Manual Swaco.pdf 2g393v

15K Disc Choke With/Without Actuator; Low Specifications Field Installation and Operation Manual For Assemblies: C1 Z _ _ 3 B 15 _ E 1 M _ _ X G A A R Z 3 X B B D X

9092A01003AENG (--) Publication Date: 07 June 2014

This document has been translated from English for the ’s convenience only. In the event of a conflict between this translated document and the English version, the English version takes precedence. M-I SWACO makes no guarantees or warranties regarding the accuracy of the translation. Therefore, the agrees to use this translated document at their own risk and to hold M-I SWACO harmless for any claims / losses / causes of action arising from their use of this translated document. This document has been translated from English for the ’s convenience only. In the event of a conflict between this translated document and the English version, the English version takes precedence. M-I SWACO makes no guarantees or warranties regarding the accuracy of the translation. Therefore, the agrees to use this translated document at their own risk and to hold M-I SWACO harmless for any claims / losses / causes of action arising from their use of this translated document.

This information is supplied solely for informational purposes and M-I SWACO makes no guarantees or warranties, either expressed or implied, with respect to the accuracy and use of this data. All product warranties and guarantees shall be governed by the Standard of Sale. Nothing in this document is legal advice or is a substitute for competent legal advice. This information is supplied solely for informational purposes and M-I SWACO makes no guarantees or warranties, either expressed or implied, with respect to the accuracy and use of this data. All product warranties and guarantees shall be governed by the Standard of Sale. Nothing in this document is legal advice or is a substitute for competent legal advice.

M-I SWACO 15K Disc Choke, Low Specifications

TABLE OF CONTENTS 1. FORWARD ............................................................................................................................................................................. 1 2. PREFACE................................................................................................................................................................................ 1 3. HEALTH SAFETY AND ENVIRONMENT (HSE) .............................................................................................................. 2 3.1 Personal Protective Equipment ....................................................................................................................................... 2 3.2 Equipment Hazards ........................................................................................................................................................ 3 3.2.1 Equipment Lock Out and Tag .............................................................................................................................. 3 3.3 Hazardous Materials ....................................................................................................................................................... 4 3.3.1 Grease Perflouropolyether Christolube MCG 136 N ........................................................................................... 4 4. SPECIFICATIONS ................................................................................................................................................................. 5 4.1 General Specifications .................................................................................................................................................... 5 5. PRINCIPLES OF EQUIPMENT USE .................................................................................................................................... 6 5.1 Restrictions of Use ......................................................................................................................................................... 7 5.1.1 Warranty ............................................................................................................................................................... 7 6. EQUIPMENT FUNCTION ..................................................................................................................................................... 7 7. PREPARING EQUIPMENT FOR INSTALLATION ............................................................................................................ 8 7.1 Actuator Assembly Position ........................................................................................................................................... 8 7.1.1 Actuator Assembly Removal ................................................................................................................................ 9 7.1.2 Actuator Assembly Installation .......................................................................................................................... 12 7.2 De-Preservation ............................................................................................................................................................ 13 8. INSTALLING / RIG-UP ....................................................................................................................................................... 16 8.1 Fabricating Interface Connections ................................................................................................................................ 16 8.2 Connecting Equipment ................................................................................................................................................. 17 8.2.1 Preparation of System ........................................................................................................................................ 17 8.2.2 Install and Secure Disc Choke ............................................................................................................................ 18 8.2.3 Connect Terminal Points .................................................................................................................................... 19 8.3 Pressure / Leak Testing ................................................................................................................................................ 20 9. COMMISSIONING ............................................................................................................................................................... 20 9.1 Calibrating .................................................................................................................................................................... 20 10. STARTING EQUIPMENT ................................................................................................................................................. 21

i

Field Installation and Operation Manual 9092A01003AENG (--)

i

M-I SWACO 15K Disc Choke, Low Specifications 10.1 Pre-Start Checklist ...................................................................................................................................................... 21 11. OPERATING DISTURBANCES ........................................................................................................................................ 21 11.1 Emergency - Open/Close Hose Failure ....................................................................................................................... 22 12. MAINTAINING EQUIPMENT .......................................................................................................................................... 23 12.1 Inspecting .................................................................................................................................................................... 23 12.1.1 Daily Visual Checks ......................................................................................................................................... 23 12.1.2 Daily Operational Checks ................................................................................................................................. 23 12.2 Adjusting..................................................................................................................................................................... 23 12.2.1 Position Indicator System ................................................................................................................................. 23 12.3 Periodic maintenance .................................................................................................................................................. 26 12.3.1 Pressure Testing ................................................................................................................................................ 26 12.3.2 Hydrostatic Test Procedure ............................................................................................................................... 26 12.3.3 Hydrostatic Seat Test Procedure ....................................................................................................................... 28 13. TROUBLESHOOTING ....................................................................................................................................................... 28 13.1 Position Indicator Not Working .................................................................................................................................. 29 14. MINOR REPAIR OF EQUIPMENT ................................................................................................................................... 30 14.1 Spool End Disassembly .............................................................................................................................................. 30 14.2 Bonnet End Disassembly ............................................................................................................................................ 36 15. REMOVING / RIG DOWN ................................................................................................................................................. 39 15.1 Disconnecting Equipment ........................................................................................................................................... 39 16. PACKING FOR TRANSPORTATION .............................................................................................................................. 41 16.1 Choke .......................................................................................................................................................................... 41 16.2 Actuator Assembly ..................................................................................................................................................... 41 17. ILLUSTRATED PARTS BREAKDOWN .......................................................................................................................... 41 17.1 Introduction................................................................................................................................................................. 41 17.1.1 How to Use Figures and Tables ........................................................................................................................ 41 17.1.2 Finished Goods ................................................................................................................................................. 41

ii


ii


1. FORWARD As equipment is updated over time, changes to ing documents may occur in the form of simple revisions or development of completely new documents. Document version information is indicated on the front cover in parenthesis with the document part number. This part number and revision is duplicated on all printed pages. The initial release of a document is represented by double dashes (--) while subsequent revisions will be represented by sequential letters (A) (B) (C) etc. To ensure that the document you are using is still active and that it has not been superseded by a more recent version, your local M-I SWACO representative. They can check the document distribution system to the document and version you have.

2. PREFACE This manual is to be used by anyone installing, operating or maintaining the 15K Disc Choke manufactured by M-I SWACO This manual is organized in paragraphs of technical information. To easily find specific information refer to the table of contents found at the front of this manual or the index found at the back of this manual. An illustrated parts breakdown of the equipment can be found at the back of this manual as well as any useful diagrams or schematics. While every effort has been made to ensure the accuracy of the information contained in this manual, M-I SWACO will not be held liable for any errors in this material or for any consequences arising from the use of information contained in this manual.

1


1

M-I SWACO 15K Disc Choke, Low Specifications 3. HEALTH SAFETY AND ENVIRONMENT (HSE) Equipment manufactured by M-I SWACO is typically installed and operated where hazardous conditions are likely to be present. Be sure to read and understand all HSE information contained in this manual before installing, operating or maintaining the 15K Disc Choke. Be sure to review any additional HSE information from local or national codes for the location where the equipment is being used as well as any job site specific regulations that must be followed. The following explains the different type of advisories that may be found in this manual. THIS ADVISORY DRAWS ATTENTION TO ACTIONS THAT COULD RESULT IN PERSONAL INJURY. WARNING

THIS ADVISORY DRAWS ATTENTION TO ACTIONS THAT COULD RESULT IN EQUIPMENT DAMAGE. CAUTION

NOTE

TIP

THIS ADVISORY GENERALLY PROVIDES RELEVANT INFORMATION TO HELP THE READER UNDERSTAND THE HIGHER LEVEL CONTEXT OF A SPECIFIC TASK.

THIS ADVISORY OFFERS A SUGGESTION OR RECOMMENDATION THAT COULD MAKE A TASK EASIER OR MORE CONVENIENT.

3.1 Personal Protective Equipment All personnel working on or around the 15K Disc Choke or any M-I SWACO equipment must be familiar with, and wear, the required Personal Protective Equipment (PPE) appropriate for the task they are performing. The PPE items listed below are required for any task. Be sure to check local and national codes as well as any job site or task specific regulations that may require you to use additional PPE. · Approved hard hat. · Approved safety footwear. · Approved safety glasses with side shields and / or approved full face shield if appropriate. · Approved gloves appropriate for the task being performed. · Approved outer garments appropriate for the task being performed.

2


2

M-I SWACO 15K Disc Choke, Low Specifications 3.2 Equipment Hazards 3.2.1 Equipment Lock Out and Tag Before installing or maintaining any equipment, be sure to lock out and tag all sources of electrical, pneumatic or hydraulic power connected to it. Lock out and tag any feed pumps or accessory equipment connected to the 15K Disc Choke and isolate any inlet piping that could deliver mud or other materials into the equipment during installation or maintenance. DISASSEMBLY OF PRESSURIZED EQUIPMENT CAN ALLOW COMPONENTS TO BE RELEASED AT BALLISTIC SPEEDS RESULTING IN PERSONAL INJURY OR DEATH. WARNING

The use of improper maintenance tools can cause unnecessary equipment damage. Making unapproved modifications to equipment could create an operational hazard or damage to equipment resulting in personal injury. Using unauthorized repair parts or hardware that are not certified to API 6A & 16C (as applicable) could create an operational hazard or damage to equipment resulting in personal injury. Failure to use proper eye protection can result in personal injury or loss of sight. Failure to use proper lifting devices or getting help when lifting heavy component parts can cause personal injury. Performing maintenance tasks on equipment that could have H2S gas trapped inside could cause personal injury or death. Only personnel trained on the hazards of H2S should maintain equipment under these conditions. Improper work practices or the use of improper tools can damage relatively soft hardware components. Distortion of the part could adversely affect the structural integrity of the equipment.

3


3

M-I SWACO 15K Disc Choke, Low Specifications 3.3 Hazardous Materials All personnel must review the hazardous material safety information listed in the following sub-paragraphs that are associated with operating and maintaining this equipment. Below the material name are potential hazards to personnel and first-aid measures to perform if exposure occurs. Where applicable, any potential environmental hazards will be listed with clean up measures to perform if release occurs.

NOTE

THE FOLLOWING ONLY COVER PERSONNEL AND ENVIRONMENTAL HAZARDS FOR THE LISTED MATERIAL. FOR COMPLETE SAFETY INFORMATION, YOU MUST OBTAIN THE LATEST MATERIAL SAFETY DATA SHEET (MSDS) FOR THAT MATERIAL.

3.3.1 Grease, Perflouropolyether Christolube MCG 136 N · Potential Physical / Chemical / Environmental Effects o Combustible: Material can release vapors that readily form flammable mixtures. · Potential Health Effects o Eye: May Irritate eyes. o Skin: May cause mild skin irritation. High-pressure injection under skin may cause serious injury. o Inhalation: May be irritating to the eyes, nose, throat, and lungs. Slightly toxic by inhalation. o Ingestion: If swallowed, may be aspirated and cause lung damage. · First Aid Measures o Inhalation: Remove from further exposure. For those providing assistance, avoid exposure to yourself or others. Use adequate respiratory protection. If respiratory irritation, dizziness, nausea, or unconsciousness occurs, seek immediate medical assistance. If breathing has stopped, assist ventilation with a mechanical device or use mouth-to-mouth resuscitation. o Skin : Wash areas with soap and water. Remove contaminated clothing. If product is injected into or under the skin, a physician should evaluate immediately as a surgical emergency. o Eye : Flush thoroughly with water. If irritation occurs, get medical assistance. o Ingestion: Seek immediate medical attention. Do not induce vomiting. o Note to Physician: If ingested, material may be aspirated into the lungs.

4


4

M-I SWACO 15K Disc Choke, Low Specifications 4. SPECIFICATIONS M-I SWACO reserves the right to update these specifications when applicable. If there are any questions concerning the data specified, please an M-I SWACO representative.

4.1 General Specifications Maximum working pressure --------------- 15000 PSI (103425 kPa) Maximum Orifice size ---------------------- 100/64 INCH DIAMETER EQ. (1.92 IN²) Inlet/Outlet Flange size & ring gasket size --------3-1/16 BX154 (API 6A) Approximate weight ------------------------ 767 LBS (347 KG) Dimensions are given in inches with millimeters shown in brackets. Designed, manufactured and monogrammed in accordance with the latest edition of API 6A & 16C and NACE MR0175 as applicable.

5


5


Figure 1. Dimensions

6


6

M-I SWACO 15K Disc Choke, Low Specifications 5. PRINCIPLES OF EQUIPMENT USE The M-I SWACO 15K Disc Choke and Console make up a reliable system for the control of wellbore pressures. The choke is designed to control high pressure gas kicks and fluid flows during drilling operations. However, the choke is commonly used in numerous other applications (see list below) because of its long life, high flow capacity, ease and simplicity of operation while stripping-in under pressure (controlled displacement). · Spotting light fluids, particularly in freeing stuck pipe · Volume "callipering" specific hole sections · Spotting heavy slugs (barite, cement, etc.) · Drilling under pressure · Displacing fluids in wells before and after work over · Testing and cleanup of new completion's where sand, lost circulation material, or perforating debris are present

WARNING

EXCEEDING THE MAXIMUM WORKING PRESSURE CAN ADVERSELY AFFECT THE STRUCTURAL INTEGRITY OF THE CHOKE AND RESULT IN PROPERTY LOSS, INJURY OR DEATH.

· The 15K Disc Choke is hydraulically operated, providing an adjustable orifice size from a maximum area of 1.92 square inches (12 cm²) to complete shutoff. The maximum working pressure of the 15K Disc Choke is 15000 psi (103425 kPa). · The orifice size is determined by the overlapping half-moon openings in two polished tungsten carbide discs (see Figure 2). The downstream disc is stationary while the upstream disc is rotated up to 180 degrees to vary the orifice size. A hydraulically driven rotary actuator (Actuator Assembly) is used to automatically rotate the disc (see Figure 3). The included manual choke operating handle can be used to rotate the disc if the hydraulic system fails.

Figure 2. Orifice Size

7


7


Figure 3. 15K Disc Choke Assembly

5.1 Restrictions of Use 5.1.1 Warranty Refer to your purchase/sales agreement for warranty information specific to your unit. In general, the warranty will be void if the unit is damaged due to intentional or accidental mishandling, improper preservation and storage, failure to follow recommended installation, operation and maintenance instructions or using the unit for anything other than the designed and intended purpose.

6. EQUIPMENT FUNCTION The M-I SWACO 15K Disc Choke is a hydraulically operated valve providing an adjustable orifice size from a maximum 1.9 square inches (12 cm2) to complete shutoff. The working pressure of this Choke is 15,000 psi (103425 kPa). The size of the Choke orifice is determined by the overlapping portion of two off-center half-moon openings in two flat highly polished Tungsten carbide discs. The downstream disc is fixed while the upstream disc may be rotated 180° by a hydraulically driven rotary actuator. This 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, and ease and simplicity of operation, the M-I SWACO 15K Disc Choke is commonly used in a number of applications such as the following: · Stripping in under pressure (controlled displacement) · Spotting light fluids, particularly in freeing stuck pipe

8


8

M-I SWACO 15K Disc Choke, Low Specifications · Volume “caliper” specific hole sections · Spotting heavy slugs (barite, cement, etc.) · Drilling under pressure · Displacing fluids in wells before and after work over · Testing and Clean-up of new completions, where sand, lost circulation material or perforating debris are present.

7. PREPARING EQUIPMENT FOR INSTALLATION 7.1 Actuator Assembly Position

NOTE

INSTALLATION OF THE DISK CHOKE WITHOUT CONSIDERING THE ACTUATOR ASSEMBLY ORIENTATION CAN RESULT IN THE COVER OPENING FACING UP WHERE RAIN, DIRT AND DEBRIS COULD FILL THE COVER AND HINDER MAINTENANCE AND/OR PERFORMANCE.

Prior to installation, check how the choke will be connected into the manifold piping and note the orientation of the actuator assembly. If the open part of the actuator assembly cover will be facing up, remove and reposition the actuator assembly so the cover opening will be facing down or to either side depending on maintenance access.

Figure 4. Choke Preparation

9


9

M-I SWACO 15K Disc Choke, Low Specifications 7.1.1 Actuator Assembly Removal 1. Remove the four screws as shown (two on each side), which fasten the adapter assembly to the choke (See Figure 5).

Figure 5. Adapter Assembly Screws

NOTE

ROTATING THE ACTUATOR WHILE THE SQUARE SHAFT IS INSERTED INTO THE INDICATOR HEAD WILL CAUSE THE DISCS TO ROTATE OUT OF ALIGNMENT. ROTATING THE SQUARE SHAFT OR INDICATOR HEAD AFTER THE ACTUATOR ASSEMBLY HAS BEEN REMOVED WILL HINDER INSTALLATION OF THE ACTUATOR ASSEMBLY AND COULD CAUSE THE DISCS TO ROTATE OUT OF ALIGNMENT.

2. Pull the actuator/adapter assembly straight off of the choke until the square shaft is clear of the indicator head (See Figure 6).

10


10


Figure 6. Actuator/Adapter Assembly Removal If the actuator assembly will be rotated 90 degrees from the original position, four bonnet bolts will need to be repositioned before installing the actuator assembly. The following steps detail the proper procedures for removal and installation of the four bonnet bolts. If the actuator assembly will be rotated 180 degrees from the original position, proceed directly to Actuator Assembly Installation and skip the following steps.

11


11

M-I SWACO 15K Disc Choke, Low Specifications 3. Remove four screws as shown which fasten the bonnet to the Disc Choke. Do not loosen the remaining four screws holding the bonnet to the Disc Choke (See Figure 7).

Figure 7. Bonnet Screws Removal OVER TIGHTENING HARDWARE FASTENERS CAN CAUSE THEM TO STRETCH, REDUCING STRENGTH AND RESULTING IN PREMATURE FAILURE. CAUTION

4. Install the four short screws removed in step 3 as shown (See Figure 8) and tighten to 210 ft-lbs. (285 Nm). Do not over tighten!

12


12


Figure 8. Bonnet Screws Installation

7.1.2 Actuator Assembly Installation 1. Apply grease onto the square shaft to ease installation and future maintenance (See Figure 9). 2. Rotate the actuator assembly 90 or 180 degrees to the desired position and align the square shaft with the indicator head. 3. Push the actuator assembly straight onto the Disc Choke. OVER TIGHTENING HARDWARE FASTENERS CAN CAUSE THEM TO STRETCH, REDUCING STRENGTH AND RESULTING IN PREMATURE FAILURE. CAUTION

4. Install the remaining four long screws and tighten to 210 ft-lbs. (285 Nm). Do not over tighten!

Figure 9. Actuator/Adapter Assembly Installation

13


13

M-I SWACO 15K Disc Choke, Low Specifications 7.2 De-Preservation Remove the four screws as shown (two on each side) which fasten the adapter assembly to the Disc Choke (See Figure 10).

Figure 10. De-Preservation

14


14

M-I SWACO 15K Disc Choke, Low Specifications Pull the actuator/adapter assembly straight off of the Disc Choke until the square shaft is clear of the indicator head (See Figure 11).

Figure 11. Separating the actuator/adapter assembly from the Disc Choke If the actuator assembly will be rotated 90 degrees from the original position, four bonnet bolts will need to be repositioned before installing the actuator assembly. The following steps detail the proper procedures for removal and installation of the four bonnet bolts. If the actuator assembly will be rotated 180 degrees from the original position, proceed directly to Actuator Assembly Installation and skip the following steps. Remove four screws as shown which fasten the bonnet to the Disc Choke. Do not loosen the remaining four screws holding the bonnet to the Disc Choke (See Figure 12).

15


15


Figure 12. Bonnet Screws Removal Install the four short screws removed in step 3 as shown and tighten to 210 ft-lbs. (285 Nm). Do not over tighten! (See Figure 13)

Figure 13. Bonnet Screws Installation

16


16

M-I SWACO 15K Disc Choke, Low Specifications 8. INSTALLING / RIG-UP 8.1 Fabricating Interface Connections Inlet and outlet flanges vary depending on choke size and rating. Mating flanges and ring gaskets must meet API 6A standards. 15K Choke: 15000 psi (103425 kPa) 3-1/16 inch flange, BX154 ring gasket the local M-I SWACO service center for information regarding the supply of companion and adapter flanges. The choke manifold should have at least one block valve upstream and one block valve downstream of the choke. The block valves can be used to isolate the choke for servicing while other sections of the manifold are in use (see API Standard 53, Blowout Prevention Equipment Systems). FAILURE TO FULLY PIPING CONNECTED TO THE CHOKE INLET AND OUTLET CAN RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE. WARNING

Pipe lines connected to the choke must be fully ed. The choke body as well as inlet and outlet connection spools are not designed to carry external pipe load. The agrees to make pipe line connections to the choke at their own risk and to hold M-I SWACO harmless for any claims / losses / causes of action arising from a connection failure as well as damage due to overloading the inlet and outlet connection spools or choke body. The discharge line from the choke must be securely anchored according to API specifications (see API Standard 53).

17


17

M-I SWACO 15K Disc Choke, Low Specifications 8.2 Connecting Equipment 8.2.1 Preparation of System 1. Route each cable or hose so that it will not interfere with pedestrian or vehicle traffic.

NOTE

IF THE CONTROL HYDRAULIC HOSE IS LONGER THAN 100 FEET (30 M) CHOKE RESPONSE TIME WILL BE AFFECTED. IF THE DISTANCE BETWEEN THE CONTROL CONSOLE AND DISC CHOKE EXCEEDS 100 FEET (30 M) REPLACE THE CONTROL HYDRAULIC HOSE (NOT THE GAUGE HOSES) WITH ½ INCH SCHEDULE 40 ASTM A312 STAINLESS STEEL PIPE OR EQUIVALENT. PIPE, THREADS, FITTINGS AND CONNECTORS MUST HAVE A MINIMUM RATED WORKING PRESSURE OF 3000 PSI (20685 KPA).

2. If the distance between the control console and Disc Choke exceeds 100 feet (30 m) replace the control hydraulic hose (not the gauge hoses) with 1/2 inch schedule 40 ASTM A312 stainless steel pipe or equivalent. Pipe, threads, fittings and connectors must have a minimum rated working pressure of 3000 psi (20685 kPa). INSTALLING THE DISC CHOKE ONTO A STANDARD COMPANION FLANGE WILL DAMAGE THE EXTENDED WEAR SLEEVE. CAUTION

The M-I SWACO Disc Chokes have a wear sleeve that extends approximately 1/4 inch (6.3 mm) beyond the outlet flange face to protect the ring groove from erosion. The downstream flange bore diameter must not interfere with the extended wear sleeve or damage can occur (See Figure 14). 3. Check Disc Choke outlet companion flange for appropriate clearance bore that will allow the extended wear sleeve to be inserted without interference or damage. The companion flange must have no smaller than a 2-9/16 inch (65.1 mm) diameter bore. If necessary, bore the companion flange to this inside diameter.

18


18


Figure 14. Wear Sleeve Clearance

8.2.2 Install and Secure Disc Choke

WARNING

COMMON BOLTS, STUDS AND NUTS DO NOT MEET THE REQUIREMENTS FOR H2S SERVICE AND CAN FAIL FROM HYDROGEN EMBRITTLEMENT. REPLACE BOLTS, STUDS AND NUTS WITH AUTHORIZED REPLACEMENT PARTS ONLY. THE MATERIAL USED TO FABRICATE THE CHOKE, BOLTS, STUDS AND NUTS IS RELATIVELY SOFT AND SUBJECT TO LOCALIZED SURFACE DISTORTION DUE TO IMPROPER WORK PRACTICES. CARE SHOULD BE EXERCISED TO AVOID DAMAGING THESE PARTS. DAMAGED PARTS CAN ADVERSELY AFFECT THE STRUCTURAL INTEGRITY OF THE CHOKE AND COULD RESULT IN PROPERTY LOSS, INJURY OR DEATH.

1. Before installing the choke, check bolts, studs and nuts for cracks, damage, wear and thread distortion. Replace parts if these conditions are observed. 2. Check choke flange faces as well as companion flange faces for any damage or deformation. If any flange face is damaged, M-I SWACO should be ed for resurfacing.

WARNING

INSTALLING THE DISC CHOKE WITH USED RING GASKETS CAN CAUSE LEAKS. IN CONDITIONS WHERE H2S IS PRESENT, THIS CAN RESULT IN PERSONAL INJURY OR DEATH.

3. Apply grease to new ring gaskets and install them.

19


19

M-I SWACO 15K Disc Choke, Low Specifications 4. Lubricate bolts and nuts. Then install them only hand tight to secure flanges. Use ASTM A193 Grade B7 or B7M fasteners. WHEN A TIGHTENED FASTENER DOES NOT HAVE ANY BOLT THREADS EXPOSED BEYOND THE NUT, THE CONNECTION IS WEAKENED. CAUTION

5. Torque the flange fasteners progressively and evenly to the specifications listed in the table below. Improper torque of flange fasteners will void API certification. Check that each fastener has at least one thread exposed beyond the nut. Typical torque values for commonly used ASTM A193 Grade B7 and B7M materials and well-lubricated bare metal are as follows. Table 1. Typical Flange Fastener Torque Values MATERIAL YIELD STRESS 80,000 PSI

MATERIAL YIELD STRESS 105,000 PSI

FASTENER DIAMETER (INCH)

THREADS PER INCH

TORQUE (FT-LB)

TORQUE (NM)

TORQUE (FT-LB)

TORQUE (NM)

1.000

8

361

490

474

643

6. When the nuts are fully tightened the flange faces should be parallel. 7. Check that the choke manifold has at least one block valve upstream and one block valve downstream of the choke. The block valves can be used to isolate the choke for servicing while other sections of the manifold are in use (see API Standard 53, Blowout Prevention Equipment Systems). 8. Securely anchor the discharge line from the choke according to API specifications (see API Standard 53).

8.2.3 Connect Terminal Points 8.2.3.1 Choke Hydraulic Control Hose Installation The hoses are provided with quick disconnect fittings that are matched with male and female ends, so it is impossible to incorrectly install these hoses. 1. Note the two fittings on the Control Console manifold are labeled "CLOSE" and "OPEN". 2. Be sure the hoses are routed and secured so they do not interfere with traffic or other equipment. 3. Using the quick disconnects provided, connect the hydraulic hoses to the fittings on the actuator assembly and to the corresponding fittings on the Control Console manifold. 8.2.3.2 Position Indicator Air Tubing Installation The fittings on the actuator assembly are not labeled. Use the figure below to identify the correct fitting (See Figure 15). 1. Note the two fittings on the Control Console manifold are labeled "AIR TO TRANS." and "AIR RETURN FROM TRANS." 2. Be sure the hoses are routed and secured so they do not interfere with traffic or other equipment. 3. Connect the 1/4 inch OD vinyl tubing from the fittings on the actuator assembly to the corresponding fittings on the Control Console manifold.

20


20


Figure 15. Connection Points

8.3 Pressure / Leak Testing Pressure test the choke after installation and make a notation on the drilling report regarding the results. Refer to the periodic maintenance paragraph 12.3 of this manual for pressure testing procedures. This test may be performed when the manifold is tested.

9. COMMISSIONING 9.1 Calibrating Calibrate the choke position indicator following procedures in the periodic maintenance paragraph 12.3 of this manual. Calibrating the choke should be performed with control console calibration. Refer to the control console manual for those calibration procedures.

21


21

M-I SWACO 15K Disc Choke, Low Specifications 10. STARTING EQUIPMENT 10.1 Pre-Start Checklist

WARNING

FAILURE TO PROPERLY ALIGN AND SET THE MANIFOLD VALVES AND CHOKES BEFORE ALLOWING WELLBORE PRESSURE OR FLOW INTO THE MANIFOLD INLET COULD RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE.

Well control operator must have a pre-start check list established and follow it to ensure the manifold valves and chokes are aligned and set properly before allowing wellbore pressure or flow into the manifold inlet.

11. OPERATING DISTURBANCES The following emergency procedures are for short term use only. Repair or replace the damaged parts as soon as possible.

11.1 Emergency - Open/Close Hose Failure 1. Relieve hydraulic pressure from the actuator cylinders. This can be accomplished by any one of the three following options. a. Option 1: Disconnect both OPEN and CLOSE hydraulic hoses and install a “jumper” hose between the OPEN and CLOSE quick disconnect fittings located on the actuator assembly.

CAUTION

CUTTING HYDRAULIC HOSES OR REMOVING QUICK-DISCONNECT FITTINGS WILL RESULT IN HYDRAULIC FLUID SPILL AND WILL REQUIRE REPLACEMENT OF HYDRAULIC HOSES OR RE-ASSEMBLY AS NECESSARY.

b. Option 2: Cut both OPEN and CLOSE hydraulic hoses. The quick-disconnect fittings located on the actuator assembly have internal check valves that prevent the hydraulic fluid from leaking out. Simply disconnecting these hoses will not relieve the hydraulic pressure to allow the choke to operate manually. c. Option 3: Disconnect both OPEN and CLOSE hydraulic hoses and remove the quick disconnect fittings located on the actuator assembly. 2. Insert a 5/8 inch (16 mm) diameter rod into one of the holes in the Head Indicator and manually position the choke as desired (See Figure 16).

22


22


Figure 16. Emergency Operation

23


23

M-I SWACO 15K Disc Choke, Low Specifications 12. MAINTAINING EQUIPMENT 12.1 Inspecting The M-I SWACO 15K Disc Chokes are key elements of the pressure control system. It is important to maintain the choke and control console in good operating condition at all times. All mechanical equipment is subject to wear caused by either use or abuse. For this reason the choke and control console should be inspected on a regular basis by qualified personnel. Repairs should be completed before undertaking any operations involving the choke and console.

12.1.1 Daily Visual Checks 1. all connections are tight with no air or fluid leaks. 2. the hydraulic hoses, pump switch cable and air lines are properly connected and not damaged.

12.1.2 Daily Operational Checks 1. Operate the choke and complete a full cycle from full OPEN to full CLOSE and back to full OPEN. The Position Indicator Gauge should track the choke disc movement according to the choke lever selection (See Figure 17). 2. OPEN the choke and the Position Indicator Gauge indicates OPEN. Check the head indicator and the choke is OPEN. 3. CLOSE the choke and the position indicator gauge indicates CLOSED. the choke is closed by visually checking the position of the indicator head. 4. If the choke does not function properly refer to troubleshooting paragraph 13.

Figure 17. Position Indicator Gauge

24


24

M-I SWACO 15K Disc Choke, Low Specifications 12.2 Adjusting 12.2.1 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 hydraulic actuator 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 1/2 or 50% open. The position indicator serves as an aid in observing the direction and speed of changes made during choke operation (See Figure 18). If the disc position gauge does not work properly, check the arrow located on the position transmitter regulator to determine the direction of air flow. If it is not convenient to use the control 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 together. 1. Connect the supply air from the Control Console to the AIR SUPPLY fitting and connect the signal return air to the AIR SIGNAL RETURN fitting. 2. Turn on the air supply.

Figure 18. Position Indicator Adjustment

25


25


NOTE

THE FOLLOWING PROCEDURES ARE USED TO "ZERO" THE POSITION INDICATOR GAUGE.

3. Completely OPEN the choke. 4. Loosen the 1/4 inch nut and set screws on the camshaft so the cam turns on the shaft. 5. Rotate the cam shaft so the scribe mark on the short side of the cam lines up with the cam follower. 6. Tighten shaft nut and set screws. 7. Loosen the pivot block 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 the OPEN on the position indicator gauge. 8. Tighten pivot block locking screws. 9. 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 3 psi (21 kPa), adjust block as previously indicated above the required 3 psi (21 kPa). 10. Completely CLOSE the choke. The test gauge should read approximately 15 psi (103 kPa), or CLOSED on the position indicator gauge.

NOTE

THE FOLLOWING PROCEDURES ARE USED TO "ZERO" THE SPAN OF THE INDICATOR GAUGE.

11. 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. 12. If less than 15 psi (103 kPa), loosen both regulator 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. 13. Tighten both socket head cap screws. 14. Completely OPEN the choke. If output is not 3 psi (21 kPa), readjust the pivot block to 3 psi (21 kPa). 15. Completely CLOSE the choke and check 15 psi (103 kPa) signals. 16. Repeat steps until 3 psi and 15 psi (21 and 103 kPa) outputs are obtained.

26


26

M-I SWACO 15K Disc Choke, Low Specifications 12.3 Periodic Maintenance 12.3.1 Pressure Testing A routine hydrostatic pressure test should be performed to the integrity of the seals, discs and the pressure containing parts. This test is not intended to supersede or duplicate standard API tests. Both of the following tests may be performed using test flanges (as detailed below) or with the choke installed in a manifold. The choke will hold a positive seal during the seat test; however, this is not an API requirement.

12.3.2 Hydrostatic Test Procedure 1. Operate and fully OPEN the choke. 2. If removed from the manifold, install test flanges to the inlet and outlet choke flanges. 3. Position the choke as shown with the outlet flange resting on the ground. The inlet flange should point upward (See Figure 19).

Figure 19. Testing Position 4. OPEN the isolation valves on the inlet and outlet flanges. 5. Fill the choke with water from the outlet flange. When the choke is full raise the outlet end until the centerline of the choke is parallel to the ground (See Figure 20). 6. When all air has been purged CLOSE the isolation valves on the inlet and outlet flanges, lower the choke to ground level. and secure the choke to prevent movement or damage to the test fittings. 7. Loosen fittings as necessary, and then purge all air from the pressure source and pressure gauge lines. CLOSE the pressure source valve when all air is purged, then tighten all fittings.

27


27


Figure 20. Water Fill

WARNING

DAMAGE TO AN ISOLATION VALVE OR FITTING WHEN THE CHOKE IS UNDER TEST PRESSURE WILL RELEASE PRESSURIZED WATER THAT COULD PROPEL THE CHOKE CAUSING SERIOUS PERSONAL INJURY OR DEATH. A LEAK IN THE CHOKE WILL RELEASE WATER AT DANGEROUSLY HIGH PRESSURE. PROTECTIVE GEAR MUST BE WORN TO PREVENT PERSONAL INJURY.

8. Be sure the choke is secure and the test fittings are protected from accidental damage, then slowly OPEN the pressure source valve and raise the pressure to 15000 psi (103425 kPa). 9. If a leak is observed investigate all possible leak paths including flange connections, connectors, valves, etc. Repair as necessary. 10. If no leaks are observed, CLOSE the pressure source valve. 11. Acceptance Criteria: No visible leakage for three minutes. 12. If a leak is observed investigate all possible leak paths including flange connections, connectors, valves, etc. Repair as necessary.

WARNING

WATER AT HIGH PRESSURE WILL BE RELEASED FROM THE ISOLATION VALVES WHEN OPENED. IF NOT OPENED AWAY FROM PERSONNEL, INJURY COULD RESULT.

13. OPEN the outlet test flange isolation valve to relieve the pressure.

28


28

M-I SWACO 15K Disc Choke, Low Specifications 12.3.3 Hydrostatic Seat Test Procedure 1. Fill the choke with water and purge all air from it following the steps in the hydrostatic test procedure above. and secure the choke to prevent movement or damage to the test fittings.

WARNING

DAMAGE TO AN ISOLATION VALVE OR FITTING WHEN THE CHOKE IS UNDER TEST PRESSURE WILL RELEASE PRESSURIZED WATER THAT COULD PROPEL THE CHOKE CAUSING SERIOUS PERSONAL INJURY OR DEATH. A LEAK IN THE CHOKE WILL RELEASE WATER AT DANGEROUSLY HIGH PRESSURE. PROTECTIVE GEAR MUST BE WORN TO PREVENT PERSONAL INJURY.

2. Be sure the choke is secure and the test fittings are protected from accidental damage then slowly open the pressure source valve and raise the pressure to 2500 psi (17238 kPa). 3. If a leak is observed investigate all possible leak paths including flange connections, connectors, valves, etc. Repair as necessary. 4. If no leaks are observed, CLOSE the choke. 5. OPEN the outlet test flange isolation valve. 6. Slowly raise the pressure to 15000 psi (103425 kPa). 7. If a leak is observed investigate all possible leak paths including flange connections, connectors, valves, etc. Repair as necessary. 8. If no leaks are observed, CLOSE the pressure source valve. 9. Acceptance Criteria: No visible leakage for three minutes. 10. If a leak is observed investigate all possible leak paths including flange connections, connectors, valves, etc. Repair as necessary. WATER AT HIGH PRESSURE WILL BE RELEASED FROM THE DISC CHOKE WHEN OPENED. IF NOT OPENED AWAY FROM PERSONNEL, INJURY COULD RESULT. WARNING

11. OPEN the choke to relieve the pressure. Remove all testing equipment. 12. Preserve the choke following preservation procedures found in this manual.

13. TROUBLESHOOTING Choke Opens and Closes Too Slowly Check for 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 inch ID high pressure hose with 1/4 inch ID hose or hard piping.

External Choke Leaks Leak is at the bonnet end of the choke.

Remove the bonnet and turning fork from the body. 29


29

M-I SWACO 15K Disc Choke, Low Specifications Clean and inspect the sealing surfaces for damage and wear. Replace the seals as required. Leak is between the choke body and outlet spool.

Remove the Disc Choke from the manifold. Clean and inspect the sealing surfaces for damage and wear. Replace the seals as required. Inlet or outlet flanges leak.

Remove the Disc Choke from the manifold. Clean and inspect the ring groove sealing surfaces for damage or wear. Replace the ring gasket seals.

Internal Choke Leaks Dirt, rust or other debris between the discs.

OPEN and CLOSE the choke several times to remove debris. If this does not work, see spool end disassembly procedures. Worn or cracked discs.

See spool end disassembly procedures and replace parts as necessary. Damaged or improper back disc o-ring.

See spool end disassembly procedures and replace parts as necessary. Damaged, dirty or corroded sealing surfaces ing the back disc o-ring.

See spool end disassembly procedures and replace parts as necessary. Missing or damaged back disc locking pin.

See spool end disassembly procedures and replace parts as necessary. Front disc frozen to the turning fork.

See spool end disassembly procedures and replace parts as necessary. Improper alignment of front disc on the turning fork.

See spool end disassembly procedures and replace parts as necessary. Missing or damaged front disc alignment pin.

See spool end disassembly procedures and replace parts as necessary. Improper alignment of actuator shaft in the indicator head.

See spool end disassembly procedures and replace parts as necessary. Improper orientation of indicator head on the turning fork.

See bonnet end disassembly procedures. Worn or damaged thrust bearing between the bonnet and turning fork.

See bonnet end disassembly procedures and replace parts as necessary.

13.1 Position Indicator Not Working 1. Inspect the air supply and signal lines for leaks and crimping. 2. Make sure the cam is correctly installed on the cam shaft connected to the actuator. The cam should turn 180 degrees when the choke position is changed from OPEN to CLOSED or from CLOSED to OPEN.

30


30

M-I SWACO 15K Disc Choke, Low Specifications 14. MINOR REPAIR OF EQUIPMENT 14.1 Spool End Disassembly This section describes a procedure for removing the choke discs from the outlet end of the body for inspection and/or replacement and removal of the wear sleeves. DISASSEMBLY OF THE CHOKE WITHOUT RELIEVING THE INTERNAL PRESSURE CAN CAUSE PERSONAL INJURY OR DEATH. WARNING

1. Slowly open the pressure relief valve and allow pressure trapped inside the choke to escape. Do not proceed until the pressure has been relieved.

WARNING

ESCAPING HIGH PRESSURE CAN CAUSE PERSONAL INJURY. THE PRESSURE RELIEF VALVE CAN BECOME OBSTRUCTED BY DEBRIS ALLOWING DANGEROUS PRESSURES TO BE TRAPPED INSIDE THE CHOKE BODY. DO NOT STAND OVER THE SEAL GAP WHEN LOOSENING BOLTS OR BREAKING THE SEAL.

2. Carefully loosen each outlet spool bolt one turn. DO NOT REMOVE THE BOLTS (See Figure 21).

Figure 21. Outlet Spool Bolts

31


31

M-I SWACO 15K Disc Choke, Low Specifications 3. With the bolts still in place and loosened only one turn each, stay clear of the seal gap and break the seal by separating the spool from the body. Any remaining pressure inside the choke will be relieved after the seal is broken. 4. Remove all outlet spool bolts. COMMON FASTENER HARDWARE WILL BECOME BRITTLE WHEN EXPOSED TO H2S GASSES AND WILL BECOME WEAK OR FAIL. WARNING

5. Inspect these bolts for damage or distortion. Replace with authorized parts suitable for H2S service as required. 6. Check all bolts, studs and nuts for cracks, damage, wear and thread distortion before installation. If any of these conditions are observed the part should be replaced. 7. Carefully separate the outlet spool from the body. Locating pins provide alignment between the body and the outlet spool (Figure 22).

Figure 22. Outlet Spool Removal 8. Rotate the front disc to the full OPEN position if this has not been previously done. 9. Wash sand, grit or other debris from around the exposed portion of the back disc and the disc opening.

32


32

M-I SWACO 15K Disc Choke, Low Specifications 10. Remove the back disc/wear sleeve o-ring. PLACING ANY PART OF YOUR HAND OR FINGER ON THE ENDS OF THE SLIDING WEIGHT CAN CAUSE PINCHING. WARNING

11. Insert the hook end of the disc puller in the disc opening as illustrated (See Figure 23) and gently remove both discs using the sliding weight on the puller. Be careful not to pinch your hand or finger between the sliding weight and disc puller end stop. Maintain the position of the hook on the puller to avoid chipping the corners of the disc orifice. If the discs are not very worn they may be reusable.

Figure 23. Disc Removal 12. Locate and inspect the back disc locking pin. Replace if damaged. 13. Clean both disc assemblies thoroughly and inspect for wear or damage. The discs are reusable if they can provide a positive seal under pressure. 14. Clean the interior of the body and the o-ring sealing surfaces.

33


33


WARNING

SUBSTITUTING AN INDIVIDUAL "OFF THE SHELF" SEAL CAN CAUSE PERSONAL INJURY OR EQUIPMENT DAMAGE DUE TO SEAL FAILURE. SEAL KIT PARTS ARE CONTROLLED BY MANUFACTURE DATE AND SHELF LIFE. THE SEALS HAVE BEEN SPECIFICALLY SELECTED TO MEET THE DEMANDING TEMPERATURE AND PRESSURE SPECIFICATIONS OF THIS CHOKE.

15. Remove the back disc/spool and body/spool o-rings and replace with new o-rings from approved Seal Kit. 16. Apply a light film of silicone grease to the o-ring groove on the back disc carrier (See Figure 24).

Figure 24. Disc Lubrication

NOTE

APPLYING GREASE OR ANY LUBRICANT TO THE POLISHED DISC FACES CAN CAUSE THE CHOKE TO LEAK WHEN TESTED.

17. Clean the polished mating faces of each disc with alcohol and a clean cloth. When installing the discs be sure to handle them carefully and avoid getting dirt or oil on the cleaned surfaces.

34


34

M-I SWACO 15K Disc Choke, Low Specifications 18. Insert the front disc assembly into the choke body so that the half-moon opening 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.

Figure 25. Front Disc Installation 19. Position the back disc locking pin in the groove on the inside diameter of the body. Align the matching pin groove in the back disc assembly and insert the back disc (See Figure 26).

35


35


Figure 26. Back Disc Installation 20. To remove the outlet spool wear sleeves carefully push them through the end which bolts to the body. There are three long trim wear sleeves, one extended trim wear sleeve and one o-ring. 21. Inspect the wear sleeves and o-ring for wear and replace as necessary. 22. Before reinserting the wear sleeves, clean and inspect the bore of the spool. Remove any dirt, rust or debris. FAILURE TO REMOVE DIRT, RUST OR DEBRIS MAY CAUSE DAMAGE TO THE DISCS WHEN THE SPOOL IS BOLTED TO THE BODY. CAUTION

23. Apply a light film of silicone grease to the bore of the spool. 24. Remove any dirt, rust or debris from the ends of the long trim wear sleeves and the shoulder on the extended trim wear sleeve. Apply a light film of silicone grease on the outside of the wear sleeves and insert them into the spool. 25. Assemble the outlet spool to the body using the alignment pins and the outlet spool bolts. the o-rings are properly positioned. 26. Tighten the bolts uniformly. Apply a torque of 165 ft-lb (224 Nm), M-I SWACO can supply a torque wrench.

36


36


DO NOT OVER TIGHTEN! APPLYING EXCESSIVE TORQUE CAN STRETCH THE BOLT, REDUCING STRENGTH AND RESULT IN PREMATURE FAILURE. CAUTION

27. CLOSE the pressure relief valve. 28. 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.

14.2 Bonnet End Disassembly This section describes a procedure for removal of the bonnet assembly from the Disc Choke. These procedures may be done with the choke installed in the manifold or removed from the manifold. Note that the back disc can only be removed and replaced from the spool end of the choke and not the bonnet end. 1. Remove the actuator assembly following procedures found in this manual under the preparation paragraph 7.1. 2. Mark the body and bonnet so they can be reassembled in the same position. DISASSEMBLY OF THE CHOKE WITHOUT RELIEVING THE INTERNAL PRESSURE CAN CAUSE PERSONAL INJURY OR DEATH. WARNING

3. Slowly OPEN the pressure relief valve and allow pressure trapped inside the choke to escape. Do not proceed until the pressure has been relieved.

WARNING

ESCAPING HIGH PRESSURE CAN CAUSE PERSONAL INJURY. THE PRESSURE RELIEF VALVE CAN BECOME OBSTRUCTED BY DEBRIS ALLOWING DANGEROUS PRESSURES TO BE TRAPPED INSIDE THE CHOKE BODY. DO NOT STAND OVER THE SEAL GAP WHEN LOOSENING BOLTS OR BREAKING THE SEAL.

4. Carefully loosen each bonnet bolts one turn. DO NOT REMOVE THE BOLTS (See Figure 27).

37


37


Figure 27. Bonnet Bolts 5. With the bolts still in place and loosened only one turn each, stay clear of the seal gap and break the seal by separating the bonnet from the body. Any remaining pressure inside the choke will be relieved after the seal is broken.

Figure 28. Indicator Head Removal

38


38

M-I SWACO 15K Disc Choke, Low Specifications 6. Remove the indicator head from the turning fork. 7. Remove all bonnet bolts. COMMON FASTENER HARDWARE WILL BECOME BRITTLE WHEN EXPOSED TO H2S GASSES AND WILL BECOME WEAK OR FAIL. WARNING

8. Inspect these bolts for damage or distortion. Replace only with new approved bolts. 9. Remove the bonnet assembly from the body (See Figure 29).

Figure 29. Bonnet Assembly Removal

39


39

M-I SWACO 15K Disc Choke, Low Specifications 10. Disassemble the bonnet assembly. ROUGH HANDLING OF THE BONNET ASSEMBLY CAN CAUSE DAMAGE TO THE BONNET BORE OR SHAFT SURFACE. CAUTION

11. Clean the turning fork and inspect for wear or damage. The thrust bearing and o-ring seal areas should be smooth. The hex on the end of the turning fork should not be rounded, cracked or deformed. Replace the turning fork if any of these conditions exist. 12. Replace the thrust bearing, shaft bushing, all o-rings and backup rings. Note that backup rings are installed toward the bonnet (see Figure 31) and the scarf cut must be aligned. Replace o-rings and backup rings only with new parts from an approved Seal Kit. 13. Lubricate the turning fork shaft with a light application of silicone grease before reassembly. Install the turning fork in the bonnet, being careful not to damage the o-rings or bushing. 14. Clean the bonnet and apply silicone grease on the surfaces where there is or close proximity to the body and turning fork. 15. 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. 16. Clean the indicator head and apply a light film of silicone grease to the square and hex sockets. 17. 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 choke. 18. Before inserting the bonnet assembly, the half-moon opening on the front disc is toward the inlet flange. Using the marks made on the bonnet and body as well as the alignment pin, insert the bonnet assembly into the body. 19. Install and uniformly tighten the bolts, securing the bonnet to the body and the actuator assembly to the bonnet. DO NOT OVER TIGHTEN! APPLYING EXCESSIVE TORQUE CAN STRETCH THE FASTENER, REDUCING STRENGTH AND RESULT IN PREMATURE FAILURE. CAUTION

20. Evenly torque the bolts to 210 ft/lbs. (285 Nm). 21. Install the actuator assembly following procedures found in this manual under the preparation paragraph 7.1. Be sure the actuator assembly shaft and choke discs are in the open position when installing the actuator assembly. 22. Close the pressure relief valve. 23. If the choke was removed from the manifold, 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.

40


40

M-I SWACO 15K Disc Choke, Low Specifications 15. REMOVING / RIG DOWN 15.1 Disconnecting Equipment The following procedures cover removal of the Disc Choke from a manifold for inspection and/or replacement. 1. Close both upstream and downstream block valves to isolate the choke from manifold pressure before servicing. 2. Operate and fully OPEN the choke.

WARNING

REMOVAL OF THE CHOKE WITHOUT RELIEVING THE INTERNAL PRESSURE CAN CAUSE PERSONAL INJURY OR DEATH. PERSONAL INJURY OR DEATH COULD RESULT FROM EXPOSURE TO H2S GAS. THE CHOKE AND/OR MANIFOLD COULD CONTAIN H2S GAS. ONLY PERSONNEL TRAINED ON THE HAZARDS OF H2S SHOULD BE PERMITTED TO WORK ON THE CHOKE OR MANIFOLD.

3. Slowly open the pressure relief valve and allow pressure trapped inside the choke to escape. Do not proceed until the pressure has been relieved.

WARNING

CAUTION

ESCAPING HIGH PRESSURE CAN CAUSE PERSONAL INJURY. THE PRESSURE RELIEF VALVE CAN BECOME OBSTRUCTED BY DEBRIS, ALLOWING DANGEROUS PRESSURES TO BE TRAPPED INSIDE THE CHOKE BODY. DO NOT STAND OVER THE SEAL GAP WHEN LOOSENING BOLTS OR BREAKING THE SEAL. FAILURE TO USE APPROVED EYE AND PERSONAL PROTECTION EQUIPMENT CAN RESULT IN SERIOUS PERSONAL INJURY. USING IMPROPER TOOLS OR WORK PRACTICES TO SERVICE THE CHOKE CAN CAUSE DAMAGE SUCH AS LOCALIZED SURFACE DISTORTION. DAMAGED PARTS CAN ADVERSELY AFFECT THE STRUCTURAL INTEGRITY OF THE CHOKE AND RESULT IN PROPERTY LOSS, INJURY OR DEATH.

DESIGNED, MANUFACTURED AND MONOGRAMMED IN ACCORDANCE WITH THE LATEST EDITION OF API 6A & 16C AND NACE MR0175 AS APPLICABLE. USE ONLY M-I SWACO PARTS TO MAINTAIN ORIGINAL DESIGN SPECIFICATIONS.

4. Carefully loosen the inlet flange nuts one turn each. DO NOT REMOVE THE NUTS. 5. With the nuts still in place and loosened only one turn each, stay clear of the seal gap and break the ring gasket seal by separating the choke inlet flange from the manifold flange. If the choke is in the OPEN position, any remaining pressure inside the choke body will be relieved after the seal is broken. THE CHOKE AND CERTAIN COMPONENT PARTS ARE HEAVY. USE APPROPRIATE LIFTING DEVICES AND PRACTICES TO AVOID PERSONAL INJURY. WARNING

6. the choke using an appropriate stand or lifting device and carefully loosen the downstream flange nuts one turn each. DO NOT REMOVE THE NUTS.

41


41


PENETRATING THE SEAL GAP WHEN USING A PRY BAR TO SEPARATE THE FLANGES CAN CAUSE DAMAGE TO THE EXTENDED WEAR SLEEVE. CAUTION

7. With the nuts still in place and loosened only one turn each, stay clear of the seal gap and break the ring gasket seal by separating the choke downstream flange from the manifold flange. If the choke was not in the OPEN position, any remaining pressure inside the choke body will be relieved after the seal is broken. 8. With the choke properly ed, remove all nuts and studs. 9. Carefully remove the choke from the manifold using great care to avoid damaging the extended wear sleeve.

16. PACKING FOR TRANSPORTATION 16.1 Choke 1. Remove the choke from the manifold. 2. Disassemble the choke. 3. Clean, inspect, repair or replace and lubricate all parts as described in the above referenced paragraphs. 4. Reassemble the choke. 5. Apply general purpose grease to ring grooves. 6. Protect flange faces with ½ inch thick marine grade plywood. Note that the downstream flange face has a wear sleeve extending approximately ¼ inch from it and the plywood must have a recess to accept and protect it.

16.2 Actuator Assembly 1. Disconnect hoses. 2. Install plug and cap for the female and male quick-disconnect fittings. 3. Install a short length of tubing between the two air signal fittings. 4. Open the cover. 5. Clean, inspect, repair or replace and lubricate all moving parts. 6. Secure cover.

17. ILLUSTRATED PARTS BREAKDOWN 17.1 Introduction This section illustrates and lists spares and repair parts required for performance of maintenance tasks presented in this manual. Items in the parts list tables are shown on the associated figures.

17.1.1 How to Use Figures and Tables To find a specific part, locate the item on one of the figures and note the ballooned item number pointing to the part. The item number on the associated parts list for that figure will show the part number, description and quantity used for that part.

42


42

M-I SWACO 15K Disc Choke, Low Specifications 17.1.2 Finished Goods Standardizing this product line has caused finished good part numbers to change as well as some replacement parts. Note that the finished goods and replacement parts listed are interchangeable with older configurations. Table 2. Smart Part Number System Key Due to the number of table columns needed to represent the part number key elements, this table has been split. Follow the flowline provided when reading the part number key elements. SMART PART NUMBER SYSTEM FOR LOW SPECIFICATION DISC CHOKES CHOKE TYPE C1

CHOKE CERTIFICATION AND PR LEVEL

ACTUATOR CERTIFICATION

PSL RATING

DISC Z API 6A (PR1) & API X NO ACTUATOR 3 PSL 3 CHOKE 16C MONOGRAMMED INSTALLED G PSL3G Z API 16C MONOGRAMMED ACTUATOR

TEMPERATURE CLASS 3

P-300 (-20°F, +300°F)

END CONNECTION B 3-1/16

SMART PART NUMBER SYSTEM FOR LOW SPECIFICATION DISC CHOKES WORKING PRESSURE 15

43

CORROSION RESISTANT INLAY

15000 PSI X NONE A INCONEL 625 INLAY IN RING GROOVES B 1625 SEAL & RING GROOVE

MATERIAL CLASS E EE-0.5

1

TRIM SIZE

OFFSET DIMENSIONS

1.5”

M M-I SWACO STANDARD

THIRD PARTY CERTIFICATION

COLOR

X NONE R RED A ABS CDS B BLUE B ABS CDS & DNV OS E101 D DNV OS E101


43

M-I SWACO 15K Disc Choke, Low Specifications Table 3. Low Specification 15K Part Conversions OLD PART NUMBER

NEW PART NUMBER

CH1ZX3PUB15X

C1ZX33B15XE1MX

CHK DSC PR1 API TRP+300 PSL3 3.06 15K MCEE0.5 1.5TRIM MI

CH1ZX3PUB15A

C1ZX33B15AE1MX

CHK DSC PR1 API TRP+300 PSL3 3.06 15K INL MCEE-0.5 1.5TRIM MI

CH1ZZ3PUB15X

C1ZZ33B15XE1MX

CHK DSC PR1 API ACT TRP+300 PSL3 3.06 15K MCEE-0.5 1.5TRIM MI

CH1ZZ3PUB15A

C1ZZ33B15AE1MX

CHK DSC PR1 API ACT TRP+300 PSL3 3.06 15K INL MCEE-0.5 1.5TRIM MI

CH1ZX3PUB15X

C1ZXG3B15XE1MX

CHK DSC PR1 API TRP+300 PSL3G 3.06 15K MCEE0.5 1.5TRIM MI

CH1ZX3PUB15A

C1ZXG3B15AE1MX

CHK DSC PR1 API TRP+300 PSL3G 3.06 15K INL MCEE-0.5 1.5TRIM MI

CH1ZZ3PUB15X

C1ZZG3B15XE1MX

CHK DSC PR1 API ACT TRP+300 PSL3G 3.06 15K MCEE-0.5 1.5TRIM MI

CH1ZZ3PUB15A

C1ZZG3B15AE1MX

CHK DSC PR1 API ACT TRP+300 PSL3G 3.06 15K INL MCEE-0.5 1.5TRIM MI

CH1ZX3PUB15X

C1ZXG3B15XE1MX

CHK DSC PR1 API TRP+300 PSL3G 3.06 15K MCEE0.5 1.5TRIM MI

CH1ZX3PUB15A

C1ZXG3B15AE1MX

CHK DSC PR1 API TRP+300 PSL3G 3.06 15K INL MCEE-0.5 1.5TRIM MI

CH1ZZ3PUB15X

C1ZZG3B15XE1MX

CHK DSC PR1 API ACT TRP+300 PSL3G 3.06 15K MCEE-0.5 1.5TRIM MI

CH1ZZ3PUB15A

C1ZZG3B15AE1MX

CHK DSC PR1 API ACT TRP+300 PSL3G 3.06 15K INL MCEE-0.5 1.5TRIM MI

44

DESCRIPTION


44


Figure 30. 15K Disc Choke ITEM

45

PART NUMBER

PARTS LIST FOR FIGURE 30

ASSY QTY

DESCRIPTION

1

0556041

KEY SHAFT 3/8 X 3/8 X 2-1/2 IN LG

1

2

1404211

SCREW FERRY HD L7M 1.00 – 8 UN X 4.00 IN

24

3

1573273

PIN ROLL SLOTTED TYPE SS 3/8 X 1-1/2 IN LG

2

4

3919160

GASKET RING STL API BX154 ZN PLT

4

5

5603574

VALVE BLEED SS 9/16-18 MALE 20000 PSI

1

6

5867257

PIN FORK TURN 416SS 3/16 DIA X .75 IN LG D19-750

2

7

5867261

PIN DOWEL SS ¼ DIA X ½ IN LG

2

8

9360904

SPRING WAVE GAP TYPE 1.55ID X 1.88OD X .14HT

1

9

9436047

BEARING THRUST 15K/20K CHOKE

1

10

9436145

HANDLE CHOKE OPERATING MANUAL

1

11

9611573

DISK 15K CHOKE

1

12

9611575

CARRIER DISC REAR 15K PSI CHOKE

1

13

9611577

DISC ASSY FRONT 15K PSI CHOKE

1


45

M-I SWACO 15K Disc Choke, Low Specifications ITEM

PART NUMBER


ASSY QTY

DESCRIPTION

14

9611578

CARRIER SEAL 15K PSI CHOKE

1

15

9611579

CARRIER THRUST BEARING 15K CHOKE

1

16

9611580

FORK TURNING 15K PSI CHOKE

1

17

9611581

SLEEVE EXTENDED WEAR 15K CHOKE

1

18

9611582

SLEEVE WEAR 15K CHOKE

2

19

9611583

COUPLER 15K CHOKE

1

20

9612549

BUSHING SHAFT 15K CHOKE API

1

21

9612550

BONNET MACHINING W/ BUSHING COUNTERBORE 15K CHOKE

1

22

9650351

BAND CALIBRATION 15K CHOKE

1

23

9650728

NAMEPLATE API DISC CHOKE

1

Figure 31. Seal Kit Parts

46


46


WARNING

SUBSTITUTING AN INDIVIDUAL "OFF THE SHELF" SEAL CAN CAUSE PERSONAL INJURY OR EQUIPMENT DAMAGE DUE TO SEAL FAILURE. SEAL KIT PARTS ARE CONTROLLED BY MANUFACTURE DATE AND SHELF LIFE. THE SEALS HAVE BEEN SPECIFICALLY SELECTED TO MEET THE DEMANDING TEMPERATURE AND PRESSURE SPECIFICATIONS OF THIS CHOKE.

ITEM

PART NUMBER

PARTS LIST FOR FIGURE 31 DESCRIPTION

QTY

1

**PART OF SEAL KIT 9612459

REAR BONNET O-RING 3.100 ID

1

2


FLANGE PROTECTOR WEAR SLEEVE OD O-RING 2.800 ID

2

3


WEAR SLEEVE OD/SPOOL INLET O-RING 2.987 ID

2

4


REAR BONNET ID O-RING ID 1.109

3

5


BONNET OD O-RING 3.359 ID

3

6


BACK DISC ASSEMBLY OD O-RING 3.600 ID

1

7


BODY OUTLET O-RING GROOVE O-RING 4.350 ID

1

8


BONNET ID O-RING BACK-UP 1.141 ID

1

9


FRONT BONNET O-RING 1.109 ID

1

10


FRONT BONNET O-RING 1.109 ID

1

**All seal kit parts are critical spare parts

47


47


Figure 32. Actuator

48


48


PART NUMBER


QTY

DESCRIPTION

49

1

5801041

ACTUATOR HYDRAULIC 30,000 IN-LB API 16C (REBUILD KIT AVAILABLE, PART NUMBER 5801041-KIT)

1

1A

PART OF REBUILD KIT 5801041-KIT

BEARING

2

1B


SEAL KIT

1

1C


RELIEF VALVE

1

2

PART OF HARDWARE BEARING BALL DBL SHIELDED 6MM BORE X 19MM OD X 6MM KIT 9612478 W HIGH CARBON STEEL

1

3

PART OF HARDWARE SCREW SOC HD SHOULDER SS 5/16 X 1/2 LG X 1/4-20 NC KIT 9612478

1

4

PART OF HARDWARE NUT HEX PLT 3/8-16UN KIT 9612478

2

5

PART OF HARDWARE NUT HEX SS 1/4-20UN KIT 9612478

1

6

PART OF HARDWARE WASHER FLAT SS 1/4 IN KIT 9612478

6

7

PART OF HARDWARE WASHER LOCK 3/4 SPLIT MS KIT 9612478

3

8

PART OF HARDWARE WASHER LOCK SPLIT PLT 3/8 IN KIT 9612478

2

9

PART OF HARDWARE LOCK WASHER 1/4 SPLIT 304SS KIT 9612478

2

10

PART OF HARDWARE WASHER FLAT SS 5/16 IN X 7/8 OD TYPE A WIDE KIT 9612478

1

11

PART OF HARDWARE SCREW HEX HD PLT 3/8-16 NC X 1 IN KIT 9612478

2

12

PART OF HARDWARE SCREW HEX HD CAP PLT 3/4-10NC X 1-1/4 KIT 9612478

3

13

PART OF HARDWARE SCREW HEX HD SS 1/4-20 NC X 1 IN ALL THREAD KIT 9612478

2

14

PART OF HARDWARE SCREW SOC HD SS 1/4-20NC X 1/2 IN KIT 9612478

4

15

PART OF HARDWARE SCREW SOC HD SS 10-32 NF X 1/2 IN KIT 9612478

2

16

PART OF HARDWARE SCREW SOC HD CAP SS 10-32NF X 1 IN KIT 9612478

2

17

PART OF HARDWARE SCREW SET HEX SOC SS 8-32 NC X 1/4 IN KIT 9612478

2

18

2010040

COUPLING QD SOCKET STL 1/4 FPT 7500 PSI 2 - WAY SHUT OFF

1

19

2010041

COUPLING QD PLUG STL 1/4 FPT 7500 PSI 2 WAY SHUT OFF

1


49


PART NUMBER


QTY

DESCRIPTION

50

20

2012021

CAP DUST QD PLUG 1/4 IN PLASTIC

1

21

2012097

CAP DUST QD SOCKET 1/4 IN PLASTIC

1

22

5201029

REGULATOR PRESS AIR 1/2-30 PSI 1/4 NPT

1

23

5401305

TUBING POLY BLACK 1/4 IN OD X .040 IN W X 9.000 IN LG

1

24

5401315

TUBING POLY NATURAL 1/4 IN OD X .040 IN W X 5.500 IN LG

1

25

5415205

COMPRESSION 90D BRASS 1/4 POLY X 1/4 NPT MALE

6

26

9611036

ARM CAM FOLLOWER SUPER CHOKE

1

27

9611037

BAR SQ SS 304 3/4 X 3/4 X 1.88 IN LG

1

28

9611038

BRACKET REGULATOR AND POSITION INDICATOR

1

29

9611039

CAM FAIRCHILD HILLER POSITION INDICATOR SUPER CHOKES

1

30

9611040

CLAMP PIVOT ADJ SCREW FAIRCHILD HILLER POS INDICATOR

1

31

9611042

ARM GUIDE FAIRCHILD HILLER POSITION INDICATOR

1

32

9611044

SCREW ADJUSTMENT FAIRCHILD HILLER POSITION INDICATOR

1

33

9611046

SCREW CAM FOLLOWER F.H. POSITION INDICATOR

1

34

9611098

HOUSING ACTUATOR CHOKE

1

35

9611099

COVER POSITION TRANSMITTER SKID LESS SUPER CHOKES

1

36

9611100

GUARD PIPING SKID LESS SUPER CHOKES

1

37

9611102

SHAFT CAM F.H. POSITION TRANSMITTER SKID LESS CHOKES

1

38

PART OF HOSING KIT 9612477

HOSE ASSEMBLY POLY-ORANGE WP 3/16 ID X 11 IN LG

2

39


HOSE ASSEMBLY POLY-ORANGE WP 3/16 ID X 18 IN LG

2

40


ELL STREET STL ZINC PLT 1/4 NPT 3000 PSI

4

41


TEE PIPE PLT 5000 LB 1/4 NPT

2

42


NIPPLE STL ZINC PLT HEX 1/4 NPT

4

43


CONNECTOR STL ZINC PLT MALE 37D 7/16 IN NC X 1/4 IN NPT

4


50


THIS PAGE INTENTIONALLY BLANK

51


51


INDEX A Actuator Assembly

L Leak Testing ................................................................... 21

Installation ..................................................................13

M B Bonnet End Disassembly ................................................37

C Calibrating ......................................................................21

Maintenance .................................................................... 24 Adjusting .................................................................... 25 Daily Operational Checks........................................... 24 Daily Visual Checks ................................................... 24 Hydrostatic Seat Test Procedure................................. 29

Choke Hose Control Installation ..................................................................20 Commissioning ...............................................................21 Connecting Equipment....................................................18

Hydrostatic Test Procedure ........................................ 27 Inspecting ................................................................... 24 Position Indicator System ........................................... 25 Pressure Testing ......................................................... 27

D

Minor Repair of Equipment ............................................ 31

De-Preservation ..............................................................14

O

Disconnecting .................................................................41

Operating Disturbances................................................... 22

E

Operational Checks ......................................................... 24

Emergency Hose Failure .................................................22

P

Equipment hazards ........................................................... 3

Packing for Transportation ............................................. 42

H

Parts ................................................................................ 42

Hazardous Materials ........................................................ 4

Seal Kit ....................................................................... 46

Hose Failure ....................................................................22

Position Indicator System ............................................... 25

HSE .................................................................................. 2

Position Indicator Tubing

Hydrostatic Seat Test Procedure .....................................29

Installation .................................................................. 20

Hydrostatic Test Procedure .............................................27

PPE ................................................................................... 2 Pre Start .......................................................................... 22

I Installation

Preparation for Installation ............................................... 9 Pressure Testing ........................................................ 21, 27

Actuator Assembly .....................................................13

Principles of Use ............................................................... 7

Choke Hose Control ...................................................20

R

Position Indicator Tubing ...........................................20 Installing .........................................................................17 Interface Connections .....................................................17

Repair Bonnet End Disassembly ............................................ 37 Spool End Disassembly .............................................. 31

52


52

M-I SWACO 15K Disc Choke, Low Specifications Restrictions of Use............................................................ 8

Specifications ................................................................... 5

Rig Down........................................................................ 41

Spool End Disassembly .................................................. 31

Rig Up ............................................................................ 17

Starting Equipment ......................................................... 22

S

T

Safety

Terminal Points

Environment ................................................................. 2

Connecting ................................................................. 20

Equipment Hazards ...................................................... 3

Transportation ................................................................ 42

Health ........................................................................... 2

Actuator Assembly ..................................................... 42

Lock Out And Tag........................................................ 3

Choke ......................................................................... 42

PPE ............................................................................... 2

Troubleshooting.............................................................. 29

Seal Kit Parts ............................................................................ 46

V

Parts List..................................................................... 46

Visual Checks ................................................................. 24

Smart Part System .......................................................... 43 Spare Parts ...................................................................... 42

W Warranty ........................................................................... 8

53


53

This document has been translated from English for the ’s convenience only. In the event of a conflict between this translated document and the English version, the English version takes precedence. M-I SWACO makes no guarantees or warranties regarding the accuracy of the translation. Therefore, the agrees to use this translated document at their own risk and to hold M-I SWACO harmless for any claims / losses / causes of action arising from their use of this translated document. This document has been translated from English for the ’s convenience only. In the event of a conflict between this translated document and the English version, the English version takes precedence. M-I SWACO makes no guarantees or warranties regarding the accuracy of the translation. Therefore, the agrees to use this translated document at their own risk and to hold M-I SWACO harmless for any claims / losses / causes of action arising from their use of this translated document.

This information is supplied solely for informational purposes and M-I SWACO makes no guarantees or warranties, either expressed or implied, with respect to the accuracy and use of this data. All product warranties and guarantees shall be governed by the Standard of Sale. Nothing in this document is legal advice or is a substitute for competent legal advice. This information is supplied solely for informational purposes and M-I SWACO makes no guarantees or warranties, either expressed or implied, with respect to the accuracy and use of this data. All product warranties and guarantees shall be governed by the Standard of Sale. Nothing in this document is legal advice or is a substitute for competent legal advice.

M-I SWACO P.O. Box 42842 Houston, Texas 77242-2842 www.miswaco.slb.com

Manual Swaco.pdf 2g393v

Overview 4q3b3c

More details 26j3b

Related Documents 171j1w

Manual 2l3473

Manual 2l3473

Manual 2l3473

Manual 2l3473

Manual 2l3473

Manual 2l3473

More Documents from "irving" 3j3i5m

Historial Terminal 5qr4m

2c82t

Candado Electronico 2w1h3s

Funcion K Esimo Mayor Excel 2010 3ku5y

Documentos Utilizados En Logistica.docx 3o2b5d

Manual Swaco.pdf 2g393v