control panel std design

OPERATIONS AND MAINTENANCE MANUAL

MAN-0032 DHSV/MV CONTROL MODULES

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Illustration showing a typical example of a DHSV/MV Control Module

OPERATIONS AND MAINTENANCE MANUAL

MAN-0032 DHSV/MV CONTROL MODULES

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Document covering the following ASEP Elmar assemblies:

L-690267-V01 6K 2BOP

L-690267-V02 10K 2BOP CE ATEX

L-6901010507 10K 3BOP

------------------------------------------------------------------------------------------------------- Originally Prepared by S. Trevaskis Edited by R. Atherton Approved by I. MacDonald ------------------------------------------------------------------------------------------------------ Publication MAN-0032 © 2012 Copyright National Oilwell Varco The information is correct at the time of print First Published in November 2004 by ASEP Elmar Engineering -------------------------------------------------------------------------------------------------------

Approval and Issue

REV ECO PREPARED CHECKED APPROVED DATE COMMENTS

E 9584 S. Trevaskis I. MacDonald I. MacDonald 05/12/2012

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1 HEALTH AND SAFETY ..................................................................................... 5

1.1 SAFETY IS EVERYONE'S RESPONSIBILITY TXT-0007 .................................. 6

1.2 SAFETY PRECAUTIONS AND WARNINGS ...................................................... 7

1.3 POTENTIAL HAZARDS IDENTIFIED AT THE DESIGN STAGE ....................... 8

1.4 AIRBORNE NOISE EMISSIONS ........................................................................ 9

1.5 FLUID DATA SHEETS ....................................................................................... 9

2 DESCRIPTION AND SPECIFICATIONS ......................................................... 10

2.1 INTRODUCTION .............................................................................................. 11

2.2 STANDARD FEATURES .................................................................................. 12

2.3 UNIT DATA SHEETS ....................................................................................... 12

3 HANDLING, INSTALLATION AND SHIPPING ................................................ 19

3.1 HANDLING INSTRUCTIONS ........................................................................... 20

3.2 INSTALLATION INSTRUCTIONS .................................................................... 20

3.3 SERVICES ....................................................................................................... 21

4 OPERATING INSTRUCTIONS......................................................................... 22

4.1 RIG-UP INSTRUCTIONS ................................................................................. 23

4.2 RIG-DOWN INSTRUCTIONS ........................................................................... 23

4.3 GENERAL CHECK BEFORE OPERATION ..................................................... 24

4.4 EMERGENCY SHUTDOWN SYSTEM ............................................................. 25

4.5 LOW PRESSURE WARNING SYSTEM ........................................................... 25

4.6 MV DHSV AND TESTLINE HYDRAULIC SYSTEM ......................................... 25

4.7 BOP HYDRAULIC SYSTEM ............................................................................. 27

4.8 EMERGENCY STOP ........................................................................................ 29

4.9 PRESSURE/FUNCTION TEST FOR DHSV/MV/TEST SYSTEM ..................... 29

4.10 PRESSURE/FUNCTION TEST FOR DHSV/MV/TEST SYSTEM ..................... 31

4.11 BOP HAND PUMP CHECK .............................................................................. 32

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4.12 ESD SYSTEM CHECK ..................................................................................... 33

5 MAINTENANCE/INSPECTION SCHEDULE .................................................... 34

6 MAINTENANCE - PUMPS ............................................................................... 35

6.1 SPECIAL PUMP MAINTENANCE FOR ATEX CLASSIFIED USE ................... 36

7 MAINTENANCE - OTHER COMPONENTS ..................................................... 37

8 MAINTENANCE SCHEDULE, SPARES AND ACCESSORIES ...................... 38

8.1 MAINTENANCE SCHEDULE ........................................................................... 39

8.2 RECOMMENDED SPARES LIST (CURRENT WELLHEAD CONT’L MODS) .. 40

9 DRAWINGS AND BILLS OF MATERIAL ........................................................ 41

9.1 GUIDE TO USE OF ASEP ELMAR DRAWINGS .............................................. 45

9.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT .................................. 45

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1 HEALTH AND SAFETY

1.1 SAFETY IS EVERYONE’S RESPONSIBILITY TXT-0007

1.2 SAFETY PRECAUTIONS AND WARNINGS

1.3 POTENTIAL HAZARDS IDENTIFIED AT THE DESIGN STAGE

1.4 AIRBORNE NOISE EMISSIONS

1.5 FLUID DATA SHEETS

CASTROL BRAYCO MICRONIC ................................................................ COM-0071

SHELL DONAX TA ...................................................................................... COM-0078

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1.1 SAFETY IS EVERYONE'S RESPONSIBILITY……………………….TXT-0007

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1.2 SAFETY PRECAUTIONS AND WARNINGS

Like all module equipment, the use and maintenance of ASEP Elmar Control

Modules involves residual risks that cannot practically be further reduced by design.

General hazards, common to all areas of the use and maintenance of a Control

Module are highlighted below. More specific hazards are detailed in the individual

sections of the operation and maintenance instructions, where occurrence of the

hazard is possible.

DANGER! – COMPETENCY OF PERSONNEL

All operation and maintenance of the Control Module should be planned and supervised by a competent person. The legal requirements and owner / user requirements for operator competency may vary between regions and between owner / users. The definition of operator competency should therefore be defined and controlled by the Control Module owner / user. However, ASEP Elmar recommend that the competent person must have, as a minimum:

Sufficient practical and theoretical knowledge of Control Modules.

Sufficient experience of the operation of the appliance in the environment in which the Control Module is used.

The ability to detect deficiencies and to assess their criticality in relation to performance, and to recommend remedial action to ensure that conditions are appropriate for safe use.

Other personnel involved in the operations should have a sound knowledge of their part of the operation.

DANGER! – STUDY AND FOLLOW THE OPERATION AND MAINTENANCE MANUAL

Before using the Control Module, an operation and maintenance manual, and all other documents referenced therein should be available to, and clearly understood by all personnel involved in the operation.

If you have not studied the operation and maintenance manual for the Control Module carefully, this can lead to fatal accidents, or serious property damage.

Follow the operating instructions exactly.

DANGER! – REGULAR MAINTENANCE OF THE CONTROL MODULE

Regular maintenance of the Control Module is essential to its continued safe operation. Before using the Control Module, ensure that the maintenance program has been adhered to and is recorded.

DANGER! – PERIODIC INSPECTION, TESTING AND EXAMINATION

Periodic inspection, testing and examination of the Control Module are essential to its continued safe operation. Before using the Control Module, ensure that the inspection, testing and examination program has been adhered to and is recorded.

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DANGER! – ALWAYS USE APPROPRIATE PPE

Always use appropriate personal protective equipment.

DANGER! – UNAUTHORISED PERSONNEL

Always clear the area of unauthorised personnel before commencing operations. Throughout the operation ensure that no unauthorised personnel are permitted to enter the area. Temporary tape barriers marking the danger area may be used for this.

1.3 POTENTIAL HAZARDS IDENTIFIED AT THE DESIGN STAGE

DANGER! RISK of crushing during lifting and transport operations.

RISK of personal injury from sharp or pointed fixed edges. Wear suitable

protective clothing.

RISK of contact with hydraulic fluid.

RISK of injury from fluid under high pressure – especially during bleeding

RISK of entrapment in machinery space (spooling hoses).

RISK of injury from dangerous chemicals. Wear suitable protective

clothing.

RISK of static electricity. When used in a hazardous area, operators

should avoid clothing which is likely to generate static. Unit should be

earthed to minimise risk.

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1.4 AIRBORNE NOISE EMISSIONS

POSITION DISTANCE NOISE LEVEL (dBA)

COMMENTS

Front 1 Metre 76 -

LH Side 1 Metre 74 -

Back 1 Metre 83

RH Side 1 Metre 74

1.5 FLUID DATA SHEETS

CASTROL BRAYCO MICRONIC ................................................................ COM-0071

SHELL DONAX TA ...................................................................................... COM-0078

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2 DESCRIPTION AND SPECIFICATIONS

2.1 INTRODUCTION

2.2 STANDARD FEATURES

2.3 UNIT DATA SHEETS

PUMP PERFORMANCE: AW & AF SERIES PUMPS ................................... TXT-0008

PRESSURE CONVERSION TABLES ........................................................... TXT-0003

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2.1 INTRODUCTION

The ASEP Elmar Wellhead Control Units are designed with a range of available

functions to operate pressure control equipment up to 10,000 psi working pressure.

Most units are designed to operate a Downhole Safety Valve (DHSV or SSSV or

SCSSSV) and a master valve (MV or UMV or PUMV), a Stuffing Box and either one,

two or three wireline BOP’s. A pressure test facility is also available. Air driven

hydraulic pumps are used to power DHSV, MV and BOP functions. A hand pump is

provided for operating the Stuffing Box, but in some units an air driven pump is

shared with the BOP controls. The Pressure Test Line utilises one of the existing

hydraulic pumps via a crossover valve.

Back-up accumulators are provided to operate the BOP’s during an emergency.

Back-up hand pumps are provided for BOP, MV and DHSV.

An Emergency Shut Down System is provided. Two types are available. A manual

hydraulic valve is normally provided, but a pneumatically operated push button ESD

system is provided if the module is to be used with a remote ESD station.

An alarm system is provided which activates an air horn in the event of low hydraulic

pressure, and depending on model, also in the event of low air supply pressure.

For the European market, CE marked and ATEX approved versions of the units are

available.

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2.2 STANDARD FEATURES

Frame enclosed with stainless steel protective panels.

All controls are mounted ergonomically on a stainless steel mimic control

panel.

Lightweight twin hoses are supplied for the BOP’s.

Lightweight single hoses are supplied for DHSV, MV, Test Line and

Stuffing Box.

All hoses are mounted on Elmar “wet centre” reels.

All tubing and many components are of stainless steel.

Fluid tanks are fitted with 10 micron return line filters.

2.3 UNIT DATA SHEETS

Unit data sheets for units covered by this manual

L-690267-V01 6K 2BOP

L-690267-V02 10K 2BOP CE ATEX

L-6901010507 10K 3BOP

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Assembly Part Number: ……………………………………............. ....... L-690267-V01

Unit Type: .............................................................. Wellhead Hydraulic Control Module

Overall Dimensions:

Length …………………… ................................................................. 1200mm

Width ……………………... .................................................................. 850mm

Height …………………… .................................................................. 1540mm

Mass:

Maximum Gross ……….. ......................................................................900Kg

Tare Weight……………… .......................................................................900Kg

Payload……………………… ..................................................................... 0Kg

Operating Temperature……………………………………………………….+5°C to +54°C

BOP Pump Model………..................................................................... ... Haskel AW-25

MV Pump Model………..................................................................... .... Haskel AW-100

DHSV Pump Model……………………………………………………….. `Haskel AW-100

Accumulator Capacity………………………………………………………….. ...... 40 litres

DHSV/MV Tank Capacity……………………………………………………….. .... 65 litres

BOP Tank Capacity………………………………………………………………. ... 40 litres

Functions:

Stuffing Box

Dual Wireline BOP

MV

DHSV

10,000 psi Test Line

Reels and Hoses:

BOP Reels c/w 3/16” Twin Hose x 75 ft + Snaptite QC Couplings.

MV Reel c/w ¼” hose x 150 ft and Pioneer QC Coupling.

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DHSV Reel c/w ¼” hose x 150 ft and Pioneer QC Coupling.

Test Line Reel c/w ¼” hose x 120 ft and Pioneer QC Coupling.

Stuffing Box Reel c/w ¼” hose x 120 ft and Pioneer QC Coupling.

Air Supply Reel c/w ½” hose x 60 ft and Chicago QC Coupling.

Special Features:

None

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Assembly Part Number: ……………………………………............. ....... L-690267-V02


Overall Dimensions:

Length …………………… ................................................................. 1220mm

Width ……………………... ................................................................ 1010mm

Height …………………… .................................................................. 1685mm

Mass:

Maximum Gross ……….. ....................................................................1050Kg

Tare Weight……………… .....................................................................1050Kg

Payload……………………… ..................................................................... 0Kg


BOP Pump Model………..................................................................... .... Haskel AF-35

MV Pump Model………..................................................................... ..... Haskel AF-100

DHSV Pump Model……………………………………………………….. . ̀ Haskel AF-100




Functions:

Stuffing Box

Dual Wireline BOP

MV

DHSV


Reels and Hoses:



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Special Features:

CE Marked for use in Europe.

ATEX classified for use in hazardous area. (Ex II 2G IIB T4).

Frame designed manufactured and tested with reference to BSEN12079,

(2006)

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Assembly Part Number: ……………………………………................... L-6901010507


Overall Dimensions:

Length …………………… ................................................................. 1220mm

Width ……………………... ................................................................ 1010mm

Height …………………… .................................................................. 1675mm

Mass:

Maximum Gross ……….. ....................................................................1050Kg

Tare Weight……………… .....................................................................1050Kg

Payload……………………… ..................................................................... 0Kg


BOP Pump Model………..................................................................... ... Haskel AW-35

MV Pump Model………..................................................................... .... Haskel AW-100

DHSV Pump Model……………………………………………………….. `Haskel AW-100




Functions:

Stuffing Box

Triple Wireline BOP

MV

DHSV


Reels and Hoses:



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Special Features:

None

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3 HANDLING, INSTALLATION AND SHIPPING

3.1 HANDLING INSTRUCTIONS

3.2 INSTALLATION INSTRUCTIONS

3.3 SERVICES

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3.1 HANDLING INSTRUCTIONS

Before handling of equipment, ensure following:

Suitable protective clothing should be worn - there may be sharp edges.

Both hydraulic and pneumatic system pressures bled down.

All control valves in OFF position.

Fluid tanks filler cap in place and tightly secured.

Drip tray in base of skid is drained and plug is in place and tightened.

All associated pneumatic / hydraulic hoses are suitably stored away.

Control panel protective cover in place and properly fastened.

Lifting set shackles securely fastened to frame lifting eyes with safety split

pins in place. Units must only be lifted using the correct 4-leg lifting set

provided.

NOTE!

Reference should also be made to Section 1.2 regards Safety and Potential Hazards identified at the Design Stage!

3.2 INSTALLATION INSTRUCTIONS

Installation of the Well Control Unit in a workshop / platform is the responsibility of the

equipment operator. However the following should be taken into account:

Unit to be placed on a level and firm surface which can hold the gross

weight of the unit.

The positioning of the unit with regards access for essential and non

essential maintenance. We recommend a minimum clearance distance of

1 metre all round the unit.

Routing of air and hydraulic hoses from the unit to the Wellhead

equipment.

The position of the control panel with regards operator access.

The unit should be placed so that the reels point towards the wellhead.

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Remote ESD stations (only fitted to some models) should be located in a

suitable position to allow activation during an emergency situation.

- Unit should be earthed to the rig earth using 6mm² or greater insulated

earth wire. An earth point is fitted to the rear of the unit, below the hose

reels.

3.3 SERVICES

Air supply

Minimum pressure 90psi. (100psi required for 10,000psi Hydraulic

Pressure)

Maximum Pressure 120psi.

Maximum Flow Rate 75scfm.

Connection type, ¾” Chicago (Crows Foot) Valved Coupling.

Electrical Earth

Units in ATEX classified areas shall be earthed

NOTE!

Air supply should be clean and free from obvious water contamination. Preferably instrument quality.

Control unit should be connected to a suitable air supply as above using a suitable air hose. Recommended size is ¾” ID. Ensure air supply valve on control panel is OFF, and air regulators are turned fully anti-clockwise before connection of air supply.

Use lockwire to secure air connection at Chicago coupling.

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4 OPERATING INSTRUCTIONS

4.1 RIG-UP INSTRUCTIONS

4.2 RIG-DOWN INSTRUCTIONS

4.3 GENERAL CHECK BEFORE OPERATION

4.4 EMERGENCY SHUT-DOWN SYSTEM

4.5 LOW PRESSURE WARNING SYSTEM

4.6 MV DHSV AND TESTLINE HYDRAULIC SYSTEM

4.7 BOP HYDRAULIC SYSTEM

4.8 EMERGENCY STOP

4.9 PRESSURE/FUNCTION TEST FOR DHSV/MV TEST SYSTEM

4.10 PRESSURE/FUNCTION TEST FOR BOP HYDRAULIC SYSTEM

4.11 BOP HAND PUMP CHECK

4.12 ESD SYSTEM CHECK

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4.1 RIG-UP INSTRUCTIONS

Place the skid with reels facing the wellhead. Do not connect to the wellhead control valves or to the air supply.

Units in ATEX classified hazardous areas shall be earthed.

A valve, located at the right-hand side of the control panel allows fluid to

be dumped externally, or back to the fluid tank. Set to DRAIN TO TANK

position.

Ensure that air supply to the pumps is OFF by turning regulators on

control panel fully anti-clockwise.

Connect unit to the air supply - min 90 psi/ max 120 psi. Check air

pressure on the AIR SUPPLY gauge.

Check operation of the unit. See function test procedures (Sections 4.12-

4.15)

Set all control panel valves to the OFF/CLOSED position.

Ensure that air supply to the pumps is OFF by turning regulators on

control panel fully anti-clockwise.

Connect hydraulic hoses onto the relevant couplings on the wellhead

control valves.

4.2 RIG-DOWN INSTRUCTIONS

Turn OFF the rig air supply and vent the supply line.

Turn OFF and vent the unit air supply by turning OFF the Off/Vent valve

located at the main air filter.

Set the LOW PRESSURE WARNING SYSTEM valve to OFF.

Turn the hydraulic pump air regulators fully anti-clockwise.

Set ACCUMULATOR valve to the ON position.

Turn the BOP dump valve to the DUMP position.

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All pressure must be removed from the BOP hoses before reeling up by

moving the BOP controls from open to close twice.

Open the DUMP valve and two crossover valves for the MV, DHSV and

Test Line.

Set the MV, DHSV and Test Line OPEN/CLOSE valves to CLOSE twice.

This will release fluid pressure in the MV, DHSV and Test Line hoses and

reels, and from the unit itself.

Check hydraulic pressure gauges to ensure that all pressure has been

released.

Disconnect the air and hydraulic lines.

Rewind hoses onto reels. Reels must not be rotated with pressure in the

hoses. This will reduce '0' ring seal life.

NOTE!

If unit is to be transported reference should be made to Section 3.1 Handling Instructions. This covers the full requirements for shipping preparation.

4.3 GENERAL CHECK BEFORE OPERATION

Airline Filter: Drain water from bowl. (If autodrain, check that it functions).

Tank Fluid Levels: Tanks should be kept filled. High and Low levels are

indicated by the high and low marks on the sight glasses.

CAUTION!

Always check hydraulic oil levels with accumulators discharged otherwise over-filling will result. Refer to Section8 for correct hydraulic fluid.

Tank Return Filters: A visual indicator on each filter shows the condition of

the filters. Replace elements as necessary.

Tubing: Check all tubing, fittings etc. for signs of damage. Replace as

necessary.

Hoses: Check all hoses, fittings etc. for signs of damage. Replace as

necessary.

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Control Panel: Ensure that all valves are OFF/CLOSED and all air

regulators are turned OFF (anti-clockwise).

4.4 EMERGENCY SHUTDOWN SYSTEM

Operate the unit until the desired operating pressures on each circuit are

reached.

To shutdown the MV and DHSV, lift the flap and turn the EMERGENCY SHUT DOWN valve anti-clockwise to the vertical position. The hydraulic

pressure in each control line will dump immediately.

CAUTION!

Operation of the ESD system will close MV and DHSV without accumulator pressure.

4.5 LOW PRESSURE WARNING SYSTEM

To prevent the warning horn sounding whilst hydraulic pressures are

building up, set the LOW PRESSURE WARNING ALARM valve to OFF.

Select ON after desired pressures have been reached. Valves for each

individual function should be set to the ON position. If the Warning Horn

sounds, turn each individual warning system valve OFF/ON to detect the

function causing the alarm.

NOTE!

See the hydraulic schematic drawing (Section 9) for the recommended alarm settings.

4.6 MV DHSV AND TESTLINE HYDRAULIC SYSTEM

MV SYSTEM MAX. WORKING PRESSURE 10,000 PSI

SSSV SYSTEM MAX. WORKING PRESSURE 10,000 PSI

AV SYSTEM MAX. WORKING PRESSURE 10,000 PSI

Ensure MV, DHSV and TEST LINE OPEN/CLOSE valves are in the OFF

position.

Ensure both crossover valves are in the horizontal OFF position.

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Ensure that the Dump Valve is in the horizontal OFF position.

Ensure that the Emergency Shutdown valve is re-set.

To open the MV, DHSV or TEST LINE, turn the appropriate valve to. the

OPEN position.

Adjust pressures by slowly turning the. air regulators, located at the

bottom right of. the control panel, clockwise until the desired pressures are

obtained on the gauges above.

To CLOSE the MV or DHSV, turn the appropriate valve to the close

position. This will dump the hydraulic pressure in the relevant circuit.

To dump TEST LINE pressure, turn the DUMP valve to the vertical DUMP

position.

NOTE!

In the event of a pump failure, one of the other pumps can be utilised.

Turn the MV, DHSV and TEST LINE valves to the OFF position.

CAUTION!

Do not CLOSE.

Turn the air regulators for MV and DHSV fully anti-clockwise (OFF).

Turn the relevant crossover valve(s) to the vertical position (ON).

For the function to be operated, turn the appropriate OPEN/CLOSE valve

to the OPEN position.

For the pump to be operated, adjust pressure by slowly turning the air

regulator clockwise until the desired working pressure is obtained on the

gauge for the function being operated.

NOTE!

In the event of an air supply failure, the hand pumps can be utilised.

Turn the MV, and DHSV valves to the OFF position.

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CAUTION!

Do not CLOSE.

Turn the air regulators for MV and DHSV fully anti-clockwise (OFF).

For TEST LINE, turn the relevant crossover valve to the. vertical position

(ON).

Operate hand pump until correct pressure is obtained on the gauge for the

function being operated. (Hand pump handle is stored at left hand side of

control panel).

4.7 BOP HYDRAULIC SYSTEM

BOP SYSTEM MAX. WORKING PRESSURE 3,000 PSI

Ensure the BOP OPEN/CLOSE valves (located in centre of panel) are in

OFF positions.

Ensure the; BOP air regulator, located at bottom of panel, is OFF (fully

anti-clockwise).

Ensure that the DUMP valve is in the vertical (OFF) position.

To charge the accumulators:-

Set the accumulator valve to the ON position.

Turn the BOP air regulator slowly anti-clockwise so that pump charges the

accumulators.

When the accumulator charge pressure has been reached, turn the

accumulator valve to the OFF position.

Turn the BOP air regulator OFF (fully anti-clockwise).

Turn the BOP dump valve to the DUMP position.

To operate the BOP normally (i.e not in an emergency):-

Ensure the BOP OPEN/CLOSE valve(s) are in OFF position.

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Ensure the BOP air regulator, located at bottom of panel, is OFF (fully

anti-clockwise).

Ensure that the BOP dump valve is in the vertical (OFF) position.

Set the accumulator valve to the OFF position.

Turn the BOP air regulator slowly clockwise until the BOP Pressure gauge

reaches the BOP operating pressure.

The BOPs may now be operated by moving the BOP OPEN/CLOSE

valves to either the OPEN or CLOSE position.

In. the. event of an air supply failure; the hand pump.can.be utilised.

Turn the air regulator fully anti-clockwise (OFF)

Ensure that the DUMP valve is in the vertical (OFF) position.

Ensure that the ACCUMULATOR valve is set to the OFF position.

Set the BOP OPEN/CLOSE valve(s) to either the OPEN or CLOSE

position(s) as required.

Set the hand pump change valve to BOP function.

Operate hand pump and maintain operating pressure on the BOP

Pressure gauge.

To operate the BOP in an emergency:-

Ensure the BOP OPEN/CLOSE valve(s) are in OFF position.

Ensure the BOP air regulator, located at bottom of panel, is OFF (fully

anti-clockwise).

Ensure that the BOP dump valve is in the vertical (OFF) position.

Ensure the SB/BOP valve is set to STUFFING BOX.

Set the accumulator valve to the ON position. Check for operating

pressure on the BOP PRESSURE gauge.

The BOP's may now be operated by moving the BOP OPEN/CLOSE

valves to either the OPEN or CLOSE position.

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4.8 EMERGENCY STOP

To STOP the unit in an emergency, turn the main air supply valve to the

OFF (vertical) position. This will stop all pumps from operating normally.

However, hydraulic pressure is stored in accumulators to maintain control

of the well.

CAUTION!

Do not confuse the Emergency Stop function with the Emergency Shutdown (ESD) system.

Operation of the ESD system by turning the Emergency Shutdown Valve on the control panel will close the well in an emergency and cut the wireline.

4.9 PRESSURE/FUNCTION TEST FOR DHSV/MV/TEST SYSTEM

DANGER!

The following pressure tests are only carried out at up to maximum working pressure (MWP) of the systems in order to check for leaks and correct operation. Any testing above MWP should be carried out in a recognised pressure test bay.

Reference should be made to the preceding operating instructions.

Fully un-spool all hoses. Check the condition of all hose ends, hoses and

quick couplings. These should all be in good condition.

Turn OFF all air regulators by turning fully anti-clockwise.

Close the DHSV/MV/TEST dump valve (horizontal position).

Set the crossover valves to OFF.

Set all Low Pressure Warning Alarm valves to OFF.

Set the MV OPEN/CLOSE valve to CLOSE position.

Slowly turn air regulator for MV clockwise.

Pump will stall. No pressure should register on the MV gauge.

Set the MV OPEN/CLOSE valve to OFF position.

Pump will stall. No pressure should register on the MV gauge.

Turn air regulator for MV OFF (fully anti-clockwise).

Set the Low Pressure Warning Alarm valve to ON.

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Set the MV Low Pressure Warning Alarm valve to ON. Alarm should

sound.

Set the MV OPEN/CLOSE valve to OPEN position.

Slowly turn air regulator for MV clockwise until MV gauge exceeds the

alarm pressure. Alarm should stop.

Use the MV hand pump to increase the MV pressure to pressure/function

test pressure.

Check for leaks behind control panel, hoses and hose ends.

Set the MV OPEN/CLOSE valve to CLOSE. (Test Line valve should be set

to OPEN) Gauge pressure should dump and Alarm should sound.

Open dump valve. Set the Low Pressure Warning Alarm to OFF.

Repeat the above procedure for the DHSV system.

Repeat the above procedure for the Test Line system, omitting alarm

tests.

SYSTEM PRESSURES

MV Alarm Pressure 2,500psi

Max Working Pressure 10,000psi

SSSV

Alarm Pressure 2,500psi


Test


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4.10 PRESSURE/FUNCTION TEST FOR DHSV/MV/TEST SYSTEM

DANGER!

The following pressure tests are only carried out at up to maximum working pressure (MWP) of the systems in order to check for leaks and correct operation. Any testing above MWP should be carried out in a recognised pressure test bay.

Reference should be made to the preceding operating instructions.

Fully un-spool all hoses. Check the condition of all hose ends, hoses and

quick couplings. These should all be in good condition.

Follow all start-up procedures and ensure all valves, regulators etc are

OFF.

Set all Low Pressure Warning Alarm valves to OFF.

Turn air regulator for BOP OFF (fully anti-clockwise).

Close the hydraulic dump valve (vertical position).

Turn the accumulator valve to OFF position.

Set BOP controls to off position.

Slowly turn air regulator for BOP clockwise until the max. required

pressure is reached.

Check for leaks behind the panel, at hose reel centres and at hose ends.

Set the BOP controls to CLOSE. Check gauge for pressure. Check for

leaks.

Set the BOP controls to OPEN. Check gauge for pressure. Check for

leaks.

Set the BOP controls to OFF.


Slowly turn air regulator for BOP clockwise until the accumulator charge

pressure is reached. Check for leaks.

Turn the accumulator valve to the OFF position.

Turn air regulator for BOP OFF (fully anti-clockwise).

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Open the dump valve. Accumulator should remain at full charge pressure.

Open the accumulator valve. Accumulator pressure should drop.

SYSTEM PRESSURES

L-690267-V01 690267-V02 690101507

Accumulator Max Working Pressure 3000psi 3,000psi 3,000psi

Gas Precharge Pressure 900psi 1,500psi 900psi

BOP Max Working Pressure 3000psi 3,000psi 3,000psi

4.11 BOP HAND PUMP CHECK

Close the hydraulic dump valve (vertical position).


Set BOP controls to OFF position.

Set Hand Pump selection valve to Function BOP's (Handle points down).

Insert the pump handle into the BOP hand pump and pressure up to 3000

psi. Check pressure on BOP pressure gauge.

Open the hydraulic dump valve (horizontal position) to release pressure.

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4.12 ESD SYSTEM CHECK

DANGER!

The ESD system check should not be carried out while the unit is connected to the Wellhead Control Valves. Operation of the ESD system could result in the accidental open/close of the DHSV and MV.

Set ESD valve to the horizontal position.

Pressure up the MV and DHSV circuits

Lift flap, and turn ESD valve to the vertical, ESD position.

Pressures in the DHSV and MV circuits should drop immediately.

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5 MAINTENANCE/INSPECTION SCHEDULE

AIRLINE FILTER/REGULATOR - NORGREN B74 ..................................... COM-0074

AIRLINE REGULATOR - NORGREN R73G ............................................... COM-0050

CAUTION:

Before carrying out any maintenance on the Control unit or hydraulic hoses isolate all power sources.

1. Isolate air supply by turning air supply valve on control panel to OFF position, and then switch shut off valve (red coloured) situated on air filter/regulator assembly to OFF/VENT position and padlock for additional security.

2. Bleed down all air and hydraulic pressure within the control unit.

__________________________________________________________________

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6 MAINTENANCE - PUMPS

6.1 SPECIAL PUMP MAINTENANCE FOR ATEX CLASSIFIED USE

PUMPS – HASKEL AW/AF SERIES ........................................................... COM-0008

__________________________________________________________________

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6.1 SPECIAL PUMP MAINTENANCE FOR ATEX CLASSIFIED USE

IMPORTANT!

FOR PUMPS BEING OPERATED IN AN ATEX CLASSIFIED HAZARDOUS AREAS.

1. ALL pump seals should be replaced with NEW seals at yearly intervals.

2. Full annual inspection should be conducted and any wearing parts replaced.

3. ALL springs should be replaced at yearly intervals.

4. Pumps should only be returned to service in good condition, equivalent to the condition of a new pump.

__________________________________________________________________

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7 MAINTENANCE - OTHER COMPONENTS

HOSES ........................................................................................................ COM-0017

REELS ........................................................................................................ COM-0016

6,000PSI RELIEF VALVE ........................................................................... COM-0006

10,000PSI RELIEF VALVE ......................................................................... COM-0005

WARNING!




__________________________________________________________________

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8 MAINTENANCE SCHEDULE, SPARES AND ACCESSORIES

8.1 MAINTENANCE SCHEDULE

8.2 RECOMMENDED SPARES LIST FOR CURRENT WELLHEAD CONTROL

UNITS

WARNING!




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8.1 MAINTENANCE SCHEDULE

Refer to the relevant section in this manual for parts identification and disassembly /

assembly instructions.

INTERVAL OPERATION

Daily a) Visually check unit for obvious damage b) Drain airline filter c) Check tank fluid levels

Monthly a) Check reels, hoses and hose ends for signs of leakage and damage. b) Disassemble airline filter and clean thoroughly

3 Monthly a) Check unit for leaks under pressure and inspect hoses for damage.

12 Monthly a) Fully service airline filter and regulators. b) Replace tank suction filters. c) Disassemble pumps. Check for corrosion and wear. d) Disassemble hose reels. Renew O-ring seals and back-up rings. e) For ATEX hazardous area pumps, all seals and springs should be replaced. All wearing parts should be replaced. Pump should only be returned to service in as new condition.

NOTE!

If required, ASEP Elmar will undertake all 12 month servicing. Please contact the Servicing Department for further details. All spare parts are available!

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8.2 RECOMMENDED SPARES LIST (CURRENT WELLHEAD CONT’L MODS)

DESCRIPTION OF SPARES ASEP ELMAR PART NO.

QTY PER UNIT

L-69

0267

-V01

L-69

0267

-V02

L-69

0101

0507

Pump Repair Kit:

AW-35 Pump L-663230 1 - 1

AW-100 Pump L-660670 2 - 2

AF-35 Pump L-6601005831K - 1 -

AF-100 Pump L-6601007660K - 1 -

Tank Suction Filter - 1/2" L-851000 3 2 3

Tank Return Filter (Element) L-8501002591 2 2 2

3K Hand Pump L-663820 1 1 1

10K Hand Pump 663810 3 3 3

Relief Valve Repair Kits:

6000 psi Relief Valve L-662810 1 1 1

10,000 psi Relief Valve L-521100 3 3 3

Airline FRL Repair Kits:

Filter/Regulator Repair Kit (model B74G)

L-660681 1 1 1

Regulator Repair Kit (model R73G) L-660679 3 3 3

Filter Element (model B74G) L-850316 - 1 -

O-Ring Seal Kits for Reels:

3" Single Port Reel L-663400 2 2 2

3" Single Port Air Reel L-663600 1 1 1

3" Twin Port Reel L-663300 3 3 3

5" Twin Port Reel L-663310 2 1 2

Consumables:

Castrol Brayco Micronic Subsea Fluid L-880234 - - -

Shell Donax TA Hydraulic Fluid L-883031 - - -

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9 DRAWINGS AND BILLS OF MATERIAL

9.1 GUIDE TO USE OF ASEP ELMAR DRAWINGS

9.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT

9.3 DRAWINGS AND BILLS OF MATERIAL

DRAWINGS FOR L-690267-V01

9.4 DHSV/MV UNIT DHSV TL 2BOP SB AIR CE .......................... DD690267-V01

9.5 HYDRAULIC SCHEMATIC F/ 690267-V01 ............................. HS690267-V01

9.6 CONTROL PANEL .......................................................................... DD651842

9.7 FRAME ASSEMBLY ....................................................................... DD650620

9.8 TANK ASSEMBLY – 90 + 70 LITRE ................................................ DD650503

9.9 TANK ASSEMBLY – 70 LITRE ........................................................ DD650494


9.11 PUMP ASSEMBLY, HASKEL AW-100 ............................................ DD650118

9.12 PUMP ASSEMBLY, HASKEL AW-100 ............................................ DD650119

9.13 PUMP ASSEMBLY, HASKEL AW-25 .............................................. DD651655

9.14 HAND PUMPS ASSEMBLY, 10K+10K+3K+3K ............................... DD651654

9.15 HAND PUMP ASSEMBLY – SS 3K ELMAR 1/4NPT ...................... DD793400

9.16 HAND PUMP ASSEMBLY – SS 10K ELMAR 1/4NPT .................... DD792000

9.17 AIR FILTER ASSEMBLY ................................................................. DD651664

9.18 RELIEF VALVES AND PILOT SWITCH ASSEMBLY ...................... DD651662

9.19 ACCUMULATOR ASSEMBLY ......................................................... DD650560

9.20 REEL LAYOUT ASSEMBLY ............................................................ DD653554

9.21 REEL ASSEMBLY 5” PORT LH ...................................................... DD730600

9.22 REEL ASSEMBLY 1P-3”-22” RH ¼-1/4N-1/2NPT ........................... DD762200

9.23 REEL ASSEMBLY 2P-3”-1/8-1/4N-1/4N RH ................................... DD711500

9.24 3” SINGLE PORT REEL 5/8”NPT-1/2”NPT RH ............................... DD712010

9.25 DOUBLE REWIND MECHANISM ASSEMBLY-SHORT .................. DD651665

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9.26 SINGLE REWIND MECHANISM ASSEMBLY-SHORT ................... DD651003

9.27 BULKHEAD ASSEMBLY – EXTERNAL DRAIN .............................. DD650510

9.28 HOSE + TUBE LIST ........................................................................ DD653555

9.29 PILOT VALVE ASSEMBLY ............................................................. DD650507

9.30 AIR HORN ASSEMBLY ................................................................... DD651567

9.31 BULKHEAD ASSEMBLY ................................................................. DD651649

DRAWINGS FOR L-690267-V02

9.32 DHSV/MV UNIT DHSV TL 2BOP SB AIR CE .......................... DD690267-V02

9.33 HYDRAULIC SCHEMATIC F/ 690267-V02 ............................. HS690267-V02

9.34 CONTROL PANEL .......................................................................... DD653565

9.35 FRAME ASSEMBLY ....................................................................... DD653566



9.38 PUMP ASSEMBLY, HASKEL AF-100, 6A, 6-8S, 4P, RH ........ DD6501049803

9.39 PUMP ASSEMBLY, HASKEL AF-100, 6A, 6-8S, 4P, RH ........ DD6501049813

9.40 PUMP ASSEMBLY, HASKEL AF-35, 6A, 6-8S, 4P, RH .......... DD6501049815

9.41 HAND PUMPS ASSEMBLY, 10K+10K+3K+10K 6S 4P .................. DD653562



9.44 AIR FILTER ASSEMBLY 12H VLV NORG 4T 8H ........................... DD653571

9.45 RELIEF VALVES AND PILOT SWITCH ASSEMBLY ...................... DD653569

9.46 ACCUMULATOR ASSEMBLY 2 x 20L HORIZ TUBE ............. DD6501049822

9.47 REEL LAYOUT ASSEMBLY DHSV/MV TL 2BOP SB AIR .............. DD653572





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9.54 BULKHEAD ASSEMBLY – EXTERNAL DRAIN .............................. DD650510

9.55 IDENTIFICATION KIT ...................................................................... DD653568

9.56 HOSE + TUBE LIST ........................................................................ DD653567

9.57 EARTH BONDING ASSEMBLY ....................................................... DD653467

9.58 PILOT VALVE ASSEMBLY ..................................................... DD6501049886

DRAWINGS FOR L-6901010507

9.59 DHSV/MV ................................................................................ DD6901010507

9.60 HYDRAULIC SCHEMATIC F/ 6901010507 ............................. HS6901010507

9.61 FRAME ASSEMBLY ........................................................................ DD650620

9.62 CONTROL PANEL ASSY DHSV MV ESD TL 3BOP SB ......... DD6501013765

9.63 AIR FILTER ASSEMBLY ................................................................. DD651664

9.64 PILOT SWITCH ASSEMBLY MV, DHSV ......................................... DD650507

9.65 TANK ASSEMBLY ........................................................................... DD650503



9.68 PUMP ASSEMBLY .......................................................................... DD651655

9.69 PUMP ASSEMBLY .......................................................................... DD650118

9.70 PUMP ASSEMBLY .......................................................................... DD650119

9.71 HAND PUMP ASSEMBLY 3K + 10K + 10K 6S 4P .......................... DD653289



9.74 ACCUMULATOR ASSEMBLY ......................................................... DD650560

9.75 REEL LAYOUT ASSEMBLY DHSV MV TL 3BOP SB AIR ...... DD6501013756



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9.82 REEL ASSEMBLY ........................................................................... DD700028



9.85 HOSE AND TUBE LIST ........................................................... DD6501013758

9.86 RELIEF VALVE ASSEMBLY, MV, DHSV ................................ DD6501014602

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9.1 GUIDE TO USE OF ASEP ELMAR DRAWINGS

IDENTIFICATION OF UNIT PART NUMBER

All ASEP Elmar units are identified by a part number beginning with L-69, e.g. L-

6901001234.

Each unit also has a serial number which is suffixed to the part number, e.g. -012.

Part numbers and serial numbers can usually be found in the following places:-

welded to the frame of the unit, normally on a base member.

stamped on the load test certification plate which is attached to the frame.

engraved on the unit control panel.

9.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT

Identify unit part number as described above, e.g. L-6901001234.

Look at the drawing with the same number, e.g. L-6901001234.

The Bill of Material for this drawing will consist of sub-assembly numbers

beginning with L-65, e.g. L-6501009999.

Look at the drawing with the same number, e.g. L-6501009999

The Bill of Material for this drawing will show the part numbers for

individual components. (In some cases L-65 sub-assemblies reference

further L-65 sub-assemblies which then reference individual part

numbers).

ELMAR SERVICES LTD No: TI-650503-D

TITLE: TANK ASSY 90+70L 3x8 HOSE S 3x4 HOSE R

ITEM

1234567

PART No

L-650495L-650494L-865861L-630407L-830020L-814010L-814100

QTY

1.001.002.002.004.004.004.00

ITEM PART No QTY DESCRIPTIONDESCRIPTION

TANK ASSYTANK ASSYNEOPRENETANK STRAPACCUM CLAMP RUBBERNYLOC NUTWASHER FLAT

REV ECO PREPARED CHECKED APPROVED DATE

3388 S.CRUICKSHANK 10/04/98DPAGE 1 OF 1

ED 4 (A)


TITLE: TANK ASSY 70L 2x8 HOSE S 2x4 HOSE R

ITEM

12345678

PART No

L-600075L-862400L-601500L-810000L-850700L-301700L-201900L-851000

QTY

1.001.001.0014.001.002.002.002.00

ITEM

910111213

PART No

L-300310L-242310L-823300L-505360L-460610

QTY

2.001.001.002.002.00

DESCRIPTION

MALE ELBOWCS PLUGSIGHT GLASSBALL VALVEHOSE END

DESCRIPTION

TANKGASKETMOUNTING PLATEPH SCREWFILLER CAPMALE ELBOWM-HEX NIPPLEFILTER STRAINER



ED 4 (A)


TITLE: TANK ASSY 90L 8 HOSE S 4 HOSE R

ITEM

12345678

PART No

L-600074L-862400L-601500L-810000L-850700L-301700L-201900L-851000

QTY

1.001.001.0014.001.001.001.001.00

ITEM

910111213

PART No

L-300310L-242310L-823300L-505360L-460610

QTY

1.001.001.001.001.00

DESCRIPTION

MALE ELBOWCS PLUGSIGHT GLASSBALL VALVEHOSE END

DESCRIPTION

TANKGASKETMOUNTING PLATEPH SCREWFILLER CAPMALE ELBOWM-HEX NIPPLEFILTER STRAINER



ED 4 (A)


TITLE: HAND PUMP-SS 3K ELMAR 1/4NPT

ITEM

1234567891011

PART No

L-792100L-812030L-792300L-790004L-680266L-792900L-793100L-813000L-680267L-813290L-870800

QTY

1.003.002.001.001.001.001.001.001.001.001.00

ITEM

12131415161718192021

PART No

L-872100L-872340L-870890L-871070L-813310L-875250L-875260L-874600L-875210L-792400

QTY

1.001.001.001.003.001.001.001.001.001.00

DESCRIPTION

O-RINGO-RINGO-RINGO-RINGHEX BOLTBALLBALLSPRINGPOLYPAKH/P PIVOT

DESCRIPTION

HANDLENYLOC NUTH/P LINK LEVERCHECK VALVE LINERCHECK VALVE BODYH/P CYLH/P PISTONWASHERMANIFOLD BLOCKSHC SCREWO-RING


2881 R. LARGUE 09/02/98DPAGE 1 OF 1

ED 4 (A)

© Elmar Services Ltd 1999

ELMAR SERVICES LTD No: TI-651662-C

TITLE: RELIEF VALVE ASSY,10K PRESSURE TEST LINE

ITEM

12345678

PART No

L-160040L-520360L-202300L-637810L-120620L-816400L-816100L-816010

QTY

1.001.001.001.001.001.001.001.00

ITEM PART No QTY DESCRIPTIONDESCRIPTION

MALE RUN TEERELIEF VALVEM-HEX NIPPLEBRACKETMALE ELBOWHEX SETWASHERNYLOC NUT


2374 R. LARGUE 06/02/98CPAGE 1 OF 1

ED 4 (A)

© Elmar Services Ltd 1999

ELMAR SERVICES LTD No: TI-650560-C

TITLE: ACCUMULATOR ASSY 2x20L HORZ 4TUBE

ITEM

12345678

PART No

L-246900L-161020L-830008L-830400L-816100L-816300L-816000L-190200

QTY

1.001.004.002.008.008.008.001.00

ITEM

9

PART No

L-120000

QTY

1.00

DESCRIPTION

MALE ELBOW

DESCRIPTION

REDUCING BUSHMALE BRANCH TEEACCUMULATOR BRACKETACCUMULATOR 20LTRWASHERWASHERNUTTUBE


3823 G. REID 08/01/99CPAGE 1 OF 1

ED 4 (A)

ELMAR SERVICES LTD No: TI-651665-B

TITLE: DOUBLE REWIND MECH ASSY - SHORT

ITEM

12345

PART No

L-750100L-671960L-680200L-670560L-811800

QTY

2.001.002.002.002.00

ITEM

6789

PART No

L-815400L-814100L-814010L-811810

QTY

2.004.002.002.00

DESCRIPTION

HEX BOLTWASHER FLATNYLOC NUTSPIROL PIN

DESCRIPTION

PINION GEARBEARING BLOCKSHAFT REEL PINGEAR DRIVE SOCKETSPIROL PIN


3859 G. REID 26/01/99BPAGE 1 OF 1

ED 4 (A)

ELMAR SERVICES LTD No: TI-651003-B

TITLE: SINGLE REWIND MECH ASSY - SHORT

ITEM

12345

PART No

L-750100L-671950L-680200L-670560L-811800

QTY

1.001.001.001.001.00

ITEM

6789

PART No

L-815400L-814100L-814010L-811810

QTY

2.004.002.001.00

DESCRIPTION

HEX BOLTWASHER FLATNYLOC NUTSPIROL PIN

DESCRIPTION

PINION GEARBEARING BLOCKSHAFT REEL PINGEAR DRIVE SOCKETSPIROL PIN


3859 G. REID 26/01/99BPAGE 1 OF 1

ED 4 (A)

control panel std design

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