Bdmi SM-6013 1 PDF

No: SM-6013
Sensor Unit
Date: 7-28-08
Basic Design and Maintenance Service Manual
Revision: C
Halliburton ESPHL Sensor Unit
Table of Contents
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Design Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly and Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Suffix Code Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ESPHL Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bill of Material (Base No. 41779) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Bill of Material (Base No. 41779) Indicating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ESPHL Controller High Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Bill of Material (Base No. 45429) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bill of Material (Base No. 45429) Indicating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Selection Guide for Spring and Piston Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Recommendation for Reducing Effects of Pressure Pulsations. . . . . . . . . . . . . . . . . . . . . . . . . . 21
Indicating ESP Range Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
J-Bolt Mounting Block Hold-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Mounting Base for Controller Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Copy is uncontrolled.
These instructions describe results from the use of Halliburton equipment, but such results are not guaranteed. Operation of equipment is subject to mechanical limitations and
Halliburton shall only be liable for merchandise and service as set forth in its general terms and contract.
© 2008 Halliburton
Page 1 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Definitions
1. Dead Band—The difference in pressure between the sensor's set point
(where the sensor blocks and bleeds) and reset point (where the sensor
goes back in service). The deadband is usually given as a percentage of
the maximum range. For example, the deadband of the ESP is 5%. To
calculate the deadband in terms of pressure, multiply the maximum
pressure range by 0.05. If a 41046-122 is used, the maximum pressure
range is 2000 and 2000 × 0.05 = 100 psi maximum. The actual
deadband should be less than this number across the range of the sensor.
2. NACE Standard MR-01-75/ISO 15156—National Association of
Corrosion Engineers' Specification which details materials and
hardnesses to be used in H2S service.
3. Pressure
a. Control Pressure—Regulated pressure used to control an actuator.
b. Instrument Pressure (Same as Pilot Pressure)—Regulated
pressure which is used through sensors and relays (normally 30 to
60 psi).
c. Sensing Pressure—The wellhead, flowline, vessel, etc. pressure
which is to be sensed.
d. Working Pressure—The maximum working pressure is the
maximum pressure which may be applied to the sensor without
danger or damage to the sensor. It normally far exceeds the range of
the sensor.
4. Relay—A device which controls a high pressure with a small pressure.
This device blocks control pressure and fast bleeds the actuator at the
command of sensors. The relay may be programmed either as a manual
or automatic reset. This type relay is required in a high/low shut-in
system with sensors which do not have manual lockouts.
5. Repeatability—The rating of a sensor which describes how accurately
it will repeat a given set point. A sensor may trip at a pressure slightly
higher or lower than the set point. The amount of variation is usually
given as a percentage of set point. For example, the repeatability of the
ESP is 3%. To calculate the repeatability in terms of pressure, multiply
the set pressure by 0.03. Now using this number, add it to the set point
for the maximum; subtract it from the set point for the minimum. If a
41046-122 is set at 1000 psi, the repeatability is 1000 × 0.03 = 30 psi.
Therefore, the trip point could vary between 970 psi (1000 – 30) and
1030 psi (1000 + 30).
Page 2 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
6. Sensing Range—The adjustable pressure range over which the sensor

is recommended to function. The sensor may be set to trip on high or
low at any point within this recommended range.
7. Sensor (or “Pilot”)—A device which detects an abnormal operating
condition and transmits a signal to perform a specific shutdown or
blowdown function. Halliburton Axelson® pressure sensors are 3-way
block and bleed valves which may be programmed as a high or low
sensor. There are many other types of sensors such as liquid level,
temperature, flow, etc.
8. Set Point or Trip Point—The set point is the pressure at which the
sensor shifts the control valve (the stem of the sensor) from the in-
service position to the block and bleed position. When a sensor is
connected as a low sensor, the set point is reached by a decrease in
sensing pressure from normal working pressures. When connected as a
high sensor, the set point is reached by increasing the sensing pressure.
Page 3 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Design Overview
The ESPHL Sensor Unit is used with safety valve installations to provide
automatic opening and closing control for safety valves at preset pressure
conditions. The Halliburton ESPHL Sensor Unit provides a means of
mounting two sensors in series to perform a “High - Low” PSHL function.
It also provides a single mounting point. A variety of ESP sensors may be
mounted on the control block. Sensors adaptable are the diaphragm, high
flow, or standard. The mounting base has a maximum working pressure of
10,000 psi and a test pressure of 15,000 psi. It is available in carbon steel
and stainless steel and has 1/2-in. NPT female mounting connections.
Low High
A
Exhaust
1/4-18 N.P.T. C
Exhaust Outlet
Inlet 1/4-18 N.P.T.
1/4-18 N.P.T. 1/4-18 N.P.T.
C B
B
Figure 1: ESP Sensors
Page 4 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Application
Use the ESPHL to mount two sensors in a series to perform a PSHL
function. The sensor may be mounted on any pressure-containing device.
The assembly has two optional test nipples, the male-to-female (40020)
with 1/2-in. NPT connections or a male-to-male test nipple (40021) with
1/2-in. NPT connections. Both nipples are equipped with 1/4-in. NPT test
port and pipe plug.
50-250
30-60 PSI
PSI
Relay
ESPHL
Flow SSV
Safety Valve
Figure 2: Typical Application for ESPHL
30-60
PSI
ESPHL
50-250
PSI
Relay
LSH ESPHL
Separator Flow
SSV
Safety Valve
Figure 3: Application of ESPHL in Series
Page 5 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Operation
The ESPHL Sensor Unit provides a means of directing flowline pressure to
sensing ports of two sensors. The unit will block and bleed instrument
pressure at a predetermined “High” or “Low” pressure setting to cause
downstream safety components to react as programmed. The operation of
individual sensors is given in detail by their respective service manuals.
Installation
The ESPHL is designed to mount on a vessel or flowline in a vertical
position; however, orientation is not critical. Connect the instrument supply
to the inlet (Port B) of the low pressure sensor and outlet (Port C), of high
pressure sensor to downstream safety components.
50-250
30-60 PSI
Low 3 High 2 PSI
Relay
ESPHL
5
A
A 4
Exhaust Flow SSV
1/4-18 N.P.T. C Safety Valve
Exhaust Outlet
Inlet 1/4-18 N.P.T.
1/4-18 N.P.T. 1/4-18 N.P.T. 30-60
C B PSI
B
ESPHL
50-250
PSI
Relay
1
LSH ESPHL
Separator Flow
SSV
Safety Valve
Figure 4: Installation
Page 6 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Disassembly and Assembly Instructions

Tools required:
• two 12-in. adjustable wrenches

• 6-in. adjustable wrench
• Teflon tape
• tubing cutter
• tubing bender
Assembly Instructions
Note Refer to Figure 6 on page 9 for detail numbers.
1. Install the high and low pressure sensor in the top 1/2-in. female
connections.
2. Apply Teflon tape or pipe dope to the 1/2-in. NPT mounting
connection. Apply only to the male threads. Do not lap the Teflon tape
over the end of the threads. Do not apply pipe dope to the female
threads of the block. Sensors have small orifices than can be blocked
with contaminants.
3. Mount the low pressure sensor (3) in the left-hand connection of the
mounting block with the instrument pressure inlet (Port B) pointing
outward. (Location is only by convention.)
4. Install the high-pressure sensor (2) in the right-hand block connection
with the instrument inlet (Port A) pointing inward and outlet (Port C)
pointing outward.
5. Install the tubing fittings (4) pointing upward as shown in Figure 6 on
page 9.
Page 7 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
6. Install the tubing (5). Ensure that the low-pressure sensor’s outlet
(Port C) is connected to the high-pressure sensor’s inlet (Port A).
Note The tubing can be stainless, copper, or plastic. If plastic tubing is

used, it will act as a fusible link and will shut the system in if burned away.
Do not plug the unused port of either ESP sensor.
The position of the high- or low-pressure sensors is not critical, as long as

the outlet of one sensor is connected to the inlet of the other sensor.
In cases where a relay is installed on an ESPHL sensor unit for manual

start-up, bypass the low sensor only. Reconnect the tubing lines as shown in
Figure 5.
Supply Actuator
Pilot
PSH PSL System
Flowline
Figure 5: Sensor Bypass Schematic
Page 8 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Low 3 High 2
5
A
A 4
Exhaust
1/4-18 N.P.T. C
Exhaust Outlet
Inlet 1/4-18 N.P.T.
1/4-18 N.P.T. 1/4-18 N.P.T.
C B
B
Figure 6: ESP Sensors Shown
Page 9 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Tests
1. If the ESPHL sensor unit is installed on a flowline as shown in Figure 7,
close Valve 2 tightly, and slowly loosen the 1/4-in. pipe plug mounted
in the tested nipple.
CAUTION Line pressure is trapped between the sensor’s inlet and Valve 2. The plug
must be loosened slowly and all pressure dissipated to zero before final
removal of the 1/4-in. plug.
Low 3 High 2
5
A
A 4
Exhaust
Gauge
1/4-18 N.P.T. C #2
Inlet Exhaust
1/4-18 N.P.T. 1/4-18 N.P.T. Outlet
C B 1/4-18 N.P.T.
B
1
Valve #1
Hyd. Pump
0-10,000
PSI Valve # 2
Gauge
#1
Flow Line
Figure 7: Test Manifold for “ESPHL”

2. If the Valve 2 is leaking, bleed flowline pressure to zero and replace
Valve 2.
Page 10 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
3. Install the hydrostatic pump connection with the test gauge in the 1/4-
in. NPT connection of the test nipple.
Note Test pressure should be changed slowly to ensure accuracy of

pressure settings.
4. To test the low-pressure setting of the PSL sensor (3) close the pump
bleed Valve 1, and increase sensing pressure until instrument pressure
shows on Gauge 2.
5. Now very slowly open Valve 1 and bleed sensing pressure until the
instrument pressure at Gauge 2 drops to zero. Close Valve 1
immediately. Read Gauge 1. Gauge 1 represents the low-pressure
setting of the sensor.
6. Repeat Steps 4 and 5 several times to ensure accuracy of the setting.
Note If low-pressure adjustments are required, see the service manual for
the individual sensor.
7. To test the high-pressure setting of the PSH sensor (2), close Valve 1
and increase the sensing pressure until Gauge 2 shows instrument
pressure.
8. Now very slowly increase pressure until Gauge 2 drops to zero. Read
Gauge 1. Gauge 1 represents the high-pressure setting.
9. Repeat Steps 7 and 8 several times to ensure accuracy of the setting.
Note If high-pressure adjustments are required, see the service manual

for the individual sensor.
Recommended Preventive Maintenance

Cycle test once a month or more often as service dictates. Disassemble,
inspect, clean, and replace the o-rings semi-annually or more often if
service dictates.
Page 11 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Suffix Code Chart

1st Digit 2nd Digit 3rd Digit 4th Digit 5th Digit 6th Digit 7th Digit
Hi Pressure Sensor Lo Pressure Sensor
Seals and Seals and Fitting

ASM Base No. Pistons Spring Piston Spring Tubing Base Manufacturer
41779-XXXXXX 0 None 0 None 0 None 0 None ( ) Any
ESPHL - STD Manufacturer
1 Viton Seals 1 41047 Light 1 Viton Seals 1 41047 Light 1 Aluminum 1 Steel P = Parker CPI
45429-XXXXXX 1 1/8 Piston Steel 1 1/8 Piston Steel (Standard)
ESPHL - HFR (Orange) (Orange)
2 Viton Seals 2 41048 Heavy 2 Viton Seals 2 41048 Heavy 2 Copper 2 Stainless Steel S = Swagelock
45879-XXXXXX
1/2 Piston Steel (Blue) 1/2 Piston Steel (Blue)
ESPHL - STD IND
3 Viton Seals 3 41049 Light 3 Viton Seals 3 41049 Light 3 Stainless Steel 3 In-Service G = Gyrolock
45880-XXXXXX 1/4 Piston Inconel 1/4 Piston Inconel Test Valve
ESPHL - HFR IND (Yellow) (Yellow)
4 Nitrile Seals 4 41050 Heavy 4 Nitrile Seals 4 41050 Heavy 4 Plastic
1 1/8 Piston Inconel 1 1/8 Piston Inconel
(Green) (Green)
5 Nitrile Seals 5 46301 Ultra- 5 Nitrile Seals 5 46301 Ultra-
1/2 Piston Light Steel 1/2 Piston Light Steel
(White) (White)
6 Nitrile Seals 6 Nitrile Seals
1/4 Piston 1/4 Piston
7 Neoprene Seals 7 Neoprene Seals
1 1/8 Piston 1 1/8 Piston
A EPDM Seals A EPDM Seals
1 1/8 Piston 1 1/8 Piston
B EPDM Seals B EPDM Seals
C EPDM Seals C EPDM Seals
D Nitrile Seals D Nitrile Seals
2-in. 2-in.
Diaphragm Diaphragm
E Viton Seals E Viton Seals
2-in. 2-in.
Diaphragm Diaphragm
F EPDM Seals F EPDM Seals
2-in. 2-in.
Diaphragm Diaphragm
Page 12 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
1st Digit 2nd Digit 3rd Digit 4th Digit 5th Digit 6th Digit 7th Digit
Hi Pressure Sensor Lo Pressure Sensor
Seals and Seals and Fitting

ASM Base No. Pistons Spring Piston Spring Tubing Base Manufacturer
G Nitrile Seals G Nitrile Seals
4-in. 4-in.
Diaphragm Diaphragm
H Viton Seals H Viton Seals
4-in. 4-in.
Diaphragm Diaphragm
J EPDM Seals J EPDM Seals
4-in. 4-in.
Diaphragm Diaphragm
Indicating scales other than psi may be ordered by adding “G” for Bar G or
“K” for Kg/cm2 as the eighth position in the suffix code. If the fitting
manufacturer is “Any Manufacturer,” insert a zero.
See “Selection Guide for Spring and Piston Sizes” on page 20.
Page 13 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
ESPHL Controller—Standard
Technical Data
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All Corrosion Resistant
Instrument Pressure (Recommended) (Gas) . . . 30 to 50 psi
Instrument Pressure (Maximum) (Gas) . . . . . . . 200 psi
Sensing Pressure Range (Liquid or Gas) . . . . . . 0.25 to 10,000 psi
The ESPHL Controller is designed for use with Safety Valve installations
providing automatic control for the opening and closing of Safety Valves at
preset pressure conditions. The indicating ESP sensors give a visual
indication of high- and low-pressure set points.
Low 3 High 2 Low 3 High 2
5 5
13 1/4" 13 1/4"
336.5 mm 336.5 mm
As Shown As Shown
14" Max. 14" Max.
355.6 mm 355.6 mm
Exhaust 4 Exhaust 4
1/4-18 N.P.T. 1/4-18 N.P.T.
Outlet
ESP ESP
Exhaust Outlet Diaphragm

Spri ng
Exhaust
Diaphragm
Spring
Inlet Inlet
PSI / Tur n PSI / Tur n
1/4-18 N.P.T. 1/4-18 N.P.T.

1/4-18 N.P.T. 1/4-18 N.P.T. 1/4-18 N.P.T. 1/4-18 N.P.T.
1 1
Optional Optional
Test Test
Nipple Nipple
8"(203.2 mm) 8"(203.2 mm)
Standard Indicating
Figure 8
Page 14 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Bill of Material (Base No. 41779) Standard

See “Suffix Code Chart” on page 12.
Index Part No. Part Name Req’d Material
1 28168 Base (Standard) 1 Carbon Steel

1 28443 Base (Stainless Steel) 1 316 Stainless Steel and Cold
Drawn
2 41046-XXX ESP Sensor (High) 1 See SM-6009.
3 41046-XXX ESP Sensor (Low) 1 See SM-6009.
4 50474 Elbow (Use with Aluminum and Copper 2 Brass
Tubing)
4 52700 Elbow (Use with Stainless Steel Tubing) 2 Stainless Steel
4 54308 Elbow (Use with Plastic Tubing) 2 Brass (Poly-Flo)
5 50853 Tubing 1 ft Aluminum
5 50135 Tubing 1 ft Copper
5 51855 Tubing 1 ft Stainless Steel (3XX Series)
5 54318 Tubing 1 ft Plastic
*6 29067 Information Plate 1 Non-tear film
Optional Parts
40020 Test Nipple Assembly, Male to Female 1 316 Stainless Steel

40021 Test Nipple Assembly, Male to Male 1 316 Stainless Steel
55400 or 70B45 Vent Closure - Bug Screen 2 Plastic and Silicone / Metal and
Rubber
* Index 6 to be used only when two sensors are hooked up in series.
Page 15 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Bill of Material (Base No. 45879) Standard Indicating


1 28443 Base (Stainless Steel) 1 316 Stainless Steel Annealed and
Cold Drawn
2 44504-XXX3 ESP Sensor (High) 1 See SM-6009.
3 44504-XXX3 ESP Sensor (Low) 1 See SM-6009.
Tubing)
Optional Parts

55400 or Vent Closure - Bug Screen 2 Plastic and Silicone / Metal and
70B45 Rubber
Page 16 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
ESPHL Controller High Flow Rate
Technical Data
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All Corrosion Resistant
Instrument Pressure (Recommended) (Gas) . . . . . . 30 to 50 psi
Instrument Pressure (Maximum) (Liquid or Gas) . . 600 psi (1,480 psi upon request)
Sensing Pressure Range (Liquid or Gas) . . . . . . . . . 0.25 to 10,000 psi
The ESPHL Controller is designed for use with Safety Valve installations
providing automatic control for the opening and closing of Safety Valves at
preset pressure conditions. The indicating ESP sensors give a visual
indication of high- and low-pressure set points.
Low 3 High 2 Low 3 High 2
5 5
13 1/4" 13 1/4"
336.5 mm 336.5 mm
As Shown As Shown
14" Max. 14" Max.
355.6 mm 355.6 mm
Exhaust 4 Exhaust 4
1/4-18 N.P.T. 1/4-18 N.P.T.
Outlet
ESP ESP
Exhaust Outlet Diaphragm

Spri ng
Exhaust
Diaphragm
Spring
Inlet Inlet
PSI / Tur n PSI / Tur n
1/4-18 N.P.T. 1/4-18 N.P.T.

1/4-18 N.P.T. 1/4-18 N.P.T. 1/4-18 N.P.T. 1/4-18 N.P.T.
1 1
Optional Optional
Test Test
Nipple Nipple
8"(203.2 mm) 8"(203.2 mm)
Standard Indicating
Figure 9
Page 17 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Bill of Material (Base No. 45429) HFR Standard


Drawn
Tubing)
Optional Parts

55400 or Vent Closure - Bug Screen 2 Plastic and Silicone / Steel and
70B45 Rubber
Page 18 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Bill of Material (Base No. 45880) HFR Indicating


Drawn
4 50474 Elbow (Use with Aluminum and 2 Brass

Copper Tubing)
4 52700 Elbow (Use with Stainless Steel 2 Stainless Steel

Tubing)
Optional Parts
55400 or Vent Closure - Bug Screen 2 Plastic and Silicone / Steel and
70B45 Rubber
Page 19 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Selection Guide for Spring and Piston Sizes

Sensing Pressure Range Sensing Unit Spring
0.25 to 5.3 psi 4-in. Diaphragm Ultra-Light

0.50 to 20 psi 4-in. Diaphragm Light
4 to 40 psi 4-in. Diaphragm Heavy
0.50 to 20 psi 2-in. Diaphragm Ultra-Light

1 to 100 psi 2-in. Diaphragm Light
2 to 200 psi 2-in. Diaphragm Heavy
1 to 60 psi 1 1/8-in. Piston Ultra-Light

10 to 125 psi 1 1/8-in. Piston Light
75 to 550 psi 1 1/8-in. Piston Heavy
300 to 1,000 psi 1/2-in. Piston Light

500 to 2,000 psi 1/2-in. Piston Heavy
1,900 to 5,000 psi 1/4-in. Piston Light

4,900 to 10,000 psi 1/4-in. Piston Heavy
10,000 to 20,000 psi* 3/16-in. Piston Heavy
* Sensing assembly has a high-pressure autoclave-type connection that

requires a special mounting block (special order only).
Page 20 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Recommendation for Reducing Effects of Pressure

Pulsations
In many applications pressure sensors are subjected to pressure pulsations in the
flowline which can cause excessive wear and false trip points. The pulsations
are short-term pressure spikes caused by pumps, compressors, or other pipeline
equipment. One common way to reduce these pressure spikes is by installing a
dampening device such as a gauge snubber in the sensing line between the
flowline and the sensing device such as a pressure gauge. Gauge snubbers are
commonly designed using either very small orifices or sintered metal elements.
These types usually provide too much restriction and cause excessive response
delays and are subject to frequent plugging resulting in system failures.
The Ray Pressure Snubber may be used to limit pulsation problems because of
its unique design. It provides dampening by restricting flow between a piston
and a cylinder. The piston is allowed to float, causing movement between the
piston and cylinder with each pulsation. This provides a cleaning action which
assists in keeping the flow passage open. Another advantage with this snubber is
that three pistons are provided with each snubber providing compensation for
different viscosities and dampening rates needed. The piston selections are as
follows:
Largest Piston (#3) - For gas or severe pulsations

Medium Piston (#2) - For most gas or light liquids
Small Piston (#02) - For heavy liquids
Availability 1/4-in. NPT Brass - 5,000 psi max. WP - Part No. 56008-401
1/4-in. NPT 316SS - 15,000 psi max. WP - Part No. 56008-403
1/2-in. NPT 316SS - 15,000 psi max. WP - Part No. 56008-803
Piston Stop
Piston
Cylinder
Figure 10: Ray Pressure Snubber
Page 21 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Recommended Locations
For Pressure Snubbers
With ESP Or ECS Sensors
H H
O O
L L
H H
O O
L L
1/2
1/4
1/2
Pressure
Or Snubbers
Sensing
Input
Figure 11: Typical Installations
55222
1/4 NPT
40022
Ø1.13
1/2 NPT 1/2 NPT

2.75
Figure 12: Test Nipple ASM — Male to Male

(40021)
Page 22 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
55222
1/4 NPT
40023
Ø1.13
1/2 NPT
1/2 NPT
2.63
Figure 13: Test Nipple ASM — Male to Female

(40020)
Page 23 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Indicating ESP Range Scales

The range scales in use on the indicating ESP assemblies are to allow
reading the set pressure or adjusting the set pressure without blocking the
pilot out and using a hand pump and gauge for setting. As noted in the
following figure, even though the scale starts at zero and goes to 260 psi,
the usable range of the spring and piston combination is 10 to 125 psi. All
pressure settings of the indicating ESP should be kept within the usable
portion of the range scale to maintain consistent operation.
Usable ranges or range scales are as follows:
Scale Part Number Scale Range Useful Range

44416-011 (1 1/8-in. with Light Spring) 0 to 260 psi 10 to 125 psi
44416-021 (1 1/8-in. with Heavy Spring) 0 to 700 psi 75 to 550 psi
44416-012 (1/2-in. with Light Spring) 0 to 1,400 psi 300 to 1,000 psi
4416-022 (1/2-in. with Heavy Spring) 0 to 3,600 psi 500 to 2,000 psi
44416-013 (1/4-in. with Light Spring) 0 to 5,500 psi 1,900 to 5,000 psi
44416-023 (1/4-in. with Heavy Spring) 0 to 14,000 psi 4,900 to 10,000 psi
44416-024 (3/16-in. with Heavy Spring) 0 to 24,000 psi 10,000 to 20,000 psi
44416-016 (2-in. Diaphragm with Light Spring) 0 to 100 psi 1 to 100 psi
44416-026 (2-in. Diaphragm with Heavy Spring) 0 to 250 psi 2 to 200 psi
44416-018 (4-in. Diaphragm with Light Spring) 0 to 20 psi 0.50 to 20 psi (also differential ESP)
44416-028 (4-in. Diaphragm with Heavy Spring) 0 to 60 psi 4 to 40 psi (also differential ESP)
44416-051 (1 1/8-in. with U-Light Spring) 0 to 60 psi 1 to 60 psi
44416-055 (2-in. Diaphragm with U-Light Spring) 0 to 20 psi 0.50 to 20 psi (also differential ESP)
44416-057 (4-in. Diaphragm with U-Light Spring) 0 to 5.5 psi 0.25 to 5.3 psi (also differential ESP)
Additional Indicating Scales (Special order ESPHL):

45789 (Bar G) 45500 (Kg/cm2)
-011 0 - 18 -011 0 - 18
-021 0 - 48 -012 0 - 100
-013 0 - 400 -021 0 - 50
-012 0 - 100 -022 0 - 250
-022 0 - 240
Page 24 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Typical Scale
Scale Part Number

44416-011
Set Point Pressure

0
20
40
60
80 Recommended Set
100 Point Range Of Sensor
120
140
160
180
200
220
240
260
PSI Calibration Slot
Piston Size
ESP
Spring Size
Piston-1 1/8
Spring Light Adjustment Rate
PSI/Turn-12.5
Figure 14
Page 25 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
J-Bolt Mounting Block Hold-Down
.38 Dia .06/.19 R Typ

Tolerances:
.X ±.1
.XX ±.015
.XXX ±.005 .5
1.25/1.28 Material:
46099-001
.375-16UNC-2A Thd Zinc Plated Carbon Steel
2.22/2.28
1.0 Min Thd 46099-002
3XX Stainless Steel
Material Certs Not Available
Figure 15
Mounting Base for Controller Box

.840Ø
1/2-14 NPT Thread

.78 Ref.
1.00
.06 R
3.50
1.62
1.44
.06 X 45° Typ

2.227Ø 2.187Ø X 1.62 Deep
2" -11- 1/2 NPT
3/4 Taper Per Foot
3.00Ø
47599 (303 SS)
Figure 16
Page 26 of 27
No: SM-6013
Sensor Unit
Date: 7-28-08
Revision: C
Troubleshooting Chart
ESP Programmed as “Low” (PSL) Sensor
Malfunction Probable Cause Remedy
Instrument pressure at Port B and zero Leak occurring at Ports C or A; Replace the o-rings and check the
pressure at the sensing port. damaged o-rings body bore.
Leak occurring at lower vent port, Replace the lower o-ring and check
damaged lower o-ring on the stem the body bore.
High pressure leak occurring at vent Damaged piston o-ring Replace the o-ring and check the
port in the lower body when line piston housing bore.
pressure is applied to the sensing port.
Sensor fails to block and bleed at low Broken spring Replace spring.
pressure set point.
Swollen o-rings Replace o-rings.
Accumulation of foreign matter Disassemble, clean, and replace all
between the stem, bodies, and piston seals.
Plugged orifices, Disassemble, clean, and replace all
Ports A, B or C seals.
Sensor has large dead band and erratic Swollen o-rings Replace o-rings.
action.
Weak or dragging (bent) spring Replace spring.
Instrument pressure at Port A and zero Leak occurring at Ports C or B; Replace the o-rings and check the
pressure at the sensing port. damaged stem o-rings. body bore.
Leak occurring at body vent port, Replace the lower o-ring and check
damaged upper o-ring on the stem. the body bore.
Sensor fails to block and bleed at high Swollen o-rings Replace o-rings.
pressure.
Plugged orifices, Disassemble, clean, and replace all
Ports A, B or C seals.
Sensor has large dead band and erratic Swollen o-rings Replace o-rings.
action.
Weak or dragging (bent) spring Replace spring
Page 27 of 27

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No: SM-6013

Halliburton ESPHL Sensor Unit

Halliburton ESPHL Sensor Unit

Halliburton ESPHL Sensor Unit

6. Sensing Range—The adjustable pressure range over which the sensor

Halliburton ESPHL Sensor Unit

Figure 1: ESP Sensors

Halliburton ESPHL Sensor Unit

Figure 2: Typical Application for ESPHL

Figure 3: Application of ESPHL in Series

Halliburton ESPHL Sensor Unit

Halliburton ESPHL Sensor Unit

Disassembly and Assembly Instructions

• two 12-in. adjustable wrenches

Halliburton ESPHL Sensor Unit

Note The tubing can be stainless, copper, or plastic. If plastic tubing is

Do not plug the unused port of either ESP sensor.

The position of the high- or low-pressure sensors is not critical, as long as

In cases where a relay is installed on an ESPHL sensor unit for manual

Figure 5: Sensor Bypass Schematic

Halliburton ESPHL Sensor Unit

Figure 6: ESP Sensors Shown

Halliburton ESPHL Sensor Unit

Figure 7: Test Manifold for “ESPHL”

Halliburton ESPHL Sensor Unit

Note Test pressure should be changed slowly to ensure accuracy of

Note If high-pressure adjustments are required, see the service manual

Recommended Preventive Maintenance

Halliburton ESPHL Sensor Unit

Suffix Code Chart

Hi Pressure Sensor Lo Pressure Sensor

Seals and Seals and Fitting

Halliburton ESPHL Sensor Unit

Hi Pressure Sensor Lo Pressure Sensor

Seals and Seals and Fitting

Halliburton ESPHL Sensor Unit

Low 3 High 2 Low 3 High 2

Exhaust Outlet Diaphragm

1/4-18 N.P.T. 1/4-18 N.P.T.

8"(203.2 mm) 8"(203.2 mm)

Halliburton ESPHL Sensor Unit

Bill of Material (Base No. 41779) Standard

Index Part No. Part Name Req’d Material

1 28168 Base (Standard) 1 Carbon Steel

40020 Test Nipple Assembly, Male to Female 1 316 Stainless Steel

* Index 6 to be used only when two sensors are hooked up in series.

Halliburton ESPHL Sensor Unit

Bill of Material (Base No. 45879) Standard Indicating

Index Part No. Part Name Req’d Material

1 28168 Base (Standard) 1 Carbon Steel

40020 Test Nipple Assembly, Male to Female 1 316 Stainless Steel

* Index 6 to be used only when two sensors are hooked up in series.

Halliburton ESPHL Sensor Unit

ESPHL Controller High Flow Rate

Low 3 High 2 Low 3 High 2

Exhaust Outlet Diaphragm

1/4-18 N.P.T. 1/4-18 N.P.T.

8"(203.2 mm) 8"(203.2 mm)

Halliburton ESPHL Sensor Unit

Bill of Material (Base No. 45429) HFR Standard

Index Part No. Part Name Req’d Material

1 28168 Base (Standard) 1 Carbon Steel

40020 Test Nipple Assembly, Male to Female 1 316 Stainless Steel