maintenance and operation manual

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P.O. BOX 718 1927 HWY 90 WEST JENNINGS, LA 70546 P 337.616.3300 F 337.616.3299 "QUALITY CREATES TRUST" MAINTENANCE AND OPERATION MANUAL HYDRAULIC CHOKE AND CONTROL CONSOLE

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  • P.O. BOX 718 1927 HWY 90 WEST JENNINGS, LA 70546

    P 337.616.3300 F 337.616.3299

    " Q U A L I T Y C R E A T E S T R U S T "

    MAINTENANCE AND OPERATION MANUAL

    HYDRAULIC CHOKE AND CONTROL CONSOLE

  • INTRODUCTION The Quality Oil Tools, Inc. remote operated Hydraulic Choke has been field proven to be a reliable choke for the drilling industry. Like all mechanical and pressure containing equipment there are certain fundamental rules which operators should observe.

    The basic mechanical operation of the QOT Hydraulic Choke is very simple. However, the applications for which this type of equipment is used may be complex enough to require specific training and experience to complete an operation successfully. The QOT Hydraulic Choke should be operated by, or under the supervision of qualified operators only.

    All mechanical equipment is subject to wear caused by either use or abuse. The QOT Hydraulic Choke and Control Console should be inspected on a regular basic by qualified personnel. Any repairs should be made before undertaking any operations involving the QOT Hydraulic Choke.

    In the event of any problems please contact: Quality Oil Tools, Inc. 1927 Highway 90 West P.O.Box 718 Jennings, Louisiana 70546 Phone: (337) 616-3300 Fax: (337) 616-3299 Email: [email protected]

    mailto:[email protected]

  • I. GENERAL INFORMATION A. CHOKE The Quality Oil Tools, Inc. Hydraulic Choke is a hydraulically operated valve with an adjustable orifice. In the fully open position the maximum orifice size is 1.9 square inches (12 cm2) to complete closed. The orifice size is controlled by means of rotating the 'Front' (upstream) disc from 00 to 180 while the 'Back' (downstream) disc remains stationary. The 'Front' disc is rotated by a hydraulically-driven rotary actuator. The discs, constructed of Tungsten Carbide, are precision ground and lapped to a mirror like finish. (See Figure 1)

    Figure 1 The Quality Oil Tools, Inc. Hydraulic Choke was designed primarily to control high pressure gas kicks and various fluid flows during drilling operations but can be used in a variety of applications. B. CONTROL PANEL The control panel is normally used to operate the QOT Hydraulic Choke from a remote location. The panel is portable and may be located at any safe location to satisfy specific needs or requirements that the customer may have. In cases where more than one panel is required to satisfy needs or requirements, additional panels may be added with only minor adjustments to hose and fittings, etc.

    Figure 2.

    -3-

  • The control panel is a completely self-contained unit with the exception of an air supply. The air input requirements are a minimum of30 PSI, however 50-125 PSI with an available 10 cubic ft/min. (CFM) is recommended for maximum performance. There are no electrical requirements for the panel or choke. The stroke counter assembly has a 6 Volt battery pack located inside the counter box. The battery pack is a replaceable/expendable item that should last approximately 36 months under normal conditions. Should the air operated hydraulic pump fail, the choke may still be operated by using the manual hydraulic pump located on the control panel base. This method of operation will work only if the remaining hydraulic systems are intact. If air pressure is lost the position indicator gauge will not work. Should the hydraulic system have a complete failure, provisions have been made for manual choke operation by inserting a bar into the indicator head. The indicator head features an indicator band so adjustment of the orifice size is still possible. For multiple choke installations, QOT also offers a Dual Choke Control Console (Figure 3). Two chokes can be operated with this console without the need for an auxiliary panel or two single consoles.

    Figure 3

    -4-

  • 2. INSTALLATION

    A. INSTALLING THE CHOKE

    The standard inlet and outlet connections supplied on the QOT Hydraulic Choke are API Type 2-9/16" 10,000 psi WP with a BX-153 ring groove or a 3-1/16" 10,000 psi WP with a BX-154 ring groove.

    All Hydraulic Choke assemblies have a series of solid Tungsten Carbide wear sleeves and a flange protector. The flange protector when installed extends 1/8" ( 4mm) from the face of the outlet flange. This will protect the ring groove and flange from 'washing out'.

    NOTE: MAKE SURE THAT THE MATING FLANGE BEING BOLTED TO THE HYDRAULIC CHOKE OUTLET SPOOL DOES NOT INTERFERE WITH THE FLANGE PROTECTOR. THIS COULD CRUSH THE CARBIDE PARTS INSIDE THE CHOKE.

    Always check all bolting studs and nuts for cracks, damages, and wear to threads before installing. Any damaged parts should be replaced.

    Always use new gaskets when installing the choke. (Refer to API Specification 6A for Wellhead and Christmas Tree Equipment).

    The nuts should be evenly torqued and have full engagement onto the stud. The stud should have 3 to 4 threads showing for best results. After torquing the nuts, the flange raised faces should come together and be parallel to the companion or adapter flanges.

    Whenever possible, two gate or positive sealing valves should be installed upstream of the choke (between the Blowout Preventer and the choke) and one downstream of the choke to permit isolation for maintenance while other sections of the manifold are in use. When using a flare line from the choke it must be securely anchored according to API Specifications. (Refer to API Bulletin RP 53).

    Whenever the choke is reassembled or installed/reinstalled in the manifold the choke should be retested. Refer to -Section 5- of this manual for test procedure.

    B. REPOSITIONING THE ACTUATOR

    After installing the Hydraulic Choke assembly in the manifold, it may be necessary to reposition the hydraulic actuator. The actuator assembly should have the open area facing down or to the side to facilitate excess water drain -off. Should the actuator assembly not be positioned properly the following procedure should be followed to rotate it to the proper position.

    1) Remove the four mounting bolts which attach the Actuator Assembly to the mounting bracket.

    2) Pull the Actuator Assembly away from the choke body until the square shaft clears the Indicator Head.

    NOTE: DO NOT ROTATE THE SQUARE SHAFT OR INDICATOR HEAD DURING THIS OPERATION. DOING SO WILL CHANGE THE ALIGNMENT OF THE DISC OR CHANGE THE POSITION INDICATOR AND THE CHOKE WILL NOT FUNCTION PROPERLY;

    3) Rotate the entire actuator assembly 90 or 180 to the desired position.

    4) Clean and grease the square shaft and push the actuator assembly into the indicator head.

    5) Install the four bolts removed previously and tighten them to 27 ft-lbs.

    -5-

  • C. HYDRAULIC CONTROL LINES

    Connect the two 3/16"3,000 psi hydraulic hoses (with 1/4" Male and Female Couplings) to the choke control panel and the Hydraulic Choke actuator assembly using the quick disconnects. (See Figure 4) They should be placed in such a manner as to prevent damage by sharp edges and hazards for rig personnel.

    D. CHOKE POSITION INDICATOR

    The panel is equipped with 1/4" O.D. vinyl poly flow tubing. Connect the 1/4" O.D. vinyl tubing from the fitting on the position indicator regulator (located inside the actuator box assembly) to the position indicator gauge (located on the control console face).

    1) Layout and cut 1/4" tubing to the desired length. 2) Connect the tubing to the rear of the panel labeled "Air to Transmitter" and "Air

    Return from Transmitter." Note: Tubing connectors provided on the panel and actuator are a "Push On" type. Simply push the tubing onto the connector and pull back to insure connection. To release: Push the ring into the fitting and pullout the hose.

    3) The fittings on the position indicator regulator are not labeled. Check the arrow located on the position indicator regulator to determine the direction of flow.

    4) Turn the air supply valve on the control panel to the on position. Operate the choke valve to the full open position by holding the controls lever in the choke open position until the pump stalls. The position indicator gauge should show open, if the gauge is not calibrated correctly, recalibrate per procedures described in Section 4.8.

    NOTE: THE CONTROL P ANEL AND CHOKE VALVE ARE SHIPPED FROM QUALITY OIL TOOLS FULLY CALIBRATED. - Push the control lever to the right toward the choke close position. 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 stalls; then release the lever. The control valve lever should return to the center position.

    If there are any problems with any of these operations, refer to -Section 6- of this manual.

    E. INSTALLING THE CONTROL PANEL

    Place the panel in a 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.

    1) AIR SUPPLY

    Connect a rig air supply to the rear of the panel. The inlet for the rig air is labeled "Rig Air Supply." (See Figure 5) The air supply should be capable of supplying a constant moisture-free 50-120 psi of air. Trash or moisture in the air supply can cause a malfunction in the air operated hydraulic pump or in the position indicator assembly. The air supply should be connected to a source that will not be disconnected from the panel.

    Care should be taken when routing the air supply to avoid damage to the hose by crimping, cutting or from excessive heat. A hose of diameter should be capable of supplying an adequate amount of air for proper operation up to 50 feet. Should a longer hose be required, a diameter hose is recommended. The panel is equipped with a 1/2" NPT male connection for installing the air supply line.

    -6-

  • 2) PUMP STROKE COUNTER

    The QOT pump stroke counter is a digital readout type, which is powered by a built in battery pack located inside the pump stroke counter box. No external electrical power supply is required. The meter comes complete with a 125' limit switch assembly (magnetic proximity switches optional).

    The limit switch assemblies mount to the mud pump frame near the exposed portion of the pump rods so that the pump rod collar or "splash guard" will contact the limit switch "whisker rod". Mount the limit switch assemblies to the pump frame using the C-Clamp bolted to the switch. There should be one full deflection and release of the "whisker rod" for each pump stroke to assure proper operation of the stroke counter and to avoid double counting. Route the cable from the switch assembly to the panel so that it will not be cut or damaged. (NOTE: The panel and switch assemblies are pre-wired and no further connections are required.)

    Operate the pump stroke counter switch assemblies by hand to determine Pump #1, #2 or #3. There is a pump selector switch located on the bottom of the pump stroke counter box inside the panel. This switch is used to select the desired pump stroke count and rate being displayed.

    3) GAUGE PROTECTOR

    Two gauge protectors have been provided with the panel. Connect the drill pipe pressure gauge protector (See Figure 5) assembly to the rig standpipe and the casing pressure gauge assembly to the choke manifold. Whenever possible mount the assembly in the upright position with the hammer nut down, this will allow the mud and drilling fluids to drain from the unit when no pressure is in the manifold Connect the hose from the gauge protector to the drill pipe pressure or casing pressure gauge on the panel Use caution when running the hose so that it does not get cut, crimped, worn, or burned by other equipment.

    The gauge protectors are rated for 10,000 psi WP and may be mounted to a 2" Figure 1502 female hammer union hub on the standpipe and choke manifold. The gauge protector lines should be filled with hydraulic fluid prior to leaving Quality Oil Tools. If the lines are not filled see -Section 4.7 .B- of this manual for the hydraulic line filling procedure.

    -7-

  • F. MULTIPLE CHOKE INSTALLATION

    Dual Panel

    If two QOT Hydraulic Choke valves are used in the manifold, they both may be operated from a Dual QOT control panel. The Dual panel is installed in the same manner as the Single panel. On the rear of the Dual panel there are OPEN and CLOSE connection ports for each choke. There are also "air to" and "air return" lines for each choke. It is very important not to interchange the lines from Choke 1 with the lines from Choke 2. It is recommended to install one set of lines at a time. The OPEN and CLOSE lines for Choke 1 and Choke 2 are clearly marked adjacent to the connections. The gauge protector assemblies and supply air are installed in the same manner as a Single Control Console.

    3. OPERATION

    The choke discs should remain in the full OPEN position when the choke is not in use. Operation of the QOT Hydraulic Choke should always begin with the choke in the OPEN position. (Closed choke discs may result in hydraulic shock in the well bore and if the mud pumps are running can result in lost returns and a downhole blowout.) For example: at the start of a well control procedure, the choke e. should not be closed until after the blowout preventer has been closed and drilling fluid is flowing through the manifold and Hydraulic 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.

    A. NORMAL OPERATING METHOD (FAST)

    1) Move master AIR SUPPLY valve to the ON position (See Figure 2).

    2) Open the HYDRAULIC REGULATOR all the way. 3) 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). Mud pumps stroke rate and stroke count.

    4) Be prepared to shift the CONTROL LEVER in either direction to maintain the desired casing or drill pipe pressure.

    NOTE: A PLUGGED CHOKE MAY RESULT IN EXCESS PRESSURE BUILD-UP IN THE SYSTEM THAT 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.

    5) 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.

    -8-

  • B. ALTERNATE OPERATING METHOD (SLOW)

    1) If slow operation is desired, close the HYDRAULIC REGULA TOR 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 disc. When the desired pressure is reached, the CONTROL LEVER should be released.

    2) Open the HYDRAULIC REGULATOR valve if a faster response is needed.

    C. EMERGENCYOPERATION

    1) Failure of air supply to air pump.

    a) 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).

    b) To change choke opening, hold the CONTROL LEVER in the desired position while stroking the HAND PUMP .

    2) Rupture in Hydraulic line or connection.

    a) If either hydraulic line is cut or ruptures, 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.

    b) Insert 5/8" (16mm) diameter rod into one of the holes in the INDICATOR HEAD (See Figure 5) and manually position the choke as desired.

    Figure 5.

    -9-

  • 4. SERVICE AND MAINTENANCE

    A. PROCEDURES

    1) ROUTINE INSPECTION

    The QOT Hydraulic Choke is a key element of the pressure control system used to prevent rig blowouts. Therefore, it is important that the Hydraulic Choke and Control Console be maintained in good operating condition at all times (See Figure 6).

    Figure 6

    2) DAILY VISUAL CHECKS

    heck the presence of a hand pump (Item 2 ), a manual choke operating bar, and all panel labels.

    Check fluid level in the hydraulic oil reservoir (Item I ). 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 l or Pump 2 and observe counter and rate display. Reset counter to zero after test.

    -10-

  • See that the pump stroke counter switches (Item 3 ) are properly attached to the mud pump and counting the correct number of strokes.

    3) DAILY OPERATIONAL CHECKS

    Turn the master air supply valve (Item 5) on. The hydraulic pressure gauge (Item 12 ) should show 1000-1100 psi (6895-7584 kPa).

    Close the hydraulic regulator (Item II) and then open I-I/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 l0) should track the choke disc movement according to the choke lever selection.

    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 the 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 value should be approximately the same as the rig gauges. Gauge faces should be clean and visible.

    4) REMOVING THE QOT HYDRAULIC CHOKE FROM THE MANIFOLD

    CAUTION: BEFORE ATTEMPTING TO WORK ON A ULTRAFLOW CHOKE IN A MANIFOLD, EXTREME CAUTION SHOULD BE EXCERCISED TO ASSURE THAT THERE IS NO PRESSURE TRAPPED IN THE CHOKE VAL YE OR CHOKE MANIFOLD. AL WAYS USE PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAYBE TRAPPED IN THE CHOKE VAL YE OR MANIFOLD. ONLY PERSONNEL WHO HA YE RECEIVED INSTRUCTION ON THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT AND PROCEDURES FOR WORKING IN AREAS WHERE H2S MAY BE PRESENT SHOULD BE PERMITED TO WORK ON THE HYDRAULIC CHOKE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN INJURY.

    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 then carefully loosen the upstream flange nuts one turn until seal is broken and any trapped pressure is released, then remove the nuts and studs on the inlet flange.

    -11-

  • CAUTION:

    THE ULTRAFLOW CHOKE IS RATED FOR H2S SERVICE THEREFORE THE MATERIALS USED TO MANUFACTURE THE FLANGES, NUTS, AND STUDS ARE RELA TIVEL Y SOFT AND SUBJECT TO SURFACE DISTORTION AND DENTS FROM POOR WORK PRACTICES. CARE SHOULD BE EXCERCISED IN THE HANDELING PROCEDURES AND USE OF TOOLS WHEN WORKING ON THE UL TRAFLOW CHOKE TO A VOID DAMAGING THESE PARTS. DAMAGED PARTS WILL ADVERSELY AFFECT THE STRUCTURAL INTEGRITY OF THE UL TRAFLOW CHOKE AND MA Y RESULT IN INJURY.

    1. Refer to -Section 2.A- of this manual for reinstalling the choke in the manifold-

    5) CHANGING THE DISC ASSEMBLIES

    This section describes the procedure for removing the discs from the outlet end of the valve body for inspection and or replacement and removal of the wear sleeves.

    CAUTION

    BEFORE ATTEMPTING TO WORK ON A ULTRAFLOW CHOKE, EXTREME CAUTION SHOULD BE EXCERCISED TO ASSURE THAT THERE IS NO PRESSURE TRAPPED IN THE CHOKE VALVE. AL WAYS USE PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAY BE TRAPPED IN THE CHOKE VALVE. ONLY PERSONNEL WHO HA VE RECEIVED INSTRUCITON ON THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT AND PROCEDURES FOR WORKING IN AREAS WHERE H2S MAYBE PRESENT SHOULD BE PERMITTED TO WORK ON THE HYDRAULIC CHOKE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN INJURY.

    Carefully loosen the outlet-spool bolts on 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. .

    1. 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 disc opening.

    2. Insert the hook end of the disc puller in the disc opening as illustrated in Figure 6a. and gently remove both discs using the sliding weight on the puller.

    CAUTION

    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.

    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.

    -12-

  • Figure 6a.

    3 . Clean both disc assemblies thoroughly and inspect for wear or damage. The primary criteria for determining whether or not the choke discs are reusable is that they can provide a positive seal under pressure when installed in the choke. See -Section 5.2- of this manual for Hydrostatic Disc Test Procedure.

    4. Wash out and clean the interior of the choke body and the O-ring sealing surfaces.

    5 Remove the O-rings on the back disc carrier and the choke body flange

    and replace these O-rings. CAUTION THE O-RINGS USED IN THE ULTRAFLOW CHOKE ARE MADE OF A SPECIAL RESISTANT MATERIAL. USE ONLY O-RINGS SPECIFIED IN PARTS LIST INCLUDED AT REAR OR THIS MANUAL

    6. 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.

    7. 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.

    -13-

  • 8. 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. Note: The moon-shaped opening must be facing the inlet flange of the choke valve. (See Figure 7).

    Figure 7

    9. 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.

    10. Inspect the wear sleeves for wear and replace as necessary.

    11. 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.

    12. 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.

    13. 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 Parts Listing at rear of this manual to assemble. Discard and replace any damaged screws. Tighten these screws uniformly. The bolts should be torqued to 165 Mbs (224 Nm). Over-torquing the bolts will cause them to stretch and reduce their strength which can result in premature failure.

    -14-

  • 14. Clean and inspect the inlet and outlet flange faces and ring grooves. Apply a light film of general purpose grease or rust inhibitor to the face and ring groove for corrosion protection.

    6) BONNET END DISASSEMBLY

    This section describes the procedure for removal of the Actuator Assembly and Bonnet from the Choke Valve. It also covers the removal and inspection of the turning fork. These procedures may be done with the Hydraulic Choke either installed in the choke manifold or removed.

    CAUTION BEFORE ATTEMPTING TO WORK ON AN HYDRAULIC 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 INSTRUCTIONS ON THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT, AND PROCEDURES FOR WOKING IN AREAS WHERE H2S MAY BE PRESENT SHOULD BE PERMITED TO WORK ON THE HYDRAULIC CHOKE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN INJURY.

    I. The first step in 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 attaching the adapter to the Actuator. This exposes the four bolts that attach the adapter to the Choke Valve. Remove these bolts and proceed to the next step.

    2. Remove the cap screw attaching the Indicator Head to the Turning

    Fork. Remove the Indicator Head from the Turning Fork shaft.

    3. 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 screw attaching the Bonnet to the body. Inspect these screws for damage or distortion and replace as necessary. Use only bolts specified in parts list at the rear of this manual. Remove the Bonnet from the Valve Body.

    CAUTION MOST COMMON BOLTS, STUDS AND NUTS AVAILABLE DO NOT MEET THE REQUIEMENTS FOR H2S SERVICE AND WILL FAIL FROM HYDROGENT EMBRITTLEMENT. REPLACE BOLTS, STUDS AND NUTS WITH AUTHORIZED REPLACEMENT PARTS.

    4. Push the Turning Fork out of the Bonnet being careful not to damage the shaft surfaces that rotate inside the Bonnet.

    5. Clean the Turning Fork and inspect for wear or damage. The Thrust

    Bearing and O-ring 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.

    -15-

  • 6. Replace the Thrust Bearing, Shaft Bushing, all O-rings and backup rings on the Bonnet. The parts that are used in the UltraFlow Choke are made of special material for exposure to H2S gas. Use only parts specified in parts list at rear of this manual to replace components in the Hydraulic Choke.

    7. Reinsert the Turning Fork in the Bonnet being careful not to damage

    the 0- 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.

    8. 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.

    9. 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 problem:; when assembling the Actuator Assembly to the valve.

    10. 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.

    11. 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 up-side 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 (224 Nm.) Over-torquing the bolts will cause them to stretch and reduce their strength which can result in premature failure.

    7) GAUGE PROTECTOR

    The purpose of the Gauge Protector is to transmit fluid pressure from the drill pipe or the casing to the Control Console and isolate the gauges from the drilling mud. A. Gauge Protector Repair

    1. 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.

    2. Remove the body from the female hub by removing the wing nut. 3. Remove the stainless steel internal snap ring from the bore of the

    gauge protector body.

    -16-

  • 4. Insert a 1/2"-13NC bolt in the tapped hole at the bottom of the piston. Use the bolt as a handle to extract the piston.

    5. Clean the piston and replace the O-rings on the piston. Use only the

    size and type O-ring called for in the parts list at the rear of this manual.

    PISTONSTYLE GAUGE PROTECTOR CAUTION THE O-RINGS USED IN THE GUAGE PROTECTOR ARE MADE OF A SPECIAL H2S RESISTANT MATERIAL. USE ONLY THE O-RINGS SPECIFIED IN THE PARTS LIST AT THE REAR OF THIS MANUAL.

    6. Clean and inspect the bore of the gauge protector body for corrosion, wear and pitting. Replace the body if these conditions exist.

    7. 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.

    8 Reinstall the stainless steel internal snap ring. Refer to -Section 4.7 B-

    of this manual for refilling the gauge protector with hydraulic fluid. The body plug is replaced during the line filling procedure.

    B. 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 disconnection 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.

    -17-

  • 1. 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.

    2. Remove the check valve cap on the back of the Control Console

    manifold and attach the hand pump loosely to the check valve (See Figure 8). Do not tighten this connection yet.

    3. Fill the manual hand pump reservoir with hydraulic fluid. While

    purging, keep the hand pump reservoir at least 1/2 full to avoid pumping air into the line.

    4. 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.

    5. Turn the damper valve on the gauge counterclockwise several

    turns to relieve the dampening effect.

    6. Remove the pipe plug on top of the gauge to allow air to bleed from the system.

    RESERVOIR COVER

    HAND PUMP Figure 8

    7. 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.

    8. Lay the hydraulic hose out as straight and flat as possible, below

    the level of the gauge.

    9. Remove the plug from the gauge protector body.

    10. 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.

    -18-

  • 11. When the signal line and gauge protector appear to be purged or 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.

    12. When all the air has been purged from the system, replace the plug on the

    gauge protector and tighten.

    13. Once the plug in the gauge protector is replaced, continue to pump hydraulic fluid into the system until the piston contact the internal snap ring in the bore of the gauge protector.

    14. Close the hand pump cover and remove the pump from the check valve. 15. Replace the check valve cap.

    8) 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 15 psi (103 kPa).

    The Position Indicator gauge is labeled OPEN and CLOSE with a mark at the middle position to indicate Y2 or 50% open. The Position Indicator serves as an aid in observing the direction and speed of changes being made in the choke opening.

    Calibration and Adjustment

    Connect the supply air from the Control Console to the left tubing fitting, and connect the signal return air to the right tubing fitting. Turn the air supply on (See figure 9).

    -19-

  • Figure 9.

    A. To Zero the "Position the Indicator" Gauge

    1. Completely OPEN the choke.

    2. Loosen the 1/4" nut and set screws on the camshaft so the cam turns on the shaft.

    3. Rotate the cam so the scribe mark on the short side of the cam lines

    up with cam follower.

    4. Tighten shaft nut and set screws.

    5. 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.

    6. Tighten pivot block locking screws.

    7. Be sure the output is 3 psi (21 kPa) when the 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 3 psi (21 kPa), adjust pivot block as indicated in Step 5 above to obtain the required 3 psi (21 kPa).

    8. Completely CLOSE the choke. The test gauge should read 15 psi

    (103 kPa), or "CLOSED" on the position indicator gauge. If not, it will be necessary to adjust the span of the Indicator Gauge.

    -20-

  • B. To Zero the "Span" of the Indicator Gauge

    1. 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.

    2. If less that 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.

    3. Tighten both socket head cap screws.

    4. 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).

    5. Completely close the choke and check 15 psi (103 kPa) signals.

    6. Repeat Steps 1 through 5 until3 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. 9) DIGITAL PUMP/STROKE RATE METER

    The QOT Digital Stroke / Rate Meter has been designed for simple maintenance. The meter contains three interconnected modules; a display module, a switch module and a battery pack. Should anyone of these modules fail, they are not repairable and must be replaced. Refer to the Troubleshooting Guide in -Section 6.5-. Parts information is given in the rear of this manual.

    10) ACTUATORASSEMBLY

    See the Appendix for the manufacturer's instructions for repair and maintenance of the Actuator Assembly.

    5. PRESSURE TESTING

    This section describes how to perform a shell and disc hydrostatic test on the Hydraulic Choke. This test is not intended to supersede or duplicate the Standard API Specification 6A Shell and Leak Test, but provide a routine procedure to verify that the seals and discs are not leaking and to verify the integrity of the pressure containing parts.

    A. PROCEDURES 1) SHELL HYDROSTATIC TEST PRESSURE

    1. Completely OPEN the choke discs.

    -21-

  • 2. Connect test flanges with isolation valves to the inlet and outlet flanges of the Hydraulic Choke.

    3. Place the Hydraulic Choke with the side of the Actuator Assembly

    housing and the outlet flange resting on the ground. The inlet flange is pointing upward.

    4. 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.

    5. 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.

    6. Open the hydraulic inlet valve and purge any air that may be trapped in the

    hydraulic feed line.

    7. 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.

    8. With the inlet and outlet 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.

    9. 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 flanges for leaks. Repair leaks as required and repeat this test procedure.

    10. Open the isolation valve on the outlet test flange and remove the test flanges.

    CAUTION 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. 2) HYDROSTATIC DISC TEST PROCEDURE

    1. 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 5.A.l- Steps 1-7.

    2. 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).

    3. 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.

    -22-

  • 4. 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.

    6. TROUBLESHOOTING A. DIAGNOSTIC GUIDES 1. CHOKE DISCS WILL NOT OPEN OR CLOSE CAUTION 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 Hydraulic Choke, turn the master air supply valve "ON". The control lever should be in the neutral "HOLD" position. Fully open the hydraulic regulator by turning the knob counterclockwise several turns. If the hydraulic pump cycles a few times and stops, proceed to Section -6.A.I-. Step 5.

    If the hydraulic pump continues to cycle, proceed with the following steps in the order listed (See Figure 10).

    1. Check the hydraulic fluid level in the reservoir. If less than half full, add the correct hydraulic fluid, Do not use diesel oil because this will cause some valve seals and hydraulic hoses to deteriorate.

    2. 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.

    3. 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.

    Figure 10

    -23-

  • 4. 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 from 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 this 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 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.

    5. 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.

    6. Remove the pump suction and discharge check valves. Check for debris or a

    frozen valve. Repair or replace as needed.

    7. Inspect the open and close hydraulic lines to the choke form crimps, pinching and damage. Replace as needed.

    8. Connect the "Choke Open" hydraulic line to the "Choke Close" hydraulic line

    using the quick-connect hose coupling 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 and proceed to Step 9. Reconnect the hydraulic lines to the Actuator Assembly.

    9. 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.

    10. 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 2.B.) and rotate the Actuator using the Control Console. If the Actuator does not rotate, check the routing of hydraulic lines inside the Actuator cover and 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 the problem has been isolated to the Choke Valve. Remove the Bonnet end of the choke using the procedure beginning the -Section 4.6-. Clear debris from the valve or repair the choke and reassemble.

    2) CHOKE OPENS OR CLOSES TOO SLOWLY

    1. Check for partial plugging in the hydraulic regulator needle valve and in the check valves of the quick disconnect hose couplings.

    -24-

  • 2. If faster choke response is desired replace the standard 3/16" ID high pressure hose with 1/4" ID hose or hard piping. DO NOT EXCEED 15 psi (103 kPa) hydraulic pressure. If the Turning Fork becomes locked, hydraulic pressure greater than 15 psi (103 kPa) could result in over- torqing and "twisting off' the end of the Turning Fork. This condition would make it impossible to control the position of the choke discs.

    3) CHOKE VALVE LEAKS

    1. 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 4.6- of this manual. Clean and inspect the sealing surface for damage and wear. Replace the seals as required and reassemble the valve as described in -Section 4.6-.

    2. If the Choke Valve leaks between the body and outlet spool, remove the

    Hydraulic Choke from the manifold and repair the outlet spool end of the valve as described in -Section 4.5-.

    If the inlet or outlet flanges leak, remove the valve and replace the seals as described in -Sections 4.5 and 4.6.

    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 disassemble the choke from the outlet end and examine the internal parts to determine the cause for the leak. -Section 4.5- 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 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

    5) DIGITAL PUMP 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.

    -25-

  • If the meter does not indicate in the test position, replace the logic module.

    A troubleshooting symptom-cure table can be found at the rear of this manual.

    6) PRESSURE GAUGES NOT READING CORRECTLY

    The pressure gauges located on the QOT Choke Control Console will, in almost all cases, be the gauges which are used to determine drillpipe pressure and casing pressure during operations involving the use of the QOT Hydraulic Choke. If these gauges are not working properly, repairs should be made before operations involving the Hydraulic Choke are undertaken.

    1. Check that the dampening valve on the gauge is not closed. 2. Check the hydraulic hose to the gauge protector for damage or

    crimping.

    3. 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 4.7.B- of this manual.

    4. 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) POSITION INDICATOR NOT WORKING

    1. Check the air supply gauge on air regulator attached to the hydraulic pump for a positive reading of 3-35 psi (27-241 kPa).

    2. Check air supply and signal lines for leaks and crimping.

    3. Make sure the cam is tight on the cam shaft and the cam shaft

    connected to the actuator unit is tight and straight. The cam should turn a fu11 180 when the choke position is changed from the OPEN to CLOSED or from CLOSED to OPEN.

    4. 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.

    If the position gauge does not agree with the calibration band on the choke, See -Section 4.8.A&B- for the correct installation and adjustment.

    -26-

  • MAINTENANCE AND OPERATION MANUAL

    PUMP STROKE RATE METER

    Quality Oil Tools, Inc. Jennings, Louisiana P: (337) 616-3300 F: (337) 616-3299

  • DISCLAIMER Any recommendation for use, oral or written, shall be considered advisory in content and as such, Quality Oil Tools, Inc. shall not be held liable under any warranty, expressed or implied, should this product not perform under conditions other than its intended use as a accumulative pump stroke counting device. Quality Oil Tools, Inc. shall in no way be liable for damages incurred while using this product. File copies of this manual are maintained. Revisions and/or additions will be made as deemed necessary by Quality Oil Tools, Inc. The drawings in this book are not drawn to scale, but any dimensions are accurate.

  • INTRODUCTION As with any electronic equipment the Quality Oil Tools, Inc. Pump Stroke/Rate Meter Assembly is subject to wear and eventual failure. Periodic disassembly and inspection is required and should be left to a qualified repair technician. Every precaution has been taken to ensure the highest quality product has been provided for use. Any question or correspondence should be directed to: Quality Oil Tools, Inc. P. O. Box 718 Jennings, Louisiana 70546 Telephone number (337) 616-3300 Fax (337) 616-3299 Email: [email protected]

  • *** TABLE OF CONTENTS *** SECTION I GENERAL INFORMATION

    W ARRANTY INFORMATION SECTION II TROUBLE SHOOTING AND MAINTENANCE SECTION III REPLACEMENT PARTS

  • SECTION I GENERALINFORMATION The Quality Oil Tools, Inc. Digital Pump Stroke Rate Meter is a intrinsically safe Class 1, Div. 1 unit designed for simple maintenance. Because this unit is intrinsically safe no explosion proof housing or switches are required. The meter contains three interconnected modules. They are the display module or PCB, the switch module and the battery pack. Should anyone of these modules fail they will have to be replaced as they are not field repairable. The logic module (PCB) can be repaired if returned to Quality Oil Tools, Inc. factory. Section II provides a trouble-shooting guide to assist in the repair of the counter assembly. Section III provides a list of replacement parts for the Quality Oil Tools, Inc. Pump Stroke/Rate Meter . We have made every effort to document all necessary information which will allow users to install and operate the QOT Rate Meter. This information has been carefully reviewed and is believed to be accurate. However, no responsibility is assumed for inadvertent omissions or errors that may appear in this document.

    -31-

  • WARRANTY INFORMATION Quality Oil Tools, Inc. Pump Stroke/Rate Meter is warranted to be free of defects in material and workmanship under normal usage for a period of one year . This warranty applies to the original purchaser only. The warranty period shall be for one year from the date shipped when the product is used in a manner for which it was manufactured. Quality Oil Tools, Inc. liability for the Meter Assembly shall be limited to replacement, free or charge on any parts found to be defective in materials or workmanship. This limited warranty does not include service to repair damage to the product resulting from accident, lightning, high voltage, disaster, misuse, abuse, modification or service to the product unauthorized by Quality Oil Tools, Inc.

  • SECTION II TROUBLESHOOTING AND MAINTAINENCE This section discusses troubleshooting and maintenance for the digital stroke/rate meter system assembly. The Pump Stroke/Rate Meter system is powered by a built in battery pack. No outside source or power is required. The meter assembly contains three modules which were designed for easy field replacement. Before replacing any of the three modules, check the counter assembly as follows:

    Place the selector switch in the "Test SPM" position. The rate meter should read: "60 strokes / min. and count 1,2,3,4 "

    Should the counter read as above it is working properly and the problem may be in the wiring or limit switch assemblies.

    If after making any necessary repairs the counter is still not working properly the

    switch module should be replaced.

    If there are no indications in the Test/Spill position or the readout is not working properly, replace the Logic Module.

    REMEMBER: LIMIT SWITCHES MUST BE WIRED IN NORMALLY OPEN

    FOR MAXIMUM BATTERY PACK LIFE.

    -33-

  • Hydraulic Choke Maintenance Manual Release 1.0 July, 2004

    8

    Quality Oil Tools, Inc. P. O. Box 718

    Jennings, Louisiana 70546 Telephone: (337) 616-3300

    Fax: (337) 616-3299 E-mail: [email protected]

    API-6A-0607 Q1-0036

    ISO 9001:2000-0308

    CoverGeneral InformationInstallationOperationService and MaintenancePressure TestingTroubleshootingMaintenance and Operation - Pump Stroke Rate MeterGeneral InformationTroubleshooting and MaintenanceReplacement Parts

    Diagram-Piston Gauge Protector Assy.Diagram-Choke Assy.