Operating and Service Manual For 10K Super Choke 2-9/16" and 3-1/16"
Swaco, A Division of M-I L.L.C. A Smith/Schlumberger Company 5950 North Course Drive Houston, Texas 77072 Tel: 281-988-1868 Fax: 281-988-1888
MANUAL PART #90-90-080 (REV. A)
DISCLAIMER Recommendations made by Swaco are advisory only. Swaco shall not be liable under any guarantees or warranties, expressed or implied, in any manner or form, AND ALL WARRANTIES, EXPRESSED OR IMPLIED, ARE HEREBY SPECIFICALLY EXCLUDED, and Swaco shall not be liable for the failure to obtain any particular results from the use of any recommendation made by it or from the use of this material. In no event shall Swaco be liable for incidental or consequential damages.
Table of Contents Section 1: 1.1: 1.2:
Introduction Notes and symbols General precautions
1 1 1
Section 2: 2.1: 2.2:
General information Choke valve Control console
2 2 3
Section 3: 3.1:
Installation Choke valve 3.1.1: Installing the choke valve 3.1.2: Repositioning the actuator assembly 3.1.3 Control lines 3.1.4 Choke disc position transmitter Control console 3.2.1: Installing the control console 3.2.2: Air supply 3.2.3: Stroke / Rate meter 3.2.4: Gauge protector Multiple choke installation 3.3.1: Dual control console assembly 3.3.2: Auxiliary control panel 3.3.3: Multiple control console installation
6 6 6 8 8 8 9 9 10 11 11 12 12 13 13
Section 4: 4.1:
Operation Procedures 4.1.1: Normal operating method (fast) 4.1.2: Alternate operating method (slow) 4.1.3: Emergency operation
13 14 14 14 14
Section 5: 5.1:
Service and maintenance Procedures 5.1.1: Routine inspection 5.1.2: Daily visual checks 5.1.3: Daily operational checks 5.1.4: Removing the choke valve from the manifold 5.1.5: Changing the disc assemblies 5.1.6: Bonnet end disassembly 5.1.7: Gauge protector 5.1.8: Gauge protector repair 5.1.9: Filling gauge protector lines
16 16 16 17 17 17 18 21 22 22 24
3.2:
3.3:
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5.1.10: Position indicator system 5.1.11: Calibration and adjustment 5.1.12: Digital stroke / Rate meter 5.1.13: Actuator assembly
25 25 27 27
Section 6: 6.1:
Pressure testing Procedures 6.1.1: Shell hydrostatic test procedure 6.1.2: Hydrostatic disc test procedure
27 27 27 29
Section 7: 7.1:
Troubleshooting Diagnostic guides 7.1.1: Choke discs will not open or close 7.1.2: Choke opens and closes too slowly 7.1.3: Choke valve leaks 7.1.4: Choke discs leak 7.1.5: Digital stroke / Rate meter 7.1.6: Pressure gauge not reading correctly 7.1.7: Position indicator not working
29 29 29 31 32 32 32 33 33
Section 8:
Drawings and Parts lists
36
Appendix A. B. C. D.
111 Barksdale SC Hydraulic Pine pump Flo-tork
111 112 117 120
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Section 1:
Introduction
The remotely operated Swaco Super Choke has been proven by experience to be a reliable choke for the drilling industry. Like all mechanical equipment there are certain fundamental rules that operators should observe. The basic mechanical operation of the Swaco Super Choke is quite simple. However, the applications for which this type of equipment is used may be complicated enough to require specific training and experience to complete an operation successfully. NOTE: For this reason, the Swaco Super Choke should be operated only by, or under the supervision of qualified operators. All mechanical equipment is subject to wear caused by either use or abuse. For this reason, the Swaco Super Choke and Control Console should be inspected on a regular basis by qualified personnel. Repairs should be made before undertaking any operations involving the Swaco Super Choke. In the event of any problems with the Super Choke, contact your nearest Swaco service center. 1.1:
Notes and symbols Symbols in the operating instructions which concern operating safety are emphasized as follows: This symbol draws attention to the safety measures which must be observed to prevent personal injury.
1.2:
ATTENTION!
This symbol draw attention to the safety measures which must be observed to prevent damage to the equipment.
NOTE:
This symbol draws attention to general operating notes which should be especially observed.
General precautions THIS DEVISE OPERATES UNDER HIGH PRESSURE. NEVER ATTEMPT TO DISASSEMBLE UNTIL ALL PRESSURE HAS BEEN RELEASED.
1
PROPER MAINTENANCE TOOLS SHOULD BE USED AND NO UNAUTHORIZED MODIFICATIONS ARE TO BE MADE. USE ONLY AUTHORIZED REPLACEMENT PARTS. WHILE PRESSURE TESTING, ASSURE THAT ALL AIR HAS BEEN PURGED FROM THE SYSTEM, APPROACH THE UNIT ONLY AFTER THE DESIRED PRESSURE HAS BEEN OBTAINED AND STABILIZED. EYE PROTECTION IS REQUIRED WHILE PERFORMING MAINTENANCE AND PRESSURE TESTING. ALWAYS USE PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAY BE TRAPPED IN THE CHOKE OR MANIFOLD. Section 2: General information 2.1:
Choke Valve The Super Choke is a hydraulically operated valve providing an adjustable orifice size from a maximum area of 1.9 square inches (12 cm²) to complete shutoff. The working pressure of this choke is 10,000 psi (68950 kPa). The size of the choke orifice is determined by the overlapping portion of two off-center half-moon openings in two highly polished tungsten carbide discs. The downstream disc is fixed while the upstream disc may be rotated up to 180º by a hydraulically driven rotary actuator (See Figure 1)
Figure 1 The Super Choke was designed primarily to control high pressure gas kicks and salt water flows during drilling operations. However, because of its long life, high capacity, ease and simplicity of operation the Super Choke is commonly used in a
2
Number of applications such as the following: • • • • • • •
2.2:
Stripping-in under pressure (controlled displacement) Spotting light fluids, particularly in freeing stuck pipe Volume "calipering" specific hole sections Spotting heavy slugs (barite, cement, etc.) Drilling under pressure Displacing fluids in wells before and after workover Testing and clean up of new completion's where sand, lost circulation material, or perforating debris are present.
Control console The Super Choke in normally operated from the Control Console located on the rig floor. However, the Control Console may be placed in a remote location or any safe working area designated by the customer. In special installations, several Control Consoles may be placed at different locations, where any Control Console can provide full control. The Control Console panel has a control lever, master air supply valve, choke disc position indicator, drill pipe gauge, casing pressure gauge and a pump stroke counter with rate meter. Mounted below the Control Console panel is the air-operated hydraulic pump, hydraulic fluid reservoir and a manually operated hydraulic pump to be used in case the air supply fails (See Figure 2). The control lever normally remains in the HOLD position, and is rotated to the OPEN or CLOSE position to open or close the choke, respectively. The control lever is spring loaded to return to the HOLD position when released. A needle valve, labeled HYDRAULIC REGULATOR, can be adjusted to control the opening and closing speed of the choke discs. The hydraulic regulator valve should normally be rotated at least 1-1/2 turns to provide a suitable speed for the choke discs during operation. The AIR SUPPLY valve controls the air supply to the air-operated hydraulic pump and the position indicator system. The recommended air pressure is 50-125 psi (342862 kPa).
3
Figure 2 For multiple choke installations, Swaco has a Dual Choke Control Console (See Figure 3). Two chokes can be operated with this console without the need for an auxiliary panel or two single consoles. The Dual Control Console panel consists of two choke control levers, two choke disc position indicators and two hydraulic regulators. The are also pressure gauges and a master air supply valve for use in operation of either or both choke valves. The operation of the Dual Control Console is identical to that of a single Control Console. Located below the panel is a hydraulic reservoir, which supplies both systems with the required hydraulic fluid. Each system has a separate air-operated hydraulic pump and a manually operated hydraulic pump to be used in case the air supply fails.
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Figure 3
5
Section 3: 3.1:
Installation
Choke valve 3.1.1: Installing the choke valve The standard inlet and outlet flanges are AIP Type 6BX, 2-9/16, 10,000 psi (68950 kPa), 3-9/16, 10,000 psi is also available. ATTENTION!
Most common bolts, studs and nuts available do not meet the requirements for H2S service and will fail from hydrogen embrittlement. Replace bolts, studs and nuts with authorized replacement parts.
ATTENTION!
All Swaco Super Chokes contain a tungsten carbide wear sleeve which extends 1/8 inch (4 mm) beyond the face of the outlet flange. This protects the ring gasket from erosion. Because of this feature, the internal diameter of the companion flange or adapter must have a minimum 2-9/16 inch bore; otherwise the wear sleeve will crush the back choke disc when the flange is installed.
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Before installation, the flange studs and nuts should be checked for cracks, damage, wear and thread distortion. When any of these conditions are detected the part should be replaced. Companion flanges and adapter flanges can be furnished with the choke and must be made from specially heat treated material. Zinc plated BX ring gaskets suitable for H2S service is also available. New ring gaskets should be used on each installation and each time the flanges are reconnected. Use gaskets will be deformed and may not seal properly. (Refer to API Specification 6A, Specification for Wellhead and Christmas tree Equipment). The nuts should be evenly torqued. The nut threads must be fully engaged with the stud threads. It is recommended that the stud be exposed by at least three or four threads to permit more even stress loading. When the nuts are fully torqued, the faces of the choke flanges should be parallel to the companion or adapter flanges. The material used to fabricate the choke is relatively soft, therefore, when fitting the choke to the manifold care should be taken not to damage the flanges. The choke manifold should have at least two positive shutoff valves between the blowout preventer and Super Choke. There should also be one valve downstream of the Super choke to permit isolation for servicing of the choke while other sections of the manifold are in use. (Refer to API Bulletin RP 53, Blowout Prevention Equipment Systems). The discharge line from the choke must be securely anchored according to API Specifications. (Refer to API Bulletin RP 53) The Super Choke valve should be pressure tested after installation and notation made on the drilling report. This test may be done when the choke manifold is being tested. Refer to Section 6 of this manual for pressure test procedures.
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3.1.2: Repositioning the actuator assembly When installing the Swaco Super Choke in the manifold, the actuator assembly should be installed with the open area facing down or to one side (See Figure 4). If the actuator assembly is not positioned properly, the following procedures should be followed to rotate it to the correct position. NOTE:
• • • • •
Do not rotate the indicator head when removing and turning the actuator assembly because this will cause misalignment of the choke discs. Also make sure the actuator assembly shaft is not rotated. When the actuator assembly is reinstalled the position indicator cam must be in the same position as it was when the actuator assembly was removed or the choke will not operate properly.
Remove the four bolts, which fasten the actuator assembly to the mounting adapter. Pull the actuator assembly away from the adapter until the square shaft is clear of the indicator head. Turn the actuator assembly 90º to 180º to the desired position. Push the actuator assembly shaft into the indicator head. A light application of grease on the actuator assembly shaft is recommended to ease installation and future changes. Replace the four bolts and tighten them to 27 ft-lbs. (366 Nm).
3.1.3: Control lines Connect the two 3/16 inch, low pressure hydraulic hoses from the Super Choke Valve to the rear manifold on the control console (See Figure 5). These two (2) hoses are provided with quick disconnect fittings that are matched with male and female ends in such a manner that is impossible to reverse and install the two (2) hoses incorrectly. Route the hydraulic hose's in such a manner as to avoid damage and hazards for rig personnel. 3.1.4: Choke disc position transmitter Connect 1/4 inch O.D. vinyl tubing from fittings on the position transmitter, located on the choke valve to the corresponding fittings on the control console (See Figure 5). The two (2) fittings on the control console manifold are labeled "Air to Transmitter" and "Air Return from Transmitter".
8
The fittings on the position transmitter are not labeled. Check the arrow located on the position transmitter regulator to determine the direction of the air flow. 3.2:
Control console 3.2.1: Installing the control console Place the control console in the desired location on the rig floor or in a safe working area designated by the customer. Normally, the best location for the control console is against the hand rail nearest the mud tanks and the choke manifold. This location provides the choke operator with a view of the fluid level in the mud tanks and other equipment related to a well killing operation.
Figure 5
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3.2.2: Air supply Connect the air supply hose from the manifold on the control console to the rig air supply (See Figure 5). The air hose should be connected to an outlet where clean, dry air may be obtained. Trash or moisture in the air supply can cause a malfunction of the air-operated hydraulic pump. This air outlet should not be sued for any other purpose which might cause the supply to be disconnected from the control console. Install the air hose to avoid crimping or cutting and excessive heat from other equipment. The recommended air supply pressure for the control console is 50-125 psi (345-862 kPa). For a hose length to 50 feet (15 m) a 1/2 inch diameter hose is adequate. For longer lengths a 3/4 inch diameter hose is desirable. The air hose supplied with the control console has 1/2 inch NPT male connection which can be adapted to the air outlet on the rig. Turn the master air supply valve on the control console to the ON position. The pointer of the position indicator gauge should show OPEN (assuming the choke was installed in the open position). If it shows CLOSED or partially closed, check to determine if the super choke valve is fully closed or if the position transmitter is properly calibrated. NOTE:
The control console and super choke valve should be calibrated together at the service center. Refer to section 5.1.10 of this manual for proper calibration procedures.
Push the control lever to the right toward the choke CLOSE label. The Hydraulic pump should start stroking and the needle of the position indicator gauge should begin moving. Hold the lever in this position until the choke is fully closed and the hydraulic pump stops stroking; then release the lever. The control valve should open. Push the control lever to the left toward the choke OPEN label until the choke is fully open. If there is any problem with any of these operations, refer to Section 5.1.10 of this manual.
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3.2.3: Stroke / Rate Meter The Swaco Digital Pump Stroke / Rate Meter, located on the control console, is powered by a built-in battery pack. No outside source of power is required. The meter comes with either limit or magnetic proximity switches. -
Limit switch: Each pump Stroke switch assembly mounts to the mud pump frame near the exposed pump rods. Position each switch assembly so the switch actuator rod moves when contacted by the pump rod collar or splash guard. There should be one full deflection and release of the actuator rod for each pump stroke to assure proper operation of the stroke counter and to avoid double counting. - Magnetic switch: Find a large mass of metal on the pump and position switch so that it can sense off of it. Be sure not to allow the mass to pass completely past the sensor or it will double count. Route the cable from the Digital Pump Stroke/Rater Meter to the junction box and connect the wires. Use wire nuts to connect the wires inside the junction box. The strain relief connections on the meter, junction box and pump switches should be used to avoid wire damage. Shielded cable is recommended between the Stroke/Rate Meter and the limit switch assembly. Ground the shielding on one end of the cable. This will prevent electrical noise from the power cables adjacent to the Stroke/Rate Meter from causing an inaccurate count. Operate each pump stroke assembly by hand to determine Pump 1, 2, or 3. The pump select switch is located on the bottom of the Stroke/Rate Meter is used to display the desired pump stroke count and rate being displayed. 3.2.4 GAUGE PROTECTOR -
Connect the drill pipe pressure gauge protector assembly (figure 5) to the rig standpipe. The assembly should be mounted in an upright position to allow mud to drain when there is no pressure in the standpipe. The hydraulic hose is connected to the drill pipe pressure gauge connection located on the control console manifold. Make sure the hose is run in a manner which will not interfere with pedestrian or vehicle traffic or be cut, crimped, worn by rig structures or burned by other equipment. - Connect the casing pressure gauge protector assembly (figure 5) to a suitable place on the choke manifold. This assembly should be mounted upright and have a valve below it that can be closed off to allow repair of the gauge protector. The hydraulic hose is connected to the casing pressure gauge connection located on the control console manifold. Make sure the hose is routed in the same manner as described above. The gauge protectors are rated for 10,000 psi (68950 kPa) working pressure and may be mounted to a 2” female hammer union hub, a 2” npt male or female connection on the standpipe and choke manifold. The gauge protector lines should be filled with hydraulic fluid at the service center prior to the control console being delivered to the rig site. If this is not possible, refer to section 5.1.9 of this manual for the hydraulic line filling procedure.
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3.3 MULTIPLE CHOKE INSTALLATION 3.2.1 DUAL CONTROL CONSOLE ASSEMBLY If two Super Choke valves are to be used in the choke manifold, they may both be controlled from the dual control console assembly (figure 6). On the rear manifold of the dual control console (drawing 20) there are OPEN and CLOSE lines for each choke, also air to and air return lines for each choke. It is important not to interchange the lines for Choke A with the lines from Choke B. Improperly installed lines will cause choke B to operate when choke A controls are actuated and vice versa. Therefore, it is recommended to install one set of lines (choke A or choke B) at a time. The OPEN and CLOSE lines for Choke A are located next to the drill pipe pressure fitting. The open and close lines for choke bare are located next to the casing pressure fitting. Facing the back of the dual control console, the air lines for choke A are the right pair and the air lines for Choke B are the left pair. The supply air and gauge protector assemblies are installed in the same manner as they are for the Single Control Console.
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3.3.2
AUXILIARY CONTROL PANEL
If a SWACO Dual Control Console is not available, the Auxiliary control panel may be used with the single control console for the operation of the two super chokes. The Auxiliary Control Panel is mounted on the right side of the Control Console. There are two hose connections that tie the Auxiliary control panel into the control console hydraulic system. One connection is located at the output of the air operated hydraulic pump. The connection will supply the necessary hydraulic pressure for operating the auxiliary choke. Use high pressure hose and fittings (minimum 3,000 psi – 20685 kPa) to make this connection. The second connection is located between the return port on the auxiliary control panel control valve and the hydraulic reservoir on the control console. To complete the installation, connect the air supply to the position transmitter on the second choke. This can be done by installing a ¼” tubing tee in the “Air to Transmitter” line between the Control Console and the primary choke. Connect this air supply to the position transmitter on the second choke. The return line from the second choke position transmitter connects directly to the position indicator gauge on the auxiliary control panel. 3.3.3
MULTIPLE CONTROL CONSOLE INSTALLATION
When using two Super Chokes it may be desirable to have more than one Control console in order to operate the chokes from different areas around the drilling site. Drawing 36 is a schematic for installing two chokes and three control consoles with auxiliary control panels on each control console. Full operation of each choke valve is possible from any of the three control locations. For two console operation use consoles at Master Station 1 and Station 2 only. The control line hoses may be replaced by ½” Schedule 40 pipe for underground routing to remote locations. This change will improve the choke response time and prevent the lines from being crushed by vehicle traffic around the rig. When making these special installations, 1/8” copper or stainless steel tubing should be used for the gauge lines if the total distance between the control console and the gauge protectors exceeds 100 ft. (30m). For multiple panel installations with the Dual Control console, the same steps can be followed as for the single control console with an auxiliary control panel. 4
OPERATION
The choke discs should remain in the fill OPEN position when the choke is not in use. Operation of the SWACO Super Choke should always begin with the choke in the OPEN position. (Closed choke discs may result in hydraulic shock on the well bore and if the mud pumps are running can result in lost returns and a down hole blowout). For example: at the start of a well control procedure, the choke should not be closed until after the blowout 13
preventer has been closed and drilling fluid is flowing through the manifold and Super Choke. This helps to seat the discs and prevents mud particles from getting between the discs. The choke should be closed slowly to avoid hydraulic shock on the surface pressure control equipment and the casing seat. 4.1 PROCEDURES 4.1.1 NORMAL OPERATING METHOD (fast) -
Move faster AIR SUPPLY valve to the ON position (see figure 2). Open the HYDRAULIC REGULATOR all the way. The control console displays the following information that is typically used in well control procedures Drill pipe pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 kPa increments) Casing pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 Kpa increments) Choke position (full OPEN to full CLOSE) Rig pumps stroke rate and stroke count Be prepared to shift the CONTROL LEVER in either direction to maintain the desired casing or drill pipe pressure. When the well control operation is complete, open the choke and turn master AIR SUPPLY valve OFF to remove all pressure on the hydraulic system
NOTE: A PLUGGED CHOKE MAY RESULT IN EXCESS PRESSURE BUILD-UP IN THE SYSTEM WHICH MAY EXCEED THE CASING PRESSURE LIMIT. IN CASE OF CHOKE PLUGGING, SHIFT THE MAIN CONTROL LEVER TO OPEN, AND OPEN THE HYDRAULIC REGULATOR FOR FAST RESPONSE. AS SOON AS THE PLUG IS CLEARED, THE CONTROL LEVER MUST BE SHIFTED TO CLOSE LONG ENOUGH TO RETURN TO THE DESIRED PRESSURE. THE HYDRAULIC REGULATOR VALVE MAY THEN BE ADJUSTED FOR A SLOWER RESPONSE. 4.1.2 ALTERNATE OPERATING METHOD (slow) -
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If slow operation is desired, close the HYDRAULIC REGULATOR all the way. Then to adjust the choke disc speed, hold the CONTROL LEVER in the CLOSE position and slowly open the HYDRAULIC REGULATOR valve. This allows only a very slow movement of the choke discs. When the desired pressure is reached, the CONTROL LEVER should be released. Open the HYDRAULIC REGULATOR valve if a faster response is needed.
4.1.3 EMERGENCY OPERATION FAILURE OF AIR SUPPLY OR AIR PUMP
14
-
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Install PUMP HANDLE on the HAND PUMP which is mounted on the base of the control console skid. (Be sure pump BLEED-OFF valve on the HAND PUMP is closed). To change choke opening, hold the control lever in the desired position while stroking the HAND PUMP.
RUPTURE IN HYDRAULIC LINE OR CONNECTION -
-
If either hydraulic line is cut or rupture’s, cut both lines at the choke. The hoses must be cut and NOT DISCONNECTED. If they are disconnected, check valves in the fittings will prevent operation. Insert 5/8” (16mm) diameter rod into one of the holes in the INDICATOR HEAD (figure 7) and manually position the choke as desired.
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5
SERVICE AND MAINTENANCE 5.1 PROCEDURES 5.1.1 ROUTINE INSPECTION The SWACO super Choke is a key element of the pressure control system used to prevent rig blowouts. Therefore, it is important that the Super Choke and Control Console be maintained in good operating condition at all times (see figure 8).
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5.1.2 DAILY VISUAL CHECKS -
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Check the presence of a hand pump handle (item 9), a manual choke operating bar and all panel labels Check fluid level in the hydraulic oil reservoir (item 1). Fill with the correct hydraulic oil. Keep a supply of oil at the choke panel or close by. See that all connections fit tight. Make sure the hydraulic hoses, pump switch cable and air lines are properly connected and not cut or pinched. Check the pump Stroke/Rate Meter (Item 8). Place the selector switch on “TEST”, the meter should be counting and should show 128 SPM. Select Pump 1 or Pump 2 and observe counter and rate display. Reset counter to zero after test. See that the pump stroke counter switches (item 3) are properly attached to the mud pump and counting the correct number of strokes. Check the air line lubricator (item 14); the bowl should be filled with the correct hydraulic oil.
5.1.3 DAILY OPERATIONAL CHECKS -
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Turn the master air supply valve (item 5) on. The hydraulic pressure gauge (item 12) should show 1500-1750 psi (10343-12066 kPa). Close the hydraulic regulator (item 11) and then open 1-1/2 turns. Operate the control lever (item 6). Complete a full cycle of the choke discs from full OPEN, to full CLOSE, back to full OPEN. The position indicator (item 10) should track the choke disc movement according to the choke lever selection. While the hydraulic pump is stroking, check the sight glass located on top of the air line lubricator (item 14). The lubricator should deliver approximately 1 drop of oil for every 20 strokes of the hydraulic pump. The adjustment screw is located on top of the lubricator. To operate the hand pump (item 2) to close or open the choke discs, shut the air supply off. Hold the choke control lever in desired position and operate hand pump. Make sure the bleed valve on the hand pump is closed. Leave the pump piston in the DOWN position to avoid rust or corrosion. Observe the Drill Pipe and Casing Pressure gauges (item 7). The pressure valve should be approximately the same as the rig gauges. Gauge faces should be clean and visible.
5.1.4 REMOVING THE CHOKE VALVE FROM THE MANIFOLD Before attempting to work on a Super Choke in a manifold, extreme caution should be exercised to assure that there is no pressure trapped in the choke valve or choke manifold. Always use proper safety precautions where H2S gas may be trapped in the choke valve or manifold. Only personnel who have received instruction on the hazards of H2S may be present should be permitted to work on the Super Choke. Failure to follow these instructions could result in injury.
17
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Rotate the choke discs to the full OPEN position. Allow the pressure in the choke valve to be relieved before continuing with this procedure. - Carefully loosen the outlet flange nuts one turn each until seal or ring gasket is broken but do not remove the nuts on the outlet flanges of the choke valve. After all the nuts are loosened, break the seal on the ring gasket by separating the outlet flange from the manifold flange. Stand on either side of the flange gap, never over it, when breaking the seal to avoid possible severe personal injury. Once the seal is broken and all pressure inside the choke is relieved, the nuts and studs may be safely removed. Do not use a pry bar to remove flange because of possibly damaging the extended wear sleeve. - Provide some manner of support for the valve, and then carefully loosen the upstream flange nuts one turn until seal is broken and any trapped pressure is released, and then remove the nuts and studs on the inlet flange. Refer to section 3.1.1 of this manual for reinstalling the choke in the manifold. ATTENTION! Because of the H2S rating for the SWACO Super Choke the steel used to fabricate the flanges, nuts and studs are relatively soft and therefore, subject to surface distortion and dents from poor work practices. Care should be exercised in the handling procedures and use of tools when working on the Super Choke to avoid damaging these parts. Damaged parts will adversely affect the structural integrity of the super choke which may result in injury. 5.1.5 CHANGING THE DISC ASSEMBLIES This section describes the procedure for removing the super choke discs from the outlet end of the valve body for inspection and/or replacement and removal of the wear sleeves. See drawing 2 for part number information. NOTE: Before attempting to work on a Super Choke, extreme caution should be exercised to assure that there is no pressure trapped in the choke valve. Always use proper safety precautions where H2S gas may be trapped in the choke valve. Only personnel who have received instruction on the hazards of H2S, the proper safety equipment and procedures for working in areas where H2S may be present should be permitted to work on the Super Choke. Failure to follow these instructions could result in injury. -
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Carefully loosen the outlet spool bolts one turn each. After all the bolts are loosened, break the o-ring seal and unbolt the outlet spool, carefully separating it from the body. The spool is fastened to the choke body with 7/8” ferry head cap screws. Locating pins provide alignment between the body and the outlet spool. To remove the choke discs, first rotate the front disc to the full OPEN position if this has not been previously done. Wash any sand, grit or weight material from around the exposed portion of the back disc and the disc opening. Insert the hook end of the disc puller (Swaco part number 96-11-083) in the disc opening as illustrated in Figure 9 and gently remove both discs using the sliding weight on the puller. 18
NOTE: To avoid injury, caution should be taken to avoid getting any part of the hand caught between the sliding weight and the stop on the end of the puller shaft. -
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Maintain the position of the hook on the puller to avoid chipping the corners of the disc orifice. Even if the discs are worn they may be repairable if not damaged from this procedure. When the discs have been removed, locate and inspect the stationary disc locking pin. Replace if damaged. Clean both disc assemblies thoroughly and inspect for wear or damage. The primary criteria for determining whether or not the choke discs are reusable are that they can provide a positive seal under pressure when installed in the choke. See section 6.1.2 of this manual for the Hydrostatic disc test procedure. Wash out and clean the interior of the choke body and the o-ring sealing surfaces. Remove the o-rings on the back disc carrier and the choke body flange and replace these o-rings.
NOTE: The o-rings used in the Super Choke are made of a special H2S resistant material. Use only the o-rings specified in drawing 2. -
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Thoroughly clean the disc assemblies and apply a light film of silicone grease to the o-ring groove on the rear disc carrier. Avoid getting grease on the polished disc faces because this can cause the choke to leak when tested. Insert the front disc assembly into the body so that the half-moon opening side is facing the choke inlet flange. Be sure that the turning fork fingers and the locating pin in one of the fingers align properly with the slots and locating pin hole in the front disc assembly. The front disc should fit loosely into the body and into the turning fork fingers. Position the back disc locking pin in the groove on the inside diameter of the choke body. Align the matching pin groove in the back disc assembly and insert the back disc. 19
NOTE: The moon-shaped opening must be facing the inlet flange of the choke valve. See figure 10. -
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To remove the outlet spool wear sleeves carefully press them out through the end which bolts to the body. There are three identical large internal diameter wear sleeves and one with a smaller opening that protects the outlet flange seal. Inspect the wear sleeves for wear and replace as necessary. Before reinserting the wear sleeves, clean and inspect the bore of the spool. Be especially careful to remove any dirt, rust or debris from the shoulder where the extended wear sleeve makes contact. Failure to do so may cause the wear sleeves to break the choke discs when the spool is bolted to the valve body.
Remove any dirt, rust or debris from the ends of the wear sleeves and the shoulder on the extended wear sleeve. Apply a light film of silicone grease on the outside of the wear sleeves and insert them into the spool. Reassemble the outlet spool to the valve body using the alignment pins and the ferry head cap screws. Check to be sure the o-rings are properly positioned. Use only the screws and bolts specified in drawing 2 to assemble. Discard and replace any damaged screws. Tighten these screws uniformly. The bolts should be torqued to 165 ft/lb (224 Nm). Over torquing the bolts will cause them to stretch and reduce their strength which, can result in premature failure. Clean and inspect the inlet and outlet flange faces and ring grooves. Apply a light film of general purpose grease or a rust inhibitor to the face and ring groove for corrosion protection.
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5.1.6 BONNET END DISASSEMBLY This section describes the procedure for removal of the actuator assembly and bonnet from choke valve. It also covers the removal and inspection of the turning fork. These procedures may be done with the super choke either installed in the manifold or removed. NOTE: Before attempting to work on a Super Choke in a manifold, extreme caution should be exercised to assure that there is not pressure trapped in the choke valve or choke manifold. Always use proper safety precautions where H2S gas may be trapped in the choke valve or manifold. Only personnel who have received instruction on the hazards of H2S, the proper safety equipment and procedures for working in areas where H2S may be present should be permitted to work on the Super Choke. Failure to follow these instructions could result in injury. -
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The first step is disassembling the Bonnet from the Choke is to remove the Actuator Assembly. Before doing this, position the choke discs in the full OPEN position. To remove the Actuator Assembly from the choke valve, remove the four bolts that attach the adapter to the choke valve. Remove these bolts and proceed to the next step. Remove the cap screw attaching the indicator head to the turning fork. Remove the indicator head from the turning fork shaft. Before removing the Bonnet, mark the valve body and bonnet so they can be reassembled with the same orientation. Remove the remaining ferry head cap screws attaching the bonnet to the body. Inspect these screws for damage or distortion and replace as necessary. Use only bolts specified in Drawing 2. Remove the bonnet from the valve body.
NOTE: Most common bolts, studs and nuts available do not meet the requirements for H2S service and will fail from hydrogen embrittlement. Replace bolts, studs, and nuts with authorized replacement parts. -
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Push the turning fork out of the bonnet being careful not to damage the shaft surfaces that rotate inside the bonnet. Clean the turning fork and inspect for wear or damage. The thrust bearing and oring seal areas should be smooth. The hex should not be rounded, cracked or deformed. Replace the turning fork if any of these conditions exist. Lubricate the turning fork shaft with a light application of silicone grease before reassembly. Replace the thrust bearing, shaft bushing, all o-rings and backup rings on the bonnet. Refer to drawing 2 for the proper location of these parts. The parts that are used in the super choke are made of special material for exposure to H2S gas. Use only parts specified in drawing 2 to replace components in the super choke. Reinsert the turning fork in the bonnet being careful not to damage the o-rings or bushing. The bonnet should be clean and have a light application of silicone grease on the surfaces where there is contact or close proximity to the valve body and turning fork. 21
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If the outlet spool is not to be removed from the body, the front disc assembly must be properly positioned on the turning fork prior to installation. Be sure to properly align the locating pin in the turning fork finger with the alignment hole in the front disc assembly. The polished surfaces on both the front and back disc must be completely clean, dry and free of grease to assure proper seating. Clean the indicator head and apply a light film of grease to the square and hex sockets. Check that the indicator head socket will fit freely on the actuator assembly shaft. This will eliminate problems when assembling the actuator assembly to the valve. When inserting the bonnet assembly into the valve body, position the half moon opening on the front disc toward the inlet flange and align the marks described in step 3 on the bonnet and valve body. Reinsert and uniformly tighten the bolts securing the bonnet to the valve body and the actuator assembly to the bonnet. Note: four of the bolts are longer than the rest. The longer bolts are used to attach the actuator assembly to the bonnet. The actuator assembly may be positioned in three possible positions, but never upside down. Care should be exercised to assure that both the actuator assembly shaft and the choke discs are in the OPEN position when these two components are reassembled. Evenly torque these bolts to 165 ft/lbs (224Nm). Over-torquing the bolts will cause them to stretch and reduce their strength, which can result in premature failure.
5.1.7 GAUGE PROTECTOR The purpose of the Gauge protector (figure 11) is to transmit fluid pressure from the drill pipe or the casing to the control console and isolate the gauges from the drilling mud. 5.1.8 GAUGE PROTECTOR REPAIR -
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If the hydraulic hose is to remain attached to the gauge protector, remove the plug from the side of the body. This will permit air to enter the body when the piston is removed. Remove the body from the female hub by removing the wing nut. Remove the stainless steel internal snap ring from the bore of the gauge protector body. Insert a ½”-13NC bolt in the tapped hole at the bottom of the piston. Use the bolt as a handle to extract the piston. Clean the piston and replace the o-rings on the piston. Use only the size and type o-ring called for in drawing 26.
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NOTE: The o-rings used in the gauge protector are made of a special H2S resistant material. Use only the o-rings specified in drawing 26. -
Clean and inspect the bore of the gauge protector body for corrosion, wear and pitting. Replace the body if these conditions exist. Before reinstalling the piston apply an ample film of silicone grease on the piston and o-rings. Manually insert the piston all the way into the body. The piston should move in the body with only moderate physical effort. If the piston sticks, replace the piston. Do not file or grind the bore of the gauge protection body, or o.d. of the piston.
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Reinstall the stainless steel internal snap ring. Refer to section 5.1.9 of this manual for refilling the gauge protector with hydraulic fluid. The body plug is replaced during the line filling procedure.
5.1.9 FILLING GAUGE PROTECTOR LINES After assembly, the gauge protector, signal line and gauge lines on the control console should be filled with hydraulic oil and purged of air. A few drops of oil will be lost each time the line is coupled or uncoupled. It is therefore advisable to avoid disconnecting these lines once the system has been purged. Loss of hydraulic fluid in the lines may cause the gauge to read incorrectly. The hydraulic fluid in the system must be free of air or full pressure cannot be transmitted to the gauge. -
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Place the gauge protector in a vertical position near the control console. The signal line should be connected tightly to the gauge protector and the control console manifold. Remove the check valve cap on the back of the control console manifold and attach the hand pump loosely to the check valve (figure 12). Do not tighten this connection yet.
Slide the cover of the hand pump to one side and fill the reservoir with hydraulic fluid. While pumping, keep the hand pump reservoir at least ½ full to avoid pumping air into the line. Pump slowly, purging air from the pump at the loose connection. When the pump is purged of air, tighten the connection between the pump and the check valve. Turn the damper valve on the gauge counterclockwise several turns to relieve the dampening effect. 24
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Remove the pipe plug on top of the gauge to allow air to bleed from the system. Pump fluid into the system until no air bubbles appear at the plug on the gauge. Tighten the plug and push the damper valve in, turning clockwise to engage the threads. Lay the hydraulic hose out as straight and flat as possible, below the level of the gauge. Remove the plug from the gauge protector body. Pump hydraulic fluid into the system to purge all air from the signal line and the gauge protector. Bleed air out at the gauge protector plug opening. When the signal line and gauge protector appear to be purged of air, continue pumping slowly and rock the gauge protector slightly to help pass any remaining air through the vent holes. Rotate the gauge protector plug end up, to displace any air from the passage. When all the air has been purged from the system, replace the plug on the gauge protector and tighten. Once the plug in the gauge protector is replaced, continue to pump hydraulic fluid into the system until the piston contacts the internal snap ring in the bore of the gauge protector. Close the hand pump cover and remove the pump from the check valve. Replace the check valve cap.
5.1.10 POSITION INDICATOR SYSTEM This system utilizes a 3 to 15 psi (21 to 103 kPa) air signal to operate an indicator gauge on the control console. The signal comes from a plunger type regulator. As the choke is rotated toward the “CLOSE” position, a cam connected to the control console shaft moves the pivot arm assembly. The pivot arm assembly pushes on the regulator plunger and increases the air signal. At the full OPEN position, the signal is 3 psi (21 kPA), at the full CLOSED position the signal is 15psi (103 kPa). The position indicator gauge is labeled OPEN and CLOSE with a mark at the middle position to indicate ½ or 50% open. (The graph in drawing 35 can be used to convert the choke position to an approximate equivalent diameter opening or choke bean size). The position indicator serves as an aid in observing the direction and speed of changes being made in the choke opening. 5.1.11 CALIBRATION AND ADJUSTMENT Connect the supply air from the control console to the left hand tubing fitting, and connect the signal return air to the right hand tubing fitting (figure 13). Turn the air supply on.
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TO ZERO THE “POSITION INDICATOR” GAUGE -
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completely OPEN the choke Loosen the ¼” nut and set screws on the camshaft so the cam turns on the shaft. Rotate the cam shaft so the scribe mark on the short side of the cam lines up with the cam follower. Tighten shaft nut and set screws. Loosen the pivot block locking screw on rear of mounting plate and turn the “zero” adjustment screw until signal output is 3 psi (21 kPa) on a test gauge, or “OPEN” on the position indicator gauge. Tighten pivot block locking screws. Be sure the output is 3 psi (21 kPa) when the locking screw is tight. Movement during tightening may slightly change the setting. This can result in inaccurate readings of the position indicator. If output is not 3psi (21 kPa), adjust block as indicated in Step 5 above the required 3 psi (21kPa). Completely CLOSE the choke. The test gauge should read about 15psi (103 kPa), or “CLOSED” on the position indicator gauge.
TO ZERO THE “SPAN” OF THE INDICATOR GAUGE -
Completely CLOSE the choke. This puts the scribe mark on the long side of the cam at the cam follower. Output should be near 15 psi (103 kPa) on the test gauge, or “CLOSED” on the position indicator gauge. 26
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If less than 15 psi (103 kPa), loosen both socket head cap screws and move regulator bracket slightly away from the pivot block. If more than 15 psi (103 kPa), move regulator bracket slightly toward the pivot block. Tighten both socket head cap screws. Completely OPEN the choke. If output is not 3 psi (21 kPa), re-adjust the pivot block as in Section 5.1.12 to 3 psi (21 kPa). Completely close the choke and check 15 psi (103 kPa) signals Repeat steps 1 through 5 until 3 and 15 psi (21 and 103 kPa) outputs are obtained.
NOTE: If it is not convenient to use the control panel to rotate the choke, use a short adapter connection between the “open” and “closed” connectors, and rotate the choke by hand. However, it is best to check the control console and choke valve together. 5.1.12 DIGITAL STROKE / RATE METER The digital stroke / rate meter is designed for simple maintenance. The meter contains three interconnected modules; a display module, a switch module and a battery pack. Should any one of these modules fail, they are not repairable and must be replaced. Refer to the troubleshooting guide in section 7.1.5. Parts information is given in Drawings 31 and 32. 5.1.13 ACTUATOR ASSEMBLY See the appendix for the manufacturer’s instructions for repair and maintenance of the actuator assembly. 6 PRESSURE TESTING This section describes how to perform a shell and disc hydrostatic test on the SWACO Super Choke. This test is not intended to supersede or duplicate the standard API specification 6A shell and leak tests, but provide a routing procedure to verify that the seals and discs are not leaking and to verify the integrity of the pressure containing parts. 6.1 PROCEDURES 6.1.1 SHELL HYDROSTATIC TEST PROCEDURE -
Completely OPEN the choke discs. Connect test flanges with the pressure manifold as shown in figure 14 to the inlet and outlet flanges of the super choke. Place the super choke with the side of the actuator assembly housing and the outlet flange resting on the ground. The inlet flange is pointing upward (see figure 14).
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With the isolation valves on the inlet and outlet flanges open, fill the choke with water from the outlet end. When the choke appears to be full, raise the outlet end until the centerline of the valve is parallel to the ground (see figure 15).
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Continue filling choke with water. When all of the air has been purged from the choke, close the isolation valve on the outlet flange and disconnect the water line. Lower the choke outlet to ground level. (See figure 14). 28
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Open the hydraulic inlet valve and purge any air that may be trapped in the hydraulic feed line. It may be necessary to purge air from the hydraulic line to the pressure gauge. Open the bleed fitting for the pressure gauge and close the isolation valve on the inlet test flange. Pump hydraulic oil through the gauge line until all air is removed. Close the bleed fitting for the gauge. With the inlet isolation valves closed and the hydraulic inlet valve open, slowly raise the pressure on the choke shell to 10,000 psi (68950 kPa). Check the valve and test flanges for leaks. If leaks occur, stop the test, take appropriate steps to correct the problem and repeat this test procedure. If no leaks are evident at this point, close the hydraulic valve on the inlet test flange and observe the pressure gauge for three (3) minutes. If the pressure begins to bleed down before three minutes inspect the choke and test flange for leaks. Repair leaks as required and repeat this test procedure. Open the isolation valve on the outlet test flange and remove the test flange.
NOTE: Do not block the discharge opening for the isolation valves. When the valves are opened under pressure a small quantity of water will shoot out of the opening. 6.1.2 HYDROSTATIC DISC TEST PROCEDURE -
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To prepare the choke for the hydrostatic disc test, fill the valve with water and remove all of the trapped air as described in Section 6.1.1. Steps 1-7. With the isolation valves on the inlet and outlet test flanges closed, slowly raise the pressure in the choke to approximately 2,500 psi (17238 kPa). With the hydraulic valve open and pump on, close the choke discs. Open the isolation valve on the outlet test flange. This should seat the choke discs. Slowly raise the pressure in the choke to 10,000 psi (68950 kPa) leaving the outlet isolation valve open. Watch the test gauge for three (3) minutes. If the pressure bleeds down, disassemble the choke to determine the cause for the leakage. Replace the discs or seals as required and repeat this test procedure.
7 TROUBLESHOOTING 7.1 DIAGNOSTIC GUIDES 7.1.1 CHOKE DISCS WILL NOT OPEN OR CLOSE Before disconnecting air or hydraulic lines, turn the system off and make absolutely sure that all pressure in the lines has been relieved. Failure to do so may result in injury. -
To locate the problem when the control console will not operate the super choke, turn the mater air supply valve “ON”. The control lever should be in neutral “HOLD” position. Fully open the hydraulic regulator by turning the knob
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counterclockwise several turns. If the hydraulic pump continues to cycle, proceed with the following steps in the order listed (see figure 16).
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Check the hydraulic fluid level in the reservoir. If less than half full, add the correct hydraulic fluid, SWACO part number LSF00003-103. Do not use diesel oil because this will cause some valve seals and hydraulic hoses to deteriorate. Check the low pressure suction hose between the reservoir and the hydraulic pump for leaks, collapse or crimping. This condition will cause the pump to lose prime and not pump fluid. Replace this hose as needed. Check the high pressure hose from the output manifold on the hydraulic pump to the hydraulic regulator and from the hydraulic regulator to the control valve for leaks. Replace these hoses as needed. Disconnect the return line on the hydraulic relief valve. This hose must temporarily be plugged to prevent hydraulic fluid in the reservoir from leaking out. Make certain to remove this plug before reinstalling the hydraulic relief valve return line. If hydraulic oil is leaking form the discharge of the relief valve when the pump is cycling, slowly tighten the pressure adjustment screw on the relief valve while observing the pressure gauge on the output manifold on the hydraulic pump. When the maximum reading on the pressure gauge reaches 1800 psi (12411 kPa) stop tightening the adjustment screw on the relief valve and lower the air pressure on the air regulator feeding the hydraulic pump until the hydraulic 30
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pressure drops to 1500 psi (10342 kPa). At this point, the pump should stop cycling and the relief valve should stop leaking from the return connection. If the relief valve continues to leak, replace it. Remove the return line from the control valve. Start the hydraulic pump and check the return connection for leakage. If hydraulic fluid leaks from this connection, repair or replace the control valve. Refer to the appendix A for the manufacturer’s instructions for the control lever. Remove the pump suction and discharge check valves. Check for debris or a frozen value. Repair or replace as needed. Inspect the open and close hydraulic lines to the choke for crimps, pinching and damage. Replace as needed. Connect the “choke open” hydraulic line to the “choke close” hydraulic line using the quick-connect hose couplings on the actuator assembly. Operate the control lever to both the OPEN and CLOSE positions. If the hydraulic pump begins to cycle when the control lever is moved to the OPEN and CLOSE positions, check the hydraulic lines for the leakage. Reconnect the hydraulic lines to the actuator assembly. Turn off the air supply to the hydraulic pump and bleed the hydraulic system to relieve the pressure in the lines between the hydraulic pump and the rear manifold on the console. Remove the high pressure hose between the hydraulic regulator and the control lever. Make sure the hydraulic regulator is open. Turn on the air supply to the hydraulic pump. If little or no fluid flows through the hydraulic regulator, then it is plugged and must be repaired or replaced. At this point if the control console will still not operate the choke, the problem has been isolated to either the actuator assembly or the choke valve. Remove the actuator assembly (see section 3.1.2) and rotate the actuator using the control console. If the actuator does not rotate, check the routing of hydraulic lines inside the actuator cover (see drawing 5), repair or replace as needed. If the actuator still does not rotate, replace the actuator. (see appendix D for manufacturer’s instructions) If the actuator rotates when the control lever is operated then problem has been isolated to the choke valve. Remove the bonnet end of the choke using the procedure beginning with section 5.1.6. Clear debris from the valve or repair the choke and reassemble.
7.1.2 CHOKE OPENS AND CLOSES TOO SLOWLY -
Check for partial plugging in the hydraulic regulator needle valve and in the check valves of the quick disconnect hose couplings If faster choke response is desired replace the standard 3/16” ID high pressure hose with ¼” ID hose or hard piping. DO NOT EXCEED 1500 psi (10342 kPa) hydraulic pressure. If the turning fork becomes locked, hydraulic pressure greater than 1500 psi (10342 kPa) could result in over-torquing and “twisting off” the end of the turning fork. This condition would make it impossible to control the position of the choke discs. 31
7.1.3 CHOKE VALVE LEAKS -
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Determine the location of the leak. If the leak is at the bonnet end of the valve, remove the bonnet and turning fork from the body as described in section 5.1.6 of this manual. Clean and inspect the sealing surfaces for damage and wear. Replace the seals as required and reassemble the valve as described in section 5.1.6. If the choke valve leaks between the body and outlet spool, remove the super choke from the manifold and repair the outlet spool end of the valve as described in section 5.1.4. If the inlet or outlet flanges leak, remove the valve and replace the seals as described in sections 5.1.4 and 5.1.5.
7.1.4 CHOKE DISCS LEAK There are several conditions that will cause the choke discs to leak. The repair procedure to stop the discs from leaking is to determine the cause for the leak. Section 5.1.5 describes the proper disassembly and inspection procedure. Below is a list of conditions to be checked that will cause the choke discs to leak. -
Dirt, rust or other debris between the discs. Worn or cracked discs. Damaged or improperly sized o-ring around the back disc. Damaged dirty or corroded sealing in surfaces contacting the o-ring around eh back dis. Missing or damaged back disc locking pin. Front disc frozen to the turning fork. Improper alignment of the front disc on the turning fork. Alignment pin may be damaged or missing. Improper orientation of the indicator head on the turning fork. Improper alignment of the actuator shaft on the indicator head. Worn or damaged thrust bearing between the bonnet and turning fork.
7.1.5 DIGITAL STROKE / RATE METER The rate meter contains three modules, which are not field repairable; however, they were designed for easy field replacement. Before replacing any of the modules, make the following check: place the selector switch in the “test SPM” position. If the rate is 128 and the counter counts, the problem is probably with the wiring or the pump stroke switches. The rate meter is working properly. If neither the wiring nor the pump switches are bad, replace the switch module and repeat this test. If the meter does not indicate in the test position, replace the logic module.
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A troubleshooting symptom-cure table follows:
PROBLEM / SYMPTOM Display flashing No display
Display on but is not counting or displaying rate, including the test mode Display is on but does not count or indicate correct rate, but works correctly in “test” mode or for only one pump. Only one input (p1 or p2) works, but okay in “test” mode Count display does not display all digits Erratic count and stroke rate display
CURE / REMEDY Low or bad batteries Replace batteries or check connection to battery pack. If okay, then replace logic module. Replace logic module Check wiring and pump stroke switches
Check wiring and pump stroke switches Replace logic module Cable to the pump switches are not properly shielded or grounded.
7.1.6 PRESSURE GAUGE NOT READING CORRECTLY The pressure gauges located on the super choke control console will, in almost all cases, be the gauges which are used to determine drill pipe pressure and casing pressure during operations involving the use of the SWACO super choke. If these gauges are not working properly, repairs should be made before operations involving the super choke are undertaken. -
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Check that the dampening valve on the gauge is not closed. Check the hydraulic hose to the gauge protector for damage or crimping If the gauge fails to register correctly at higher pressures, check for air in the hydraulic lines or improperly charged lines to the gauge protectors. See section 5.1.9 of this manual. If the hydraulic lines to the gauge protector are longer than 100 ft. (30 meters) hard piping or special steel braided hose will be required.
7.1.7 POSITION INDICATOR NOT WORKING -
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Check the air supply gauge on air regulator attached to the hydraulic pump for a positive reading of 3-35 psi (27-241 kPa). Check air supply and signal lines for leaks and crimping. Make sure the cam is tight on the cam shaft connected to the actuator unit is tight and straight. The cam should turn a full 1800 when the choke position is changed from OPEN to CLOSED or from CLOSED to OPEN. Check choke position, 3 psi (21 kPa) applied directly to the gauge should indicate “OPEN” of the gauge, and 15 psi (103 kPa) should indicate “CLOSED”, if the gauge is in good condition. 33
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If the position gauge does not agree with the calibration band on the choke, see section 5.1.10 for the correct installation and adjustment.
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8 DRAWINGS AND PARTS LIST
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ITEM NO. 1 2 3 4 5 6 7 8 9 10
QTY. 4 4 4 4 2 1 1 1 1 1 2
PART NO. 13-45-295 14-04-164 14-08-562 14-92-031 39-19-153 84-20-200 96-11-376 96-11-421 96-11-631 96-50-384 96-11-431
DRAWING 1, 2-9/16 SUPER CHOKE ASSY. 96-11-630 DESCRIPTION WASHER, LOCK ¾ IN SCREW FERRY ¾-10NC X 3-1/1 IN SCREW SOC HD GRD 8 ¾-10NC X 1-3/4 IN SCREW DRIVE #4 X 3/16 IN GASKET RING API BX153 (NOT SHOWN) DECAL SWACO 6 X 2-1/2 IN ADAPTER ACTUATOR CHOKE ASSY. 10K 2-9/16 IN ACTUATOR NAMEPLATE FLANGE COMPANION 2-9/16 IN (NOT SHOWN)
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ITEM NO. 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
QTY. 4 4 12 16 2 1 1 2 1 1 1 1 2 1 1 1 2 1 1 1 1 6 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PART NUMBER 13-05-043 13-45-127 14-04-163 14-04-183 14-92-031 14-92-250 15-73-243 15-73-273 39-66-338 39-67-149 39-67-151 39-67-216 39-67-237 39-67-342 39-67-348 39-67-915 39-67-916 58-67-261 58-67-430 58-67-436 58-67-521 80-87-264 93-60-904 94-36-145 96-11-111 96-11-214 96-11-215 96-11-216 96-11-352 96-11-354 96-11-360 96-11-422 96-11-423 96-11-425 96-11-427 96-11-428 96-11-429 96-11-432 96-11-439 96-11-556
DRAWING 2, 2-9/16 CHOKE VALVE 96-11-421 DESCRIPTION NUT HEX 7/8-9 NC WASHER FLAT 7/8 IN SCREW FERRY HD ¾-10 NC X 2-1/2 IN SCREW FERRY HD 7/8-9 NC X 3 IN SCREW DRIVE SS # 4 X 3/16 IN SCREW SOC HD 3/8-16 NC X 5/8 IN PIN ROLL SS 3/16 DIA X ½ IN PIN ROLL SS 3/8 DIA X 1-1/2 IN O-RING BUNA-N 90 O-RING VITON 90 O-RING VITON 90 O-RING VITON 90 O-RING VITON 90 O-RING VITON 90 O-RING VITON 90 O-RING TEFLON O-RING BACKUP TEFLON PIN DOWWL SS ¼ SS DIA X ½ IN PLUG CAP 1-5/8 IN PLUG CAP 2-9/16 IN PROTECTOR 9 IN TIE CABLE 8 IN (NOT SHOWN) SPRING WAVE HANDLE CHOKE MANUAL (NOT SHOWN) SLEEVE WEAR 2-9/16 DISC FRONT DISC BACK SLEEVE WEAR FLANGE PROTECTOR RING PROTECTOR 4 IN RING PROTECTOR 5-1/4 IN PROTECTOR, BODY OUTLET BODY, CHOKE 2-9/16 IN SPOOL,OUTLET 2-9/16 IN FORK TURNING BUSHING SHAFT RING THRUST BAND CALIBRATION INDICATOR HEAD BONNET COLLAR
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ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
QTY.
PART NO.
DRAWING 9 PANEL ASSY. SINGLE 96-11-155 DESCRIPTION
2 1 6 4 2 4 6 4 1 2 REF 4 1 2 1 2 4 1 1 1 1 1 1
13-05-236 13-45-241 13-45-338 13-45-339 13-45-489 14-06-649 14-07-051 14-07-472 20-32-544 24-22-244 34-91-100 50-05-096 50-30-196 50-30-352 50-30-449 54-17-526 54-17-567 56-03-156 56-03-292 56-03-368 96-11-052 96-11-143 96-11-398
NUT HEX SS 10-32 WASHER FLAT SS ½ ID X 1 IN OD WASHER LOCK ¼ IN WASHER LOCK 5/16 IN WASHER LOCK # 10 SCREW HEX HD 10-32 NF X ½ IN SCREW HEX HD ¼-20 NC X 5/8 IN SCREW HEX HD SS 5/16-18 NC X ¾ IN HOSE ASSY, 10K 3/16 ID X 18 IN GAUGE 0-10,000 PSI 0-70 KPA 6 IN HANDLE PUMP NIPPLE BRSPUSH LOC ¼ ID X ¼ NPT ELBOW 90D 150 PSI ¼ NPT ELBOW STR 150 PSI ¼ NPT ELBOW 90D 3,000 PSI ¼ IN CONNECOTR FLARED 37D 7/16 NC X ¼ NPT ELBOW MALE 37D ¼ X ¼ NPT VALVE BALL ¼ NPT VALVE 4 WAY 3 POS ¼ NPT VALVE REGULATING ¼ FPT BRACKET PUMP HANDLE GAUGE POSITION INDICATOR ¼ IN BOX CONTROL PANEL
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ITEM NO. 1 2
QTY. PART NO. 1 3
60-07-124 65-60-049
3 4 5
5 2 1
80-62-680 96-11-049 96-11-321
DRAWING 27, METER 2 PUMP W/LIMIT SWITCH 96-11-626 DESCRIPTION BOX CONDUIT EP 3 PRT ½ NPT CONNECTOR CABLE NYLON .250-.375 DIA ½ NPT NUT WIRE WING 12-18 AWG SWITCH LIMIT ASSY. PUMP STROKE METER ASSY, DIGITAL 2 PUMP
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ITEM NO. 1 2
QTY. PART NO. 1 4
60-07-125 65-60-049
3 4 5
6 3 1
80-62-680 96-11-049 96-11-612
DRAWING 28, METER 3 PUMP W/LIMIT SWITCH 96-11-625 DESCRIPTION BOX CONDUIT EP 4 PRT ½ NPT CONNECTOR CABLE NYLON .250-.375 DIA ½ NPT NUT WIRE WING 12-18 AWG SWITCH LIMIT ASSY PUMP STROKE METER ASSY DIGITAL 3 PUMP
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QTY.
PART NO.
DRAWING 29, METER 2 PUMP W/MAG SWITCH 96-11-641 DESCRIPTION
1 2 1 4 1 2
60-07-124 65-60-042 65-60-049 80-62-680 96-11-321 96-11-635
BOX CONDUIT EP 3 PRT ½ NPT CONNECOTR, CABLE NYLON .187-.250 DIA ½ NPT CONNECTOR CABLE NYLON .250-.375 DIA ½ NPT NUT WIRE WING 12-18 AWG METER ASSY DIGITAL 2 PUMP SWITCH ASSY PROXIMITY MAGNETIC
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DRAWING 30, METER 3 PUMP W/MAG SWITCH 96-11-633 QTY. PART NO. DESCRIPTION
ITEM NO. 1 2
1 3
60-07-125 65-60-042
3
1
65-60-049
4 5 6
6 1 3
80-62-680 96-11-612 96-11-635
BOX CONDUIT EP 4 PRT ½ NPT CONNECOTR CABLE NYLON .187-.250 DIA ½ NPT CONNECTOR CABLE NYLON .250-.375 DIA ½ NPT NUT WIRE WING 12-18 AWG METER ASSY DIGITAL 3 PUMP SWITCH ASSY PROXIMITY MAGNETIC
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9 APPENDIX 9.1 BARKSDALE
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9.2 SC HYDRAULIC
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9.3 PINE PUMP
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9.4 FLO-TORK
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