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)
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Issue date
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RPL-X-P04-MA-IOM
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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

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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.

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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)

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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.

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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

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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

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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.

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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]

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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.

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Interval
Recommended maintenance
Weekly
Inspect connection points and downstream pressure.
Watch for pressure build up or leakage.
Listen for leakage across return line.
2 years
Change O-rings in the Pressure sensor.
(WOCS and other systems with high operation frequencies)
3 years
Change O-rings in the Pressure sensor.
(HPU and other static systems)
3-5 years
Full service: Replacement of Inlet Valve and Dump Valve and all O-rings.
If there are any concerns or no qualified personnel at site, we recommend that each RPL-X unit in operational
use should be sent to OBS for maintenance at least every third year. OBS have qualified offshore personnel
and are able to perform service on site if necessary.
Mail contact: [e-mail].
Full service at OBS will include the following steps:
Service tasks
Internal procedure
Inspection, control prior to disassembly
OBS-P06-KA-000190
Maintenance incl. complete disassembly, cleaning and
inspection of all parts, replacement of all O-rings. If Inlet Valve
and Dump Valve are worn, we also replace these parts.
OBS-P06-KA-000190
OBS-P06-KA-000157
Re-Assembly
OBS-P06-KM-000206
Final test RPL-X-regulator (functional testing in the test rig,
functionality due to customers requested working pressure.)
OBS-P06-KC-000207
Fill in Service Report
OBS-P06-KA-000190
7 SERVICE RPL-X-SERIES
The RPL-X-Series are based on the same principal, Rep Kit service procedure cover each RPL-X-series
regulator. Some may vary, depending on which RPL-X model in use.

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7.1 PROCEDURE FOR CHANGE OF INLET VALVE
7.2 PROCEDURE FOR CHANGE OF DUMP VALVE
•1 refers to Spare Part 01-00432 Valve Seat with Guide,
2 refers to Spare Part 01-00438 Valve Seat with Guide and
Filter.
•The system must be without pressure, and all valves upstream/downstream
to the regulator must be closed.
•Make sure to follow local procedures if necessary.
•Remove cap by using a 5mm hex-key.
•Remove Spring
•Inspect O-ring, replace if damaged. Lubricate threads with DX paste if
necessary.
•Pull out Valve Body
•Pull out Valve Seat, use special tool to avoid damaging the Valve Seat.
•Position the Valve Seat, push the Valve seat into the Pressure Housing by
using you finger or special tool. Make sure not damaging the Valve seat
while assembling. Holes in Valve seat must be placed 90% across the
inlet/outlet ports.
•Insert Valve Body into Valve Seat
•Insert Spring
•Assemble the Cap into Pressure Housing, make sure the Spring is in
position, if friction reassemble for inspection.
•Lubricate threads with Molykote DX paste
•Lubricate all O-rings with Molykote 111
•
The system must be without pressure, and all valves upstream/downstream to the
regulator must be closed
•Make sure to follow local procedures if necessary
•Split the regulator, separate HP housing/Spring Housing
•Disassemble Ring using a special tool
•Pull out O-ring’s stack with Dump valve.
•Visually inspect O-rings and rings, change parts if damaged.
•Insert rings and O-rings, according to drawing.
•Use the same Calibration bolt, assemble Guide Ring. Sleeve (10-01668) enters
assembled Dump Valve. Insert this into the Piston Guide (10-01669).
•Assemble complete Dump Valve into High Pressure Housing, tightening torque
40Nm.
•Lubricate threads with Molykote DX paste.
•Lubricate all O-rings with Molykote 111
•Calibration of “dead band” by tuning the calibration bolt:
Clockwise = less “dead band”
Counterclockwise = Increasing “dead band”

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7.3 SPARE PART LIST
7.3.1 RPL-X14 / RPL-X21 / RPL-X-Fixed
OBS Product Code regulator
RPL-X14-F-S-P690
RPL-X14-M-S-P370
RPL-X14-M-SP690
RPL-X14-M-D-P900
RPL-X21-F-S-P690
RPL-X21-M-S-P370
RPL-X21-M-S-P690
QPN: 70-00001
1
1
Q. PN:60-00055
101-00432 Valve Seat w/guide Sub-assembly
110-01706 Valve Body Titanium Gr.5
101-00486 Dump Valve kit 370/690 Sub-assembly
1
24-00021
Q. PN:60-00056
101-00468 Valve Seat w/guide & filter Sub-assembly
110-01706 Valve Body Titanium Gr.5
101-00486 Dump Valve kit 370/690 Sub-assembly
1
24-00021
Q. PN:60-00057
101-00432 Valve Seat w/guide Sub-assembly
110-01706 Valve Body Titanium Gr.5
101-00487 Dump Valve kit 900 Sub-assembly
1
24-00022
Q. PN:60-00058
101-00468 Valve Seat w/guide & filter Sub-assembly
110-01706 Valve Body Titanium Gr.5
101-00487 Dump Valve kit 900 Sub-assembly
1
24-00022
Q. PN:60-00017
101-00432 Valve Seat w/guide Sub-assembly
110-01706 Valve Body Titanium Gr.5
129C00675 O-ring HNBR 90 Shore A, black
Q. PN:60-00053
101-00468 Valve Seat w/guide & filter Sub-assembly
110-01706 Valve Body Titanium Gr.5
129C00675 O-ring HNBR 90 Shore A, black
Q. PN:60-00020
101-00486 Dump Valve kit 370/690 Sub-assembly
529C01082 O-ring HNBR 90 Shore A, black
Q. PN:60-00022
101-00487 Dump Valve kit 900 Sub-assembly
529C00875 O-ring HNBR 90 Shore A, black
RPL-X14 370/690 Complete rep kit (RK1-IF/RK4/SSK1)
Service/overhaul of RPL-X14 or RPL-X21 regulator
Overhaul incl. replacement of inlet valve, dump valve and soft sealings, calibration and test.
Doc. incl: COC and test certificate
Service report
RPL-X14 370/690 Complete rep kit (RK1-NF/RK4/SSK1)
XHPR-14 SSK-1 SOFT SEAL KIT FOR 370/690 BARG (SAME AS FOR XHPR-08)
XHPR-14 SSK-1 SOFT SEAL KIT FOR 370/690 BARG (SAME AS FOR XHPR-08)
RPL-X14 900Barg Complete rep kit (RK1-NF/RK5/SSK2)
XHPR-14 SSK-2 SOFT SEAL KIT FOR 900 BARG
RPL-X14 900Barg Complete rep kit (RK1-IF/RK5/SSK2)
XHPR-14 SSK-2 SOFT SEAL KIT FOR 900 BARG
XHPR-14 RK1 INLET REP KIT (-NF SAME AS FOR XHPR-08)
XHPR-14 RK1 INLET REP KIT -IF (Swith internal filter)
XHPR-14 RK4 DUMP VALVE KIT FOR 370/690 BARG
XHPR-14 RK5 DUMP VALVE KIT FOR 900 BARG

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Q. PN:24-00021
129C00675 O-ring HNBR 90 Shore A, black
529C01082 O-ring HNBR 90 Shore A, black
129C01400 O-ring HNBR 90 Shore A, black
129K02900 O-ring HNBR 90 Shore A, black
Q. PN:24-00022
129C00675 O-ring HNBR 90 Shore A, black
529C00875 O-ring HNBR 90 Shore A, black
129C01400 O-ring HNBR 90 Shore A, black
129K02900 O-ring HNBR 90 Shore A, black
Q. PN:60-00035
1
10-01809 Dump Tool AISI 316L
Q. PN:60-00037 XHPR-14 CALIBRATION BOLT
1
01-00476 Calibration Bolt X14 with screw Sub-assembly
Q. PN:60-00034
XHPR-14 GUIDE RINGS FOR SPRING SLEEVE (SAME AS FOR XHPR-08)
225-00017 Guide Rings Turcon (length: 115mm x 2)
Q. PN:60-00033 XHPR-14 GUIDE RINGS FOR DUMP VALVE
125-00017L061 Guide Ring Turcon (length: 61,5mm)
125-00017L045 Guide Ring Turcon (length: 45mm)
XHPR-14 DUMP TOOL (SAME AS FOR XHPR-08)
XHPR-14 SSK-1 SOFT SEAL KIT FOR 370/690 BARG (SAME AS FOR XHPR-08)
XHPR-14 SSK-2 SOFT SEAL KIT FOR 900 BARG

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7.3.2 RPL-X08
OBS Product Code regulator
RPL-X08-M-S-P370
RPL-X08-M-S-P690
RPL-X08-M-D-P900
Q. PN:60-00017
101-00432 Valve Seat w/guide Sub-assembly
110-01706 Valve Body Titanium Gr.5
129C00675 O-ring HNBR 90 Shore A, black
Q. PN:60-00018
110-02280 Sleeve AISI 316L
110-01667 Valve body 22 Cr. Duplex
110-02312 Dump X-08 AISI 316L
114-00174 Spring SS2331
Q. PN:60-00019 XHPR-08 RK-3 DUMP VALVE KIT FOR 900 BARG
110-02280 Sleeve AISI 316L
110-01667 Valve body 22 Cr. Duplex
110-01842 Piston AISI 316L
114-00174 Spring SS2331
Q. PN:24-00021
XHPR-08 SSK-1 SOFT SEAL KIT FOR 370/690 BARG (SAME AS FOR XHPR-14)
129C00675 O-ring HNBR 90 Shore A, black
529C01082 O-ring HNBR 90 Shore A, black
129C01400 O-ring HNBR 90 Shore A, black
129K02900 O-ring HNBR 90 Shore A, black
Q. PN:24-00022
129C00675 O-ring HNBR 90 Shore A, black
529C00875 O-ring HNBR 90 Shore A, black
129C01400 O-ring HNBR 90 Shore A, black
129K02900 O-ring HNBR 90 Shore A, black
Q. PN:60-00035
XHPR-08 DUMP TOOL (SAME AS FOR XHPR-14)
110-01809 Dump Tool AISI 316L
Q. PN:60-00036
1
01-00475
Calibration Bolt X08 with screw
Sub-assembly
Q. PN:60-00034
XHPR-08 GUIDE RINGS FOR SPRING SLEEVE (SAME AS FOR XHPR-14)
225-00017 Guide Rings Turcon (length: 115mm
x 2)
Q. PN:60-00032
125-00017L061 Guide Ring Turcon (length: 61mm)
125-00017L062 Guide Ring Turcon (length: 62mm)
XHPR-08 RK-1 INLET COMPLETE REP KIT (SAME AS FOR XHPR-14)
XHPR-08 RK-2 DUMP VALVE KIT FOR 370/690 BARG
XHPR-08 SSK-2 SOFT SEAL KIT FOR 900 BARG (SAME AS FOR XHPR-14)
XHPR-08 CALIBRATION BOLT
XHPR-08 GUIDE RINGS FOR DUMP VALVE