recommended but will occur if pressure drop across regulator is not
limited by downstream system (the Cv value of a fully open inlet valve is approximately 0,2).
1.1.2 RPL-X14
The RPL-X14 is an improved version of the RPL-X08 with the same specifications. Below a short description on
performed redesign from RPL-X08(XHPR-08)

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
5 av 15
1.1.3 RPL-X21
The RPL-X21 is a high flow regulator developed for fluid operations. The regulator is designed for 863 to 345 barg
(12.500 to 5000 psi) inlet pressure, and a range from 50 to 690 barg (725 to 10.000 psi) regulated output pressure.
Extreme pressure drops across regulators must be controlled to avoid critical flow conditions. Operator should be
fully conversant with this document before attempting to operate regulator.
The RPL-X21 regulator is another version of the RPL-X14 regulator, Inlet/Outlet ports are extended upon
customer request.

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
6 av 15
1.1.4 RPL-X-Fixed
The RPL-X14-F is a simplified high-pressure reduction valve based on our RPL-X (XHPR) regulators. The
regulator is compatible with the same fluids as the RPL-X (XHPR). The adjustment wheel and geared mechanism
from the XHPR has been removed. No adjustment during operation is possible. The pressure output is pre-set
and fixed by OBS, but the pressure regulation functioning is identical. The spring has been selected for the
required pressure range and compressed according to the outlet pressure into the spring housing. The rest of the
RPL-X14-F is identical with the original RPL-X (XHPR) regulator and work according to the same principles.
Downstream the RPL-X14-F will now receive lower and almost constant pressure, and will operate with less
severe conditions, which will improve its performance and reduce wear.
Like RPL-X (XHPR), the RPL-X14-F has an internal dump valve which offloads pressure if downstream pressure
increases due to thermal expansion or similar. The dump valve has been set during manufacturing and its actual
offload pressure is recorded in the test certificate of the regulator. The offloading pressure will be approximately
25-35 barg above its set pressure. The dumped fluid should be collected in an atmospheric storage tank.
The regulator is designed for the same flow ranges as the RPL-X (XHPR); up to 10 liter/minute during normal
operation and intermittent flow up to 30 liter/minute.
Figure 4: Section View RPL-X14

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
7 av 15
2 INSTALLATION
The function of the RPL-X-series is virtually unaffected by its orientation. The RPL-X-M-versions (Manually
operated) is typically mounted with clamps around the body. Some of the RPL-X-series regulators are available
with actuator.
To mount/dismount regulator and actuator, the wheel with gear (7) must be removed.
First remove cover (2) held by 4x M5x10 screws (1). Then remove plastic cover (3) by using a bent pin. Undo
the M10 nut (4) and lift of disc (5) and wheel (7). Be careful not to lose the key (6) or the plastic disc inside the
wheel. Regulator and actuator can now be removed by undoing M4x20 screws (8) and M5x12 screws (9). The
small gear (13) is mounted on top of actuator with disc (12) and M4x10 screw (10).
Installing is done by the same operations in backwards order. Lock M10 nut with medium strong Loctite
Figure 5: Actuator assembly

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
8 av 15
3 START-UP
The critical part of operating a fluid regulator is the startup sequence due to possible presence of air/gas in the
downstream systems. This may cause very high flows and water hammers. To avoid damaging the regulator the
following procedure shall be employed at start up.
1. Close valve 1 and valve 2 and verify that regulator is set fully CCW (counterclockwise).
2. Turn the regulator handwheel approx. 2 turns CW (clockwise). This will result in 50 to 100 barg output
pressure, but no indication will be visible on PI since valve 1 is closed.
3. Carefully open valve 1 and verify pressure on PI.
4. Continue to open valve 1 fully.
5. Set regulator to correct pressure.
6. Open valve 2 carefully and let downstream system pressurize.
7. The regulator is now set and will keep the pressure at set pressure.
For the RPL-X14-Fixed version, make sure inlet pressure increases stabile and slow up to set working
pressure.
IMPORTANT NOTICE:
The RPL-X series are manufactured to high precision and with tight tolerances and relies on metal-to-
metal sealing in the valve to maintain proper operation. Hence, the cleanliness of connected tubing,
fittings, and other auxiliary equipment as well as the hydraulic fluid is of utmost importance to the function
and reliability of the regulator. Ensure that all connected units and tubing is properly flushed and that the
fluid is filtered and verified clean before it is set in operation.

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
9 av 15
4 OPERATION
The outlet pressure is set by operating the handwheel on top of the regulator.
•CW turns will increase regulated pressure.
•CCW will decrease regulated pressure.
•Increase/decrease regulated pressure can be done manually or by actuator if such is installed.
There are no additional limitations to flow or operation of the valve if the regulator is operated within the parameters
defined as “Normal operation”.
During operation no actions are required. The regulator will keep the pressure at set pressure. High pressure
difference combined with high flow rate must be avoided.
Make sure that P in – P out, do not exceed 300 bars
IMPORTANT NOTICE:
If significant force must be exerted to rotate the adjustment wheel, there may be an
internal damaged. Normally you should be able to rotate the wheel with one hand. Contact
OBS support if necessary, mail contact: [e-mail]

Installation, operation, and maintenance manual
Document:
RPL-X-P04-MA-IOM
RPL-X-P04-MA-IOM
Version:
04
Issue date:
25.01.2022
10 av 15
5 TROUBLE SHOOTING
Symptom / problem
Probable cause.
Action
Regulator show
unstable regulating
characteristic
Pressure sensor damaged. Replace Pressure sensor.
Leaking to return line Dump valve damaged.
- Dump valve may be damaged due to
contamination.
- Dump valve may be damaged due to
wrongful operation. Downstream
system shall NOT be bled down
through the regulator, but by
separate bleed valves in system.
O-rings damaged.
- If O-rings get damaged quickly after
operation start this is a sign that the
fluid is not compatible with the O-ring
material.
Replace pressure sensor complete
with integrated Dump valve.
- Verify fluid cleanliness in the system.
- Verify correct operational procedures
and operation.
Replace O-rings.
- Verify fluid and material compatibility.
Pressure build up in
downstream system
Leakage across Inlet valve.
- Inlet valve may be damaged due to
contamination.
- Inlet valve may be damaged due to
wrongful operation.
Replace Inlet valve.
- Verify fluid cleanliness in the system.
- Start up and operation procedure
must be followed.
If above actions don’t fix the problem or for any other issues, the regulator should be returned to vendor for
service/refurbishment.
6 PERIODIC MAINTENANCE
All maintenance of the regulator should be performed by qualified maintenance personnel. Any maintenance not
performed, or executed by unqualified personnel, may void manufacturer guaranty and/or reduce system
integrity and/or lead to damage of downstream system.