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STEP 1: The 29GPM Denison Vane Pump (022) supplies the Crane Functions as long as the Two-Way Valve

(24) is closed. STEP 2: The Pressure Relief Valve (7) limits the pressure in the circuit below 2,500psi. Excess pressure will be bled back to the tank.

STEP 1: The 29GPM Denison Vane Pump (022) supplies the Hose Reels Pressure and the Power Hose Reel Pressure when the The 3-Way Valve Auxiliary/Hose Reel Selector (6) is in this position. STEP 2: The 3-Way Valve Auxiliary/Hose Reel Selector (6) will also supply the Auxiliary Pressure (in our case used for the Jacking Frame). STEP 3: The Pressure Relief Valve (7-4), mounted on the pump drive assembly, limits the pressure in the circuit below 2,500psi and is pilot-operated by the Relief Valve (49-3), mounted on the hydraulic control panel. STEP 4: Excess pressure will be bled back to the tank.

STEP 1: The 14GPM Denison Vane Pump (010) supplies the BOP Pressure as long as the Needle Valve (133) is closed. The 3-Way 2-Position Ball Valve (38) will either allow the pressure to go to the BOPS accumulators and system or will bleed the pressure back to the tank. The Check Valve (11) will keep the system pressurized in case the pump stops. STEP 2: The Unloader Valve (9-4), mounted on the pump drive assembly, limits the pressure in the circuit to 3,000psi. Excess pressure will be bled back to the tank. This Unloader Valve (9-4) is normally closed; as soon as the pressure in the circuit builds up above 3,000psi, the valve opens down to 2,700psi (90% of the maximum pressure in the circuit). The objective of the check valve between the pump and the pilot line to the unloader valve is to keep the BOP circuit system pressure pressurized at all times (between 2,700 3,000psi). The Needle Valve (13-3) is on mounted on the power pack control panel (valve 6 BOP Bleed on the CTU 1236 schematic). The The 3-Way 2-Position Ball Valve (38) is on the power pack close to the BOP accumulators. This valve is open to the return tank when maintenance is performed on the BOP circuit.

Step 1: Out put pressure from the the pump goes to the 4-way valve and also to the remote compensator function. At the same time it is being sensed by the remote compensator function which controls the swash plate angle (pump stroke). Initially, as the Denison Injector Pressure Pilot Adjust is fully open there will be no build up of pressure in the remote compensator so the valve can open allowing pump out put pressure to de-stroke the pump ( swash plate angle to 0 ). As a result there will be no flow delivered from the pump. Step 2: When the Munson Tison Injector Direction Forward (or reverse), is selected this will move the 4way valve and allow pump out put to be directed to the injector head. Still there will be no pressure to turn the injector as the Denison Injector pressure pilot adjust is still open and the pump is still de-stroked. Step 3: As the Denison Injector Pressure Pilot Adjust is closed in, the pressure in the remote compensator will increase causing more resistance for the valve to open, therefore the pump swash plate angle will tend to increase. As the angle increases and the pump starts to stroke, the pressure will increase. When the pressure that the Denison Injector Pressure Pilot Adjust has been set to is reached, the valve will then open again allow pump out put pressure to again de-stroke the pump. This all happens in an instant and actually finds a balance thus the pump maintains a continuous flow and pressure based on the Denison Injector Pressure Pilot Adjust setting. Step 4: At the same time the pressure is increased by the Denison Injector Pressure Pilot Adjust the load sensor is measuring the pressure on the injector side of the 4 way valve via the shuttle valve. ( the shuttle valve allows the pressure to be read in either RIH or POH direction). The load sensor is set to maintain the pump out put pressure at 250psi greater than the injector line pressure. While the Injector pressure pilot adjust is closed in the, out put of the pump will direct the flow to the injector. If the pump discharge pressure pressure is more than 250 psi above the injector line pressure (going to the IH motors) then the load sensor valve opens allowing a drop in pressure in the remote compensator resulting in a de-stroke of the pump. Injector Pressure Pilot Adjust and Load Sensor work together to maintain the pressure and flow rate to turn the injector at the desired pressure. The 4 way valve can be opened and closed, by the Munson Tison to effectively choke or meter the flow rate going to the injector independent of pressure.

STEP 1: The 14GPM Denison Vane Pump (010) supplies the Priority Pressure as long as the Needle Valve (13) is closed. The Check Valve (11) will keep the system pressurized in case the pump stops. STEP 2: The Unloader Valve (9-4), mounted on the pump drive assembly, limits the pressure in the circuit to 2,500psi. Excess pressure will be bled back to the tank through the main return line (stops at the Check Valve 51 so that it does not tee to the charge pressure feeding the suction of the Injector Head Pump).

STEP 1: The 29GPM Denison Vane Pump (022) supplies the Levelwind Override Pressure as long as the Two-Way Valve (24) is closed and the 3-Way Valve (20) is open to the Levelwind Override. The 3-Way Valve (20) will also supply the Winch Pressure (in our case used to drive the Crane). STEP 2: The Relief Valve (7-4), mounted on the pump drive assembly, limits the pressure in the circuit to 2,500psi. Returns from the Levelwind and Reel Circuits will flow back through the Tubing Reel Return via the 4-Way Injector Head Directional Control Valve to the suction of the P16 Injector Head Piston Pump.

STEP 1: The 29GPM Denison Vane Pump (022) supplies the Reel Pressure as long as the Two-Way Valve (24) is closed. STEP 2: The Relief Valve (7-4), mounted on the pump drive assembly, limits the pressure in the circuit to 2,500psi. Returns from the Levelwind and Reel Circuits will flow back through the Tubing Reel Return via the 4-Way Injector Head Directional Control Valve to the suction of the P16 Injector Head Piston Pump.

Reference: HR Training Material 2000. Chapter 5. HPOP PP. General Guidelines. The high pressure open loop injector drive circuit utilizes a load sensed, variable displacement, pressure compensated piston pump. This may be a Denison P16 pump (16 inch3/revolution displacement). The system is capable of operating at 5,000 PSI. However, the main relief valve is set at 4,600 PSI. In simple terms, oil is taken from the tank, through the pump and valves, and to the injector motors. The oil returns to the pump inlet (supercharging the pump) after passing through a filter and heat exchanger. A pressure relief valve in the return line ensures oil that is not required by the pump is routed back to the tank. The high pressure open loop power pack is designed to operate the newer injectors. When a HR440 injector is used with a high pressure open loop power pack, the injector is rated for a maximum pull of 60,000 pounds. When a HR480 injector is used with a high pressure open loop power pack, the injector is rated for a maximum pull of 100,000 pounds. An older style injector (e.g., HR125, HR240, or HR260) can be used with a high pressure open loop power pack only if operating pressures are modified to a maximum of 3,000 psi. Pressure Compensator Valve An internal pilot signal provides pressure to control the pressure compensator valve. The pressure compensator relief valve is set for a maximum system operating pressure of 4,800 PSI. If a pressure of 4,800 PSI is obtained, the compensator valve will shift and destroke the pump by allowing high pressure to this stroking piston. The compensator will then ensure that a maximum of 4,800 PSI is maintained (independent of the flow rate). The pressure compensator valve can also be remotely operated by installing a remote relief valve (typically a Denison RE102 valve) in the control cabin. The pressure can be varied to limit the maximum pull or push of the injector. Load Sensed Option The load sense option works in conjunction with the pressure compensator to optimally control the horsepower required by the pump. The pump senses a restriction and will provide the necessary flow (and the required pressure) to perform a particular operation. In other words, if only 75 gpm at 3,000 psi is required to move the injector at the desired speed, the pump will provide 75 gpm but not more (unless the operator changes the Injector Pressure Pilot Adjust setting and tells the pump to provide more flow). Reference: UTC Power Pack Operations Manual. Specific to this schematic. Injector Circuit (High Pressure Open Loop) 4.1.1 The injector circuit is effected by a P-16 open loop pressure compensated pump with load sensing, the pumps pressure is remotely controlled via its vent port a the remote valve. 4.1.2 Directional control and flow control of the injector is effected by cabin control pressure which shifts the 4-way valve to the in or out hole position and then controls the pressure to open or close the speed control valve through lines 12 or 50. 4.1.3 Load sensing is an automatic function which requires the pump pressure to maintain a 200 psi differential between the discharge pressure and the pressure at the injector motors. This operation maximizes usable horsepower by reducing pressure drops and reduces the heat load. 4.1.4 When the injector is placed in neutral, the load-sense lowers the stand-by or pressure compensated pressure to 440 psi approximately. 4.1.5 The intake of the pump is closed to the reservoir during normal operations. The pumps full volume can be passed through the heat exchanger along withan excess volume of approximately 58 gpm. The excess 58 gpm passes over a low-pressure relief back to tank but assures a constant pressure volume to the pumps intake.