Elmar 10k School July 2002 Printable

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E-Lite Series Grease and Hydraulic Control Module Operating and Reference Manual
E-Lite Series Grease and Hydraulic Control Module Operating and Reference Manual
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Commercial Confidential Copyright
Commercial © Elmar 2002, not not
to be copied without permission Revision 2 July 2002
Commercial Confidential
Confidential Copyright
Copyright ©
© Elmar
Elmar 2002,
2002, not to
to be
be copied
copied without
without permission
permission Revision
Revision 22 July
July 2002
2002
10K PRESSURE CONTROL SCHOOL
IMPORTANT NOTICES
1. Whilst Elmar will attempt to exercise due care in the preparation and passing
on of information in any documentation or material or during any course or
instruction, Elmar gives no warranty, express or implied, as to the accuracy
thereof and shall have no liability (irrespective of any negligence) in respect of
any errors or defects in such information or the consequences thereof.
2. Whilst Elmar will attempt to exercise reasonable care in the running of

courses or instruction, attendees of such courses or receiving such instruction
attend or participate (wherever the location) entirely at their own risk and Elmar
shall assume no liability (irrespective of any negligence) for any harm or
damage to person or property arising from such attendance or participation.
3. Any safety policies, procedures or instructions of the employers or the

sponsors of any such attendees or participators will take precedence over
those of Elmar.
4. Copyright in this manual is vested in Elmar. No copying in whole or in part is

allowed without prior permission from Elmar.
Commercial Confidential Copyright © Elmar 2002, not to be copied without permission
July 2002 Revision: 2 Important Notices

SECTION TABLE OF CONTENTS
1 Introduction to Elmar and Elmar Customer Services
2 Training School Outline
3 Assessment System
4 Introduction to Wireline Pressure Control Equipment
5 Pressure Control Safety
6 Relevant Design, Manufacturing and Certification Standards
Wireline Pressure Control Equipment – Hardware

7 (maintenance and servicing)
8 Grease and Hydraulic Control Module
9 Pressure Tight Seals & Fittings
10 Using the Cased Hole Pressure Equipment
11 Problem Situations
12 Large Diameter Pressure Equipment for Open Hole and Cased Hole
Operations
July 2002 Revision: 2 Contents - Page 1

SECTION 1 - ELMAR SERVICES
Elmar Services was established in 1981 and was subsequently acquired by Varco in
September 2001. Elmar now plays an important part in this multinational Oilfield Service
Company’s operations.
One of the first projects for Elmar was to design a state of the art wireline pressure
control skid to be used at the well site by all of the major wireline service companies.
These skids, in various configurations, have the “Rolls-Royce” image and have now
become the industry standard for all pressure control operations in most of the world’s
oil and gas fields.
Once the skids had been perfected, the company turned to developing the very best in
wireline pressure control equipment, and since 2000 with the introduction of the
lightweight lubricators, lightweight BOP’s and ancillary equipment Elmar has become
the undisputed leader in this market. Continual equipment review, Research &
Development has been the key to the company’s success.
Over the years the Company has also established a solid record in design and
manufacturing of mast trucks, offshore masts, wireline units, spooling units, pressure
test units and chemical injection skids. With a global capacity close to 100,000 feet per
month, Elmar is also a world leader in supplying TCP and wireline perforating guns to
customer’s specifications. In addition, holing and slotting of casing plus wire wrapped
screens play an important part in the operations at Elmar’s Headquarters in Aberdeen.
As part of the Varco Group, Elmar and the sister companies SSR, EOT, PCE and
Hydrolex are able to supply both wireline service companies and oil companies with the
majority of their equipment needs plus professional training associated with all wireline
and slickline pressure operations.
With manufacturing, training and rental bases in Aberdeen, Houston, Dubai, Perth and
Singapore plus additional rental bases in Victoria, Texas and Edmonton, Canada, Elmar
now offers its customers worldwide support – where ever there is pressure for a well
intervention operation, your Elmar support is close at hand.
July 2002 Revision: 2 Section 1 - Page 1

SECTION 2 - OUTLINE OF THE COURSE
DAY 1
Class Room
• Introductions
• General Overview of Pressure Control Operations
• Safety - Standards, Policies and Guidelines
- H2S, Gas
• Equipment - Wireline Valves (BOPs)

- Lubricators (Risers)
- Tool Trap
- Tool Catcher - Ball Check Valve
Work Shop
• Divide into groups, dismantle, inspect, assemble and test equipment

• Question and answer session to close.
DAY 2
Class Room
• Quick re-cap of day 1.
• Equipment - Grease seal flow tubes

- Stuffing box (pack off)
- Line wiper
- Control modules
- Wellhead adapters
- Pressure tight seals and fittings
Work Shop
• Divide into groups, dismantle, inspect, assemble and test equipment.

• Question and answer session to close.

SECTION 2 – OUTLINE CONTINUED
DAY 3
Class Room
• Quick re-cap of day 2
• Using cased hole logging equipment

• Rig up procedures
• Pressure testing
• Running the job
• Loss of grease seal
Move Outside to Well Site
• Rig up equipment
• Pressure testing
• Loss of grease seal - simulation
• Running the job
DAY 4
Class Room
• Quick re-cap of day 3
• Discuss operational problems

• Stranded cable
• Bird caged wire
Move Outside to Well Site
• Simulate stranded cable

• Rig down
• Maintenance
• Tidy up
Class Room
• Re-cap
• Quiz and feedback questionnaire

SECTION 3 - ASSESSMENT SYSTEM
The most important objective of this course is to provide the student with an
understanding of how the equipment works and the safe way to operate it. The
effectiveness of the course is measured by assessing each attendee's comprehension
and by verifying that he or she can operate the equipment in a safe and efficient
manner.
PRACTICAL SKILLS
All trainees will perform the following tasks and be assessed as they do so.
• Job preparation
• Function and pressure testing
• Rigging up
• Operational procedures
• Pressure test equipment - pumps, etc
• Operational procedure, loss of grease seal - regain grease seal procedure, stranded
wire procedure.
WRITTEN QUIZ
A total of 65 questions, 35 are written answers, 30 are multiple choice.
Purpose of the test is to verify that the attendee has received all the important
information from the instructor and that he/she has gained a thorough understanding of
the basic principles of Wireline Pressure control.
COURSE QUESTIONNAIRE
A questionnaire will be handed out at the end of the course and the student is invited to
give feedback concerning the instructor, course content, facilities and course
organisation. This will allow the course to be improved as time progresses.

SECTION 4 - INTRODUCTION TO WIRELINE PRESSURE

CONTROL EQUIPMENT
The need for wireline pressure control equipment arises when a client requests a
wireline company to carry out an operation on a live well or a potentially live well. A live
well is a well that is under pressure. Pressure control equipment provides a safe means
of entering and exiting a well with wireline equipment while remaining in control of the
well at all times.
Pressure control equipment is available in a variety of sizes and ratings and is selected
according to the particular need of the job. Jobs with wellhead pressure are usually
performed with small OD cables, e.g. 7/32" monocable, or with slickline for mechanical
services. This is because the upward thrust caused by well pressure acting on the
cross-sectional area of the cable, is much less for a 7/32" cable than for a 15/32" cable.
For example, 5,000 psi well pressure exerts an upward force of 830 lbs on a 15/32" OD
cable but only 190 lbs on a 7/32" OD cable. Another problem related to large OD cables
is maintaining a working grease seal at the grease injection head. It is far easier to
make a good seal around 7/32" cables due to the smaller strands and higher armour
coverage.
The mechanical strength of a smaller OD wireline is considerably less than that of a

heptacable. The smaller and lighter downhole tools that are designed to be run through
tubing are usually run on small O.D. slickline or small O.D. coax or monoconductor
cables. These tools are normally referred to as “Production Tools” and range in size
from 3/4” O.D. through 2.5” O.D. Most common sizes are 2-1/8", 1-11/16" or 1-3/8. The
majority of pressure equipment for high pressure work has been designed to
accommodate tools of this size so that the pressure control equipment may be as light
as possible.
Some modern tools and perforating guns require larger bore Pressure Control
Equipment. 3" ID, 4" ID, and larger strings have been developed for this purpose.
Slickline Pressure Control Equipment may have "tapered" bore (6 5/8”-5"-4”- 3" ID) to
accommodate plugs and special tools.
Pressure Control Equipment, often referred to as wellhead equipment (WHE) normally

has working pressures of 5,000 psi, 10,000 psi and 15,000 psi. If there is a need to go
higher than 15,000 psi then special equipment is required.
After studying this book and attending the training school, an attentive student should
have gained the theoretical knowledge needed to be competent to run a job using

wireline pressure control equipment. Full proficiency will be gained only after practical
experience on actual jobs with wellhead pressure.

SECTION 5 - PRESSURE CONTROL SAFETY
1. BASIC SAFETY
• Pressure control equipment is used to safely perform operations when

pressure is present or is likely to develop at the wellhead
• A routine pressure job does not exist. Potential safety hazards always exist
during any operation performed under pressure
• Well trained personnel and well maintained equipment are a fundamental
requirement for a safe pressure job
• All personnel should wear adequate safety clothing, for example safety
glasses, gloves, boots, hard hat and overalls
• Special precautions are necessary if H2S may be present at the wellsite.
2. RESPONSIBILITY
• Safety is everyone's responsibility. You are responsible for your own safety
and you have a duty of care to other personnel present on the rig or wellsite.
3. GENERAL
• Never heat or weld any part of the pressure control equipment

• Never tamper with equipment which is subjected to pressure
• Never turn hose reels with pressure applied to the hose
• Never replace pressure fittings unless you are sure of the new parts thread
type, service type, and pressure rating.
• Never use any piece of Pressure Control Equipment that does not have a
Working Pressure Rating
4. PRE-DEPARTURE
• Detailed, advanced planning of a job is essential to ensure safe operations

• In order to gain details of possible safety hazards either visit the wellsite or
call the client. Points to discuss include:

Wellhead pressure and temperature

Fluid in the well and fluids produced: gas, oil, hydrates, H2S, CO2,
chlorides
Inhibitors, corrosive fluids, chemical injection
Rig: Height – Christmas Tree or BOP, adapters, flanges
Tubing, casing, restrictions, deviation
Wellhead crossover connection
Lifting equipment, catlines, travelling blocks, cranes.
• Select proper equipment depending on pressure and type of service.

Equipment is usually chosen to have a Working Pressure Rating of 1.2 times
the Maximum Expected Well Head Pressure. Check rating and compatibility
of all connections
• Perform a complete system check
• The pressure rating of a complete control system is equal to the rating of the
lowest rated individual item - the weakest link in the chain. This includes the
pressure fitting, needle valves, gauges, hoses, etc
• Ensure that enough lubricators are available to cover the tool and allow at
least 3 ft (1 metre) clearance. This applies to fixed structures – more may be
required for floating rigs
• Check spare parts box.
5. ON LOCATION
• Review all operational steps, possible safety hazards, open and shut-in well
procedures
• Be aware of rig emergency procedures, including shut-in, fire, H2S, abandon
ship, etc
• Never fill lubricator (riser) or pressure test with diesel oil. Air in the lubricator
will be compressed and mixed with diesel vapour; this can cause a diesel
explosion
• Drill floors are dangerous places. Be more alert and take necessary
precautions when working on a rig floor

6. RIGGING UP
• Clear area of all unnecessary personnel

• Ensure drill floor is free of mud and debris
• Rig up wellhead adapter, BOP and tool retainer first
• Secure all flow and drain lines
• Ensure drain lines are coupled to a closed drain system or environmental
secure area
• Pressure test the complete Pressure Equipment String to 1.2 times the
expected wellhead pressure. Hold pressure for 10 minutes and record. Use
water or glycol to test and never diesel. Ensure that no air remains in the
system during a pressure test
• Client representative normally controls the Wellhead/ X-mas Tree master
valves
• When closing the Master Valve, count the number of turns and tag the valve
• Never tighten or loosen connections under pressure
• Use a rope, not the pressure hoses, to help align the lubricator string with the
wellhead when making connections.
7. RIGGING DOWN
• Be aware that trapped pressure may exist in the equipment even after it has
been rigged down and apparently bled down. A sure sign of trapped pressure
is an unusually tight union connection or a stiff hose.
8. AFTER JOB
• Perform maintenance
• Concentration is often low after the job is complete and this can lead to
accidents. Please remember that the equipment is heavy and should still be
treated with care and attention.

PRESSURE EQUIPMENT - THE DO'S AND DON'TS
Because wellhead equipment is specially heat-treated steel, the following guidelines

should be followed:
1. NEVER weld on any WHE component.
2. Avoid using sharp V stamps on WHE. Mark only on non-critical areas with low
stress dot stamps.
3. Do not make modifications by drilling, boring, filing, cutting, etc.
4. To prevent damage to the risers/lubricators they should be secured during

transportation.
5. Restrain all parts of the WHE, especially the Grease Injection Head, when
picking up the equipment to prevent it from slamming into the rig structure.
6. Avoid using pipe wrenches on WHE. This is imperative for lightweight

lubricators/risers.
7. DO perform the required regular certification pressure tests and wellsite pressure
tests.
Generally, treat pressure control equipment with care!

H2S OVERVIEW
A. INTRODUCTION
Hydrogen Sulphide = DANGER
Hydrogen Sulphide, H2S, often called "Sour Gas", packs a double-barrelled

punch. First, there is its direct effect on humans. H2S is a poisonous gas; IT
KILLS!! Second, there is the indirect threat to human safety caused by H2S
attack on metals, especially steel, used in pressure control equipment. H2S can
literally destroy the strength of steel causing it to fracture while under pressure
with disastrous results.
B. EFFECTS ON PERSONNEL
1. PHYSICAL AND CHEMICAL CHARACTERISTICS
H2S is a colourless, inflammable gas having an offensive odour and sweet taste.
It is highly toxic. In fact, it is almost as toxic as hydrogen cyanide and is between
five and six times as toxic as carbon monoxide. Another hazardous feature of
H2S is that it is heavier than air (density 1.19).
2. TOXICITY
As stated, H2S is an extremely toxic gas. The sense of smell is lost after a few
minutes of exposure in concentrations as low as 0.010 to 0.015% volume of the
gas. Exposure to higher concentrations for less than a minute dulls the sense of
smell completely and gives a person a false sense of security.
Do not rely on the sense of smell for H2S detection.
It is rather hard to visualise the small concentrations or amounts about which we

are speaking. Generally we speak of H2S concentrations in Parts Per Million
(PPM). Suppose we have a room or box in the form of a cube, 100 inches to the
side. Each individual cubic inch in this volume would represent one part per
million.
1/1,000,000 = 1 PPM
0.05% = 500 PPM
2% = 20,000 PPM

3. SYMPTOMS
a. Subacute Poisoning
Exposure results in irritation, principally smarting of the eyes, a persistent cough,

tightening or burning of the chest and skin irritation. Recovery from these
exposures is usually complete.
b. Acute Poisoning
In high concentrations of H2S, the results are almost instantaneous resulting in

asphyxia (or strangulation) with seeming paralysis of the respiratory system.
Symptoms are heavy breathing, pallor, cramps, paralysis of the pupil, loss of
speech and almost immediate loss of consciousness. Death may follow with
extreme rapidity, caused by respiratory and cardiac paralysis. The reason for the
speed with which H2S reacts is that it is very quickly absorbed by the blood
stream.
Experience has shown that there is no predictable pattern to any one person's
exposure to H2S and any departure from normal behaviour in a suspected
environment should be checked.
Remember: One sniff of a sufficiently high concentration of H2S can cause acute
poisoning.
4. Treatment
It should be remembered that there is no known antidote for H2S. However,

prompt and safe action may save lives. Victims should be removed to fresh air
immediately by rescuers who are protected by gas masks.
Artificial respiration should be administered if breathing has stopped. Although

breathing is paralysed, the heart may continue beating for ten minutes after the
attack. If breathing is slow, laboured or impaired, artificial respiration should be
supplemented by the administration of diluted oxygen. In all cases, victims of
poisoning should have a doctor's care as soon as possible after exposure.

5. Personal Protective Equipment
a) Conventional Type Gas Masks: These masks consist of a canister,

flexible hose and face mask. They are designed for use in open areas
and for protection in concentrations less than 2%.
b) Self Contained Breathing Apparatus: These units consist of a tank of
diluted oxygen with hose and face mask.
Note: Men with beards are not allowed to work on H2S jobs, unless they shave.
This is to ensure that the face mask is tight to the outside atmosphere.
C. EFFECTS ON EQUIPMENT
H2S attacks steel in three ways:
• Corrosive attack
• Carbide attack
• Hydrogen embrittlement.
1. Corrosive Attack
When water is present along with H2S, the iron in steel reacts with sulphur
forming iron sulphide (FeS) and releases free hydrogen. Carbon dioxide, (CO2)
combines with the water to form carbonic acid, (CH2CO3) which in turn attacks
the steel. In either case, water is necessary to permit the reaction to occur.
2. Carbide Attack
Once liberated by the corrosive action or furnished from any source, the
hydrogen atoms may unite with the carbon in the steel to form methane gas,
CH4. This leaves voids making the steel spongy and greatly weakened.
3. Hydrogen Embrittlement
The most spectacular effect of hydrogen on steel is known as hydrogen

embrittlement. It occurs when hydrogen atoms invade the steel lattice structure
along planes of stress and, once inside, combine with other free atoms to form
molecular hydrogen, H2S.

The molecular hydrogen is much larger than the atomic hydrogen and exerts
tremendous pressure against the steel structure causing it to crack and
eventually fail.
Failure can be quite sudden and can occur at stress levels far lower than the
material's normal yield strength. Temperature, pressure and H2S concentration
affect the rate at which free hydrogen invades the steel. Tensile strength of the
steel and the stress level to which it is subjected determine its susceptibility to
attack. Generally, steel with relatively low hardness (Rc 22 or less) and low yield
strength (say less than or equal to 75,000 psi) are ductile enough to resist
permanent damage.

D. EQUIPMENT PROTECTION
1. Film Forming Inhibitors
One of the most effective ways of combating the effects of low concentrations of
H2S is the use of film forming inhibitors. These substances form a protective film
over the steel surface to prevent contact by the H2S solution and thereby retard
corrosive action. Thus, the supply of free atomic hydrogen is greatly reduced
and embrittlement does not occur. In cases where H2S concentrations are below
2%, the use of an inhibitor alone is sufficient protection for short time operations.
Oil soluble inhibitors, such as Baroid Coat C-1815, can be blended with diesel or
with the grease pumped through the flow tubes. Use inhibited sealing grease, or
one mixed with Baroid Coat C-1815. Make sure to maintain a suitable viscosity
for grease pumped in the flow tubes.
2. Application
Mix one part inhibitor with four parts diesel and apply to all internal surfaces of
lubricator pipe, wireline valves and wellhead adapters before erecting them on
the well. The best way to treat the lubricator is to immerse each joint in a trough
filled with the inhibitor-diesel mixture. The Wireline Valve should be capped off,
filled with the mixture then drained. Be certain the rams are fully open when
treating the Wireline Valve. The exterior surfaces may be wiped down to
facilitate handling. Do not wipe the interior surfaces because this will remove the
inhibitor film.
N.B. Verify with the Client that regulations allow using inhibitor/diesel mixtures at
the well site.
3. Special Equipment
H2S resistant equipment is recommended by NACE whenever the H2S

concentration is unknown or higher than 10 PPM for 5,000 psi operations or 5
PPM for 10,000 psi operations. The steel composition and hardness is such that
it should not fail regardless of concentration or time exposed to H2S. When H2S
resistant equipment is not available, standard equipment can be used for jobs
lasting less than 12 hours with a maximum 2% H2S concentration but the
equipment must be protected as per paragraphs above.

4. Recovery
When non-H2S pressure control equipment is used for a limited time on an H2S
operation, a certain amount of hydrogen will invade the steel structure, even
though an inhibitor was used. After the operation, this hydrogen must be allowed
time to diffuse or bleed out before more hydrogen is introduced. The equipment
must be left to rest for two to three days. High temperature will accelerate the
recovery time while cold temperatures will retard the recovery time.
5. Recommendations
As the duration of a job, and the need for subsequent use are not fully
controllable, we recommend using H2S resistant equipment whenever H2S is
present or suspected.
E. OPERATING PROCEDURES
Find out as much as possible about the conditions in and around the well. Check
specifically for:
• Concentration of H2S
• Type of well fluid
• Presence of any other corrosive source such as CO2.
Check the well site for hazardous areas such as cellars, mud pit, etc, where H2S
might accumulate. Remember, H2S is heavier than air; be cautious of low areas.
When it is necessary to enter confined areas, such as cellars or pits, always use
self-contained breathing apparatus and station a rescue man outside. Also, be
cautious of ice; H2S is soluble in water and high concentrations may be frozen in
water surrounding the well. When such ice melts, the H2S will be released.
Make certain that gas masks and breathing apparatus are in proper working
order and that air or oxygen tanks are full and free of oil. Have spare masks and
apparatus in case of failure or if additional personnel are required.
Have H2S detectors with alarm, positioned next to the wellhead
Spot the truck cross wind or upwind from the well.

When rigging up the lubricator, do not leave it with a bend since this would raise
the stress level due to the addition of bending stresses.
Attach a bleed-off hose to the lubricator manifold and direct it at least 50 feet
away downwind, when bleeding down the lubricator. Be sure the hose is tied
down and the end is fitted with a “T” piece. Preferably secure the end in a vented
waste tank.
Attach an 80-foot long hose to the grease flow line beyond the valve and secure
the end to a structure downwind. Preferably secure the end in a vented waste
tank, or place a bucket or barrel at this end to capture any escaping fluids.
Make each run as quickly as good operating techniques permit. Do not linger in
the well unnecessarily.

TOXICITY OF HYDROGEN SULPHIDE TO MEN
PPM** 0-2 Minutes 2-15 Minutes 15-30 Minutes 30 Minutes-1 Hr 1-4 Hours 4-8 Hours 8-48 Hours
Mild, conjunctivitis, Symptoms

20-100 respiratory tract, worsen, fatigue, Symptoms worsen
irritation headache
Salivation and
Coughing, irritation Disturbed
mucous discharge, Increased
100-150 of eyes, loss of respiration, pain in Throat irritation Death*
sharp pain in eyes, symptoms
sense of smell eyes, sleepiness
coughing
Loss of sense of Throat and eye Throat and eye Difficult, blurred
150-200 Death*
smell irritation irritation vision, light shy
Light shy, nasal

Irritation of eyes, Painful secretion catarrh, pain in Suffocate, poison
200-350 Irritation of eyes
loss of smell of tears, weariness eyes, difficult in blood, Death*
breathing
Difficult
respiration,
Loss of sense of Irritation of eyes,
350-450 coughing, irritation Death*
smell dizziness
of eyes, fatigue,
nausea
Respiratory
Coughing,
disturbances,
collapse, Palpitation of
450-700 irritation of eyes,
unconsciousness, heart, Death*
collapse,
Death*
unconsciousness
Collapse,
Over 700 unconsciousness,
Death*

SECTION 6 - RELEVANT DESIGN, MANUFACTURING &

CERTIFICATION STANDARDS
The following section is mainly provided for background information and as an aid to
understanding the certification requirements and terminology.
6.1 FUNDAMENTALS OF DESIGN
When designing a piece of equipment containing pressure, the material is chosen

on the basis of its "Yield Strength". Yield Strength, normally measured in Pounds
per Square Inch (psi), is the stress at which the material exhibits a specified
deviation from the proportionality of stress to strain, or more simply at which the
material starts to exhibit a permanent deformation under stress. Metallic
materials will fail ("break") at a stress above the Yield Strength, the ultimate
Tensile Strength. Details on the procedure to determine Yield Strength of
materials are found in ASTM Specification ASTM-A370. (ASTM: American
Society for Testing and Materials).
In cylindrical containers subject to a pressure "P" (absolute or differential), the

stress induced is approximately proportional to P.
Safety Factor
Pressure-containing equipment is designed to perform with a sufficient margin of

safety to allow for several variables and uncertainties, such as materials Yield
Strength variations, approximations in design calculations, stress concentrations,
machining tolerances, shock loading, abuse and misuse in the field. Such
margin of safety is embodied in a "Factor of Safety" (FS), defined as:
Minimum Yield Strength

FS =
Design Working Stress
For example, a Factor of Safety 2 means that the Design Working Stress is only
half of the minimum Yield Strength of the materials used. The value of FS is
imposed by design codes, industry rules, government agencies, or internal
manufacturers' regulations. Its value will also be a function of the risks presented
by an equipment failure in terms of personnel safety and assets damage.

Therefore equipment under pressure coming in contact with personnel will be

designed with a larger safety factor than downhole tools whose failure will not
result in direct injury or loss of life.
Working Pressure
The choices of FS and of the materials Yield Strength define the pressure rating
of the equipment, usually expressed in psi (pounds per square inch) working
Pressure, WP. This is the maximum allowable pressure never to be exceeded
during field operations of the equipment. Normal Working Pressure ratings are
3,000 psi, 5,000 psi and 10,000 psi. Special equipment is manufactured with
15,000 or 20,000 psi WP rating.
Test Pressure
To ensure proper operation at WP, pressure equipment is tested at a maximum

pressure greater than or equal to WP, defined as Test Pressure TP. The value
of TP is recommended by the manufacturer and often stipulated by industry
standards. For WHE equipment normally TP = 2 x WP for Working Pressure
ratings up to 5,000 psi, and TP = 1.5 x WP for ratings 10,000 psi and higher.
Obviously, the multiplier must be smaller than the Safety Factor.
6.2 INDUSTRY STANDARDS
Pressure control equipment must be designed and manufactured to specific

internationally recognised standards. These standards are API 6A, (American
Petroleum Institute Specification 6A: Specification for Wellhead and Christmas
Tree Equipment) and for H2S equipment, NACE MR-01-75 (National Association
of Corrosion Engineers Material Requirements: Sulfide Stress Cracking
Resistant Metallic Material for Oilfield Equipment).
API 6A defines the design and test criteria for all pressure containing equipment
used on a wellhead, while NACE MR-01-75 defines the type of metallic materials
that are allowed in conditions where H2S is present.
A summary of API 6A requirements is given in tables 6-1 and 6-2. The technical
requirements are defined for four "Product Specification Levels" (PSL). PSL1
corresponds to the "easiest" service conditions and PSL4 to the "toughest" ones.

All Elmar pressure control equipment is manufactured either to API 6A or both

API 6A and NACE MR-01-75 specifications. Design temperature is -30°C to
121°C (-20°F to +250°F).
Equipment conforming to NACE Standards is normally built with steel alloys

having reduced hardness and reduced yield strength. Therefore all pressure
containing equipment must have thicker walls and is heavier than standard
equipment.
Hardness
Hardness is a property of a material to resist an indentation under a specified

load. Hardness is measured either as Brinell hardness, or Rockwell hardness,
with methods described in ASTM E 10 (Brinell) or ASTM E 18 (Rockwell).
Rockwell Hardness numbers are quoted with a symbol ('B', 'C') depending on the
type of penetrator and load used for the test.
Rockwell 'C' hardness number (HRC) is obtained using a cone-shaped diamond

indentor and a load of 150 Kg, as per ASTM-E 18.
Brinell Hardness number (HB) is obtained using a 10 mm hardened steel or

carbide ball, and normally a load of 3,000 Kg, as per ASTM-E 10.
For low alloy and carbon steels there is a direct correlation between Hardness
and Tensile Strength. Therefore hardness testing provides a non-destructive
method to verify the Strength of the material. Low alloy and carbon steels must
exhibit Rockwell hardness below 22 Rockwell 'C' to be H2S resistant.
For WHE we normally use:
• 4140 AISI Steel, with 18-22 HRC (Rockwell 'C' Hardness) and 80,000 psi
minimum yield strength for H2S resistant equipment
• Std Service Material with 30-36 HRC and 110,000 psi minimum yield strength.
(AISI is the American Iron and Steel Institute and the AISI Number is a grading
system for steels)

• Other alloys or metals such as titanium, monel, stainless steel, etc can be
used based on cost, weight and strength requirements.
Impact Tests
In very cold conditions, the steel tends to become brittle and can shatter under
an impact. To define the resistance of materials in very cold environments a
toughness test is made. (Toughness = ability to resist shock loads). The most
common impact tests are the Charpy and Izod Tests, described in ASTM E 23
(see Figure 6-1).
CHARPY TEST IZOD TEST
FIGURE 6-1
API 6A Specification accepts only the Charpy method of Impact Testing. Charpy
value should be a minimum of 15 ft-lbs for equipment to be certified for use below
0°F (-20°C). Elmar equipment is Charpy tested to 31 ft-lb at -30°C.
High Temperatures
Most metals used in WHE are suitable for operations at temperatures well above
the temperatures normally encountered on "HT" WHE operations. Elastomer
seals set the high temperatures operating limits. In special cases (Geothermal
operations) WHE might be subject to temperatures as high as 500°F. In these
cases, besides using special seal systems, the WHE maximum Working
Pressure is derated - Refer to API 6A for the derating factors.

6.3 CERTIFICATION, QUALITY FILE
"Certification" for pressure bearing equipment is very often requested by clients

or dictated by regulations.
A certification document can be issued by the service company operating the

equipment, (in-house certification), by the manufacturer (sometimes called
manufacturer survey), or by a third party. Certifications state that the
components, equipment, or assemblies meet the requirements specified by the
industry standards (e.g. API 6A) or by local government regulations, such as SI
289 for Mobile Rigs in the UK Sector of the North Sea, the Safety Case Regime
(SCR) and Design and Construction regime (DCR) for fixed platforms in the UK,
Norwegian Petroleum Directorate Regulations in the Norwegian Sector of the UK,
Alberta Recommended Practices (ARP) in Canada, etc.
Lifting slings and lifting points of equipment usually require a load test certificate
as determined by local regulations (BS 7072 and BS 1290 in the UK, DNV 2.7-1
in Norway).
It is beyond the scope of this course to cover all local regulations and you must
become familiar with the specific ones applying in your area, which are available
through certification agencies. Normally North Sea regulations are the most
restrictive ones and have wide acceptance throughout the Oil Industry. Elmar
equipment conforms to North Sea regulations.
Third party certification documents are issued by recognised certifying agencies

such as Bureau Veritas, American Bureau of Shipping (ABS), Lloyds, Det Norske
Veritas (DNV). There are two kinds of certificate:
• Design Approval Certificates: Type Approval (TA), Independent Review

Certificate (IRC), Design Verification Report (DVR). These are assessments
by a competent body verifying that the specifications for manufacture of an
assembly meet the requirements of the authorities' regulations and the
industry standards.
• Certificates of Conformity (COC): These certify that a specific asset or

assembly, identified by its serial number conforms to the approved design and
manufacturing file and/or the industry regulations. They often include test and
inspection reports that certify to the performance of tests (pressure, load, lifting
capacity, etc), according to standards and to the validity of test results.

All pressure control equipment must have a recognised certificate of conformity

issued by a third party agency. A certificate of conformity is valid for a limited
period of time, normally five years and must be renewed.
Renewal of certification normally requires a major survey: A detailed inspection

and performance verification carried out or controlled by a certification agency.
This survey entails as a minimum:
• Visual inspection
• Random thickness tests on all pressure containing parts using direct
measurements, X-rays, or Ultrasonics
• Dye-penetrant or MPI examination on all threads and any damaged area
determined at visual inspection
• Hydrostatic body test at Test Pressure (TP)
• Operational test at Working Pressure (WP)
• Review of quality files.
Traceability
Traceability is often part of certifications' requirements. By "traceability" we mean

the ability for parts to be identified as to their origin, manufacturing process and
materials used. Traceability requirements for certified items cover also
replacement parts used in maintenance and repairs, e.g. O-rings.
Quality File
A Quality File is a compilation of documents showing, for one individual asset or

assembly the following information:
• Manufacturer's bulletins or manuals

• Certification documents, usually a COC, with all relevant renewals
• Traceability of critical components and materials when required
• Maintenance, test and inspection records
• Operating history notes.

6.4 FUNDAMENTAL RULES FOR PROPER OPERATIONS
The following fundamental rules apply to all operations with WHE Equipment:
• All equipment used for pressure control operations must be pressure rated, to
a defined Working Pressure, WP and a Test Pressure, TP. For high
temperature applications a Temperature Rating must also be defined
• Pressure control equipment shall never be used above its Working Pressure
(WP) rating, nor outside its temperature rating
• In a string of WHE equipment, the WP of the weakest component gives the
string overall pressure rating (*)
• All WHE components holding pressure must have valid certification
• All WHE components holding pressure must have a quality file
• All WHE equipment used on the well-site is qualified for its use by passing
annually a hydrostatic body test and an operational check at WP
• A well-site pressure test must be carried out after set-up on each job. The
Maximum Allowable Working Pressure during the job equals the wellsite test
pressure
• All crews operating WHE equipment must be qualified to carry out pressure
operations.
• In the presence of H2S, only H2S certified equipment must be used. API
threaded connections are not acceptable, only integral connections or
premium connections must be used.
(*)
An exception is the line wiper placed above a grease-head stuffing box. Refer to the specific
description in chapter 7

TABLE 6-1: API 6A EQUIPMENT REQUIREMENTS

PRESSURE CONTROLLING
MATERIAL CLASS BODY, BONNET & FLANGE RELATIVE CORROSIVITY PARTIAL PRESSURE OF CO2 (psia)
PARTS
AA-General Service Carbon or low alloy steel Carbon or low alloy steel Noncorrosive <7
BB-General Service Carbon or low alloy steel Stainless Steel Slightly corrosive 7 to 30
CC-General Service
Stainless Steel Stainless Steel Moderately to highly corrosive > 30
DD-Sour Service Carbon or low alloy steel Carbon or low alloy steel Noncorrosive <7
EE-Sour Service Carbon or low alloy steel Stainless Steel Slightly corrosive 7 to 30
FF-Sour Service Stainless Steel Stainless Steel Moderately to highly corrosive >30
HH-Sour Service Corrosion Resistant Alloys Corrosion Resistant Alloys Very corrosive >30
If H2S is present then NACE applies.

RECOMMENDED MINIMUM PSL REQUIREMENT
NACE? NO YES YES YES NO YES High concentration is if the 100 PPM radius of exposure (ROE) of H2S is >50 ft.
HIGH H2S CONC? NO NO YES NO NO YES Close proximity is yes if:
CLOSE PROXIMITY NO NO NO YES YES YES 1. If you have high H2S.
WORKING PRESS PSL PSL PSL PSL PSL PSL 2. 500 PPM of H2S >50 ft ROE.
> 5000 PSI 1 1 2 2 1 3 3. Well is situated in an environmentally sensitive area.
> 10000 PSI 2 2 3 3 3 4 4. Well is situated within 150 ft of an open flame of fired equipment.
> 15000 PSI 3 3 4 4 4 4 5. Well is located within 50 ft of a public road.
6. Well is located in state or federal waters.
7. Well is located in or near inland navigable waters.
8. Well is located in or near surface domestic water supplies.
9. Well is located within 350 ft of any dwelling.
TEMPERATURE RATINGS
CLASS °F °C
K -75 to 180 -70 to 82
L -50 to 180 -46 to 82
P -20 to 180 -29 to 82
R 40 to 120 4 to 49
S 0 to 150 -18 to 65
T 0 to 180 -18 to 82
U 0 to 250 -18 to 121

TABLE 6-2: API 6A EQUIPMENT REQUIREMENTS

METALLIC PARTS PSL - 1 PSL - 2 PSL - 3 PSL - 4
Tensile Testing 1 Tensile test required 1 Tensile test required 1 Tensile test required 1 Tensile test required
Impact Testing: 3 Tests. Only 1 Only req temp class K & L Only req temp class K, L & P All temp class req. All temp class req.
value below av. No value below 2/3 Max expansion of 10x10 specimen
of av. 27J @ min temp longitudinal to be no more than 0.015" at test
temp.
Hardness values 1 test on finished body on all parts 1 test on finished body of all parts 1 test on finished body of all parts 1 test on finished body of all parts
over 10K and 1 test on each end face and 1 test on each end face
Dimensional verification Inspection of sample can be used Inspection of sample can be used Complete inspection required Complete inspection required
Traceability None Job lot traceability required All parts traceable to specific heat All parts traceable to specific heat
and heat treat lot and heat treat lot
Chemical analysis None Required Required Required
Surface NDE None Required on wetted on seal areas Required on all parts Required on all parts
Serialisation None None Each piece of equipment to have Each piece of equipment to have
serial number serial number
Volumetric NDE None None Ultrasonic tests on raw material Ultrasonic tests on raw material
O-RINGS
Dimensional verification Sample checked Sample checked Sample checked Sample checked
Visual examination Sample checked Sample checked Sample checked Sample checked
Hardness Sample checked Sample checked Sample checked Sample checked
Documentation None Certificate: Part number, Certificate: Part number, Certificate: Part number,
specification number and compound specification number and compound specification number and compound
number number number
Batch traceability None None Batch number, cure/mould date shelf Batch number, cure/mould date shelf
life expiration date life expiration date
Physical property data Copy of test results of the physical
properties of the compound supplied
OVERALL DESIGN TEST
Pressure test Two visual 3 min tests at test Two visual 3 min tests at test Two chart recorded tests at test Two chart recorded tests at test
pressure pressure pressure. Test 1 for 3 mins and test pressure. Test 1 for 3 mins and test
2 for 15 mins 2 for 15 mins. Addition 15 min
nitrogen test

SECTION 7
A TYPICAL STRING OF WIRELINE PRESSURE CONTROL EQUIPMENT

SECTION 7 - EQUIPMENT
1.0 WIRELINE VALVES
The Wireline Valve (commonly called wireline “BOP”) is designed to control well
pressure by sealing around the cable and is used primarily when a cable must be
repaired under pressure, or when you are unable to regain control of seal at the
grease injection head. The sealing elements are two, elastomer-faced, metal
rams which have been contoured to fit a particular size of cable. The elastomer
seals are commonly called “rubbers”. Special sealing elements have been
developed recently that can adapt to different line sizes. When the Wireline
Valve is activated the elastomer faces will make a seal around the wireline by
extruding into the interstitial spaces between the armour strands (Figure 7-1).
Wireline Valves are available in many different sizes with various ratings
depending on expected wellhead pressures and the type of pressure control
equipment in use.
A Wireline Valve must always be used together with a line wiper or a grease
injection system. A Wireline Valve will not normally close on a well flowing out of
control.
Wireline Cable Elastomer Elements
Metal
Direction
of Force
Direction
of Force
Elastomer faced rams sealing on outer strands of a monocable
Figure 7-1

1.1 MANUAL SINGLE RAM WIRELINE VALVE
The most basic design is that of the manually operated, single ram Wireline
Valve, such as the BOP-M used in most open hole work and low-pressure cased
hole work. It is operated by turning two handles that are connected to a threaded
shaft, which screws into the body of the Wireline Valve. At the end of the shaft is
a plate that pushes the ram toward the cable . (Figure 7-2).
Mechanically Operated Wireline Valve
Figure 7-2
The rams are released by turning the handles in the opposite direction. Although
manual single ram Wireline Valves are in service for ratings up to 5,000 psi, it is
recommended to limit their use to 3,000 psi maximum. Drawbacks with manual
Wireline Valves are slow closing cycle and the impossibility to operate remotely.
1.2 HYDRAULIC SINGLE RAM WIRELINE VALVE
Hydraulically operated Wireline Valves are essentially of the same design, as the
manual type, except that the rams are activated by hydraulic pressure instead of

a mechanical force. However, manual handles are also provided as a back up

system.
When the rams are closed, hydraulic fluid is pumped into the outer chamber,
pushing the piston (which is connected to the rams) inwards. Hydraulic fluid from
the inner chamber returns to a reservoir. When the rams have been closed
hydraulically, the handles are manually screwed in to provide a back up for
additional safety. With these handles closed, the Wireline Valve cannot be
opened hydraulically.
To open the Wireline Valve, the handles must first be unscrewed. The rams
remain closed. Hydraulic pressure applied to the inner chambers will push the
piston connected to the rams. Hydraulic fluid in the outer chamber will be
returned to the reservoir (Figure 7-3).
Hydraulic Wireline Valves are preferred since they are operated remotely and
more quickly and consequently place personnel in less danger should the rams
need to be closed in an emergency. If the hydraulic pump fails the Wireline
Valve can still be operated manually by first opening the hydraulic lines (pump in
"neutral” position) at either side of the piston to allow free movement of the
hydraulic fluid. The handles may then be used to manually close the Wireline
Valve. However, due to the Wireline Valve design they cannot be used to open it
again. This must be done hydraulically.
Hydraulic Wireline Valves are available with a typical pressure rating of 5,000,
10,000 and 15,000 psi working pressure. However, for any job involving
pressures of more than 5,000 psi, or any job on a gas well, or when H2S is
present a dual or triple ram Wireline Valve with grease injection facility should be
used. Major Service Companies specify a triple ram whenever the maximum
expected pressure is above 5,000 psi.
1.3 TWIN RAM WIRELINE VALVE
The dual ram (Figure 7-4) is composed of two hydraulically operated rams
mounted one above the other. The lower ram is inverted when operating with
braided lines. A grease injection port is located between the two rams where
grease can be injected under pressure to achieve a seal. This is the only way to

provide a seal against gas as the gas can migrate up between the strands of wire
on the braided cable. To see how the Wireline Valve works, we need to look a
little closer at the design of a Wireline Valve in section 1.4.
Triple ram Wireline Valves (Figure 7-15) are used in high pressure and gas wells.
They are composed of two sets of "normal" rams for redundancy and one set of
inverted rams.
Fluid in from pump Fluid out to reservoir
Wireline Valve in open position
Fluid out to reservoir Fluid in from pump
Wireline Valve in closed position with mechanical handles screwed in
Figure 7-3
Note: Position of hydraulic coupling is 90° out of actual position for pictorial purposes.

Block Manifold Piston
Open
Closed
Ram with seals
Dual Compact Hydraulic Wireline Valve with lower ram inverted
Figure 7-4

Dual Elmar Compact Wireline Valve
Open
Close

1.4 CONSTRUCTION OF A WIRELINE VALVE
The sealing surface of the Wireline Valve ram is composed of an elastomer strip,
or inner seal, which is inserted in the face of the ram body. Around the upper
part of the ram body is an outer seal in the shape of a horseshoe. The two
sealing elements join together on the side of the ram body. The inner seal
provides a seal around the wireline while the outer seal prevents well fluids from
leaking around the rams inside the main Wireline Valve body (Figure 7-5).
The ram bodies must be prevented from turning. For this purpose, a key is
located under the ram body that sits in a groove cut inside the arms of the
Wireline Valve body. The key prevents the ram body from turning.
More recent designs, e.g. Elmar’s Compact BOP have locating rods that screw
into the hydraulic cylinder body and slide into the corresponding hole on the ram
body.
Two ram guides complete the assembly. One of them is located on each ram
and they guide the wireline on to the shaped part of the rams as they are being
closed. Modern design rams have integral ram guides (Figure 7-6).
When the Wireline Valve is closed and pressure equalised, the well pressure,
acting behind the rams, will help in the actuation of the rams (Figure 7-10)
because the well pressure behind the rams will help to gain a positive seal. The
ratio of pressure on the Wireline Valve cylinder to wellhead pressure to create an
effective seal is approximately 10:1, i.e. 200 psi hydraulic pressure applied to the
rams by the hydraulic pump (or by using the manual closing system) will seal
against approximately 2,000 psi of wellhead pressure
However, should the Wireline Valve be inadvertently mounted upside down

(which can happen since the connections at each end may be identical on old
models without quick union couplings) well pressure will be opposed to the
sealing pressure of the ram. Hence it is important to check that the Wireline
Valve is mounted properly. The surest way of doing this is to remove the ram
assembly from the Wireline Valve and check the position of the alignment key. It
should be located on the lower side of the Wireline Valve body for a ram sealing
against well pressure. As explained later, for braided line operations, the lower
most ram of a dual or triple must be inverted. Therefore the keyway on the lower

Wireline Valve of a dual should be located on the upper side of the body. This
does not apply to slickline wireline valves, where all the rams close against well
pressure and none is inverted.
The bleed off port should be above the rams when the Wireline Valve is correctly
mounted. Some Wireline Valves will also have an arrow marked on the outside
of the body which points downwards towards the well, i.e. towards the high
pressure side.
The position is similar for rams having a guide rod. (e.g. Elmar Compact BOP)
Normally sealing rams have the rod and the guide hole on the lower part of the
body; inverted rams have the guide hole and the rod on the upper part of the
body. Notice that it is easy to “invert” a normal ram by moving the position of the
guide rod and turning the ram body upside-down. For this purpose there are two
threaded holes 180 degrees apart in the hydraulic cylinder face.
1.4.1 BRAIDED LINE INNER SEAL
A braided/electric line inner seal is manufactured as a sandwich of two steel

plates with an elastomer compound in the middle (commonly called “rubber”).
The steel plates and the elastomer have a semicircular groove cut to line size
dimensions. When the wireline valve is closed around the line, and pressure is
applied onto the ram body, the “rubbers” will expand around the wireline and
make the seal. The function of the steel plates is to limit extrusion of the rubbers.
The two grooved halves mate when the rams are closed, leaving a very small
space for the rubbers to extrude. The wireline is positioned into these grooves via
guides on the ram
The inner seals are held in place in the ram body with two Socket Head retaining
screws that fit loosely into slots machined in the steel plates of the inner seal.

Ram body
Ram guide
Outer seal
Inner seal
Figure 7-5: Exploded view Heavy Duty Ram
Figure 7-6: Integral Guide Rams body

1.4.2 SLICK LINE INNER SEAL
A slickline inner seal is manufactured as a sandwich of steel plates with an

elastomer compound in the centre, similar to the braided line seals The steel
plates and the elastomer have a rectangular groove cut that will accept up to
0.125" max dia wire.
When the wireline valve is closed around the line, and pressure is applied the
elastomer will expand around the wire and make a seal. The steel plates limit the
extrusion of the elastomer, and extend their life. The grooves mate when the
rams are closed leaving a rectangular slot in the steel face. Positioning of the
wire is not as critical as for semicircular slots. (See fig 7.7)
Figure 7-7: Slickline Inner Seal

1.4.3 MULTI LINE RAM SEAL
While conventional seals are sized for one line size only, the Multi Line Ram Seal
has been designed to seal a range of line sizes from blind through to 0.312”
braided line using a specially developed elastomer. (See fig. 7-8). Under
development is a ram seal, which will seal from 5/16” through to 15/32” braided
wireline. The ram seals are directly interchangeable with conventional seals in
Elmar’s Wireline Valves with up to 10,000 psi working pressure rating and -29°C
to 121°C, H2S service.
Figure 7-8: Multiline Ram Seal
1.4.4 Q-GUIDE™ RAM DESIGN
The Elmar Q-GUIDE™ ram is a new proprietary design (Patents Pending) that
provides a positive alignment for the wireline. V-shaped flat guides on either side
of the inner seal restrict the wireline so that the section of line contacting the
inner seal is always centred and parallel to the Wireline Valve axis. (See fig. 7-9)
The Q-GUIDE™ has been designed to accommodate eccentric set-ups where

the wireline goes through the Wireline Valve body at an angle and can be
trapped by the rams before falling in the cable groove.

The Q-GUIDE™ style of ram has been developed to replace integral and standard
guide style rams. Inner and outer seals used in the Q-GUIDE™ are the same as
used in the current styles of ram bodies.
The Elmar multi-line inner seal can be used with the Q-GUIDE™ ram.
The Q-GUIDE™ is available for all sizes of Wireline Valves.
Q-Guide™ Ram body
Figure 7-9:
Q-Guide™ Patents Pending

ED 4 (A)
ELMAR SERVICES LTD TITLE: DATA SHEET 3" BOP RAM ASSEMBLIES
REV ECO PREPARED CHECKED APPROVED DATE
No: TI-970669-B PAGE 3 OF 5
B 3941 K. COULL 25/03/99
July 2002 Revision: 2 Copyright © Elmar 2002 Section 7 - Page 14

ED 4 (A)
ELMAR SERVICES LTD No: TI-972668-A
TITLE: RAM ASSY 4-4.5"EC Q-GUIDE

PAGE 1 OF 1
A - C. WOOD 19/09/00

Figure 7-10: Figure 7-11:

Wireline Valve Assembly correctly Wireline Valve upside down will not
sealing from below seal from below
INJECT GREASE
Figure 7-12:
Grease sealed Wireline Valve
Grease injected at higher pressure than well pressure
blocks migration of gas through cable

1.5 GREASE INJECTION
We are now in a position to understand how the twin Wireline Valve works. The
twin Wireline Valve has one pair of rams (the lower pair) mounted upside down.
In a twin ram Wireline Valve, this is done automatically. Two single ram Wireline
Valves can be used by mounting the lower one upside down with the appropriate
adapters.
Grease is injected between the two rams as shown in Figure 7-12. The grease is
injected at higher pressure than well pressure so that both sets of rams make a
positive seal.
Why do we need to inject grease? From what has been said so far it would
seem that two Wireline Valves should make a good seal. However, a problem
arises due to the type of construction of a wireline (Figure 7-13). Fluid, especially
gas, can leak through the cable between the inner and outer strands. The ram
face effectively seals around the outer surface of a wireline by displacement of an
elastomer which flows into the crevices of the outer strands. No ram elastomer
can seal the spaces between the inner strands. If the line is new, these small
openings may allow substantial leakage, which can often be observed as
gas/liquids spraying out of the line above the sealed rams.
Outer armour
Rubber seal
Inner armour
Insulating Conductor
material
Gas
Rubber seal around monocable allows gas to migrate between

inner and outer armour strands
Figure 7-13

Occasionally a complete seal will be achieved on an older line in which the voids
between inner strands have been closed by wax, dirt, etc. This is the exception,
however, and cannot be relied upon in service. Special cables are available with
filler material in the voids between armour wires. These cables are much easier
to seal upon but still require grease injection for a perfect seal in gas.
Obviously, the above does not apply to solid slickline, easier to seal-in, but it
does apply to braided line used for fishing. Notice that some braided lines are
die-formed, i.e. the individual armour strands are flattened by pulling the line
through a tight die. This process reduces the amount of voids, making it easier to
obtain a seal when injecting grease.
Pressure testing a Wireline Valve on a stranded line is generally a waste of time

as such a test only determines the degree of opening through the interstices of
the line. The Wireline Valve must be tested on a solid rod allowing a perfect seal
to determine if it is functioning properly.
In order to demonstrate complete sealing ability on a wireline, it is necessary to

use two Wireline Valves closed on the line and inject grease or oil between them
at 1.2 times higher than well pressure. The grease or oil will penetrate the line
and fill the voids between strands so that a complete seal is effected. The seal
will hold indefinitely as long as grease pressure is maintained and will often hold
for some time after grease pressure is removed.
Notice that it is good practice to ‘break-in’ a new cable in the shop by injecting
grease into the voids between armour strands. A special ‘cable injector’ set-up is
needed in the spooling shop to saturate the cable (Figure 7-14).
Wireline grease injection system
Figure 7-14

1.5.1 TRIPLE WIRELINE VALVE
In a triple Wireline Valve, (See fig 7-15) the middle ram is used as a redundant
ram in case of failure of the top one. In normal operations, the topmost and
lowermost rams are closed and grease injected between the two. In case of
failure of the top ram to hold seal, the middle one can be closed, and the top ram
serviced after ensuring that a perfect seal has been achieved.
Triple Compact Hydraulic Wireline Valve with lower ram inverted
Figure 7-15

1.6 WIRELINE VALVE MANIFOLDS
There are various types of Wireline Valve equalising manifolds but they all do the
same function, i.e. allow the pressure from below and above a closed Wireline
Valve ram to equalise. The various types are the manifolds and equalising hose
(Figure 7-16), the Elmar flush type equaliser valve (Figure 7-17) and the
integrated manifold block type as fitted to Elmar Compact Wireline Valves (Figure
7-18 & 7-19).
EQUALISING HOSE-TYPE MANIFOLD
The two manifolds are connected by a flexible equaliser hose. This couples to
each of the manifold assemblies by means of identical threaded adapters at each
end of the hose. Each adapter mates with a grease injection union and a seal is
made by means of an 'O' ring on the face of the adapter. The system has been
designed for maximum flexibility of operation. If the rams are closed on the
cable, pressure can be bled off from the risers by opening valves 1, 2 and 3 and
closing 4. (The necessity for this becomes clear when dealing with the problem
of a stranded cable). By closing valves 1 and 3 and opening valves 2 and 4, the
well pressure can be monitored when the rams are closed. Before opening the
Wireline Valve, the pressure is equalised by opening valves 1, 2 and 4, keeping
valve 3 closed.
IIIII IIIII
II I I I I
II
II I
I I I
I I
I I
I
II
Pressure Gauge
I
IIIIII IIIII
I
I III
I
I I
I I I
I I I
II IIIII
I I
II
I I
I I
II I
I
II
I
I
I
II
II
II
1 2
Upper BOP Manifold

Single Ram Equalising Hose
BOP Lower BOP Manifold
4
3
Equalising manifold hook-up for WHE

Figure 7-16

FLUSH TYPE EQUALISING MANIFOLD
Some Wireline Valves include a flush type equaliser valve. This valve equalises
the differences between well pressure and lubricator pressure when the wireline
valve has been closed. The equaliser valve must be opened to assist in backing
off the rams. One manifold is provided per each ram set.
Typical Elmar flush type equaliser valve
Figure 7-17

ELMAR INTEGRAL MANIFOLD BLOCK
Newer dual and triple wireline valve design have a block manifold in which all
connections, valves and external ports are located in a single steel block,
connected by bolts to the Wireline Valve Body. They provide equalizing
functions, and also the connections for grease injection, for glycol/methanol
injection or pressure testing, and a gauge port for measuring the pressure
above or below the rams. A dump port is included to bleed-off the lubricator
string when required, although for routine operations it is recommended to use
a separate, larger ported connection. This could be a pump-in sub, or part of the
Christmas tree.
The clear advantage of this design is that there are no protruding valves,
nipples, etc, which can be knocked-off by careless handling.
In Elmar block design, (Fig 7-18 & 7-19) the valves are actuated by a
Hexagonal (Allen) Key supplied with each manifold.
The cartridge valve assemblies have replaceable seats. The check valves are
also replaceable units (see Fig 7-20).

Manifold Block for Triple Compact Wireline Valve
Figure 7-18

Triple Compact Manifold Block Part Numbers
Figure 7-18a
Item Part No QTY Description Item Part No QTY Description
1 L-241100 3 HEX PLUG 16 L-814500 10 SCREW
2 L-976935 6 CARTRIDGE VALVE 17 L-871290 4 O-RING

ASSY
3 L-976937 6 LOCK WASHER 18 L-974364 2 ELBOW
4 L-817134 6 SCREW 19 L-202600 1 M-HEX NIPPLE
5 L-980119 1 Wireline Valve 20 L-580900 1 QC-HUBER

MANIFOLD BLOCK
1
6 L-980120 1 Wireline Valve 21 L-204900 REDUCING NIPPLE
MANIFOLD BLOCK
1 QC-COUPLER
7 L-975694 5 PLUG 22 L-582000
8 L-871400 11 O-RING
9 L-873410 11 BACK-UP RING
10 L-870110 2 O-RING
12 L-976702 1 MANIFOLD BLOCK

PIN

ARM
14 L-972764 2 CHECK VALVE
15 L-871810 2 O-RING

Manifold Block for Dual Compact Wireline Valve
Figure 7-19

Dual Compact Manifold Block Part Numbers
Figure 7-19a
Item Part No QTY Description Item Part No QTY Description
1 L-241100 4 HEX PLUG 16 L-871290 4 O-RING
2 L-976935 5 CARTRIDGE VALVE 17 L-974364 2 ELBOW

ASSY
3 L-976937 5 LOCK WASHER 18 L-202600 1 M-HEX NIPPLE
4 L-817134 5 SHC SCREW 19 L-580900 1 QC-HUBER
5 L-980073 1 Wireline Valve 20 L-204900 1 REDUCING NIPPLE

MANIFOLD BLOCK
1
6 L-975694 3 PLUG 21 L-582000 QC-COUPLER
7 L-871400 7 O-RING
9 L-870110 2 O-RING

PIN

ARM
14 L-871810 2 O-RING
15 L-814500 6 SHC SCREW

Elmar Integral Manifold Check Valves
Figure 7-20

1.7 GAS VENTED WIRELINE VALVE CYLINDERS
All new hydraulic Wireline Valves are supplied fitted with gas vented hydraulic
cylinders. They are recognised by the small hole in the adapter cylinder close
to the Wireline Valve body (Figure 7-21)
All new hydraulic Wireline Valves are supplied fitted with vented hydraulic
cylinders. Two vent holes, located opposite each other, are situated under the
lock ring close to the Wireline Valve body. Both holes should always be packed
with grease. Screwed to the transport frame is a long reach grease nipple
which can be fitted once the only through drilled hole in the lock ring is rotated
to align with the corresponding threaded hole in the hydraulic cylinder this will
allow grease through to the hydraulic ram stem. In the event of 'O' ring failure
on the stem of the hydraulic cylinder the vent hole prevents gas and well fluids
from contaminating the hydraulic system. Any well fluids reaching the cylinder
will have a dual effect.
• Well fluid and pressure getting into the hydraulic system could migrate back
to the pump via the hydraulic hose. The pump and hose are not rated for
high pressures and could rupture.
• Gas getting into the hydraulic fluid could expand the fluid and cause the
Wireline Valve to open. High pressure well fluids could also cause the
Wireline Valve to open.
Vent Hole
Figure 7-21
Dual Compact Hydraulic Wireline Valve with gas vented cylinders

Dual Compact Manifold Block Test Procedure
VALVES VALVES
CARTRIDGE VALVE AND CHECK VALVE TEST PROCEDURE
OPEN CLOSED
1. MOUNT MANIFOLD BLOCK ASSEMBLY ONTO WIRELINE VALVE. ABCDE -

ALL PRESSURE TESTING DONE THROUGH WIRELINE VALVE TEST
FIXTURES.
REMOVE CHECK VALVES & O-RINGS (13 & 14) FROM ELBOWS (17).
ENSURE BOTTOM, DUMP, GREASE INJECT AND GAUGE PLUGS (1)
ARE IN PLACE.
PRESSURE TEST TO WIRELINE VALVE TEST PRESSURE FOR 5 MINS.
BLEED TO ZERO.
2. REPLACE CHECK VALVES & O-RINGS INTO ELBOWS. ACDE B

REMOVE PLUG LOCATED IN HUBER UNION (19) & QC COUPLER (21).
REMOVE DUMP PLUG.
PRESSURE TEST TO WIRELINE VALVE WORKING PRESSURE FOR 5
MINS.
BLEED TO ZERO.
3. REPLACE DUMP PLUG & REMOVE BOTTOM PLUG. BC ADE

PRESSURE TEST TO WIRELINE VALVE WORKING PRESSURE FOR 5
MINS.
BLEED TO ZERO.
4. PRESSURE TEST TO WIRELINE VALVE WORKING PRESSURE FOR 5 A BCDE

MINS.
BLEED TO ZERO.
NO LEAKAGE ACCEPTABLE

Triple Compact Manifold Block Test Procedure
VALVES VALVES
CARTRIDGE VALVE AND CHECK VALVE TEST PROCEDURE
OPEN CLOSED
1. MOUNT MANIFOLD BLOCK ASSEMBLY ONTO WIRELINE VALVE. ABCDEF -

ALL PRESSURE TESTING DONE THROUGH WIRELINE VALVE TEST
FIXTURES.
REMOVE CHECK VALVES & O-RINGS (14 & 15) FROM ELBOWS (18).
ENSURE BOTTOM, DUMP, GREASE INJECT AND GAUGE PLUGS (1)
ARE IN PLACE.
PRESSURE TEST TO WIRELINE VALVE TEST PRESSURE FOR 5
MINS.
BLEED TO ZERO.
2. REPLACE CHECK VALVES & O-RINGS INTO ELBOWS. ACDEF B

REMOVE PLUG LOCATED IN HUBER UNION (20) & QC COUPLER
(22). REMOVE DUMP PLUG.
PRESSURE TEST TO WIRELINE VALVE WORKING PRESSURE FOR
5 MINS.
BLEED TO ZERO.
3. REPLACE DUMP PLUG & REMOVE BOTTOM PLUG. BC ADEF

PRESSURE TEST TO WIRELINE VALVE WORKING PRESSURE FOR
5 MINS.
BLEED TO ZERO.
4. PRESSURE TEST TO WIRELINE VALVE WORKING PRESSURE FOR A BCDEF

5 MINS.
BLEED TO ZERO.

1.8 WIRELINE VALVE PRESSURE TEST
Wireline Valves are pressure tested at the well site before a job (to the Maximum
Allowable Well Pressure) and in the shop (to working pressure or test) at regular
maintenance intervals, or whenever ram seals are changed.
If a test is conducted to the full test pressure (TP), the rams should be open to
prevent unnecessary damage to the ram seal. Testing with the rams closed
should be limited to the rated working pressure (WP) of the Wireline Valve. It is
advisable to close the rams on a solid test rod of the correct size rather than use
a braided line. When closing on a braided line the seal rubber extrudes into the
voids between armour wires. Not all the deformation is reversible and the rams
will loose the ability to seal on a different section of the line. In any case new
cables will often leak due to fluid passing between the inner and outer armour
strands and give the impression that the rams are not sealing properly.
Wireline Valve test rods (see Figure 7-22) should not be made locally and should
have certain design features, for example:
• The rod has a handle to lift in and out of the Wireline Valve. A cross piece is
attached to prevent the rod from being dropped through the Wireline Valve
during a rig pressure test
• End plates are fitted at both ends.
• Sealing surface is smooth and machined to match the diameter of the
wireline
Design for a Wireline Valve Test Rod Figure 7-22
End Plate
TEST ROD ASSEMBLY
Part Number Size Test Load

Cross Bar/Handle
L-974956 3/16" ROD DIA 500 kg
L-973440 7/32" ROD DIA 500 kg
Test Rod of
Specific Diameter L-974957 5/16" ROD DIA 1000 kg
L-972775 3/8" ROD DIA 1000 kg
L-973114 0.390" CABLE 1000 kg

L-974959 7/16" CABLE 1000 kg
L-974958 15/32" ROD DIA 1000 kg
End Plate
The plate should be located just under the rams during a pressure test to prevent the
rod being blown out. 3,000 psi pressure test on a Wireline Valve fitted with rams for a
15/32’’ cable would exert a force of nearly 500 lbs on the test rod.

1.9 WIRELINE VALVE MAINTENANCE
Wireline Valves need to be carefully maintained to perform properly.
Level 1 Service - To be carried out after every job
1. Wash down.
2. Initial inspection - remove rams and cylinders

- inspect all seals and sealing surfaces
- remove valves and inspect.
3. Grease up and rebuild.
4. Function and pressure test at working pressure.
5. Check lifting gear and record last certification type and date.
Level 2 Service - To be carried out once a year
1. Carry out Level 1 service procedure.
2. Replace all 'O' rings, inspecting all components and sealing surfaces for
corrosion or damage along the way. Pay particular attention to the surfaces
below the rams.
3. Rebuild Wireline Valve and pressure test to Working Pressure.
4. Third party agency to witness pressure test and function test.
Level 3 Service - To be carried out every 5 years
1. Carry out Levels 1 and 2 service procedure.
2. Strip Wireline Valve to component parts discarding all 'O' rings/back-up

rings.
3. MPI (Magnetic Particle Inspection) of all parts.


4. Rebuild using seal kit and any necessary new parts.
5. Pressure and function test to Test Pressure where applicable.
6. Third party certificate of final test and inspection, certificate of conformity

and lifting certification. It is very important to keep the Wireline Valve
cleaned and greased since the chemicals in the mud and wells can, with
time, cause a certain amount of corrosion to the inside of the body. The
resulting pitting and corrosion can prevent a good seal at high pressures
and at the very least, will make the closing of the rams very difficult.
Elmar Wireline Valves can be purchased with an internal coat of a Teflon

type compound called ‘Everslick’ to prevent such internal corrosion. This
extends the service life of the Wireline Valve considerably.
1.10 TRANSPORTATION
The Wireline Valves should always be transported, rigged up and down, with the
ram stems screwed into the body and handles removed. This will prevent the
stems from being bent due to mishandling of the Wireline Valve.
The Wireline Valve should be enclosed in a protective cage during use and
transportation and stored in the transport frame when not in use (Figure 7-23).
The frame is also used for lifting the valve, and provides a work platform.
Figure 7-23: Protective cage

2.0 LUBRICATORS
The lubricators (also known as risers) are simply a series of inter-connected

lengths of pipe, the purpose of which is to provide a space for the tool to be
contained in under pressure, when opening and closing the wellhead. The length
of the lubricator is calculated to be as long as the tools string plus any additional
weights, centralisers, etc, necessary for the job. The ID of the lubricator should
be 0.15" to 0.25" larger than the OD of the largest tool being run.
Lubricator sections are supplied in 4, 5, 6, 8, 10 and 12 ft lengths. For operations

with Mast Trucks, special extra-long joints (24-28 ft) are also available. Each
lubricator joint comes supplied with high pressure quick unions. Quick unions
can be threaded, butt-welded, or be an integral part of the lubricator body.
Some lubricators are ported to allow attachment of bleed valves with drain hoses
and pressure gauges.
Some lubricators are designed with a hang off facility to allow the collar to be
held clear of the pin as the lubricators are assembled vertically.
Elmar HIGHLY RECOMMENDS the use of integral or premium threaded

lubricators over threaded or welded types to eliminate unnecessary seals or
potential weld failures in the pressure control equipment. Ported lubricators are
not recommended due to the danger of knocking off a protruding fitting. Elmar
recommends the use of short ported subs instead of ported lubricators.
Lubricator seals are made of different elastomeric compounds, depending on the

operating temperature and the nature of well fluids. Special seals must be used
for arctic conditions, for extra-corrosive fluids (high H2S, CO2), or for steam-
injection operations.
2.1 QUICK UNIONS
Wireline valves and the other components of a WHE string are connected to
each other with unions. Quick Unions are self-aligning due to the profile of the
box and pin section (Figure 7-24). The seal is made by an internal O-Ring on the
pin end sealing in the box end of the union. (See chapter 9 for more details on
High Pressure Unions). The two ends are kept together by a knurled collar
resting on the shoulder of the pin end, and screwing onto the external thread on
the box end. ACME threads are used. With this configuration the threaded

connection does not need to be made-up tight to energise the O-ring. The
collars can be made-up and undone by hand easily and quickly if the mating
pieces are well aligned. There is no need to use a spanner or wrenches on
these connections to make them up tightly.
There are two commonly used types of Quick Unions, with different profiles:
• Bowen Quick Unions

• Otis Quick Unions (Flopetrol QU use a profile similar to Otis)
Elmar Quick Unions can be either Bowen or Otis shape, but are designed to
minimise the overall weight or have special premium-thread connections.
Otis and Bowen types are not compatible. Bowen connections are more
compact, Otis connections are easier to stab when not perfectly aligned and are
the preferable choice. They come in standard sizes, related to ID of the
connection and pressure rating.
Flopetrol QU have a different size range and different tolerances than Otis. Some
are compatible with Otis some are not. Even if nominal sizes are the same, it is
safer to assume that they are not compatible to avoid problems due to tolerances
stack-up. They are being discontinued.
Elmar’s WHE are manufactured with either Bowen, Otis, or Elmar QU

connection. (Flopetrol QU on special request).
A quick union is defined by: (see fig 7-24 and section 7 pages 37-40)
∗ Type: Bowen or Otis (or Flopetrol)

∗ ACME thread diameter in inches
∗ Thread pitch in threads per inch (TPI). Some connections use double start
threads (DL, sometimes also identified as “x2”)
∗ Seal diameter in inches, to the thousandth.
Example: BOWEN 8 1/4”- 4DL – (6.000”) connection is a Bowen connection with

a 8 1/4” ACME thread, 4 Threads Per Inch, double start, with a seal diameter of
6.000 inches. Can also be designated as BOWEN 8.25 - 4x2 – (6.000)
It can be used for 4” ID equipment rated 10K psi, H2S service.

Quick Union Connections
Figure 7-24
Seal
Diameter
Thread
size
BOWEN
Seal
Diameter
Thread
size
OTIS

ELMAR SERVICES LTD TI- BOWEN-A-1
TITLE: BOWEN QUICK UNION TYPE CONNECTIONS
THREAD SIZE NOMINAL ID SEAL DIA MAX OD
BOX UNION PIN UNION
ELMAR CONNECTIONS
WORKING BU-RING
ELMAR NO THREAD SIZE TPI SEAL Ø NOMINAL ID MAX OD PRESSURE SERVICE O-RING BU-RING RETAINER
E06 (LIGHTWEIGHT) 4.75 4 3.750 3.00 5.33 10K H2S 870470 873660 N/A
E09 (LIGHTWEIGHT) 4.75 4x2 3.750 3.00 5.33 10K H2S 870470 873660 N/A
BOWEN QUICK UNION TYPE CONNECTIONS

WORKING BU-RING
B01 4.75 4 3.750 3.00 5.36 5K H2S 870470 N/A N/A
B02 6.31 4 4.375 3.00 7.33 10K H2S 870520 873700 N/A
B03 6.31 4 3.750 2.50 7.33 15K H2S 870470 974535 873170
B04 5.50 4x2 4.375 3.00 6.39 5K H2S 870520 N/A N/A
B06 7.00 5 4.375 3.00 7.81 15K H2S 870520 974603 873260
B07 8.25 4x2 6.000 4.00 9.45 10K H2S 870690 875340 N/A
B08 7.00 5 5.250 4.00 8.08 5K H2S 875560 N/A N/A
B09 8.25 4x2 6.750 5.50 9.63 5K H2S 870850 N/A N/A
B10 9.15 4x2 6.750 5.50 10.99 10K H2S 870850 876160 N/A
B11 9.88 4x2 8.000 6.38 10.99 5K H2S 873120 N/A N/A
B12 4.75 4 3.750 3.00 6.08 10K STD 870470 873660 N/A
B13 5.50 4x2 4.375 3.00 6.86 10K STD 870520 873700 N/A
B14 4.062 4 3.000 2.00 4.94 5K H2S 870430 N/A N/A
B15 10.62 4 7.500 5.63 12.11 10K H2S 870720 870021 N/A
B16 4.50 4 3.000 2.00 N/A 10K H2S 870430 873630 N/A
B17 8.88 4x2 6.500 5.00 10.49 10K STD 873280 875540 N/A
B18 13.00 4 9.500 7.06 15.11 10K H2S 874008 874009 N/A
ITEM PART NO QTY DESCRIPTION
REV ECO DRAWN BY CHECKED BY APPROVED BY DATE 1st ANGLE

PROJECTION
- - - - - -
A W. THOMSON C. WOOD C. WOOD 09/04/01 PAGE 1 OF 1
ELMAR SERVICES LTD TI- OTIS-A-1
TITLE: OTIS QUICK UNION TYPE CONNECTIONS
NOMINAL ID
THREAD SIZE SEAL DIA MAX OD
BOX UNION PIN UNION
ELMAR CONNECTIONS
WORKING BU-RING
E11 (LIGHTWEIGHT) 9.375 4x2 7.500 6.38 N/A 10K H2S N/A
OTIS QUICK UNION TYPE CONNECTIONS

WORKING BU-RING
O01 5.00 4 3.500 3.00 5.86 5K STD 870310 N/A N/A
O02 5.75 4 4.000 3.00 6.62 10K H2S 870490 873680 N/A
O03 6.25 4 4.000 2.50 7.63 15K H2S 870490 974353 873260
O04 6.50 4 4.750 4.00 7.58 10K STD 870540 873720 N/A
O05 6.50 4 5.188 4.00 7.61 5K STD 873140 N/A N/A
O06 7.50 4 5.500 3.00 8.87 15K H2S 870580 974602 876260
O07 8.25 4 6.188 5.00 9.61 5K H2S 870710 N/A N/A
O08 8.38 4 5.250 4.00 9.64 10K H2S 875560 875570 N/A
O09 8.75 4 7.500 6.38 9.88 5K STD 870720 N/A N/A
O10 9.00 4 6.750 5.00 10.12 10K H2S 870850 876160 N/A
O11 9.50 4 6.250 4.00 10.88 15K H2S 872560 977411 871005
O12 9.50 4 8.000 6.38 10.58 5K H2S 873120 N/A N/A
O13 11.50 4 8.250 6.38 13.08 10K H2S 876060 876070 N/A
O14 12.00 4 10.312 9.00 13.36 5K H2S 872440 N/A N/A
O15 12.25 4 7.000 5.00 15K H2S
O16 5.00 4 3.500 3.00 5.86 5K H2S 870310 N/A N/A
O17 6.50 4 4.750 4.00 7.58 5K H2S 870540 N/A N/A
O18 7.50 4 5.500 4.50 8.62 10K H2S 870580 873760 N/A
O19 6.50 4 4.750 3.00 7.58 10K H2S 870540 873720 N/A
O20 5.00 4 3.500 2.50 5.86 15K STD 870460 976083 875640
O21 5.00 4 3.500 3.00 5.86 10K STD 870310 873570 N/A
O22 8.25 4 6.188 5.12 9.61 10K H2S 870710 875001 N/A

PROJECTION
- - - - - -
ELMAR SERVICES LTD TI- FLOPETROL-A-1
TITLE: FLOPETROL QUICK UNION TYPE CONNECTIONS
MAX OD
THREAD SIZE NOMINAL ID SEAL DIA
BOX UNION PIN UNION
FLOPETROL QUICK UNION TYPE CONNECTIONS

WORKING BU-RING
F01 5.000 4 3.500 3.00 5.88 5K STD 870460 N/A N/A
F02 6.500 4 4.750 4.00 7.38 5K STD 870540 N/A N/A
F03 8.661 4 5.906 4.50 9.63 5K STD 871620 N/A N/A
F04 5.060 4 3.515 2.50 6.02 5K H2S 870460 976083 870150
F05 6.375 4 4.515 3.00 7.50 5K H2S 870530 976063 872590
F06 7.125 4 5.512 4.50 5K H2S
F07 5.875 4 4.015 2.50 10K H2S
F08 8.625 4 6.035 4.50 10K H2S
F09 5.750 4 4.000 3.00 7.08 10K H2S 870490 974353 873260
F10 6.500 4 4.750 4.00 7.38 5K H2S 870540 N/A N/A
F11 8.661 4 5.906 4.00 9.63 10K H2S 871620 975935 874250
F12 5.750 4x2 4.000 2.50 7.11 10K H2S 870490 974353 873260
F13 5.000 4 3.500 3.00 5.88 5K H2S 870460 N/A N/A
F14 6.500 4 4.750 3.00 7.99 10K H2S 870540 974858 871560
F15 6.000 4 4.015 2.50 7.25 10K H2S 870490 974353 873260
F16 8.661 4 5.906 4.50 9.63 5K H2S 871620 N/A N/A
F17 11.023 4 8.661 6.70 12.64 10K H2S 873290 874006 N/A

PROJECTION
- - - - - -

ELMAR SERVICES LTD TITLE: ELMAR CONNECTIONS
1st ANGLE
REV ECO DRAWN BY CHECKED BY APPROVED BY DATE
PROJECTION
- - - - - - TI- ELMAR-A-1
ELMAR CONNECTIONS
WORKING BU-RING
E01 (PECO) 5.50 4 3.500 2.50 6.83 15K H2S 870460 979800 870137
E02 (SHEARWATER) 19.00 4 10.825 7.06 22.14 15K (High Temp) H2S 874013 980072 875042
E03 (SHEARWATER) 8.75 4 5.000 3.00 10.08 15K (High Temp) H2S 872190 980160 870165
E04 (SLIMLINE) 6.75 4 5.375 4.892 7.59 5K STD 870610 N/A N/A
E06 (LIGHTWEIGHT) 4.75 4 3.750 3.00 5.33 10K H2S 870470 873660 N/A
E08 (HYDROLEX) 8.75 4 6.500 5.00 9.88 10K STD 873280 875540 N/A
E10 (L/W X-OVER) 3.75 6 3.340 3.00 4.39 10K H2S 872017 N/A N/A
E11 (LIGHTWEIGHT) 9.375 4x2 7.500 6.38 N/A 10K H2S N/A
E13 (TC/BCV) 3.750 8 2.500 N/A 4.39 10K H2S 875630 872700 N/A
E14 (SLIMLINE) 9.00 4 7.500 6.62 9.99 5K H2S 870660 N/A

2.2.1 OPERATION
Prior to use, union seal areas together with union and collar threads should be
inspected to ensure that they are clean and corrosion-free. Union O-rings should
be in good condition. A small amount of grease on these areas will assist
assembly.
At assembly, ensure unions are properly made up hand tight. Lubricators should
be lifted using an appropriate lifting bail or lifting clamp, where this is available.
2.2.2 STORAGE
Lubricators should be cleaned out specially the inside area, have seal areas
dried and greased to prevent corrosion and be fitted with thread protectors during
storage. For long storage it is advisable to lightly coat the inside with corrosion
inhibitor.
2.2.3 INSPECTION AND TESTING
1. Thoroughly inspect the whole length of the lubricator. Look for dents,
tong marks, over-corroded areas
2. Locate appropriate test plug and test cap to the ends of the lubricator and make
up tight.
3. Apply test pressure to the lubricator for 3 minutes; release pressure and
apply again for a further 15 minutes. Bleed to zero. No leakage acceptable.
2.2.4 SERVICE
Routine service of lubricators is normally limited to what previously mentioned.

However, should leakage occur between lubricator tube and adapter on non-
integral lubricator assemblies, or between mating parts of lubricator unions, this
will be due to damage to the O-rings and/or seal surfaces and will require
replacement or re-manufacturing of the faulty parts.

2.3 LIGHTWEIGHT LUBRICATOR
The Elmar lightweight lubricator is designed to minimise weight while maintaining

full 10K psi, H2S Service Rating. By using high strength Stainless Steel Alloys,
the weight of the lubricator section is reduced by up to 70%. Various quick union
configurations can be supplied for the upper and lower connections but for
optimum weight reduction and full service specification, Elmar lightweight quick
unions should be selected.
The Elmar lightweight lubricator (see fig 7-25 & 7-26.) is composed of four basic
parts: a quick union collar, a male quick union adapter, a lubricator tube and a
female quick union adapter. The use of stainless steel alloys tubes reduces the
amount of maintenance required between jobs. Painting is not required to protect
the lubricator tubes from corrosive attack.
The quick union adapters are connected to the lubricator tube by a premium-
threaded connection with metal-to-metal seal, backed up by an elastomer seal.
With this configuration the primary seal is the metal-to-metal one, and the O-ring
never sees well fluid if the metal-to-metal seal remains active.
A special tool is recommended to install the end adapters to the proper torque
(see para.2.3.4). Once the adapter is set at the proper torque, a grub screw locks
the connection.
Elmar optimised lightweight unions have the basic Bowen profile, but have
double-start threads to avoid inadvertent connection to other unions with similar
dimensions and lower ratings.
On specific clients’ requests, some single start unions have been supplied, which
can be used with existing Bowen unions. This practice is not recommended.
Care must be taken when connecting these unions to lesser-rated equipment.
For example, the E06 single start union (3” equipment) is rated for 10K H2S
service but can be connected to Bowen 5 000 psi H2S or 10 000 psi Standard
service unions.
The in-service rating of the Elmar E06 union is limited by the rating of the
equipment it is connected to.
When Lightweight Lubricators are used with existing equipment having different
unions, there are two possible solutions:
2Use of crossover subs
3Use of upper and lower crossover lubricators.

The crossover lubricators have a special Elmar double start thread union adapter
at one end, and union adapter with the thread compatible with the rest of the
equipment at the other end.
The lower crossover lubricator adapter can also be designed with a bleed-off port
when required for Slick Line applications. A bleed-off sub can also be used
allowing all the lubricators to be identical.
2.3.1 USING LIGHTWEIGHT LUBRICATORS
Lightweight lubricators use thin-wall tubes made out of high-strength steel alloys.
Certain precautions are to be taken when using the lubricators:
• Avoid dropping heavy objects that can create indentations in the lubricator
tube.
• Avoid using chain tongs or wrenches on the tube section. Use only non
marking equipment such as “strap wrenches or “friction tongs”, adapted to the
actual diameter of the lubricator tube.
2.3.2 RIGGING-UP LIGHTWEIGHT LUBRICATORS
Lightweight lubricators are NOT intended for use as freestanding equipment and
therefore must be fully supported at the upper end by a wireline mast or derrick
when used with braided and electric lines.
The upper sheave must always be suspended from an independent structure
such as a mast or derrick during braided line operations either directly, or using a
lubricator lifting clamp and spreader beam.
For slick line operation, an offset sheave wheel, attached to the stuffing box is
acceptable.
Take care to ensure that the lower sheave is as close to the centreline of the
WHE as possible, to reduce bending stresses in the lubricator sections.
Up to 3 x 10 ft joints of lubricator can be used freestanding with slickline. For

longer rig-ups it is imperative to have the stuffing box supported with a suitable
strap, or a lubricator lifting clamp.
Due to large bending stresses induced in the lubricator sections, the maximum
length of lubricator that can be lifted from the horizontal position is 60 feet. This
maximum length is assuming a total tool string weight inside the lubricator of not
more than the self-weight of the lubricator.
If the tool string weight exceeds the lubricator weight then the maximum
allowable length of lubricator is reduced.

Do NOT attempt to lift the lubricator string with overweight tools inside. First rig
up the lubricator with a section of tool string that is within the allowable weight
and then insert the remaining tools using vertical make-up as required.
2.2.3 MAINTENANCE OF LIGHTWEIGHT LUBRICATORS
2.3.3 MAINTENANCE OF LIGHTWEIGHT LUBRICATORS
PRE JOB
• Inspect all lubricator tubes for signs of external damage.
• Inspect union adapters for sign of scoring or wireline tracking.
• Make sure that quick union threads and sealing surfaces are free from grit.
• Inspect quick union seals and replace if necessary.
• Coat quick union threads and sealing surfaces with grease.
POST JOB
• Flush out well fluids and clean lubricator bores.
• Clean quick union threads and sealing surfaces.
• Inspect all lubricator tubes for signs of external damage.
• Inspect union adapters for sign of scoring or wireline tracking.
• Inspect and replace damaged or worn union seals.
• Grease union threads and sealing surfaces and fit thread protectors.
• Clean all external surfaces.
YEARLY
• As per “post job” plus the following.
• Remove lubricator end adapters, thoroughly clean and degrease threads and
sealing surfaces.
• Inspect the condition of all sealing surfaces and surface coatings.
• Recoat threads and sealing surfaces if necessary.
• Replace all elastomer seals.
• Replace adapter locking screws if necessary.
• Inspect paintwork and repair where necessary.
• Re-assemble lubricator, following assembly drawing instructions and torque
adapters using the recommended tools
• Drift lubricator with recommended drift gauge.
• Pressure test to maximum Working Pressure (and to 300 psig when
required). A Certifying Authority must witness the yearly test where
applicable.
FIVE YEARLY
• As per “yearly”, plus the following
• Carry out surface NDT on all threads and any damaged surfaces.

• Pressure test to equipment’s maximum Test Pressure and 300 psig. A

• Certifying Authority must witness the 5-yearly test.
2.3.4 LIGHTWEIGHT LUBRICATORS ASSEMBLY PROCEDURE
The adapters at either end of a lightweight lubricator require a specific assembly

procedure, so that the metal-to-metal seal can be properly torqued-up. A torque
of approximately 500 lbxft is needed for the metal-to-metal seal.
There are two types of special tool sets to be used: (see figures 7-27 & 7-28)
• An assembly for “Centralised Districts” handling a large volume of lubricators

• An assembly for “Remote Locations” handling only a few strings
Both assemblies include special vice inserts and a torque tool.
The vice inserts firmly grip the lubricator body without marking it. They are to be
used with a dedicated vice bench for the Centralised Districts’ Assembly, and in a
Baker Vice for the “Remote” assembly.
The torque tool consists of a collet that is secured to the adapter body using two
torque pins, and of two long bar handles. 25 Kgf are required on each handle to
obtain the proper torque.
Notice that it is important to hold the tube stationary and rotate the adapters to
avoid cross-threading or damaging the metal-to-metal seal.
Procedure for assembling the lubricator is as follows:
LUBRICATOR ASSEMBLY PROCEDURE

• Fit the appropriate inserts, corresponding with the tube OD, in the torque vice.
• Place the lubricator tube in the vice and lightly tighten.
• Remove adapter locking screws.
• Ensure all threads and mating surfaces are clean and in good condition.
• Lightly grease threads and sealing surfaces.
• Screw the end adaptors onto the tube until the metal-to-metal seal bottoms
out. (Feel internally for a gap)
• Assemble the appropriate collet assembly around the adapter and tighten
collet retaining screws.
• Adjust the orientation of the lubricator until the collet spigots are horizontal.
(or at a comfortable angle for operation)

• Fully clamp the tube in the vice avoiding over tightening. Note: very little force
is required to grip the tube.
• Using two people of comparable build, work as a team to torque up the
adapters with the collet bars provided.
• Note: A minimum torque of 500 ft-lb is required to achieve a seal. This is
approximately equivalent to 55 lbf per bar.
• Fit adapter locking screws hand tight.
Note: Approximately equal force is required on each bar to provide a good torque
couple and achieve a seal. If the adapter is fully home prior to tightening then do
not expect to see significant rotation during loading.
Disassembly is the reverse of the above assembly procedure.
2.3.5 LW LUBRICATOR ACCESSORIES
ACCESSORIES – 3” LIGHTWEIGHT LUBRICATORS

Part No Description
L-690572 Lifting Clamp and Spreader Beam, 3” Lubricator
L-971397 Lifting Bail 4 3/4”-4x2 E09 (2 Ton SWL)
L-971262 Quick Union Test Cap 4 3/4”-4x2 (3.750” seal dia) E09 Box
L-971263 Quick Union Test Plug 4 3/4”-4x2 (3.750” seal dia) E09 Pin & Collar
L-971489 Torque Tool Assembly, 3” Lightweight Lubricator
L-973957 Torque Tool Assembly, 3” Lightweight Lubricator-Remote
L-970852 “C” Spanner, 3” Lightweight Lubricator
L-971190 Drift Gauge for 3” Lubricator
L-690777-E09 Lubricator Dolly 4 3/4”-4x2 E09
L-973233 Metal Thread Protector 4 3/4”-4x2 (3.750” seal dia) E09 Box
L-971752 Metal Thread Protector 4 3/4”-4x2 (3.750” seal dia) E09 Pin
ACCESSORIES – 4 1/16” LIGHTWEIGHT LUBRICATORS

Part No Description
L-690613 Lifting Clamp and Spreader Beam, 4 1/16” Lubricator
L-971802 Lifting Bail, 6 1/8”-4x2 (3.25 Ton SWL)
L-971803 Quick Union Test Cap 6 1/8”-4x2 (4.750” seal dia) Box
L-971804 Quick Union Test Plug 6 1/8”-4x2 (4.750” seal dia) Pin & Collar
L-972196 Torque Tool Assembly, 4 1/16” Lightweight Lubricator
L-973958 Torque Tool Assembly, 4 1/16” Lightweight Lubricator- Remote
L-971983 “C” Spanner, 4 1/16” Lightweight Lubricator
L-980082 Drift Gauge for 4 1/16” Lubricator
L-972879 Metal Thread Protector 6 1/8”-4x2 (4.750” seal dia) Box
L-972878 Metal Thread Protector 6 1/8”-4x2 (4.750” seal dia) Pin

Typical Elmar Lightweight Lubricator Section
Figure 7-25

Typical Elmar Lightweight Lubricator Section Assembly
Figure 7-26

3” Lightweight Lubricator
LIGHTWEIGHT LUBRICATOR
Part No Upper Connection Lower Connection ID WP Service Length Weight
L- 971246 4 3/4”-4x2(3.750”) Elmar Box 4 3/4”-4x2(3.750”) Elmar Pin 3” 10,000 psi H2S 4ft 54 lb
INTEGRAL TYPE LUBRICATOR WEIGHT TABLE (COMPARISON ONLY)

Connection WP Service 4FT 5FT 6FT 8FT 10FT
4 3/4”-4 (3.750”) Bowen 5,000 psi H2S 99 lb 110 lb 123 lb 148 lb 172 lb
6 5/16” -4 (3.375”) Bowen 10,000 psi H2S 165 lb 185 lb 205 lb 243 lb 282 lb
6 1/2” -4 (4.750”) Otis 10,000 psi H2S 187 lb 209 lb 231 lb 276 lb 320 lb
ACCESSORIES – 3” LIGHTWEIGHT LUBRICATORS

Part No Description
L-690572 Lifting Clamp and Spreader Beam, 3” Lubricator
L-971397 Lifting Bail 4 3/4”-4x2 E09 (2 Ton SWL)
L-971262 Quick Union Test Cap 4 3/4”-4x2 (3.750” seal dia) E09 Box
L-971263 Quick Union Test Plug 4 3/4”-4x2 (3.750” seal dia) E09 Pin & Collar
L-971489 Torque Tool Assembly, 3” Lightweight Lubricator
L-973957 Torque Tool Assembly, 3” Lightweight Lubricator-Remote
L-970852 “C” Spanner, 3” Lightweight Lubricator
L-971190 Drift Gauge for 3” Lubricator
L-973233 Metal Thread Protector 4 3/4”-4x2 (3.750” seal dia) E09 Box
L-971752 Metal Thread Protector 4 3/4”-4x2 (3.750” seal dia) E09 Pin
4 1/16” Lightweight Lubricator
LIGHTWEIGHT LUBRICATOR
Part No Upper Connection Lower Connection ID WP Service Length Weight
L - 971846A 6 1/8”-4x2 (4.750”) Elmar Box 6 1/8”-4x2 (4.750”) Elmar Pin 4.06” 10,000 psi H2S 4ft 96 lb
L - 971846B 6 1/8”-4x2 (4.750”) Elmar Box 6 1/8”-4x2 (4.750”) Elmar Pin 4.06” 10,000 psi H 2S 5ft 113 lb
L - 971846C 6 1/8”-4x2 (4.750”) Elmar Box 6 1/8”-4x2 (4.750”) Elmar Pin 4.06” 10,000 psi H 2S 6ft 129 lb
L - 971846D 6 1/8”-4x2 (4.750”) Elmar Box 6 1/8”-4x2 (4.750”) Elmar Pin 4.06” 10,000 psi H 2S 8ft 161 lb
L - 971846E 6 1/8”-4x2 (4.750”) Elmar Box 6 1/8”-4x2 (4.750”) Elmar Pin 4.06” 10,000 psi H 2S 10ft 193 lb
INTEGRAL TYPE LUBRICATOR WEIGHT TABLE (COMPARISON ONLY)

Connection WP Service 4FT 5FT 6FT 8FT 10FT
6 1/2”-4 (4.750”) Otis 5,000 psi H2S 158 lb 182 lb 206 lb 255 lb 304 lb
8 1/4”-4x2 (6.000”) Bowen 10,000 psi H2S 304 lb 342 lb 379 lb 454 lb 528 lb
ACCESSORIES – 4 1/16” LIGHTWEIGHT LUBRICATORS

Part No Description
L-690613 Lifting Clamp and Spreader Beam, 4 1/16” Lubricator
L-971802 Lifting Bail, 6 1/8”-4x2 (3.25 Ton SWL)
L-971803 Quick Union Test Cap 6 1/8”-4x2 (4.750” seal dia) Box
L-971804 Quick Union Test Plug 6 1/8”-4x2 (4.750” seal dia) Pin & Collar
L-972196 Torque Tool Assembly, 4 1/16” Lightweight Lubricator
L-973958 Torque Tool Assembly, 4 1/16” Lightweight Lubricator- Remote
L-971983 “C” Spanner, 4 1/16” Lightweight Lubricator
L-980082 Drift Gauge for 4 1/16” Lubricator
L-972879 Metal Thread Protector 6 1/8”-4x2 (4.750” seal dia) Box
L-972878 Metal Thread Protector 6 1/8”-4x2 (4.750” seal dia) Pin

FIGURE 7-27
ELMAR SERVICES LTD TITLE: TORQUE TOOL ASSY 4.06" REMOTE

FIGURE 7-28

3.0 TOOL TRAPS, MANUAL, HYDRAULIC
Hydraulic tool traps are available in all the common pressure ratings, and for H2S
or standard service. The flappers (sometimes called “stop dogs” or “retainer
plates”) have a slot larger than the wireline, but smaller than the tool string. They
are spring-loaded and will be lifted as a tool is pulled through but will fall back as
soon as the tool is above the trap. To open the flapper externally, hydraulic
pressure must be applied. A hollow piston is pumped upwards inside the tool
trap and pushes open the flapper. Pumping hydraulic fluid in the upper of the two
hydraulic ports will push the piston back down and allow the flapper to return
back under the influence of the spring.
The tool trap remains closed during normal operation. It is only opened at the
commencement of a job to allow the downhole tool to descend from the
lubricators into the well. It is closed again once the tool is in the well.
Other types of tool traps are available and include manual tools traps (Figure 7-
29) and hydraulic tool traps with external indicators (Figure 30).
The external indicator type is very useful as it provides a positive indication to the
wireline crew that the tool has passed the trap and that the well can be closed in.
In manual tool traps, the flapper is connected directly to a pressure-balanced

shaft and an external handle. The handle acts as an indicator. By lifting the
handle, the flapper is raised, allowing the tool to go down. When the handle is
lowered, the flapper returns to the closed position, with the wireline running
through its slot. When the tool string is pulled back, it hits the plate deflecting it
upwards. The handle will move with the plate, giving an external indication. The
flapper will drop back into the trap position under the force of a spring once the
tool string bottom has cleared it.
Elmar has developed a hydraulic tool trap with external indicator. It operates on
the same principle as a manual trap but has an external hydraulic actuator to
operate the handle.
3.1 OPERATION
Prior to use, union seal areas together with union and collar threads should be
inspected to ensure that they are clean and corrosion-free. A small quantity of
grease on these areas will assist assembly.

Tool traps should be function tested before use. Ensure the flapper returns to
closed position when the piston or the handle is in closed position.
Manual Tool Trap
Figure 7-29

ED 4 (A)
ELMAR SERVICES LTD No: TI-971169-C
TITLE: TT ASSY 3" E09 10K H2S EXT IND

PAGE 1 OF 2
C 4537 T. MURPHY 20/11/00

ED 4 (A)
ELMAR SERVICES LTD No: TI-971169-C
TITLE: TT ASSY 3" E09 10K H2S EXT IND
ITEM PART No QTY DESCRIPTION ITEM PART No QTY DESCRIPTION
1 L-971239 1.00 THREAD PROTECTOR 15 L-812900 1.00 WASHER

2 L-971268 1.00 TT UPPER BODY 16 L-813200 1.00 NUT
3 L-971165 2.00 PROTECTOR STRAP 17 L-974908 1.00 FLAPPER
4 L-800547 6.00 SHCS 18 L-870480 1.00 O-RING
5 L-801500 6.00 WASHER 19 L-873670 1.00 BACK-UP RING
6 L-971373 1.00 ACTUATOR ASSY 20 L-971269 1.00 TT LOWER BODY
7 L-974904 2.00 RET NUT 3"HYD TTRAP 21 L-971235 1.00 STD COLLAR
8 L-974903 1.00 FLAPPER SHAFT 22 L-873660 1.00 BACK-UP RING
9 L-974607 4.00 BACK-UP RING 23 L-870470 1.00 O-RING
10 L-870300 4.00 O-RING 24 L-971238 1.00 THREAD PROTECTOR
11 L-871290 2.00 O-RING
12 L-872910 2.00 BACK UP RING
13 L-974621 1.00 TORSION SPRING TT
14 L-974954 1.00 INDICATOR LEVER

PAGE 2 OF 2
C 4537 T. MURPHY 20/11/00

3.2 SERVICE
Wash both the inner and outer body of tool trap, clean O-ring sealing areas and
union threads, inspect for damage. Grease threads and O-ring seal areas.
Check function of flapper and condition of flapper return spring. Grease flapper
pin and spring, replace thread protectors.
Plan view of a flapper assembly

for a manual tool trap
Figure 7-29

Hydraulically Actuated Tool Trap
Figure 7-30

4.0 TOOL CATCHER (OR HEAD CATCHER)
The tool catcher is normally placed above the lubricator string and below the ball
check valve/grease injection head.
Its purpose is to save a possible fishing job should the tool be inadvertently
pulled into the top end of the lubricator and the weak point broken. When the
catcher is activated, it latches onto the fishing neck of the cable head or slick-line
rope socket, and holds the tool safely in the risers.
It is compulsory to have at least one ‘catching’ system, either tool trap or tool
catcher in the WHE string.
4.1 BOWEN STYLE TOOL CATCHER (old style)
The catcher must be activated before it can catch the head. The catcher is
activated either:
• Automatically by a well pressure of 400 psi or greater in the riser, or

• Hydraulically, by applying external pressure via a pump.
Later models have an added feature that allows the catcher to be pumped open.
This is used to release a tool, which has been caught due to well pressure before
running in the hole. These latest versions of Bowen catcher have two hydraulic
lines: one open, one close. These obsolete catchers are now seldom seen.
4.2 ELMAR TYPE TOOL CATCHER
The Elmar tool catcher is normally used with no hydraulic pressure applied (See
page 61-62). In this condition, the Elmar catcher will automatically catch and hold
the fishing neck of a tool that is pulled up into the catcher. To release the tool,
hydraulic pressure is applied to the tool catcher, causing the collets to retract and
release the tool. When the tool has been released, hydraulic pressure should be
bled-off in order to prepare the catcher to safely catch as necessary.
This opposite system between the two catchers is a potential source of problems.
One must know the type of catcher connected in the string. ‘Elmar’ type tool
catcher is fail-safe and is the recommended version.
Latest models of Elmar tool catchers are adapted to catch different sizes of
fishing heads. These range from 1’’- 2 5/16’’. Older models are limited to one
size only.

4.2.1 QUICK-INTERCHANGE TOOL CATCHER FOR 1.375” LOGGING HEAD
The Elmar Quick-Interchange Tool Catcher allows the field crew to quickly and
easily change between slickline and electric line operations without remaking
either rope socket.
This is made possible by the unique features of a 1.5” through-bore and a split
tool stop that can be inserted after the head is passed through the Tool Catcher
body (see Figure 7-31).
This configuration allows considerable savings in rig time, minimises the use of
consumable supplies and reduces the risks of human error when making-up new
rope sockets between runs. An optional cable head protector sleeve is also
available to protect the cable, head and rope socket during interchange or
transportation.
The slickline and electric line heads can be made up before the operation after
passing the lines through their respective Stuffing Box and Ball Check Valve
Assembly or Enviro™ Grease Injection Head and Ball Check Valve Assembly.
The Cable Head Protector Sleeve is installed, connected to the Ball Check Valve
Quick Union.
When ready to rig up, the protector sleeve is removed, the Tool Catcher is
pumped open, the tool stop removed and the required cable head (slickline or
electric line) is passed through the 1.5” through bore of the Tool Catcher body.
After installing the split tool stop around the cable, the quick union at the bottom
of the Ball Check Valve is made up to the Tool Catcher and the hydraulic
pressure released, resetting the Tool Catcher to the catch position.
The procedure is reversed to rig down one line and replace it with the other. Up
to one hour of rig time is saved at each change-over.
The fishing neck size can be changed by installing the corresponding collet
assembly and tool stop.
Multi-catch fish neck collects can not be installed to standard Tool Catchers.

Typical Elmar Quick-Interchange Tool Catcher Section
Figure 7-31
Stuffing Box
Enviro™
Line Wiper
Slickline
Stuffing Box
and Blowout Plug
Grease Head
BCV with
Elmar Quick
Union
Electric Line
Cable Head
Cable Head
Slickline Protector
Cable Head Sleeve
Split Tool Stop
Handling Sub
Elmar Quick
Union Tool Catcher

QUICK-INTERCHANGE TOOL CATCHER SYSTEM

Part Number Description
L - 979540 Slickline Stuffing Box 10,000 psi, H2S, 0.108”, 16” wheel
L - 979184 Slickline Stuffing Box 10,000 psi, H2S, 0.125”, 16” wheel
L - 971444 Enviro™ Grease Injection Control Head 10,000 psi, H2S, (4) Concentric Flotubes - wire size to be specified
L - 972019 Ball Check Valve 10,000 psi, H2S, with 3 3/4”-5thd (2.500”) Elmar male pin and collar
Combination Tool Catcher and Ball Check Valve, 10,000 psi, H2S with 6 5/16”-4thd (3.750”) Bowen male
L - 975279
pin and collar - fish neck size to be specified
Combination Tool Catcher and Ball Check Valve, 10,000 psi H2S with 6 1/2”-4thd (3.750”) Otis male pin
L - 978707
and collar - fish neck size to be specified
L - 971174 Cable Head Protection Sleeve
L - 972027 Tool Catcher Handling Sub for 3 3/4”-5thd Elmar Union
Similar equipment is available for alternative flowtube types, quick union sizes,
working pressures and services.
A Split Tool Stop is available for modification of many types of existing Elmar
Combination Tool Catchers with Ball Check Valve so as to up-grade to the
Quick-Interchange feature.

ED 4 (A)
ELMAR SERVICES LTD No: TI-971167-D
TITLE: TC ASSY BWN E09 PIN 10K H2S 1.18"FN

PAGE 1 OF 2
D 4770 G. REID 13/08/01

ED 4 (A)
ELMAR SERVICES LTD No: TI-971167-D
TITLE: TC ASSY BWN E09 PIN 10K H2S 1.18"FN
1 L-822810 1.00 EYEBOLT 22 L-978862 1.00 PISTON

2 L-974505 1.00 THREAD PROTECTOR 23 L-873730 2.00 BACK-UP RING
3 L-812900 4.00 WASHER 24 L-875780 1.00 O-RING
4 L-974329 1.00 TC TOP ADAPTER 25 L-974328 1.00 SPRING SLEEVE
5 L-870260 1.00 O-RING 26 L-212000 1.00 STREET ELBOW
6 L-870160 1.00 O-RING 27 L-820640 1.00 GREASE NIPPLE
7 L-870250 1.00 O-RING 28 L-585200 1.00 QC-NIPPLE
8 L-974332 1.00 BALL CV HOUSING 29 L-875660 4.00 BACK-UP RING
9 L-870110 1.00 O-RING 30 L-875770 2.00 O-RING
10 L-875470 1.00 BALL 31 L-971206 1.00 TC LOWER BODY
11 L-875670 1.00 CIRCLIP 32 L-974330 1.00 COLLET ASSY
12 L-974326 1.00 COLLAR 33 L-817100 2.00 GRUB SCREW
13 L-872700 1.00 BACK UP RING 34 L-810445 2.00 SPIROL PIN
14 L-875630 1.00 O-RING 35 L-974110 1.00 COLLAR INSERT
15 L-971204 1.00 TOOL STOP 36 L-971194 1.00 COLLAR RING
16 L-971205 1.00 TC UPPER BODY 37 L-873660 1.00 BACK-UP RING
17 L-974546 1.00 COLLET MANDREL 38 L-870470 1.00 O-RING
18 L-974483 1.00 PISTON SPRING 39 L-971238 1.00 THREAD PROTECTOR
19 L-975189 1.00 COLLET SPRING 40 L-975071 1.00 PROTECTOR STRAP
20 L-873670 2.00 BACK-UP RING 41 L-813300 4.00 HEX SET
21 L-870480 1.00 O-RING 42 L-971688 1.00 GARTER SPRING

PAGE 2 OF 2
D 4770 G. REID 13/08/01

4.3 OPERATION
Prior to use, union seal areas, together with union and collar threads, should be
inspected to ensure that they are clean and corrosion free. A small amount of
At assembly, the unions should be made up hand tight and a hydraulic line for
collet operation should be connected to the quick-connect on the Tool Catcher
body.
4.4 SERVICE
Leakage at the various connections will be caused by damage to the O-rings

and/or seal surfaces and will require replacement of the faulty parts.
Failure to catch a fishing neck may occur for a number of reasons:
1. Hydraulic pressure applied to quick-connect, causing collets to retract.

Release hydraulic pressure. (Elmar type)
2. Piston and/or collet springs broken. Replace faulty parts.
3. Damage to piston and/or collets. Replace faulty parts.
4. Incorrect collet and/or collet mandrel assembly for size of fishing neck.
Replace with correct size.
Failure to release a fishing neck may also occur for a number of reasons:
1. Insufficient hydraulic pressure applied to release collets. Increase pressure

in stages up to 3,000 psi.
2. Loss of hydraulic pressure due to damaged piston/body O-rings and/or seal

surfaces. Replace faulty parts.
3. Damage to piston and/or collet assembly. Replace faulty parts.

4.5 TESTING
1. Locate a fishing neck assembly into the Tool Catcher and ensure the fishing
neck has been secured by the collets.
2. Pump the collet assembly fully open using hydraulic pressure and ensure
that the fishing neck cannot "hang up" on the retracted collets.
3. Release the hydraulic pressure and ensure that the time taken for the collet
assembly to return does not exceed 30 seconds.
4. Locate the fishing neck assembly, complete with a one-ton weight, into the
Tool Catcher and suspend from the Tool Catcher. Ensure that the fishing
neck cannot wriggle out. Using hydraulic pressure, pump open the collets
and release the load.
5. Locate fishing neck assembly into the Tool Catcher and blank off each end
of the Tool Catcher with the appropriate Test Cap and Test Plug.
6. Pressurise the assembly to Working Pressure for 5 minutes. Using

hydraulic pressure, pump open the collet assembly and listen carefully for
the fishing neck assembly being released. Then function test 3 or 4 times
under pressure.
7. Continue to body test to Test Pressure and hold for 15 minutes minimum.
No pressure drop or leakage acceptable.

5.0 BALL CHECK VALVE
The Ball Check Valve (BCV) is an absolutely essential piece of equipment in

terms of overall safety. The pressure control equipment will, however, function
under normal circumstances without the check valve (See page 68).
The ball valve is situated directly under the Grease Injection Head (GIH). Its
function is to automatically shut off the well if the cable should be pulled off the
tool and the cable blown out of the hole. It must be in perfect condition to be able
to serve that purpose. You may remember that the GIH will only seal against
pressure if the space between the cable and the flowtubes is small. Should the
cable be blown out of the hole, the grease will no longer seal and the well fluids
would be free to blow out of the top of the GIH.
The BCV housing is designed so that the ball is kept away from the cable in
normal operations but is unseated and forced up by the velocity of escaping fluid.
The greater the well pressure, the tighter the seal will be.
To reduce the overall length of the equipment, the Ball Check Valve can be
integrated with the hydraulic tool catcher or the bottom sub of the grease injection
head .
5.1 OPERATION
Prior to use, seal areas, threads and O-Rings should be inspected to ensure that
they are clean, corrosion-free and in good condition. A small amount of grease
on the seal areas will assist assembly. At assembly, ensure connections are
made up tight.
The ball check valve is automatic in operation. It is only necessary to ensure that
the ball is free to move and that the ball, its seat and the O-Ring are in good
condition.

5.2 TESTING
In order to test the assembly, an appropriate test cap should be fitted to the union
end and an appropriate adapter to the other end. This adapter should be fitted
with a ball or needle valve of sufficient pressure rating, and connected to a dump
line. With the valve closed, apply 1,000 psi Test Pressure. On opening the valve
the ball check valve should close. This can be detected by an initial release of
pressure through the dump line, followed by sealing of the ball check valve, with
no further release of pressure.
On completion of function testing, the assembly should be pressure tested to

Test Pressure for 5 minutes, then bled to zero. No leakage acceptable.
5.3 SERVICE
Servicing is limited to inspection of O-Rings, seal surfaces, ball and ball seat to
ensure that they are clean, corrosion-free, and in good condition, as previously
stated. Replace any ball showing any degree of damage even small scratches.

ED 4 (A)
TITLE: BCV ASSY BWN E09 PIN 10K H2S

2 L-972186 1.00 BCV BODY 9 L-870470 1.00 O-RING
4 L-870250 1.00 O-RING 11 L-875470 1.00 BALL
5 L-974332 1.00 BALL CV HOUSING 12 L-870110 1.00 O-RING
6 L-875450 1.00 CIRCLIP 13 L-870160 1.00 O-RING
7 L-971235 1.00 STD COLLAR
PAGE 1 OF 1
A - G. REID 02/02/01

6.0 GREASE SEAL FLOWTUBE SYSTEM
This section of the Pressure Control Equipment permits the control of well
pressure while allowing free movement of the wireline. The pressure seal is
maintained by a thick, viscous grease, which is pumped into a small annular
space between the wireline and the flowtubes. (Figure 7-32) is a simplified
drawing of a wireline passing through a grease seal system. The annular space
between the wireline and inner wall of the tube is very small, i.e. of the order of
0.002" – 0.008” difference in the diameter. An external pump supplies
pressurised grease to the port at the centre of the flowtube system. If there were
zero well pressure the grease would flow down and out the end of the lower tube,
but the well pressure keeps the grease in the tube, and it flows upward to exit
through the port at the upper end of the tube. In practice, small amounts of
grease are lost at both ends, particularly when the wireline is moving, but both
well pressure and well fluids are contained.
The flowtubes are able to seal against well pressure because of the resistance
against flow of a viscous fluid passing through a restriction. However, the laws of
fluid mechanics governing the behaviour of such greases are outside the scope
of this course. Suffice to say that grease in the flowtube is able to withstand a
pressure gradient P/L which is in excess of that which can be developed by the
well fluids assuming the difference between the wireline OD and the flowtube ID
is small (Figure 7-32).
The ability to seal increases with decreasing clearance between the wireline and
the tube ID, but a certain amount of clearance is needed to accommodate OD
variations of the wireline and to control friction and wear. The amount of well
pressure that can be controlled by a flowtube assembly increases with increasing
length of the flowtubes.
7.0 GREASE INJECTION HEAD (SOLID AND CONCENTRIC TYPE FLOWTUBES)
The Grease Injection Head (GIH) consists of a set of grease and flowtubes and a
stuffing box. Two types of grease injection head are commonly used. Both types
do the same job and work in the same way but are of a different construction.
The solid type flow-tubes are longer (24") than the concentric and come in one
piece with two small tungsten carbide inserts at either end (see page 73). This
style is commonly known as the SWS flowtube. The concentric type has an outer
flowtube sleeve and an inner tube known as the flowtube that is slightly longer
(14") and fits in to the GIH couplings (See page 82). The flowtube sleeve ensures
the mechanical strength of the assembly, while the flowtube contains the grease

around the wireline. This design is easier to manufacture and less expensive to
maintain than the solid one.
7.1 GREASE SEAL FLOWTUBES
The tubes must be matched to the size of the wireline in use, taking into account
any wear on the wireline. Thus for each nominal wireline size there is a choice of
tubes (Table 7-7.1, page 79). The supervisor must decide what size tubes are
most appropriate for the cable. For example, a brand new 7/32 cable will
probably require flowtubes that have an ID of .226". After the first five to ten jobs
the cable will stretch and become slightly worn. The cable will then possibly pass
through the .222" tubes. As the cable approaches the end of its life, the outer
armour may become very worn and flattened and the .219" tubes may be used.
The Flowtube ID should be selected to have 0.002" to 0.008" clearance to

wireline OD. Wirelines should be completely run through a flowtube of same or
smaller ID before its first wellsite operation.
Notice that wireline run in mud, and not properly conditioned beforehand, can
swell instead of wearing out, because of rust and mud solids build-up between
the armour layers. If a cable has been run in mud without grease injection, it is
important to check the OD over the whole length exposed to mud.
It is very important to use the correct number of flowtubes as well as the correct
size. A single flowtube of the correct ID size can hold approximately:
• For the solid type: 2,500 psi in Liquid, 2,000 psi in gas
• For the concentric type: 2,000 psi in Liquid, 1,500 psi in gas
Below is the recommended number of total flow tubes suggested--including the

tube below the grease injection collar. Remember it is safer to have too many
than too few. In gas more flowtubes must be used, as it is easier for gas to break
through the grease, and push it out as the gas expands. If the flowtube length is
not adequate, grease consumption increases and it is difficult or impossible to
establish a seal.
Number of Concentric Number of Solid Flow

Well Pressure Type
Flow Tubes Tubes
0-5,000 psi Liquid 4 3
0-5,000 psi Gas 5 4
5-10,000 psi Liquid 6 5
5-10,000 psi Gas 6+ 5+

For high pressure gas work it might be necessary to use more than one grease
injection point to increase the length of the barrier, maintain the seal and
lubricate the wireline.
WARNING
If the wireline is not cut regularly from the down-hole, the cable becomes
tapered with the outer armour strands flattened – this requires smaller ID
flow-tubes. However, if a slightly deeper well than normal is being logged,
or say 1000 ft of cable has been cut for some reason, new cable will be fed
off the drum into the hole as the tool nears the bottom of the well. The
chances are that the tension is insufficient to reduce the diameter to allow
the cable to pass through the tight grease tubes - result the cable will not
pass through the flow-tubes and the job cannot proceed. This can be a
source of severe embarrassment to an experienced crew. Remember: The
cable diameter should be consistent all along its length.

Principle of maintaining a grease seal with a cable

passing through a flowtube
Figure 7-32
Wire Line
Stuffing Box
Grease Return
Flowtube
Coupling
Insert
Grease Injection Through

a Check Valve
Pressure gradient in a flowtube system

Figure 7-32
INJECTION GRE
1.2 P ASE
PRESSURE FLO
W
WELL
P
PRESSURE
PRESSURE IN TUBE
OW
FL
SE
EA
GR
GREASE IN
ATMOSPHERIC
0
PRESSURE
0 TUBE LENGTH 2L 3L
GREASE IN THROUGH A CHECK VALVE

(AT INJECTION PRESSURE 1.2 P)
GREASE OUT
(AT ATMOSPHERIC PRESSURE)
FLOWTUBE FLOWTUBE
TO WELL
STUFFING BOX (AT WELL PRESSURE P)

ED 4 (A)
TITLE: GIE ASSY 3SWS 0.237" 10K H2S

PAGE 1 OF 2
A - G. REID 25/05/00

ED 4 (A)
TITLE: GIE ASSY 3SWS 0.237" 10K H2S
1 L-971790 1.00 PACKING NUT 13 L-873540 1.00 BACK-UP RING

2 L-971820 1.00 PISTON 14 L-870240 1.00 O-RING
3 L-870390 1.00 O-RING 15 L-212000 1.00 ELBOW
4 L-873610 1.00 BACK-UP RING 16 L-585200 1.00 QC-NIPPLE
5 L-740510 3.00 ELBOW 17 L-971480 1.00 SPRING
6 L-202600 6.00 M-HEX NIPPLE 18 L-972150 1.00 GLAND
7 L-580900 3.00 QC-HUBER 19 L-972200 1.00 LINE RUBBER
8 L-241100 3.00 HEX PLUG 20 L-972250 1.00 BRASS SEAT
9 L-975058 3.00 FLO TUBE 21 L-975060 1.00 INSERT BODY
10 L-870250 12.00 O-RING 22 L-870170 1.00 O-RING
11 L-974399 1.00 COUPLING 23 L-971800 1.00 LINE WIPER
12 L-520100 1.00 RELIEF VALVE 24 L-973860 1.00 COUPLING

PAGE 2 OF 2
A - G. REID 25/05/00

ED 4 (A)
ELMAR SERVICES LTD No: TI-691400-B
TITLE: CHECK VALVE MANIFOLD ASSY 10K WP
1 L-740510 1 ELBOW
2 L-202600 3 M-HEX NIPPLE
4 L-580900 1 QC-HUBER

PAGE 1 OF 1
B 2065 M. CLARK 25/11/94

7.2 INSERTS FOR SOLID STYLE FLOWTUBES
The flowtubes are machined to a very close tolerance. The armoured cable
passing through the tubes obviously has a tendency to wear and enlarge the
tubes. To avoid this happening, tungsten carbide inserts are placed at each end
of the solid style tube. These are also matched to the wireline size (Figure 7-33).
Solid style (SWS) Flowtube Detail
Figure 7-33
O-Rings Flowtube
Insert Retaining Screws
Flowtube insert
(Note Position of Chamfers)
The function of the inserts is to centralise the cable in the tubes to avoid the
tubes being exposed to excessive wear. Nevertheless a certain amount of wear
will always take place. Wear tends to be larger in the central portion of the
flowtubes. It is no good putting the correct sized inserts into an oversized or
enlarged flowtube and expecting the flowtube to maintain an efficient grease
seal. The seal is made along the length of the flowtube not at the insert. Once
tubes are excessively worn they should be junked. However, frequent checks on
the condition of the inserts and regular replacement will prevent the tubes from
being worn and prolong their useful life considerably.
NOTE: The inserts are placed in the flowtube with the bevelled edge facing
outward. This is to facilitate inserting the wireline end through the GIH. Inserts
are held in place by two screws.
7.3 WIRELINE OD MEASUREMENT
Remember to measure your wireline with a micrometer at the cable head end,
half way in the hole and at TD. Record these measurements in the cable record
book. This will greatly help in the correct selection of flowtubes. The wireline OD
should be measured from two directions in case it is oval.

7.4 GREASE INJECTION HEAD WITH CONCENTRIC FLOWTUBES
The concentric GIH is made up of flowtubes and flowtube sleeves (See pages
82-83) The flowtube is slightly longer than the sleeve and is sealed with an O-
Ring at both ends of the GIH couplings. The flowtube sleeve fits over the
flowtube and also seals by an O-Ring seal at the couplings. The concentric style
flow tubes work in exactly the same way as the solid type flowtubes discussed
earlier in this section. With this design it is possible to change the inner flowtube
more often, thus maintaining optimum clearance. Tables 7-8.1 and 7-8.2 give
dimensional data and wear tolerances for concentric flowtubes. (See pages 86-
87)
7.5 CHECK VALVE
In case of loss of grease seal, the well fluid could invade the flowtubes and,
through the grease injection line, reach the grease pump. This is a potentially
catastrophic situation. To avoid it, a check valve must be installed at the end of
the grease hose. Solid (SWS) flowtubes Grease Injection Heads use an external
check valve manifold. (See page 75) Ensure that it is correctly mounted, with the
arrow pointing away from the hose.
For concentric GIHs the check valve is an integral part of the Grease Injection
Coupling Assembly. The check valve is of the replaceable type. An 1/8” NPT
internal thread in its body allows the use of a simple extraction tool. (See page
78)

A B C D E F G H
DRAWING No
971466-A1-1
MINOR REVISION CHANGES
Rev DESCRIPTION OF CHANGE
REPLACED OLD BALL CHECK
A1 VALVE WITH POPPET STYLE
1 1
10 11
3 5
2 2
4 6 7 8 9
1 2
TEST PROCEDURE
3 1. ENSURE CHECK VALVE (15) IS REMOVED. 3
2. LOCATE TEST PLUGS (L-979688) ON THE ENDS.

3. ENSURE ALL EXTERNAL SURFACES ARE DRY.
4. PRESSURE TEST TO 15 000 PSI FOR 3 MINUTES.
5. REDUCE PRESSURE TO ZERO AND REPEAT TEST FOR
15 MINUTES MINIMUM.
4 4
FUNCTION TEST PROCEDURE
1. ENSURE CHECK VALVE (15) IS IN THE CORRECT

POSITION AND REMOVE HEX PLUG (11).
2. LOCATE TEST PLUGS (L-979688) ON THE ENDS.
5 3. BLEED OFF ALL AIR FROM WITHIN THE ASSEMBLY. 5
4. ENSURE ALL EXTERNAL SURFACES ARE DRY.
5. PRESSURE TEST TO 10 000 PSI FOR 3 MINUTES.
STAMP (WITH LOW STRESS STAMPS): 1/8" NPT THREAD 15 13 12 6. REDUCE PRESSURE TO ZERO AND REPEAT TEST FOR
ASSY NUMBER 15 MINUTES MINIMUM.
SERIAL NUMBER 14
W.O. NUMBER NO LEAKAGE ACCEPTABLE
10K WP
6 15K TP 6
H2S/STD SERVICE
1 L-974365 MODIFIED COUPLING F/MAN BLOCK 10K H2S EACH 1.00 -
2 L-870160 O-RING 210 90 D NITRILE EACH 2.00 -
3 L-974367 MANIFOLD BLOCK FOR STD GREASE CPLG 10K EACH 1.00 -
4 L-801210 SHCS 5/16"UNC x 2 1/4" - S EACH 4.00 -
6 L-872900 BACK UP RING 116 90 D NITRILE EACH 1.00 -
8 L-974368 CHECK VALVE HOUSING 10K H2S MANIFOLD > EACH 1.00 -
9 L-202600 M-HEX NIPPLE 1/2"-10K-SS x 1.75" LONG EACH 1.00 -
TECHNICAL DETAILS 10 L-580900 QC-HUBER ASSEMBLY 1/2N(F) 10K STEEL EACH 1.00 -
11 L-241100 HEX PLUG 1/2"HP-SS EACH 1.00 -
7 GREASE INJECTION 7
DESCRIPTION 13 L-871290 O-RING 117 90 D NITRILE EACH 1.00 -
COUPLING ASSEMBLY
14 L-872910 BACK UP RING 117 90 D NITRILE EACH 1.00 -
UPPER CONNECTION 2"-10 ACME BOX A1 4500 G. REID 20/10/00 W. THOMSON C. WOOD
15 L-972764 CHECK VALVE CIRCLE SEAL CV23-58 EACH 1.00 -
A G. REID 05/10/99 C. WOOD C. WOOD
ITEM No/
LOWER CONNECTION 2"-10 ACME BOX REV ECO DRAWN DATE CHECKED BY APPROVED BY No
PART No DESCRIPTION SIZE UNITS ASSY COMMENTS
MANIFOLD PORT 1/2" NPT ISSUED FOR ISSUED TO. PRINT STATUS
MAX WORKING PRESSURE 10 000 PSI PRINT DATE 20/5/02 APPROVED FOR PRODUCTION
ELMAR SERVICES LIMITED
MAX TEST PRESSURE 15 000 PSI NOTES:- (UNLESS OTHERWISE STATED)
THIS DRAWING IS THE PROPERTY OF Westhill Industrial Estate,Westhill,Aberdeen AB32 6TQ
ALL DIMENSIONS IN INCHES
SERVICE H2S/STD ELMAR SERVICES LIMITED FRACTIONAL DIMENSIONS TO } 1/64" Telephone:(01224) 740261 Telex:739568 Fax:(01224) 743138
IT IS ONLY VALID FOR THE ORDER THAT
8 APPROX WEIGHT 4.5 kg IT IS ISSUED FOR AS SHOWN ABOVE.
DECIMAL DIMENSIONS .XX TO } 0.015" 8
IT MUST NOT BE ALTERED,COPIED OR .XXX TO } 0.005" TITLE
SEAL KIT L-971466K SHOWN TO ANY THIRD PARTY WITHOUT ANGULARITY TO } 0.5ß
WRITTEN PERMISSION AND IS SUBMITTED REMOVE ALL SHARP: EDGES 1/32"x45ß CHAMFER GIE INJ COUPLING ASSY BWN 10K H2S
WITHOUT PREJUDICE TO ANY PATENTS
FILLETS 1/32" RAD
OR DESIGNS PENDING OR TO BE APPLIED SCALE USED ON DRAWING No
SURFACE ROUGHNESS TO BE 125 ~ain MAX. 1st ANGLE SHEET 1
FOR BY THE COMPANY.
ALL DIAMETERS TO BE WITHIN 0.010" T.I.R. PROJECTION 1:1 L-971218 OF 1 971466-A1-1
A2
A B C D E F G H

TABLE 7-7.1: Options for solid type flowtubes
INSERT *
CABLE SIZE HOLE SIZE ASSY NUMBER
PART NUMBER
0.177" L-977979 L-977930
1-18 0.181" L-977980 L-977931
3/16" 0.184" L-977981 L-977932
0.188" L-974492 L-974490
0.204" L-977982 L-976651

1-20 0.207" L-977983 L-977933
0.211" L-977984 L-977934
0.214" L-977985 L-977935
0.211" L-977984 L-977934

0.214" L-977985 L-977935
1-22 0.219" L-974376 L-977936
7/32" 0.222" L-972350 L-972360
0.224" L-977986 L-977929
0.226" L-972700 L-972710
0.230" L-977987 L-977937

2-23 0.233" L-974506 L-977938
15/64" 0.237" L-975058 L-975059
0.240" L-976662 L-976663
1-25 0.262" L-977988 L-977939

9/32"
1-32 0.319" L-976264 L-975835

5/16" 0.326" L-976263 L-977940
0.332" L-975143 L-977941
1-33 0.332" L-975143 L-977941

0.339" L-977990 L-977942
7-38 0.377" L-977991 L-977943

3/8" 0.386" L-977992 L-977944
0.386" L-977992 L-977944

7-39 0.393" L-977993 L-977945
7/16" 0.399" L-977994 L-977946
0.405" L-977995 L-977947
0.411" L-977996 L-977948
0.462" L-977997 L-977949

7-46 0.468" L-977998 L-977950
15/32" 0.474" L-977999 L-977951
0.480" L-976293 L-976297
*2 each required

8.0 OPERATION (This applies to both types of GIH)
Prior to use, seal areas, threads and O-ring seals should be inspected to ensure
that they are clean, corrosion-free and in good condition. A small amount of
The Grease Injection Head should be rigged up with the Grease supply line
connected to the lower Huber connection, the Grease Return line connected to
the upper Huber connection and hydraulic line for Stuffing Box operation
connected to the quick-connect on the Grease Injection Head Packing Nut.
In use, a sufficient flow of grease should be maintained through the flowtubes, by

means of the Grease supply and Return lines. In order to operate the Stuffing
Box, hydraulic pressure should be applied to the Stuffing Box line, which will
cause the line rubber to be compressed around the wire.
8.1 TESTING
In order to test the Grease Injection Head, a test rod of appropriate size should
be inserted into the packing area of the assembly. It is important that the test rod
used has a larger diameter at one end and that this end fits below the stuffing
box bushing, in order that the test rod cannot be forced through the stuffing box
packing.
The Grease Return line connection should be plugged and the Flotubes, sleeves
and connection blocks made up. An appropriate adapter should be fitted to the
bottom of the assembly.
With hydraulic pressure applied to the Stuffing Box connection, apply Test
Pressure to the assembly for 5 minutes. Bleed to zero. No leakage acceptable.
8.2 SERVICE
Inserts in solid flowtubes must be checked monthly for wear and replaced when
any sign of wear becomes apparent. Make sure to replace with the correct size
insert for the flowtube used.

Flowtubes must be checked quarterly for internal wear. This is difficult to

accomplish and can be attempted with calibrated short cylindrical gauges at the
end of a 25" rod.
As a narrow gap between the flowtube ID and the wireline OD is essential for
proper operations, the flowtube must be replaced if internal wear is detected.
With the concentric design it is cheaper to replace the whole flowtube.

ED 4 (A)
ELMAR SERVICES LTD No: TI-978385-G1
TITLE: GIE ASSY 4BWN SB 10K H2S

PAGE 1 OF 2
G1 4500 G. REID 23/10/00

ED 4 (A)
ELMAR SERVICES LTD No: TI-978385-G1
TITLE: GIE ASSY 4BWN SB 10K H2S
1 L-971278 1.00 SB ASSY

2 L-971274 1.00 GIE ASSY

PAGE 2 OF 2
G1 4500 G. REID 23/10/00

DRAWING No
WHECHART-1-1
LINE SIZE KITS

1.1
(CONSISTS OF SEAT, GLAND AND RUBBER)
MAX WIRE WIRE SIZES LINE
PART NUMBER
SIZE ALLOWED COVERED RUBBER
L-971278BL 0.210" 1-18 0.188" 3/16" L-870232
L-971278CL 0.245" 1-20/1-22/2-23 0.219" 7/32" L-972200
L-971278DL 0.275" 0.250" 1/4" L-972200
L-971278EL 0.305" 0.281" 9/32" L-978180
L-971278FL 0.340" 1-32 0.312" 5/16" L-972210

L-971278GL 0.400" 7-39 0.375" 3/8" L-972220
L-971278HL 0.465" 7-42 0.438" 7/16" L-972230

L-971278JL 0.495" 7-46 0.469" 15/32" L-976295
GIE ASSEMBLY (10K H2S)

1
3 TUBE 4 TUBE 5 TUBE 6 TUBE
PART No. L-979470 L-978385 L-970635 L-971229
SEAL KIT L-979470K L-978385K L-970635K L-971229K
HOW TO SPECIFY A COMPLETE GREASE INJECTION HEAD

(AS SEPERATE LINE ITEMS ON THE ORDER)
1 CHOOSE BASIC GREASE INJECTION HEAD ASSEMBLY.
1.1 CHOOSE RELEVANT STUFFING BOX LINE SIZE KIT.
CHOOSE RELEVANT FLOTUBE SIZE AND QUANTITY

1.2
(SEE CHART: F:/FORUM/ENGINEER/EXCEL/FLOTUBE.XLS).
OPTIONAL GREASE INJECTION COUPLING FOR A DUAL

1.3
INJECTION SYSTEM.
ADDITIONAL GREASE INJECTION COUPLING

ASSEMBLY WITH FLOW TUBE SLEEVE
PART No. L-971218
1.3
SEAL KIT L-971218K
A - G. REID 21/09/00 C. WOOD C. WOOD

THIS DRAWING IS THE PROPERTY OF
REV ECO DRAWN DATE CHECKED BY APPROVED BY

IT IS ISSUED FOR AS SHOWN ABOVE.
IT MUST NOT BE ALTERED,COPIED OR
SHOWN TO ANY THIRD PARTY WITHOUT
WRITTEN PERMISSION AND IS SUBMITTED
Westhill Industrial Estate,Westhill,Aberdeen AB32 6TQ
WITHOUT PREJUDICE TO ANY PATENTS Telephone:(01224) 740261 Telex:739568 Fax:(01224) 743138
OR DESIGNS PENDING OR TO BE APPLIED
FOR BY THE COMPANY.
TITLE
CONVENTIONAL SB GREASEHEAD

DRAWING No
WHECHART-1-2
LINE SIZE KITS (CONSISTS OF UPPER BUSH, UPPER GLAND,

1.1 PACKING, SPACER GLAND, RUBBER AND LOWER BUSH)
MAX WIRE WIRE SIZES PACKING LINE WIPER

PART NUMBER
SIZE ALLOWED COVERED RUBBER RUBBER
L-972039BL 0.210" 1-18 0.188" 3/16" L-870232 L-831140
L-972039CL 0.245" 1-20/1-22/2-23 0.219" 7/32" L-972200 L-831150
L-972039DL 0.275" 0.250" 1/4" L-972200 L-831150
L-972039EL 0.305" 0.281" 9/32" L-978180 L-831006

L-972039FL 0.340" 1-32 0.312" 5/16" L-972210 L-831130
L-972039GL 0.400" 7-39 0.375" 3/8" L-972220 L-831005
L-972039HL 0.465" 7-42 0.438" 7/16" L-972230 L-830056

L-972039JL 0.495" 7-46 0.469" 15/32" L-976295 L-831270
GIE ASSEMBLY (10K H2S)

1
3 TUBE 4 TUBE 5 TUBE 6 TUBE
PART No. L-971443 L-971444 L-971445 L-971446
SEAL KIT L-971443K L-971444K L-971445K L-971446K
HOW TO SPECIFY A COMPLETE GREASE INJECTION HEAD

(AS SEPERATE LINE ITEMS ON THE ORDER)
1 CHOOSE BASIC GREASE INJECTION HEAD ASSEMBLY.
1.1 CHOOSE RELEVANT ENVIRO LINE SIZE KIT.
CHOOSE RELEVANT FLOTUBE SIZE AND QUANTITY

1.2
(SEE CHART: F:/FORUM/ENGINEER/EXCEL/FLOTUBE.XLS).
OPTIONAL GREASE INJECTION COUPLING FOR A DUAL

1.3
INJECTION SYSTEM.
ADDITIONAL GREASE INJECTION COUPLING

ASSEMBLY WITH FLOW TUBE SLEEVE
PART No. L-971218

1.3 SEAL KIT L-971218K
A - G. REID 21/09/00 C. WOOD C. WOOD

THIS DRAWING IS THE PROPERTY OF
REV ECO DRAWN DATE CHECKED BY APPROVED BY

IT IS ISSUED FOR AS SHOWN ABOVE.
IT MUST NOT BE ALTERED,COPIED OR
SHOWN TO ANY THIRD PARTY WITHOUT
WRITTEN PERMISSION AND IS SUBMITTED
Westhill Industrial Estate,Westhill,Aberdeen AB32 6TQ
WITHOUT PREJUDICE TO ANY PATENTS Telephone:(01224) 740261 Telex:739568 Fax:(01224) 743138
OR DESIGNS PENDING OR TO BE APPLIED
FOR BY THE COMPANY.
TITLE
NEW ENVIRO GREASEHEAD

Grease Injection Control Head Flowtube Selection

and Wear Data for concentric style
TABLE 7-8.1
MAXIMUM TUBE ID
USE FOR RANGE OF
NOMINAL LINE SIZE - INCLUDING WEAR - DO NOT
ACTUAL (AVERAGE) LINE
INCHES USE WHEN GREATER -
SIZE - INCHES
INCHES
1/8 .124 - .125 .134
.127 - .129 .137
.174 - .176 .184
.177 - .180 .187
3/16 .181 - .183 .191
.184 - .186 .194
.188 - .190 .198
.192 - .193 .202
.194 - 1.96 .204
.195 - 1.98 .205
.199 - .201 .209
.201 - .205 .211
7/32 .206 - .208 .216
.211 - .213 .221
.214 - .216 .224
.216 - .219 .226
.219 - .221 .229
.222 - .225 .232
.224 - .228 .234
.227 - .229 .237
1/4 .231 - .233 .241
.242 - .245 .252
.251 - .253 .256
.262 - .264 .274
9/32 .290 - .292 .302
.300 - .303 .312
.307 - 3.09 .319
.310 - .312 .322
.311 - .313 .323
5/16 .315 - .318 .327
.321 - .323 .333
.327 - .329 .339
.332 - .334 .344
.360 - .363 .372
3/8 .368 - .370 .380
.379 - .381 .391
.394 - .396 .406
.398 - .401 .410
7/16 .406 - .408 .418
.410 - .413 .422
.417 - .420 .429
.425 - .430 .437
15/32 .462 - .464 .477
17/32 .524 - .526 .539

CONCENTRIC STYLE FLOTUBES

TABLE 7-8.2: FLOWTUBE SELECTION AND PART NUMBERS
NOMINAL LINE SIZE

ACTUAL LINE SIZE ACTUAL TUBE BORE ELMAR PART NUMBER
INCHES
1/8" .124-.125 .128
.127-.129 .130
.174-.176 .177
.177-.180 .183 L-976184
3/16" .181-.183 .186 L-974570
.184-.186 .189 L-972380
.188-.190 .193 L-974571
.192-.193 .196 L-976696
.194-.196 .199 L-976650
.195-.198 .201 L-977163
.199-.201 .204 L-977167
.201-.205 .208
7/32" .206-.208 .211
.211-.213 .216 L-975439
.214-.216 .219 L-975440
.216-.219 .222 L-974572
.219-.221 .224 L-974538
.221-.223 .226 L-971129
.222-.225 .228 L-972370
.224-.228 .231 L-972680
.227-.229 .232 L-978002
.231-.233 .236 L-977887
1/4" .234-.236 .239 L-977899
.235-.237 .240 L-971130
.237-.240 .243 L-977315
.242-.245 .248 L-974573
.249-.251 .254 L-972868
.251-.253 .256 L-974507
.253-.255 .258 L-972869
.255-.257 .260 L-972871
.256-.258 .261 L-973449
.257-.259 .262 L-973571
.259-.261 .264 L-973572
.262-.264 .267
.282-.284 .287 L-978175
9/32" .290-.292 .295 L-971312
.293-.295 .298 L-971436
.300-.303 .306 L-979643
.307-.309 .312 L-976938
.310-.312 .315 L-976538
.311-.313 .316 L-976539
5/16" .315-.318 .321 L-976258
.321-.323 .326 L-976605
.324-.326 .329 L-973937
.327-.329 .332 L-976606
.330-.332 .335 L-973234
.332-.334 .337 L-976607
.336-.338 .341 L-980217
.360-.363 .366
3/8" .368-.370 .373
.371-.373 .376 L-970429
.379-.381 .384 L-978176
.394-.396 .399 L-970946
.398-.401 .404
7/16" .406-.408 .411
.410-.413 .416
.417-.420 .423 L-970571
.419-.422 .425 L-970572
.421-.424 .427 L-970573
.425-.430 .433 L-970106
.430-.433 .436 L-971639
15/32" .462-.464 .467 L-972906
.467-.469 .472 L-979388
.472-.474 .477 L-979088
17/32" .524-.526 .529

9.0 PACKOFF (STUFFING BOX)
The second part of the GIH grease seal equipment is the Packoff (also called the
Stuffing Box), which is located immediately above the grease tubes. It is used to
seal around the wireline in an emergency or when the wireline will be stationary
for an extended period of time. The device remains open during normal
operation.
CAUTION: This packoff is not designed to be used as a line wiper. The wireline
is not free to move when the packoff is closed. It is possible for the rubbers to
grip the wireline tightly enough so that the cable will break if sufficient pull is
applied. Alternatively, the outer armours of electrical lines can be squeezed and
deformed, the cable could bird-cage and eventually armour strands will wear out
and break or wedge into the flowtubes.
The GIH packoff (See page 93) consists of a rubber element that fits around the
wireline and is mounted under a spring-loaded piston. The open position is
shown in (Figure 7-34). The rubber packoff fits loosely around the wireline and
presents little resistance to its movements. To close the packoff (Figure 7-34)
hydraulic fluid is pumped into a chamber above the piston. The piston is pushed
down against the force of the spring and squeezes the rubber element. When
hydraulic pressure is released the spring pushes up the piston and the rubber
expands to release the cable.
Stuffing boxes are available in 5K, 10K and 15K psi service ratings with a
maximum 6,250 psi hydraulic pressure rating. 15K psi equipment usually has
dual stuffing boxes. Test Pressure for the packoff depends on the WP rating,
either 1.5 times WP for 10K and 15K or 2 times for 5K psi. Test Pressure can
only be applied when you use a dummy insert, part number L-972410, otherwise
test to working pressure.
9.1 SERVICE
Leakage through the Packoff will occur if insufficient hydraulic pressure is applied
to sufficiently compress the Line Rubber and cause it to seal around the wire, or
if the Line Rubber is excessively worn after a period of use. If increasing the
applied hydraulic pressure does not affect a seal, the Grease Injection Head
should be dismantled and the Line Rubber replaced.
Leakage at the various connections will be caused by damage to the O-rings
and/or seal surfaces and will require replacement of the faulty parts.

Hydraulic Port
GIH Packoff in the open position.

Wireline free to move
Figure 7-34
Hydraulic Fluid In
GIH Packoff in the closed position.

Rubber element grips the wireline
Figure 7-34

10.0 LINE WIPER
The liner wiper is mounted above the packoff and is not designed to hold
pressure. Its function is to remove excess grease from the surface of the wireline.
The most common line wiper in use is the Regal/Bell Rubber Company Model
HR Stripmaster Oil Saver. Older models in the field are only rated to 3,000 psi
WP. However, more recent models are rated to 5,000 psi WP. In either case the
line wiper should not be used as a pressure retaining element. When the line
wiper is used with the adapter kit for the GIH it is limited to a wiping action only
since a 100 or 200 psi relief valve is placed between it and the GIH packoff. The
Regal/Bell line wiper is not certified for H2S work. It can be used with H2S
service equipment only in the configuration with the relief valve, which limits the
maximum allowable pressure.
The action of the Regal/Bell line wiper (See page 92) is very similar to that of the
packoff except that the rubber element of the line wiper has several
interconnecting fingers. As the grease is wiped off the wireline, it is removed
through the fingers and is allowed to drip down inside the device. A special hose,
located in the top of the packoff housing, is used to return the grease to the
control module and closed drain system.
The poppet valve, or relief valve, (see item 23 on page 93) opens at only 100 psi.
It ensures that the Regal/Bell Oil Saver is limited to a wiping action only and is
not used as a stuffing box. If the line or the one-way valve becomes blocked,
with old grease for instance, grease will be seen flowing from the relief valve. In
any case, it is impossible for the Bell Line Wiper to be used as a pressure
retaining element instead of the stuffing box even if the relief valve L-520100 is
replaced by a blind plug. This is because well fluids under pressure would leak
through the hole in the packing nut (see page 93) since there is no seal between
the line wiper piston and the brass gland. (The packoff is designed to hold
pressure from below not from above). In fact this may happen even if the
equipment is in perfect order, especially with very thick greases. The
backpressure on the drain line may become too high and the grease will
preferentially flow through the air hole.
On older assemblies the excess grease is returned to the grease return line of
the packoff through a short hose and a check valve. With thick grease or cold
weather, the pressure needed to open the check valve might be too high and the
grease will flow preferentially through the air hole. For this reason, Elmar
recommends using, for this design of the Packoff/Line Wiper combination, a
separate, large ID, low-pressure drain hose all the way to the control module.

10.1 MAINTENANCE
Dismantle and clean all parts. Check condition of piston and piston gland.
Replace if excessively worn or damaged. Replace packing if worn and check
packing screw for wear on threads.

ED 4 (A)
ELMAR SERVICES LTD No: TI-831200-I
TITLE: BELL HR5000 7/32" W/GUIDE NO PKG SCREW >
G
N
H
M I
L J

PAGE 1 OF 1
I 4237 A. SMITH 09/12/99

ENVIRO™ WIRELINE GREASE INJECTION CONTROL HEAD

11.0 ENVIRO™ WIRELINE GREASE INJECTION CONTROL HEAD
The Elmar Enviro™ Grease Injection Control Head is an evolution of the

conventional control head previously discussed on page 66. It is designed to
serve the same functions, with an improved grease containing action.
Positioned at the uppermost point of the pressure control equipment string, the
Elmar Enviro™ Grease Injection Control Head comprises two major sub-
assemblies, the Enviro™ Combination Stuffing Box and Line Wiper and the
Flowtube Assembly.
The hydraulic stuffing box is designed to pack-off on a stationary wireline by
means of a pack-off rubber; the hydraulic line wiper will wipe excess grease from
a moving wireline.
Two types of Flowtube assemblies are available, the "solid” type and the
“concentric” type, (see fig 7-35). The concentric Flowtube assembly is made up
of an inner Flowtube sized to fit tightly around the wireline and an outer sleeve to
support the assembly.
To prepare for operations, the wireline is threaded through the components of the
Elmar Enviro™ Grease Injection Control Head before the rope socket and
wireline head are made-up. When entering a well under pressure, viscous
grease is injected into the Flowtubes at a pressure greater than the existing well
pressure. The grease fills the annular space between the inner wall of the
Flowtube and the outside surface of the wireline, forming a liquid seal that
contains the well fluids while allowing wireline movement.
The Elmar Enviro™ Grease Injection Control Head is supplied with a pin
threaded connection on bottom and a wire tulip guide on top.
When changing line size, a different line size kit is needed for the Enviro™
Combination Stuffing Box and Line Wiper, identified by the Line Size Code letter.
Flowtubes recommended ID = wireline OD + 0.002" to 0.008".

Figure 7-35: Typical Elmar Enviro™ Grease Injection Control Head

with Concentric Flowtubes
Upper Bush 1
Upper Gland 1
Line Rubber 1
Spacer 1
Packing 1
Lower Gland 1
Flotube
Injection
Check Valve
Additional Flotube
and Injection
Coupling
Assembly
L-971218
1. Parts included in line size kit.

2. Seal Kit (O-Ring and BURs) does not include line size kit.
ORDERING INFORMATION
Part No. of Enviro Grease Injection Control Head (from table below)
Line size (kit) to be specified - L-972039 * L (see table overleaf)
Flotube size to be specified (see table overleaf)
If dual injection is required, order separately (Qty 1) L-971218 in addition
to the standard grease head with 1 x manifold
TEST FIXTURE
L - 972201 Test Plug (Dummy Packer) for Stuffing Box
L - 972241 Test Spacer for Line Wiper
L - 972264 Test Cap 2”-10 TPI Box for flotube/sleeve connection
ACCESSORIES (Other sizes available on request)

L - 971641 Flotube Go-NoGo gauge 0.233” and 0.235”
L - 971642 Flotube Go-NoGo gauge 0.237” and 0.240”

Part No Number of Working Service Bottom Connection Top Connection Seal Kit
2
Flow Tubes Pressure
L - 971443 3 10,000 psi H2S 2” -10 TPI Acme Pin Wire Tulip Guide L - 971443K
L - 971446 6 10,000 psi H 2S 2” -10 TPI Acme Pin Wire Tulip Guide L - 971446K
L - 971218 1 10,000 psi H 2S 2” -10 TPI Acme Pin 2”-10 TPI Acme Box L-971218K
Tube Size
* Line Size Code Line Size Stuffing Box Line Wiper Line Size Flotube
Tolerance:
Packing Rubber
+/- .001
.174 - .176 .177”
.177 - .180 .183” L - 976184
3/16”
B 0.188” L - 870232 L - 831140 .181 - .183 .186” L - 974570
(1-18) .184 - .186 .189” L - 972380
.188 - .190 .193” L- 974571
.192 - .193 .196” L - 976696

.194 - .196 .199” L - 976650
.195 - .198 .201” L - 977163
.199 - .201 .204” L- 977167
.201 - .205 .208”
.206 - .208 .211”
.211 - .213 .216” L - 975439
7/32” .214 - .216 .219” L - 975440
0.219” .216 - .219 .222” L - 974572
C (1-20) L - 972200 L - 831150
.219 - .221 .224” L- 974538
(1-22)
.221 - .223 .226” L - 971129
(2-23)
.222 - .225 .228” L - 972370
.224 - .228 .231” L- 972680
.227 - .229 .232” L - 978002

.231 - .233 .236” L - 977887
.234 - .236 .239” L - 977899
.235 - .237 .240” L- 971130
.237 - .240 .243” L - 977315
.242 - .245 .248” L - 974573
1/4” .251 - .253 .256” L - 974507

D L - 972200 L - 831150
0.250” .262 - .264 .267”
.282 - .284 .287” L - 978175
9/32” .290 - .292 .295” L- 971312

E L - 978180 L - 831006
0.281” .293 - .295 .298” L - 971436
.300 - .303 .306” L - 979643
.307 - .309 .312” L - 976938

.310 - .312 .315” L- 976538
.311 - .313 .316” L - 976539
5/16” .315 - .318 .321” L - 976258
F 0.312” L - 972210 L - 831130
.321 - .323 .326” L - 976605
(1-32)
.327 - .329 .332” L- 976606
.332 - .334 .337” L - 976607
.336 - .338 .341” L - 980217
.360 - .363 .366”

3/8”
G L - 972220 L - 831005 .368 - .370 .373”
0.375”
.379 - .381 .384” L - 978176
.394 - .396 .399” L - 970946

.398 - .401 .404”
.406 - .408 .411”
7/16” .410 - .413 .416”
H 0.438” L - 972230 L - 830056 .417 - .420 .423” L - 970571
(7-42) .419 - .422 .425” L- 970572
.421 - .424 .427” L - 970573
.425 - .430 .433” L - 970106
.430 - .433 .436” L - 971639
15/32” .462 - .464 .467”

J 0.469” L - 976295 L - 831270 .467 - .469 .472” L - 979388
(7-46) .472 - .474 .477” L - 979088
17/32” .524 - .526 .529”

0.531”
(7-52)

ED 4 (A)
ELMAR SERVICES LTD No: TI-971444-A1
TITLE: GIE ASSY 4BWN ENVIRO 10K H2S
1 L-972039 1.00 ENVIRO ASSY

2 L-971274 1.00 GIE ASSY

PAGE 1 OF 2
A1 4500 G. REID 23/10/00

ED 4 (A)
TITLE: GIE ASSY 4BWN ENVIRO 10K H2S

PAGE 2 OF 2
A1 4500 G. REID 23/10/00

11.1 ENVIRO™ COMBINATION STUFFING BOX AND LINE WIPER
The Elmar Enviro™ Combination Stuffing Box and Line Wiper is designed for use
with wireline grease injection control heads, for wiping excess grease from the
moving wire and for packing off on a stationary wire.
The hydraulic stuffing box is designed to pack-off on a stationary wireline by
means of a pack-off rubber; the hydraulic line wiper will wipe excess grease from
a moving wireline.
In the conventional design the line wiper and the pack-off (stuffing box) are in
separate bodies.
In the Enviro™ Combination Stuffing Box and Line Wiper (see fig 7-36 and page
7-100) both the pack-off and the line wiper functions are contained in one single
high-pressure body (rated 10,000 psi; H2S Service), connected on top of the
Grease Injection Head flow-tubes. The line wiper is positioned below the stuffing
box, immediately on top of the flow tubes.
This new design improves the wiping action as the wiped-off grease has
sufficient residual pressure to flow easily through the grease return hose. There
is no need to have separate return hoses for the line wiper and the flow tubes.
Grease spillage is also reduced significantly, as there is no bleed hole or pop-off
valve, as in the old design.
The combination is therefore rated 10,000 psi H2S service. It has only one high
pressure grease return hose.
The Enviro™ Stuffing Box and Line Wiper can be dressed for use with braided
wire from 0.188” to 0.520” diameter and can be supplied for use with concentric
(2”-10TPI) or solid (2”-6-60° SWS) type Flowtubes.

Figure 7-36: Elmar ENVIRO™ Combination Stuffing Box Line Wiper
Wireline
Guide
Upper Bush (3)
Upper Gland (3)
Line Rubber (3)

Overall
Intermediate
Length
Bushing (3)
32.3”
Max O.D. 4”
Wiper Packing
Element (3)
Lower
Bushing (3)
Grease Return
Manifold
Part No. Working Pressure Service Bottom Connection Seal Kit

L - 971279 10,000 psi H 2S 2”-6-60˚ SWS Flotube Box L-971279K
L - 972039 10,000 psi H 2S 2”-10TPI Acme Concentric Flotube Box L-972039K
Note: 1. Wire size to be specified when ordering 2. Seal Kits comprise O-Rings and BURs only 3. Line Size Kit

ED 4 (A)
TITLE: ENVIRO SB/LW ASSY BWN 10K H2S

PAGE 1 OF 2
A1 4817 G. REID 06/09/01

ED 4 (A)
TITLE: ENVIRO SB/LW ASSY BWN 10K H2S
1 L-972081 1.00 TULIP 19 L-200014 1.00 M-HEX NIPPLE

2 L-972043 1.00 SB PISTON 20 L-580900 1.00 QC-HUBER
3 L-972044 1.00 PISTON HOUSING 21 L-241100 1.00 HEX PLUG
4 L-212000 2.00 STREET ELBOW 22 L-972047 1.00 LWR BODY
5 L-611102 1.00 LABEL 23 L-870260 1.00 O-RING
6 L-585200 1.00 QC-NIPPLE 24 L-870160 1.00 O-RING
7 L-971480 1.00 SPRING 25 L-581000 1.00 QC-NIPPLE - FIT TO LW HOSE
8 L-972045 1.00 COUPLING 26 L-870950 1.00 O-RING
9 L-873640 2.00 BACK-UP RING 27 L-870268 1.00 BACK-UP RING
10 L-870440 2.00 O-RING 28 L-585300 1.00 QC-COUPLER
11 L-831040 1.00 SLEEVE 29 L-611103 1.00 LABEL
12 L-972046 1.00 UPR BODY 30 L-873220 1.00 O-RING
13 L-971507 1.00 CAGE 31 L-820005 1.00 GREASE NIPPLE
14 L-971504 1.00 PISTON 32 L-870267 1.00 BACK-UP RING
15 L-871200 1.00 O-RING 33 L-870036 1.00 O-RING
16 L-873840 1.00 BACK-UP RING 34 L-872800 1.00 BACK UP RING
17 L-870420 1.00 O-RING 35 L-870100 1.00 O-RING
18 L-971505 1.00 PISTON WIPER 36 L-611101 1.00 LABEL - ATT. TO MODULE PANEL

PAGE 2 OF 2
A1 4817 G. REID 06/09/01

12.0 QUICK PRESSURE TEST SYSTEM
Best practice for multiple runs wireline operations dictates that the full lubricator
string is pressure tested before the first run in the well.
For subsequent runs, it is required to pressure test only the connection that has
been broken to introduce the wireline tool or perforating gun into the lubricator
string.
Figure 7-37: The Elmar Quick Pressure Test System

using Typical Wireline Pressure Control Equipment String

The Elmar Quick Test System has been designed to save rig time when pressure
testing the Wireline Pressure Control String.
The full system comprises a Quick Test Sub - QTS, and a hydraulically operated
Venting/Glycol Injection Valve. (See fig 7-37)
12-1 QUICK TEST SUB - QTS
The Elmar Quick Test Sub (See fig 7-38) is inserted either above or below the
Wireline Valve at the position of the joint normally opened to insert and retrieve
tools from the well.
HAND PUMP ASSEMBLY

Part Number
L-690573
HYDRAULIC HOSE ASSEMBLY

Hose Assembly
L-690587 25ft 6mm ID, 10,000psi Hose
with Quick Connectors
L-690586 50ft and Dust Covers
Figure 7-38: Typical Elmar Hydraulic Wireline Quick Test Sub

10,000 psi WP (STD or H2S Service)
The Quick Test Sub has Quick Unions top and bottom, and a special quick test
joint in the centre, with a longer pin. The box has two “O-Rings” either side of an
external port. The lower most O-Ring (on the well head side) holds the hydraulic
fluid pressure during the test. The top O-Ring with back-up ring will hold the well
pressure.
The external port is normally closed with a metal-to-metal seal needle valve.

After the initial pressure test to check the integrity of the string, subsequent
pressure tests can be made using the Quick Test Sub to verify the integrity of the
‘O’ rings at the quick test joint, rather than having to test the whole assembly.
This is achieved by connecting a small hydraulic hand-pump to the Quick Test
Sub port and testing the joint ‘O’ ring seal from the outside. Seen the small
annular volume involved this requires only a few strokes of the pump.
12-2 PRESSURE TESTING THE STRING USING THE QUICK TEST SUB
• Install the Quick Test Sub in the position where the string is opened when
inserting wireline tools into the lubricator string. Check that the Test Port
needle valve is closed.
• Insert tool in the lubricator by opening the quick joint on QTS. Proceed to
pressure test the whole lubricator string to Wellsite Test Pressure. If pressure
test is successful proceed with running in.
• For subsequent runs: Bleed off pressure in the lubricator string, break the quick
joint on the QTS, retrieve the wireline tool and insert a new tool.
• Remake the QTS connection and connect the hand pump to the QTS test port.
• Open the QTS needle valve and pressure test the QTS quick union O-ring seal
by pumping test fluid with the Hand Pump to well-site test pressure. Hold test
pressure for three minutes and observe pressure gauge on the hand pump.
• If no drop of pressure is observed, bleed down pressure at the pump, and close
the needle valve on QTS
• Equalise pressure across the wellhead
• Proceed with operations.
The QTS can also be used for perforating operations, to avoid subjecting the gun
to the full test pressure. In this case the entire lubricator string is pressure tested
using a dummy gun or no gun in the wireline string.
After a successful lubricator test, the WHE string is broken at the Quick Test Sub,
the gun connected, and the connection broken is tested with the Hand Pump,
without building-up pressure in the lubricator.

12.3 VENTING/GLYCOL INJECTION VALVE
The Elmar Venting/Glycol Injection Valve is designed to save rig time while
pressure testing the Wireline Pressure Control Equipment String, by allowing
faster filling of the lubricator string.
The Elmar Venting/Glycol Injection Valve can be hydraulically opened from a test
pump unit. (See page 7-109) It has three functions:
(1). Before pumping commences, hydraulic pressure is applied thereby opening

the vent valve, which allows air to escape, making the filling operation
quicker. Once escaping fluid is observed the valve is closed allowing the
operator to pressure test, confident that no air is trapped.
(2). When bleeding down the lubricator this valve can be opened to allow the
test unit to pump air back into the system thereby discharging the fluid
quickly.
(3). Glycol can be injected below the grease head - the point most effective to
prevent the formation of hydrates.

ED 4 (A)
TITLE: QT SUB ASSY 3" E09 10K H2S

PAGE 1 OF 2
B 4481 K. COULL 14/09/00

ED 4 (A)
TITLE: QT SUB ASSY 3" E09 10K H2S

2 L-971567 1.00 UPPER BODY 15 L-870740 1.00 O-RING
3 L-817100 4.00 GRUB SCREW 16 L-870012 1.00 SPRING
4 L-810445 4.00 SPIROL PIN 17 L-873410 2.00 BACK-UP RING
5 L-974110 2.00 COLLAR INSERT 18 L-871400 2.00 O-RING
6 L-971194 2.00 COLLAR RING 19 L-971568 1.00 LOWER BODY
8 L-870510 2.00 O-RING 21 L-873660 1.00 BACK-UP RING
9 L-202300 1.00 M-HEX NIPPLE 22 L-971238 1.00 THREAD PROTECTOR
10 L-976400 1.00 OUTER RING 23 L-581251 1.00 QC-NIPPLE
11 L-807110 1.00 BH SCREW 24 L-500111 1.00 DUST CAP F/NIPPLE
12 L-970968 1.00 VALVE STEM 25 L-581250 1.00 QC-COUPLER (NOT SHOWN)
13 L-970809 1.00 VALVE BODY 26 L-500109 1.00 DUST PLUG (NOT SHOWN)
PAGE 2 OF 2
B 4481 K. COULL 14/09/00

ED 4 (A)
ELMAR SERVICES LTD No: TI-975716-C2
TITLE: HYD VENT VALVE ASSEMBLY 10K H2S
1 L-975952 1.00 VENT VALVE HOUSING 8 L-245300 1.00 REDUCING BUSH

2 L-973910 1.00 BLEED VALVE ROD 9 L-585200 1.00 QC-NIPPLE
4 L-870770 1.00 O-RING 11 L-875300 1.00 BACK-UP RING
5 L-875730 1.00 SPRING 12 L-204900 1.00 REDUCING NIPPLE
6 L-973930 1.00 BLEED VALVE PISTON 13 L-870730 1.00 O-RING
7 L-974459 1.00 VENT VALVE ADAPTER
PAGE 1 OF 1
C2 VIEW G. REID 19/02/01

13.0 WIRELINE SAFETY VALVE
The Wireline Safety Valve is a full-opening, hydraulically controlled Ball Valve,

designed for use with Wellhead Pressure Control Equipment. (See fig 7-39) It is
normally positioned directly above the wellhead tree and below the Wireline
Valve. As it holds pressure from both above and below, the Wireline Safety
Valve can be used for a number of functions:
• It can be used to isolate the Christmas tree when pressure testing the
Pressure Control Equipment string. Some Christmas tree valves are not
designed to hold pressure from above.
• It can be used as an added safety to shut-off the well remotely on rigless
operations, and provides a second barrier when operating on producing well.
• Should the need arise, it can be closed hydraulically from a remote position,
and will cut wireline or small diameter coiled tubing and simultaneously seal
off the well.
• The wireline safety valve also allows pressure testing of the surface pressure
control equipment without submitting perforating guns to test pressure. It can
also be used to simplify wellsite pressure testing in multiple run operations.
Notice that the Quick Test Sub, simpler, more compact and less expensive,
also supplies this function.
The Wireline Safety Valve normally incorporates an equalizer valve system.
13.1 PRESSURE TESTING PERFORATING GUNS USING A SAFETY VALVE:
• Install the safety valve between the wireline BOP and wellhead with the
safety valve in the open position
• Pressure test the Pressure Control string to wellsite test pressure using a
dummy gun or no gun string in the lubricator
• Bleed off pressure, break the connection between the wellhead and the
safety valve, make up the gun string and enter it into the lubricator
• Remake the wellhead connection and close the safety valve
• Test the previously broken connection below the safety valve to wellsite test
pressure. Open the needle valve at the wireline BOP manifold to allow
venting of the lubricator to atmosphere in the event the wireline safety valve
fails when pressured up.
• After test, bleed down pressure and open safety valve, close needle valve

• Equalize pressure across the wellhead

• Proceed with operations
Figure 7-39: Hydrolex 3.06", 10K, H2S Ball Valve Assembly

14.0 GREASES TO BE USED WITH WHE
Wireline Seal Grease is used with WHE to ensure a good pressure seal in the
grease head while permitting to move the wireline in and out of the well.
Secondary but important functions are to lubricate the wireline, avoiding
excessive wear, and to protect it from corrosive attacks by the well fluids.
The ideal characteristics of the wireline grease are:
• The grease should be able to ensure a good seal at the range of operating
temperatures and pressures normally encountered throughout the day and
the seasons
• Viscosity should be in the range of 3,000 to 30,000 cPs in the desired
temperature range. (centiPoise=cPs is a unit of Kinematic Viscosity). When
viscosity increases, sealing properties improve, but it becomes increasing
difficult to pump the grease. Optimum viscosity values are 5,000 to 18,000
cps
• It should be stringy and tacky at the temperatures to be used, to form a
continuous film and to reduce spatter
• It should be of low toxicity, non flammable and chemically inert
• It should have low solubility in well fluids, glycol
• It should have H2S and CO2 inhibiting properties or mix with H2S and CO2
inhibitors if needed
• It should have a clear colour, be harmless to the environment and easy to
clean up from the rig site. It should be as much as possible biodegradable
• It should be easily available and cost effective
The viscosity of a fluid is a measure of its resistance to flow, or the resistance

opposed to the movement of a solid inside the fluid. The higher the value of the
viscosity then the greater is the resistance. So, a substance with a low viscosity
will flow more freely than another substance with a higher viscosity.
There are several ways of expressing viscosity of a fluid.
Most common measurement is “absolute” or “dynamic” viscosity, expressed in

centiPoise (cPs). Water at 20ºC has a viscosity of 1.0 cPs
“Kinematic” viscosity of a substance is a measure of its dynamic viscosity per

unity density of that substance. Kinematic viscosity is measured in centiStokes
(cSt) centiPoise=centiStokes X specific gravity

Another way to indicate viscosity is the Viscosity “number”: VIS 10, 12,.. 30
related to increasing viscosity at 25°C
Viscosity is the most important characteristic of WHE Grease: if too low, it will be
impossible to create a seal, if too high the pressure drop in the grease hoses will
be excessive and it will be difficult to pump enough grease to replace the amount
carried out of the flow-tubes by the moving wireline cable.
The viscosity of grease/oil decreases rapidly with increasing temperature.

Therefore different products must be used depending on the weather and the
seasons.
A number of products more or less meet the above ideal characteristics. The
most common are polybutenes, also called “honey grease” or “honey oil”
Polybutene is a generic name for a series of products resulting from the

polymerisation of butene and isobutene and are produced by several chemical
companies. AltaVis is the commercial name of the grease by Chevron Oil Co;
BP Chemicals uses the Hyvis trade name, Caltex the "LDS Special" name, etc..
Some products are specifically created for wireline seal applications.
Champion (formerly Blacksmith), a UK chemical supplier, has developed a

“Polybutene Multigrade” Grease, containing H2S inhibitors.
There are three formulations on the market:

“Polybutene Multigrade K” for cold conditions: -20°C to +5°C
“Polybutene Multigrade ”for mild conditions: -2°C to +20°C
“Polybutene Multigrade HP-HT” for warmer conditions: 0°C to +40°C
Oil Center Research Inc, a US specialist supplier has developed a patented

“Liquid-O-Ring” series of greases with viscosities ranging from 1,000 to 30,000
cPs at 77°F. These are also available in an enhanced Biodegradable form as
“780” Grease Seal. Care must be taken not to intermix the Biodegradable with
petroleum-based oils or oils from other manufacturers as the mixture can gel and
plug the supply and return lines.
Polybutene Multigrade and OCR Greases can be obtained from Elmar.

Elmar markets the OCR higher- temperatures Greases under the “Elmar Seal”
trade name.
Elmar Seal is supplied in 55 US gallon drums and is available in a range of

viscosities from VIS 24 to VIS 30 and as a Bio-degradable Seal in selected
viscosities.
Kinematic Viscosity
Part Number DESCRIPTION Bio-Degradable
CSt @ 40°C
L-880102 Elmar Seal 24 No 10,500 – 12,000
L-880103 Elmar Seal 28 No 13,000 – 14,500
L-880217 Elmar Seal 30 No 16,500 – 18,500
L-880104 Elmar Seal B 24 Yes 10,500 – 12,000
L-880101 Elmar Seal B 28 Yes 13,000 – 14,500
Table 7-14.1: Elmar Seal Range
Fig 7-40 gives the range of application of some greases vs. ambient temperature

Figure 7-40 Grease Type vs. Temperature

15.0 WHE PRESSURE TESTING AFTER MAINTENANCE
The pressure rating of any item is expressed in pounds per square inch (psi) and
it is shown as two numbers; a test pressure (TP) rating and a working pressure
(WP) rating. For example, an item rated at 5,000 psi WP and 10,000 psi TP can
be used on a job where pressure is 5,000 psi or less, but the item must be tested
to 10,000 psi. Every item of pressure control equipment has a particular
pressure rating, and care must be taken to ensure that no item is used in a
situation that might cause its working pressure to be exceeded.
Although the test pressure rating is always higher than the working pressure
rating, the difference between the two must not be considered as a safety
margin. This is because the actual use of the equipment under field conditions
involves forces that result from both well pressure and mechanical stress. For
example, if well pressure exerts a force of 5,000 psi on a given unit area (one
square inch) of the equipment and that same unit area is also subjected to
bending stress caused by winds, the total force at the point of maximum stress
can momentarily approach or exceed the test pressure rating of an item. For this
reason, all pressure control equipment must be handled and secured in such a
way that the external stresses are kept to an absolute minimum. For example,
lubricators should be kept straight and vertical whilst in use.
15.1 CERTIFICATION
Test Pressure
The American Petroleum Institute, Specification 6A, "API Specification for

Wellhead Equipment" is used as the basis for conducting pressure tests. It
specifies that an "in-house" pressure test for wellhead equipment should be 1.5
to 2 times the working pressure, depending on the particular equipment.
Wellhead adapters, flanges and threaded connections must never be subjected
to pressures greater than the weakest portion of the adapter. As an example, a
10,000 psi flange, fitted with a three inch line pipe thread, is rated at 3,000 psi
due to the line pipe thread rating. The maximum test pressure is 6,000 psi.
Some older equipment was rated for pressures greater than allowed by API. Do
not test above the manufacturer's recommended test pressure since this rating
may be based on factors other than thread strength.

Test Limitations
In-house hydrostatic test pressure is not to be applied across the rams of

Wireline Valves, packoff rubbers and ball check valves unless specifically
permitted by the manufacturer. These seals are specifically limited to working
pressure by API specifications. Threaded joints of permanently assembled joints
must be leak proof at test pressure.
Test Set-Up
Field locations usually prefer to test as much of the equipment assembled as

possible. This also allows the detection of worn mating parts. They are more
likely to fail when mated with another worn part than when mated with a relatively
unused test adapter.
In all tests, fill the equipment with water to eliminate trapped air.
Caution: Trapped air requires a considerable time to compress and when it is
compressed is highly dangerous. It has enough stored energy to separate parts
with considerable force. The test should be performed away from people and
behind a barricade or wall. These tests are designed to detect leaks and will
rupture steel, should a weakness exist in the body of the metal or separate
threaded connections, if the threads are worn.
The test pressure should be held for at least three minutes. Release the
pressure to zero, re-pressure and hold for at least 15 minutes. Be sure all new
equipment has been tested and certified before field use.
Test Liquid
The most common test liquid used is water. This is cheap, plentiful, but also
corrosive. If untreated water is used for testing, the equipment should be
thoroughly dried after the test and a light coat of corrosion inhibitor applied.
It is better to use a test fluid made of a mixture of water and soluble oil. In cold
climates use inhibited anti-freeze instead of soluble oil.
15.2 TEST PROCEDURE
a) Remove the piston and the rubber packing gland from the stuffing box and
install a solid piston part L-972410.
b) Assemble the stuffing box, tool catcher, ball check valve, lubricator, tool
trap, Wireline Valve and adapters in the order they are used on a well.
c) Blank off the open end with the appropriate blank-off plug

d) Open Wireline Valve rams.

e) Ensure that the Wireline Valve equaliser manifold is installed and tested.
f) Connect the test pump, bleed air and pressure up to test pressure.
g) Hoses may be tested individually or attached together. They are tested to
1.5 times the working pressure. For example, 1/2" ID hoses are rated to
10,000 psi and are tested to 15,000 psi. The pack-off pump hoses are rated
at 3,000 psi and are tested to 4,500 psi. On grease return hoses, do not
install a blanking plug on the valve end; close the valve and test the ability of
the valve to seal. Be sure you know the working pressure of the
equipment you are testing.
Components can be tested individually as well. This requires the installation of

the correct end blanking plugs. Test the part to the correct test pressure and
hold for three minutes. Release the pressure, re-pressure and hold for three
minutes minimum.
15.3 OPERATIONAL TESTS
Equipment with moving parts must be retested to working pressure to assure that
it functions properly, after any certification test.
1. Wireline Valve
a) Install bottom blanking plug, manifold or equaliser valves; attach test pump.
b) Open rams fully with hydraulic pump.
c) Insert a Wireline Valve test rod into Wireline Valve and close rams until they
are almost closed.
d) Fill with water.
e) Pump rams completely closed.
f) Pressure to working pressure for three minutes. Turn off pumps.
g) Open equaliser valve to bleed pressure from below rams and to check that
the equaliser valve is operating.
h) Pump rams completely open.
i) Close rams manually. The pump valve must be open to allow oil to move
from one side of the cylinder to the other. Count the turns. Unscrew handles
the full number of turns. The rams should not retract.
j) Pump rams closed, re-pressure to working pressure for fifteen minutes.
Rams should not leak.
k) Bleed pressure from Wireline Valves.
l) Pump rams open. They should retract fully leaving the Wireline Valve clear.

2. Grease Injection Head
a) Remove the test plug and reassemble packing rubber.

b) Insert a cable-sized rod, complete with nut on the bottom, through the
stuffing box.
c) Install blanking plug on bottom of the GIH.
d) Pump the packing rubber closed and apply working pressure to the GIH.
should not leak.
3. Tool Traps and Catchers
a) Cap both ends of the tool trap and apply working pressure.
b) On the manual type, move the handle through its full open and close
position twice.
c) On the hydraulic type, pump the activating system open and closed twice.
d) The tool catcher should be pumped open twice.
e) Release pressure, remove caps, visually check insides
to determine condition of moveable parts. Replace thread protectors.
4. Ball Check Valve
Cap the lower end and turn assembly upside down to allow the ball to go on
seat. Pressure the assembly to working pressure.
15.5 PRESSURE TEST UNITS
In performing these certification tests it is recommended to use pumps specially

designed for this purpose. Purpose built wall mounted pressure test units (fig 7-
41) and portable test pumps are available. (See Figure 7-42). The tests must be
carried out in a Pressure Test Bay specifically designed for this purpose.
WALL MOUNTED PRESSURE TEST UNIT
This Elmar 22,500 psi pressure test unit has been designed for wall mounting
within a workshop test bay and includes features essential for safe and efficient
hydrostatic pressure testing.
• Calibrated 30,000 psi Dial Gauge and 8” 2/8 hour chart recorder
• Adjustable cut-off on gauge cuts out pump at preset test pressure

• Door interlock relays prevent testing when personnel or test bay door is open
• Automatic bleed-off if door is open
• Flashing lights indicate when unit is in use
• Further options to enhance safety and efficiency include:
• A 4 cameras CCTV system and a VCR to allow close observation of the
equipment under test, without entering the test bay.
• An electronic pressure recorder and digital display
• A low-pressure, high-volume pump.
See Fig. 7-43 for a typical Pressure Test Bay installation.
Figure 7-41: Wall mounted Pressure Test Unit

Figure 7-42: Elmar testing skid designed to test

WHE in the shop and on the wellsite

Figure 7-43: Typical Pressure Test Bay Installation
WALL MOUNTED
PRESSURE TEST UNIT
CAMERA MONITORING SYSTEM
III
IIIII III
IIII I I
PRESSURE VESSEL C/W 4 x VIDEO CAMERAS, MONITOR
II I
II II
I II
I
IIII II
II
IIII
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I I I I
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I I I I I II I I I I I I I I
DUMP
III
& VIDEO RECORDER

I I
III I
IIII
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SURE
TEST PRES
ELMAR
s Ltd
Service
PULL & TURN
T
TO ADJUS
REGULATOR
TER ON
ON
ATER
UPPLY
PLY
AIR SUP
ON
FF
SLIDING
DOOR
LOCK
CONTROL
ROOM
LIGHT
SLIDING LIGHT
CAMERA DOOR
HINGED DOORS
CAMERA CAMERA
HOSE REEL
ASSEMBLY
HINGED
DOOR
LOCK

16.0 WELLHEAD ADAPTERS
The Pressure Control Equipment must be connected to the client’s wellhead,

ensuring both mechanical strength and pressure integrity. For this purpose a
critical piece of equipment, called “Wellhead Adapter” is used. The Wellhead
Adapter connects to the well bore on one side and to the WHE on the other side.
On the WHE side it is equipped with a quick union (see Figure 7-44). In most
circumstances on the well bore side the WHE is connected on top of the Client’s
Christmas Tree. However pressure equipment may be required in a wide variety
of situations, and may be connected to the rig BOP stack, to a testing flow-head,
to drill pipes, or even directly to a tubing string.
In normal conditions the preferred method of connection is to use a flanged

adapter, bolted to the uppermost flange of the Christmas tree, i.e., on top of the
swab valve (see Figure 7-45). A second choice is to use a threaded adapter to
the top threaded connection on the tree. This is acceptable only for low pressure
and non-H2S well conditions.
Unusual operations may require special adapters, made up with more than one
crossover.
Discussion with the client will establish which combination of adapters will best
suit the job.
NOTE: A SAFETY HAZARD EXISTS WHENEVER A NON-STANDARD ITEM IS

USED WITH PRESSURE EQUIPMENT.
The engineer must reduce the number of separate crossovers used to the
absolute minimum, and check carefully the pressure rating and limitations of
each item used, e.g., Some line pipe threads are limited to 3,000 psi working
pressure and some 8 round casing threads are limited to 2,000 psi working
pressure depending on their size.
For operations in producing fields where wellheads are standard, the operating
districts must agree with their clients as to the type and rating of wellhead
adapters needed to fit their clients’ Christmas Trees.
Standard adapters must be managed the same way as all other WHE items: be
certified, traceable, identified by a unique ID number, be regularly maintained
and pressure tested, and a record kept of their maintenance history.

Table 7-16.1: API Threaded connections Pressure Ratings
Rated Working
Type of API Thread Nominal Size (In.) Test Pressure (PSI)
Pressure (PSI)
½ 10,000 15,000
¾-2 5,000 10,000
Line Pipe (NPT)
2 ½-6 3,000 6,000
Tubing, non upset and

1.05-4 ½ 5,000 10,000
external upset, round
thread
Casing, 8-round, 4 ½-10 ¾ 5,000 10,000

buttress, and extreme 11 ¾-13 3/8 3,000 6,000
line 16-20 2,000 4,000

16.1 FLANGED ADAPTERS
A flanged adapter is the safest method of connecting a WHE string to a wellhead,

as it distributes more evenly the weight of the entire lubricator string, and any
bending stresses transmitted through it (see Figure 7-44).
With flanged connections, the seal is effected by means of a metal ring placed in
grooves on the two mating faces of the flanges. The ring is squeezed by
tightening the bolts placed on the outer rim of the flanges, and a metal-to-metal
seal is created. The pressure rating of the equipment determines the number and
diameter of the bolts required and the size of the flange.
Common flanges used on a wellhead have a circular shape and a full circle of
bolt holes.
There are speciality flanges with “D” or “V” shapes and various clamping
arrangements, but when a customer orders a flange we can assume it is the
common circular type unless specifically mentioned otherwise.
Flanges are identified using nomenclature defined by the American Petroleum

Institute. The nomenclature has changed over the years. The current
nomenclature is found in Bulletin API 6A.
A flange is defined by:
• Its nominal size

• Its pressure rating
• Its ring number.
API has dropped the “Series” numbers from the description, but this is still
commonly used. The “Series” number of a flange was a code related to its
working pressure rating. API 6A bulletin classifies flanges as type 6B (normal) or
type 6BX (hi-pressure) flanges.
16.2 TYPE 6B / 6BX FLANGES
Common flanges are described in API Bulletin 6A and they are officially classified
as type 6B (normal) or 6BX (hi-pressure) flanges.

Figure 7-44: Wellhead adapter
BOP
Quick Union
Nuts
Adapter Flange
Studbolts
Ring Gasket
Wellhead Flange
Wellhead

FIGURE 7-45: WHE adapter connection to Xmas tree
Flanged Adapter II
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Threaded Adapter
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Gauge Valve
Top Connection
Swab Valve
Choke Choke
Wing Valve Wing Valve
(Flowline Valve) (Flowline Valve)
Master Valve
Tubing Head Adapter
The following are series numbers and corresponding pressure ratings for API
type 6B flanges:
Series Working Pressure Rating (psi)
300 720
400 960
600 2,000
900 3,000
1500 5,000
2900 10,000

Equivalent descriptions of the same flange might be "six-inch 1500 series", "six-
inch 5,000 psi", or "six-inch 5,000 psi R-46". Referring to the attached flange
chart (see Tables 7-16.6 through 7-16.13) we find under 6B flanges, a table of
1500 series (5,000 psi) flanges. In the nominal size column is a six inch size.
This is the flange described above. Note that the API ring number for this flange
is a R-46 (or RX-46). Thus the "R-46" in the latter part of the above description is
somewhat redundant, but it can be useful in avoiding confusion and it is
recommended to confirm the ring number whenever possible to help assure we
get the correct flange. Note that the ring number and nominal size are not
enough to uniquely describe a flange. You can find many examples where the
same ring is used on more than one flange. Note that the charts give enough
dimensions so that we could identify an unknown flange by comparing various
measurements to the charts. The column "Pitch diameter of ring or groove" gives
the diameter of the centreline of the ring groove in the flange.
16.3 TYPE 6BX FLANGE
Refer to the chart for type 6BX flange. The common description of one of these
flanges would be "7-1/16 10,000" or "7-1/16 10,000 BX 156" (ring number is BX
156) or "7-1/16 BX 156". Note that the latter description is ambiguous because
we don't know if the client wants a 7-1/16 10,000 psi or a 7 1/16 15,000 psi
flange, and although they both use the same ring, they are not in any way inter-
changeable (they don't even use the same number of bolts.
If we describe a flange with the three items--nominal size, pressure rating (or
series) and ring number-- we will have very little chance of misunderstanding.
16.4 API SEAL RINGS
The pressure seal between two mating flanges is obtained by a soft metal ring,
which is squeezed into the mating grooves in the two flanges. Called the seal
ring or ring gasket, this soft metal ring deforms to match the exact contour of the
grooves and gives a metal-to-metal seal. Since the seal rings are soft, they must
be handled carefully. Often a seal ring will leak if used more than once.
The "R" rings used on type 6B flanges are oval in cross section. "RX" rings are a
tall octagon in cross section and are inter-changeable with the "R" type rings in
type 6B flanges.

The "BX" type rings used in the 6BX type flanges are almost square in cross
section.
Normally, all seal rings have the ring size stamped on the side (except for H2S
rated rings).
Everything can be very confusing to the new engineer. However, it is vital that he
knows what the client means when he describes what wellhead adapter is
needed. The engineer should be aware of possible pressure limitations imposed
by the wellhead configuration, e.g. the old series 900 flanges are only rated to
3,000 psi. He must also be aware of possible restrictions that may cause
problems when entering or coming out of the well, e.g. bore size of flange,
internal upset pipe, etc. Unfortunately, the nominal sizes quoted often give little
information of the real size of a flange or pipe connection. The following data
sheets give some examples of flange and pipe data. It can be seen that, for
example, a 6" series 900 flange does not have any dimensions which actually
measure 6" and a nominal 2½" EU tubing may have a pipe OD of 2.875" and ID
of 2.259" and have a screw thread which tapers down from a maximum of 3.093".
Several data books have been produced which tabulate the performance
properties and physical dimensions of pipes and flanges. A small compact
booklet produced by Joy Petroleum called "What Keeps Your String Together?"
is worth obtaining for this sort of essential information. Other books such as the
Baker "Tech Facts" abound and various companies such as Cameron produce a
slide rule to give flange specifications. Unfortunately, there is no easy way to
learn the thousands of possible wellhead configurations. The only way to learn
this information is by talking to people on the wellsite and by experience.
16.5 FLANGE CONNECTION PROCEDURES
1. Clean and inspect ring grooves.
2. Lightly grease ring groove. Do not fill the groove with grease.
3. Inspect seal ring for nicks.
4. Install and connect flanges together with an appropriate ring in the grooves.

5. Make sure the gap between flanges is uniform all around as you tighten
bolts. Alternatively, tighten bolts on opposite sides of the flange to bring the
flanges together uniformly.
6. Use all bolts.

A = Pitch Dia of Ring and Groove

D
TABLE 7-16.6: FLANGES WITH RING GROOVES B = Dia of Bolt Circle
A
C = OD of Flange
B Type R Type RX Type BX
OBSOLETE SERIES 300-720 PSI WORKING PRESSURE C D = Minimum Flange Thickness
API ring gasket cross-sections
"C" "B" BOLT "A"

FLANGE CASING OD MINIMUM DIA OF PITCH DIA API
SIZE SIZE OF FLANGE BOLT o OF RING RING
No SIZE LENGTH
NOM OD FLANGE THICKNESS CIRCLE & GROOVE
1-1/4 1.660 5-1/4 1 3-7/8 4 5/8 3-3/4 2-3/8 R-18
1-1/2 1.900 6-1/8 1-1/16 4-1/2 4 3/4 4-1/4 2-11/16 R-20
2 2-3/8 6-1/2 1-3/16 5 8 5/8 4-1/2 3-1/4 R-23
2-1/2 2-7/8 7-1/2 1-5/16 5-7/8 8 3/4 5 4 R-26
3 3-1/2 8-1/4 1-7/16 6-5/8 8 3/4 5-1/4 4-7/8 R-31
3-1/2 4 9 1-1/2 7-1/4 8 3/4 5-1/2 5-3/16 R-34
4 4-3/4 10 1-9/16 7-7/8 8 3/4 5-3/4 5-7/8 R-37
5 5-1/2 11 1-11/16 9-1/4 8 3/4 5-3/4 7-1/8 R-41
6 6 6-5/8 7 12-1/2 1-3/4 10-5/8 12 3/4 6 8-5/16 R-45
8 7-5/8 9 15 1-15/16 13 12 7/8 6-1/2 10-5/8 R-49
10 9-5/8 10-3/4 17-1/2 2-3/16 15-1/4 16 1 7-5/8 12-3/4 R-53
12 11-3/4 13-3/8 20-1/2 2-5/16 17-3/4 16 1-1/8 7-7/8 15 R-57
16 16 25-1/2 2-9/16 22-1/2 20 1-1/4 9 18-1/2 R-65
20 18-5/8 20 30-1/2 2-7/8 27 24 1-1/4 9-3/4 23 R-73
ALL DIMENSIONS GIVEN ABOVE ARE CITED IN INCHES.

o
REQUIRED STUD LENGTH WITH TWO NUTS.


D
A
C = OD of Flange
OBSOLETE SERIES 400-960 PSI WORKING PRESSURE D = Minimum Flange Thickness
C API ring gasket cross-sections
"C" "B" BOLT "A"

FLANGE CASING OD MINIMUM DIA OF PITCH DIA
API
SIZE SIZE OF FLANGE BOLT OF RING
o RING
NOM OD FLANGE THICKNESS CIRCLE No SIZE LENGTH & GROOVE
1-1/4 1.660 5-1/4 1-1/16 3-7/8 4 5/8 3-3/4 2-3/8 R-18

1-1/2 1.900 6-1/8 1-1/8 4-1/2 4 3/4 4-1/2 2-11/16 R-20
2 2-3/8 6-1/2 1-5/16 5 8 5/8 4-3/4 3-1/4 R-23
2-1/2 2-7/8 7-1/2 1-7/16 5-7/8 8 3/4 5-1/4 4 R-26
3 3-1/2 8-1/4 1-9/16 6-5/8 8 3/4 5-1/2 4-7/8 R-31
3-1/2 4 9 1-11/16 7-1/4 8 7/8 5-3/4 5-3/16 R-34
4 4-3/4 10 1-11/16 7-7/8 8 7/8 6-1/4 5-7/8 R-37
5 5-1/2 11 1-13/16 9-1/4 8 7/8 7-1/8 7-1/8 R-41
6 6 6-5/8 7 12-1/2 1-15/16 10-5/8 12 7/8 7-3/8 8-5/16 R-45
8 7-5/8 9 15 2-3/16 13 12 1 8-3/8 10-5/8 R-49
10 9-5/8 10-3/4 17-1/2 2-7/16 15-1/4 16 1-1/8 9-1/4 12-3/4 R-53
12 11-3/4 13-3/8 20-1/2 2-9/16 17-3/4 16 1-1/4 8-1/2 15 R-57
16 16 25-1/2 2-13/16 22-1/2 20 1-3/8 9-1/4 18-1/2 R-65
20 18-5/8 20 30-1/2 3-1/8 27 24 1-1/2 10-1/4 23 R-73

o
REQUIRED STUD LENGTH WITH TWO NUTS

TABLE 7-16.8: FLANGES WITH RING GROOVES A = Pitch Dia of Ring and Groove
D
B = Dia of Bolt Circle
A
API TYPE 6B FOR 2,000 PSI WORKING PRESSURE C = OD of Flange Type R Type RX Type BX
B
(OLD SERIES 600) C D = Minimum Flange Thickness API ring gasket cross-sections
"C" "B" BOLT "A"

FLANGE OLD NOM CASING OD MINIMUM DIA OF PITCH DIA
API
SIZE SIZE OF SIZE OF FLANGE BOLT OF RING
o RING
NOM FLANGE OD FLANGE THICKNESS CIRCLE No SIZE LENGTH & GROOVE
* 1-1/4 1.660 5-1/4 1-1/16 3-7/8 4 5/8 3-3/4 2-3/8 R-18
†1-13/16 1-1/2 1.900 6-1/8 1-1/8 4-1/2 4 3/4 4-1/4 2-11/16 R-20
2-1/16 2 2-3/8 6-1/2 1-5/16 5 8 5/8 4-1/2 3-1/4 R-23
2-9/16 2-1/2 2-7/8 7-1/2 1-7/16 5-7/8 8 3/4 5 4 R-26
3-1/8 3 3-1/2 8-1/4 1-9/16 6-5/8 8 3/4 5-1/4 4-7/8 R-31
* 3-1/2 4 9 1-11/16 7-1/4 8 7/8 5-3/4 5-3/16 R-34
4-1/16 4 4-1/2 10-3/4 1-13/16 8-1/2 8 7/8 6 5-7/8 R-37
†6-1/8 5 5-1/2 13 2-1/16 10-1/2 8 1 6-3/4 7-1/8 R-41
7-1/16 6 6 6-5/8 7 14 2-3/16 11-1/2 12 1 7 8-5/16 R-45
9 8 7-5/8 9 16-1/2 2-1/2 13-3/4 12 1-1/8 8 10-5/8 R-49
11 10 9-5/8 10-3/4 20 2-13/16 17 16 1-1/4 8-3/4 12-3/4 R-53
13-5/8 12 11-3/4 13-3/8 22 2-15/16 19-1/4 20 1-1/4 9 15 R-57
16-3/4 16 16 27 3-5/16 23-3/4 20 1-1/2 10-1/4 18-1/2 R-65
†17-3/4 18 29-1/4 3-9/16 25-3/4 20 1-5/8 11 21 R-69
21-1/4 20 18-5/8 20 32 3-7/8 28-1/2 24 1-5/8 11-3/4 23 R-73
ALL DIMENSIONS GIVEN ABOVE ARE CITED IN INCHES. † INACTIVE - SPECIAL ORDER ONLY.
o
REQUIRED STUD LENGTH WITH TWO NUTS. * OBSOLETE BY API.

D
A
C = OD of Flange Type R Type RX Type BX
API TYPE 6B FOR 3,000 PSI WORKING PRESSURE B
C D = Minimum Flange Thickness API ring gasket cross-sections
(OLD SERIES 900)
"C" "B" BOLT "A"

API
o RING
* 1-1/4 1.660 6-1/4 1-3/8 4-3/8 4 7/8 5 2-3/8 R-18
†1-13/16 1-1/2 1.900 7 1-1/2 4-7/8 4 1 5-1/2 2-11/16 R-20
2-1/16 2 2-3/8 8-1/2 1-13/16 6-1/2 8 7/8 6 3-3/4 R-24
2-9/16 2-1/2 2-7/8 9-5/8 1-15/16 7-1/2 8 1 6-1/2 4-1/4 R-27
3-1/8 3 3-1/2 9-1/2 1-13/16 7-1/2 8 7/8 6 4-7/8 R-31
* 3-1/2 4 10-3/4 1-15/16 8-1/2 8 1 6-1/2 5-1/16 R-34
4-1/16 4 4-1/2 11-1/2 2-1/16 9-1/4 8 1-1/8 7 5-7/8 R-37
†6-1/8 5 5-1/2 13-3/4 2-5/16 11 8 1-1/4 7-3/4 7-1/8 R-41
7-1/16 6 6 6-5/8 7 15 2-1/2 12-1/2 12 1-1/8 8 8-5/16 R-45
9 8 7-5/8 9 18-1/2 2-13/16 15-1/2 12 1-3/8 9 10-5/8 R-49
11 10 9-5/8 10-1/2 21-1/2 3-1/16 18-1/2 16 1-3/8 9-1/2 12-3/4 R-53
13-5/8 12 11-3/4 13-3/8 24 3-7/16 21 20 1-3/8 10-1/4 15 R-57
16-3/4 16 16 27-3/4 3-15/16 24-1/4 20 1-5/8 11-3/4 18-1/2 R-66
†17-3/4 18 31 4-1/2 27 20 1-7/8 13-3/4 21 R-70
20-3/4 20 18-5/8 20 33-3/4 4-3/4 29-1/2 20 2 14-1/2 23 R-74
o
REQUIRED STUD LENGTH WITH TWO NUTS. * OBSOLETE BY API

D
A
C = OD of Flange
API TYPE 6B FOR 5,000 PSI WORKING PRESSURE B
C D = Minimum Flange Thickness Type R Type RX Type BX
(OLD SERIES 1500)
"C" "B" BOLT "A"

API
o RING
* 1 1.315 5-7/8 1-3/8 4 4 7/8 5 2 R-16
* 1-1/4 1.660 6-1/4 1-3/8 4-3/8 4 7/8 5 2-3/8 R-18
†1-3/16 1-1/2 1.900 7 1-1/2 4-7/8 4 1 5-1/2 2-11/16 R-20
2-1/16 2 2-3/8 8-1/2 1-13/16 6-1/2 8 7/8 6 3-3/4 R-24
2-9/16 2-1/2 2-7/8 9-5/8 1-15/16 7-1/2 8 1 6-1/2 4-1/4 R-27
3-1/8 3 3-1/2 10-1/2 2-3/16 8 8 1-1/8 7-1/4 5-3/8 R-35
* 3-1/2 4 11 2-5/16 8-1/2 8 1-1/8 7-1/2 5-7/8 R-37
4-1/16 4 4-1/2 12-1/4 2-7/16 9-1/2 8 1-1/4 8 6-3/8 R-39
†6-1/8 5 5-1/2 14-3/4 3-3/16 11-1/2 8 1-1/2 10 7-5/8 R-44
7-1/16 6 6 6-5/8 7 15-1/2 3-5/8 12-1/2 12 1-3/8 10-3/4 8-5/16 R-46
9 8 7-5/8 9 19 4-1/16 15-1/2 12 1-5/8 12 10-5/8 R-50
11 10 9-5/8 10-3/4 23 4-11/16 19 12 1-7/8 13-3/4 12-3/4 R-54
13-5/8 12 11-3/4 13-3/8 26-1/2 4-7/16 23-1/4 16 1-5/8 12-1/2 15.270 BX-160
16-3/4 16 16 30-3/8 5-1/8 26-5/8 16 1-7/8 14-1/2 18.127 BX-162
18-3/4 35-5/8 6-17/32 31-5/8 20 2 17-1/2 21.179 BX-163
21-1/4 20 20 39 7-1/8 34-7/8 24 2 18-3/4 23.833 BX-165
o


D
A
C = OD of Flange
B
API TYPE 6BX FOR 10,000 PSI WORKING PRESSURE D = Minimum Flange Thickness
Type R Type RX Type BX
C
"C" "B" BOLT "A"

API
o RING
†1-11/16 1-1/4 1.660 7-3/16 1-21/32 5-9/16 8 3/4 5 2.443 BX-150

1-13/16 1-1/2 1.900 7-3/8 1-21/32 5-3/4 8 3/4 5 2.596 BX-151
2-1/16 2 2-3/8 7-7/8 1-47/64 6-1/4 8 3/4 5-1/4 2.897 BX-152
2-9/16 2-1/2 2-7/8 9-1/8 2-1/64 7-1/4 8 7/8 6 3.492 BX-153
3-1/16 3 3-1/2 10-5/8 2-19/64 8-1/2 8 1 6-3/4 4.079 BX-154
4-1/16 4 4-1/2 12-7/16 2-49/64 10-3/16 8 1-1/8 8 5.232 BX-155
5-1/8 5 5-1/2 14-1/16 3-1/8 11-13/16 12 1-1/8 8-3/4 6.289 BX-169
7-1/16 6 6 6-5/8 7 18-7/8 4-1/16 15-7/8 12 1-1/2 11-1/4 8.600 BX-156
9 8 7-5/8 9 21-3/4 4-7/8 18-3/4 16 1-1/2 13 10.735 BX-157
11 10 9-5/8 10-3/4 25-3/4 5-9/16 22-1/4 16 1-3/4 15 12.915 BX-158
13-5/8 12 11-3/4 13-3/8 30-1/4 6-5/8 26-1/2 20 1-7/8 17-1/4 15.754 BX-159
16-3/4 26 16 34-5/16 6-5/8 30-9/16 24 1-7/8 17-1/2 18.127 BX-162
18-3/4 40-15/16 8-25/32 36-7/16 24 2-1/4 22-1/2 21.462 BX-164
21-1/4 45 9-1/2 40-1/4 24 2-1/2 24-1/2 24.134 BX-166
o

D
OBSOLETE SERIES 2900-10,000 PSI WORKING PRESSURE A
C = OD of Flange
C D = Minimum Flange Thickness API ring gasket cross-sections
"C" "B" BOLT "A"

FLANGE CASING OD MINIMUM DIA OF PITCH DIA
API
SIZE SIZE OF FLANGE BOLT OF RING
o RING
NOM OD FLANGE THICKNESS CIRCLE No SIZE LENGTH & GROOVE
2 2-3/8 7-3/4 2-3/8 5-3/4 8 7/8 7 3-1/8 R-85

2-1/2 2-7/8 8-7/8 2-3/4 6-5/8 8 1 8 3-9/16 R-86
3 3-1/2 10 3-1/16 7-1/2 8 1-1/8 9 3-15/16 R-87
3-1/2 4 11-1/2 3-3/8 8-1/2 8 1-1/4 9-3/4 4-1/2 R-89
4 4-3/4 12-1/2 3-5/8 9-1/2 8 1-3/8 10-1/2 4-7/8 R-88
5 5-1/2 14-1/8 4-3/16 11 8 1-5/8 12-1/2 6-1/8 R-90
6 6 6-5/8 7 NO INFORMATION AVAILABLE
8 7-5/8 9
10 9-5/8 10-3/4 20-3/4 5-11/16 16-3/4 12 2 16-1/2 10-1/4 R-91
11 9-5/8 10-3/4 25-3/4 5-9/16 22-1/4 16 1-3/4 15-1/8 12.915 BX-158

o

D
A
API TYPE 6BX FOR 15,000 PSI WORKING PRESSURE C = OD of Flange
C D = Minimum Flange Thickness
"C" "B" BOLT "A"

API
o RING
†1-11/16 1-1/4 1.660 7-5/8 1-3/4 6 8 3/4 5-1/4 2-443 BX-150

1-13/16 1-1/2 1.900 8-3/16 1-25/32 6-5/16 8 7/8 5-1/2 2.596 BX-151
2-1/16 2 2-3/8 8-3/4 2 6-7/8 8 7/8 6 2.897 BX-152
2-9/16 2-1/2 2-7/8 10 2-1/4 7-7/8 8 1 6-3/4 3.492 BX-153
3-1/16 3 3-1/2 11-5/16 2-17/32 9-1/16 8 1-1/8 7-1/2 4.079 BX-154
4-1/16 4 4-1/2 14-3/16 3-3/32 11-7/16 8 1-3/8 9-1/4 5.232 BX-155
7-1/16 6 6 6-5/8 7 19-7/8 4-11/16 16-7/8 16 1-1/2 12-3/4 8.600 BX-156
9 7-5/8 8-5/8 25-1/2 5-3/4 21-3/4 16 1-7/8 15-3/4 10.735 BX-157
11 8-5/8 9-5/8 32 7-3/8 28 20 2 19-1/4 12.915 BX-158

o
† INACTIVE - SPECIAL ORDER ONLY.

17.0 PUMP-IN SUB
The Pump-In Sub (PIS) (see page 7-142) is normally positioned below the
Wireline Valve and above the Wellhead. Its main function is to allow well control
by pumping fluid below a Wireline Valve closed on the wireline. Notice that in
many cases a kill or control line is provided in the Wellhead or Christmas Tree on
which the Pressure Control Equipment is rigged-up. In this case a PIS is not
needed.
The PIS has quick unions top and bottom, and a side port ending with one half of
a Hammer Union (WECO). The WECO union is connected to the main body of
the PIS with stud connections.
Pump-in Subs can also be used as wellhead adapter X-overs, with different top
and bottom unions. They are also used to provide a large bleed-off path for the
string, particularly useful for gas wells.
Pump-in Subs are normally supplied with the WECO port closed with a blind
plug. It is essential to replace the blind plug with a suitable plug valve so that a
pump can be connected in case of need. It is impossible to remove the blind plug
and install the valve if wellhead pressure is present and the wireline is in the
hole.
17.1 HAMMER UNIONS (WECO)
Hammer Unions, also called “Wing Unions” or WECO Unions are quick makeup
and break-out pipe and fitting connectors often used to connect oil-field
temporary piping. The original design of the WECO connector belongs to FMC,
but it has been copied by several other manufacturers. The primary components
in these connectors are (see fig 7-46):
• A male sub with a spherical sealing surface

• A female sub with external acme threads and an elastomeric seal
• A wing nut with internal acme threads to hold the components together.
Wing Unions are identified by their “figure number” corresponding to the pressure
rating, and by their ID.

Size Fig. Working Pressure PSI Test Pressure PSI Thread ACME
602 3,000 6,000 3 13/16” mod - 3 TPI
2” 1002 5,000 10,000 3 13/16” mod - 3 TPI
1502 10,000 15,000 4 1/8” std - 3 TPI
602 3,000 6,000 5 3/8” mod - 3 TPI
3” 1002 5,000 10,000 5 3/8” std - 4 TPI
1502 10,000 15,000 5 3/8” std - 3.5 TPI
Table 7-17.1: WECO Unions
Caution!
WECO unions with different figure numbers can be screwed together. This
has lead to several accidents and fatalities
2” WECO Fig. 602 and 1002 have the same thread. 2” WECO Fig. 1502 has a
larger thread but with the same 3 TPI pitch. It is therefore possible to screw
together a Fig. 1502 half to a 1202 or 602 half. The thread overlap is only 0.010”
and the union will strip under pressure.
2” Female 2” Wing Results

602 602 Rated 3,000 psi WP
1002 1002 Rated 5,000 psi WP
1502 1502 Rated 10,000 psi WP
602 1002 Caution! WP 3,000 psi
1002 602 Caution! WP 3,000 psi
602 1502 DANGER! Will strip at ~ 2,000 psi
1002 1502 DANGER! Will strip at ~ 2, 000psi
1502 602 Will not screw together
1502 1002 Will not screw together
Table 7-17.2: Hammer Union Combinations
Other possible mismatches:

1. A 2” WECO Wing Nut Fig. 1502 fits over a 2” WECO Fig. 602 or 1002 male
sub, but the shoulder has a very small, insufficient overlap.
2. A 3” WECO Wing Nut fits over a 3” WECO Fig. 602 or 1002 male sub, again
with insufficient shoulder overlap.

Figure 7-46: WECO Wing Union

ED 4 (A)
TITLE: PIS ASSY 3" E09 10K H2S 2" 1502
1 L-971239 1.00 THREAD PROTECTOR 9 L-972609 1.00 PIS BODY

2 L-801180 6.00 NUT 10 L-817100 2.00 GRUB SCREW
3 L-801170 6.00 STUD BOLT 11 L-810445 2.00 SPIROL PIN
4 L-975164 1.00 MALE ADAPTER 2" 1502 12 L-974110 1.00 COLLAR INSERT
5 L-975092 1.00 2"-1502 PLUG & NUT 13 L-971194 1.00 COLLAR RING
6 L-874130 1.00 GLEN VITON SEAL 2" 1 14 L-873660 1.00 BACK-UP RING

PAGE 1 OF 1
B 4537 G. REID 23/11/00

18.0 TURN AROUND SHEAVE
The Turn Around Sheave (TAS) has been specially designed to reduce the
overall height of the pressure equipment string. (See fig. 7-47)
The sheave is also known as the Pressurised Sheave Wheel (PSW). With the
conventional pressure equipment system the top sheave is positioned above the
tool catcher, grease injection control head and line wiper. By installing the sheave
inside a pressure retaining chamber and connecting one end to the tool catcher,
the grease injection control head and line wiper can be connected vertically
downward, thus reducing the overall height of the system. The design of the Turn
Around Sheave allows the operator to utilise some existing equipment (grease
injection control heads and line wipers), eliminating the need to purchase all new
items.
Figure 7-47: Typical Turn Around Sheave
1. Grease Head and Tool Catcher adapters required according to flowtube type.
2. Sheave wheels available for alternative line sizes.
Part No. Working Service Wellhead Sheave Size Line Size

Pressure Connection
L - 976713 5,000 psi STD 2” - 8 UN Box 12” .22
L - 977112 5,000 psi H 2S 2” - 8 UN Box 12” .22

L - 973111 10,000 psi H 2S 2” - 8 UN Box 14” .22

18.1 RIGGING UP AND USING THE TURN AROUND SHEAVE
The Turn Around Sheave relies on continuous grease injection into its body to
lubricate and protect the bearing. For this purpose one can use the BOP Grease
Injection circuit, which is not required while the wireline is moving.
As the TAS must support the load due to the Wireline tension, it is imperative to
support the TAS on a structure capable of withstanding twice the maximum
possible pull-on-line. If this precaution is not observed the lubricator string can be
loaded in compression and fail by buckling.
Never use the TAS on an unsupported lubricator string!
It is also important to position the bottom sheave in such a way that the wireline
is very nearly vertical and parallel to the lubricator. Failing to observe this
precaution can put a considerable side load on the lubricator and exceed its
rating. For this purpose special bottom sheave clamps are available (see fig. 7-
48)
The TAS is a specialised piece of equipment and any operator using it must
undergo further advanced training that is beyond the scope of this manual.

Figure 7-48: Turn Around Sheave Assembly using

Typical Pressure Equipment String and Gin Pole Mast
Drop Sheave
Turn Around Sheave Gin Pole Mast

Turnaround Sheave Adapters
Ball Check Valve
Tool Catcher
Spreader Beam
Grease Injection Head

Stuffing Box and
Line Wiper
Lubricator
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BOP

ELMAR E-LITE SERIES GREASE AND HYDRAULIC

CONTROL MODULE
Typical example of a grease and hydraulic control module within

the Elmar E-Lite series range

SECTION 8 - ELMAR E-LITE SERIES GREASE AND

HYDRAULIC CONTROL MODULE
1.0 GENERAL
The Elmar E-Lite Series Grease and Hydraulic Control Modules are designed
with a wide range of available functions to operate pressure control equipment up
to 10,000 psi working pressure. They can operate Wireline Valves, Tool Catcher,
Tool Trap, Stuffing Box and Line Wiper. An air driven hydraulic pump is used to
power all hydraulic functions. Back-up hand pumps are provided for the event of
an air/hydraulic pump failure. The back up hand pump has a maximum working
pressure of 3,000 psi while the stuffing box pump is rated to 10,000 psi. The
units also have two independent grease injection circuits to supply grease to
Wireline Valves and grease head. These have a working pressure up to 15,000
psi (depending on pump option) and have a crossover valve allowing one pump
to drive either grease injection line. Optional built in auxiliary units are available,
e.g. Glycol Injection Unit, Water/Glycol Pressure Test Unit, Valve Control Unit.
All hoses are mounted on Elmar "wet centre" reels. All tubing and many
components are of stainless steel. All controls are mounted ergonomically on
stainless steel mimic control panels.
A "mimic" panel is designed to layout the controls on a picture format so that the
Operator can more easily visualise the state of the equipment.
The module is usually supplied with a Haskel AW-25 air/hydraulic pump for
Wireline Valve, tool trap, tool catcher, line wiper and stuffing box operation.
These pumps can produce a fluid pressure of 2,500 psi with 100 psi air. Older
modules were supplied with an SC 500-1 air/hydraulic pump.
Depending on model, accumulators with a total capacity of 10, 20 or 40 litres (or

multiples thereof), are fitted as a back-up for the air-powered pump. They are
normally pre-charged by Elmar to 900 psi with Nitrogen.
Two hydraulic hand pumps are provided. The back-up hand pump has maximum
working pressure of 3,000 psi while the stuffing box pump is rated to 10,000 psi.

2.0 GREASE AND HYDRAULIC CONTROL MODULE SAFETY
SAFETY IS EVERYONE'S RESPONSIBILITY
CAUTION
• Read the service manual before operating

• Observe all safety precautions and ensure other crew members have been
made aware of them
• This system is capable of producing high pressure
• To avoid component rupture and possible injury, regulate inlet air pressure so
outlet pressure does not exceed the maximum working pressure of any
component in the set up
• Check pressure rating and compatibility of all connections
• Clear area of unnecessary personnel
• Make sure valves and regulators are in correct position throughout the
operation
• Do not try to tighten or loosen connections under pressure
• Do not weld, file or use metal stamps on the pressure equipment - these can
start cracks
• Do not over-tighten any control valves (hand tight only)
• Do not attach anything to this equipment unless you are sure of its pressure
rating
• Watch for trapped pressure. Bleed off fully before breaking down unions, etc.
Warning: High Pressure
Never allow any part of the human body to come in front of or in direct
contact with the material outlet. Accidental operation of the pump could
cause an injection into the flesh. If injection occurs, medical aid must be
immediately obtained from a physician.
Component Rupture: The E-Lite series control module is capable of producing

high fluid pressure as stated on the pump model plate. To avoid components

rupture and possible injury do not exceed 75 cycles per minute or operate at
an air inlet pressure greater than 150 psi [10 bar].
Servicing: Before servicing, cleaning or removing any component, always

disconnect or shut-off power source and carefully relieve all fluid pressure from
the system.
3.0 GENERAL CHECK OF CONTROL MODULE BEFORE OPERATION
Walk around the module and check:
• Hydraulic oil level

• Caution: Always check hydraulic oil level with accumulator discharged
otherwise over-filling will result
• Glycol level (only on modules fitted with glycol injection unit)
• Airline filter drained
• Airline lubricators topped up with suitable lubricant. ("Kilfrost" - Elmar Part N°
L-880000 is available)
• All air valves and regulators OFF (regulators fully anti-clockwise).
3.1 UNIT OPERATION
Elmar E-Lite Series Grease/Hydraulic Modules can be fitted with an optional

auxiliary unit, e.g. Glycol Injection Unit or Water/Glycol Pressure Test Unit. For
operating instructions refer to the appropriate section of the manual.
All grease injection controls are located on the left hand side of the control panel.
All hydraulic controls are located on the right hand side of the control panel.
TO OPERATE HYDRAULIC CIRCUIT (Refer to Figure 8-1)
• Turn hydraulic pump air regulator (1) fully anti-clockwise

• Close dump valve (2), located above of the hydraulic pump pressure gauge

• Turn on air supply valve (4)

• Turn on accumulator isolating valve (3) and pump up accumulator pressure to
2,000 psi
• Turn off accumulator isolating valve (3)
• Adjust regulator (1) for hydraulic pump clockwise until the hydraulic system
pressure gauge indicates the desired operating pressure, normally 1,200 psi
• The Wireline Valves and tool catcher lines may now be operated by moving
the appropriate valve into the desired position
• The main hydraulic pressure can be dumped if required by opening the dump
valve (2), located to the right of the hydraulic pump pressure gauge
• The line wiper is operated by turning the selector valve (5), located at the top
right of the control panel, to line wiper. Now crack open the pressure
adjusting metering valve (6), located just above the two hand pumps. Watch
the line wiper pressure gauge until the desired line wiper operating pressure
has been reached, then close the metering valve. To dump the line wiper
pressure, open the dump valve (7) located to the right of the line wiper
pressure gauge
• The stuffing box is operated by turning the selector valve (5), located at the
top right of the control panel, to stuffing box. Now crack open the pressure
adjusting metering valve (6), located just above the two hand pumps. Watch
the stuffing box pressure gauge until the desired stuffing box operating
pressure has been reached, then close the metering valve. If the stuffing box
requires an operating pressure greater than 1,200 psi, the high-pressure hand
pump can be used. The stuffing box pressure can be dumped by opening the
dump valve (8) located to the right of the stuffing box pressure gauge.
(See 5.0 for accumulator operating instructions).

Elmar E-Lite Series Control Panel
Figure 8-1
7 8
DRAIN VALVE
LINE WIPER PRESSURE
LINE WIPER 5
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RELEASE CAUTION
TOOL CLOSE VALVE
CATCHER AFTER SETTING
GREASE PRESSURE PRESSURE
DUMP
DUMP
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PUMP NO.1 PUMP NO.2 UPPER PUMP
BOP
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BACK-UP HI PRESSURE
HAND PUMP HAND PUMP
OPEN OFF
ON
SET ACCUMULATOR
ON
PRESSSURE
TO 2000 PSI
1
OFF CLOSE
LOWER
BOP I IIIII IIIII
II
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I I
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I I I I
II
II
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II
IIIIII IIII
IIIII IIIII
I I
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CAUTION
I IIIII IIIII
I I I I I
II I
I I
I I
I I I I
I I I I
II
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II
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IIIIII IIII
CLOSE THIS VALVE

I IIIII IIIII
I I
I I I
I I I I
I
OPEN
I
I I I
BEFORE DUMPING
I I
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II I
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II I
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AIR SUPPLY PRESSURE
I
HOSE PRESSURE
I
4 3

3.2 PRESSURE TEST PROCEDURE FOR HYDRAULIC CIRCUIT
Note: Fully unspool all hoses. Do not rotate reels with pressure in the hoses, as
this will reduce 'O' ring seal life.
HYDRAULIC SYSTEM CHECK (Refer to Control Panel Sketch, Figure 8-1)
• Turn the air regulator (1) for the hydraulic pump fully anti-clockwise
• Close the hydraulic dump valve (2), located above the hydraulic pump
pressure gauge
• Turn off the accumulator isolating valve (3), located beside the accumulator
pressure gauge
• Set the selector valve (5), located at the top right of the control panel, to line
wiper
• Check all other valves are in off position
• Open the pressure adjusting metering valve (6), located just above the two
hand pumps
• Turn on the air supply valve (4) to the hydraulic pump
• Turn the air regulator (1) for the hydraulic pump clockwise until the hydraulic
pump stalls out (approximately 2,500 psi depending on air pressure). Use
back-up hand pump to increase the pressure to 3,000 psi
• Set the tool catcher valve to release, tool trap valve to close and all Wireline
Valve controls to close
• Check for leaks behind the panel, at the reels and hose ends
• Set the tool catcher valve to catch, tool trap valve to open and all Wireline
Valve controls to open. Check for leaks
• Turn off the air supply valve (4) to the hydraulic pump
• Open the dump valve (2), located above the hydraulic pump pressure gauge
• Move Wireline Valve, tool trap and tool catcher valves from open to close and
catch to release, to remove any trapped hose pressure
• Close the dump valve (2), located above the hydraulic pump pressure gauge.
(See 5.1 for accumulator check).

3.3 MAINTENANCE & SERVICING of HYDRAULIC PUMPS
Minimal maintenance is required if:
1. The air motor air is kept clean. Ensure air filter is properly maintained.
2. The fluid being pumped is clean and free of water. The pump inlet filters
should be removed and cleaned every year.
Every year the pumps should be disassembled and checked for corrosion and
wear. Disassembly should be carried out on a clean workbench and care must
be taken to keep the pump components clean. Replacement parts and repair kits
for the pumps are available.

View Haskel operating principles (PC only)
Figure 8-2
Air Drive End Cap Pilot Valve
Air Barrel Air Piston

Hydraulic End Cap
Air Cycling Valve Hydraulic Piston
Air Drive Inlet Port
Air Drive Outlet To

Exhaust Silencer
Liquid Inlet Liquid Outlet
Intlet Check Outlet Check

Valve Valve
High Pressure Air
Low Pressure Oil
High Pressure Oil
Haskel AW hydraulic pump

HASKEL AW AIR DRIVEN LIQUID PUMPS
This consists of a light weight inertia reducing piston complete with o-ring seal
inside an epoxy filled wound fibreglass or hard coated aluminium barrel.
The diameter of the air piston is constant for any series of air driven pumps.
When compressed air is fed into the air drive it forces the piston down on the
compression stroke. The air then drives the piston back on the suction stroke
(except in the case of the M series pumps which have a spring return).
Unlike many competitive pumps, air drive line lubricators are not required nor
desired due to the inherent low friction characteristics of the Haskel design and
lubrication during assembly.
The pump consists of an unbalanced, pilot operated, light weight spool that
channels the compressed air to either side of the air piston, depending on
position of the valve.
The air piston actuates pilot valves at the top and bottom of the piston stroke,
alternately pressurising or venting the large area at the end of the spool valve,
causing it to reciprocate and control the air flow to the air piston to maintain
automatic cycling. The air is exhausted from the pump through an exhaust
muffler.
Unlike many competitive pumps, Haskel does not use close metal fits in their
design. This eliminates the costly air leakage that would otherwise result in a
spool hang up condition.
The hydraulic piston/plunger is directly linked to the air piston and its lower
portion is housed inside the hydraulic body. Its diameter determines the ratio of
the pump (for any particular series), which in turn determines the output flow and
maximum pressure capability. Its function is to induce liquid into the hydraulic
body through the inlet check valve and force liquid out through the outlet check
valve at a higher pressure.
The check valves are spring-loaded non-return valves that control the passage of
liquid into and out of the pump. When the hydraulic piston/plunger is on the
suction stroke the inlet check valve opens to the maximum, the liquid is induced
into the pump while the outlet check valve is held closed by its spring.

On the pressure stroke the inlet check valve is closed as the hydraulic
piston/plunger force the liquid out through the outlet check valve.
A dynamic seal encircles the hydraulic piston/plunger, and is one of the few
wearing parts. Its function is to contain the liquid under pressure during cycling
and prevent external leakage or leakage into the air drive. Different seal
materials and configurations are used, based on the compatibility of the liquid to
be pumped, operating temperature and the pressure rating.
NOTE: With most Haskel pumps a distance piece can be incorporated, between
the air drive section and the hydraulic section, for complete separation and
contaminant free operation.

7.2 PUMP PERFORMANCE
The module has been supplied with one or more of the following pumps.
OUTLET PRESSURES OUTLET FLOWS
AWB-10 PUMP
400 psi 15.5 l/min (4.1 US gall/min)
800 psi 11.5 l/min (3.1 US gall/min)
1,000 psi 6.5 l/min (1.7 US gall/min)
AW-25 PUMP
1,000 psi 6.0 l/min (366 cubic inches/min)
AWB-32 PUMP
AW-35 PUMP
AW-60 PUMP
AW-100 PUMP
AW-150 PUMP
The above performance figures are based on an air supply pressure of 6.9 bar (100 psi).

7.3 PUMP MAINTENANCE
MINIMAL MAINTENANCE IS REQUIRED IF:-

1. The air motor air is kept clean. Ensure air filter is properly maintained.
2. The fluid being pumped is clean and free of water. The pump inlet filters should be
removed and cleaned every year.
Every year the pumps should be disassembled and checked for corrosion and wear.
Replacement parts and repair kits for the pumps are available.
Disconnect pump from system and remove to a clean, well lit work bench with access
to vice, tools, seal kits and spares. All parts removed for inspection should be washed
in a suitable de-greasing agent such as Gramasol or equivalent. Inspect all moving
parts for wear or scratches. Damaged parts should be replaced. It is recommended
that all seals and 'O' rings are replaced. Specially packed seal kits for complete
pumps are available for:
AWB-10 L-660620
AW-25 L-660510
AWB-32 L-661590
AW-35 L-663230
AW-60 L-660610
AW-100 L-660670
AW-150 L-660570
See separate parts list drawings for individual hydraulic seal kit part numbers.
TROUBLE SHOOTING GUIDE
1. AIR DRIVE SECTION
Pump will not cycle and air exhausts continuously from muffler. (Figure 8-2a)
Remove air exhaust muffler and fitting located in the end cap. Pull out spool.
Change all 'O' rings. Re-lubricate sleeve, spool and 'O' rings with Silicone grease
and re-assemble. Re-test before further disassembly.
N.B. Air Drive Piston and Hydraulic Piston is a non-separable assembly and
component parts thereof cannot be supplied.
If 'O' ring swollen - (probably due to Phosphate Esther in air compressor lubricant)
replace with different 'O' ring (Elmar part L-836066).
Increase pipeline size so that pump sees required air pressure and flow.
2. Pump will not cycle and air exhausts continuously from pilot vent.
Check air cycling valve as in paragraph 1 and replace the pilot stem(s) and seals as
detailed below.

3. False cycling if pump will not cycle properly, the following test procedure will
determine which of the two pilot valves is faulty.
(a) Install a 15 bar (200 psi) pressure gauge to show pilot pressure at the 1/8" NPT port in
upper cap (plug item 4), (Figure 8-2h), or the 1/2" NPT port in lower cap (plug item
23), (Figure 8-2h).
(b) Apply air pressure to the air drive inlet to cycle pump against a load. Gauge will read
zero pressure if lower pilot valve has not been actuated. Gauge will read full drive
pressure after lower valve is actuated and before upper pilot valve has been actuated.
Therefore correct pilot valve action will cause gauge to sharply rise and fall from zero
to drive pressure as pump cycles. A slow increase in gauge reading indicates leakage
past lower pilot valve seat, upper pilot valve seat, or 'O' rings on inside end of spool. A
slow decrease in pressure indicates upper valve seat or stem or pilot tube end seals
are faulty and repair is necessary. Check also for external air leaks at plugs.
Remove faulty pilot stem for inspection and replacement of any damaged component
as follows:
1. Remove plugs item 11 (one in each end cap), (Figure 8-2h).

2. Remove springs and pilot stems, (Figure 8-2e).
3. Inspect valve stem and seat. Replace if bent or damaged.
Note: To replace the stem 'O' ring seals requires access from inside the air section.
If replacement is required, care must be taken in installing the Tru-Arc retainer for the
seal and back-up concentrically. As shown in (Figure 8-2e), use the pilot stem valve
as seating tool. Place the rubber valve face against the retainer and tap the top of the
valve lightly to evenly bend the legs of the retainer.
N.B. DO NOT re-use retainer (item 17), (Figure 8-2e).
Spool Extractor, Air Cycling Valve Assembly, Elmar Part L-836017:
A pin is located on one end of the tool for hooking the spool or sleeve and extracting
them from the air valve housing. If the sleeve is stuck, grooves in the centre of the tool
are provided as leverage points for prying. At other end, bumper hook is used by
inserting into centre of bumper to pull it straight out of housing.
HYDRAULIC SECTION
1. Pump cycles but will not pump.

See section on priming.
Inspect inlet check valve parts for contamination or damage.
2. Pump will not stall.

Inspect inlet check valve parts. Repair as required per instructions in following section.

3. Outlet pressure drops during suction stroke.
Inspect outlet check valve parts. Repair as follows:
Check valves use either an internal snap ring to secure the retainer or stepped bore
construction. With either of these, all parts may be disassembled for individual
replacement as necessary. Metal seat models may be re-worked (if damage is not
severe) with lapping tool rotated on the seat using a fine grade of lapping compound.
After replacement of soft seat type checks, pump should be pressurised to
approximately 140 bar (2,000 psi) to seat the check valves.
N.B. Repair of the check valves can be simplified by using the special tool (Elmar part
L-836065) for 1/2" Semi Soft Seat Ball Check Valves.
This rod sleeve assembly can be used to assemble or disassemble these check
valves. To disassemble, depress the retaining ring in the check with the inner rod or
tool. Then slide the sleeve down to force the retaining ring out of the fitting body
groove and into the recess of the tool. Extract the tool, and other components of the
check valve are free for removal. To assemble, follow the procedure in reverse,
(Figure 8-2c).
4. Pumped fluid appears at muffler (or distance piece vent).
Replace high pressure seals as follows:
(a) Hydraulic pressure within the pump body is the most convenient method to remove a
small plunger seal. (However, if large enough, simply remove by inserting finger into
I.D. of parts after withdrawing plunger). Hydraulic pressure may be generated
mechanically by tapping top end of plunger with soft mallet, after removing gland nut
or distance piece and filling pump body with light fluid and plugging outlet port, (Figure
8-2b).
(b) To install new gland parts, lightly coat with lubricant (if compatible with fluid) and insert
in cavity in order detailed on parts/assembly drawing. Leave gland nut loose.
(c) Carefully insert plunger through gland parts before tightening gland nut or tie rods.
(d) Reassemble pump body and air drive as shown on parts/assembly drawing.
When reassembling single and double air head pumps torque tie bolt nuts evenly to
22-25 Nm (16-18 lb f ft). Triple air head pumps should be torqued to 28.6-34.7 Nm
(20.8-25 lb f ft).
N.B. Some models have components wired together with 0.32" stainless steel wire.
Replace with new wire when reassembling.
When ordering spare parts advise pump serial number, model, spare part number and
description.

PRIMING
Install a valve of suitable working pressure to the pump outlet that is capable of being
used as an air bleed at start up. Open air control valve slowly. Allow pump to cycle for
approximattely 15 seconds, pumping fluid through the valve. If adequately primed
close the valve. The pump will cycle slower and then stall due to increase in output
resistance. If the pump does not stall, open the valve and repeat procedure.

Fig
8-2a
Fig Fig
8-2b 8-2c
Fig
8-2d
Fig
8-2e
Fig
8-2f

Figure 8-2G
ITEM QTY/
DESCRIPTION
NO ASSY
*1 UPPER CAP 1
2 NAME PLATE 1
*3 NAME PLATE 1
*&**4 PLUG 2
*5 PLUG 1
6 BOLT 2
7 BOLT 2
8 NUT 4
9 LOCKWASHER 4
10 WASHER 8
*&**11 PLUG 2
*&**12 O-RING 2
5/8" ODx1/16"
*&**13 SPRING 2
*&**14 PILOT STEM 2
*&**15 O-RING 2
1/4" ODx1/16"
*&**16 SPACER 2
*&**17 RETAINER 2
18 O-RING 2
3/8"ODx1/16"
19 O-RING 2
5/8"ODx1/16"
20 PILOT TUBE 1
21 FLOW TUBE 1
**22 LOWER CAP 1
**23 PLUG 1
**24 FITTING 1
**25 SPACER 1
**26 SLEEVE 1
**27 O-RING 5
1"ODx1/16"
**28 SPOOL 1
**29 O-RING 8
13/16"ODx1/16"
**30 RETAINER 1
**31 O-RING 1
11/16"ODx1/16"
32 O-RING 2
5-3/8"ODx1/16"
33 BARREL 1
34 O-RING 1
35 DECAL,LUBE 1
36 DECAL,PATENT 1
37 O-RING 1
2-3/8"ODx1/16"
38 EXTERNAL NUT 1
39 INTERNAL NUT 1
55 MTG. BRACKET 1
* UPPER CAP ASSY

** LOWER CAP ASSY
NOTES:
1 SEE PUMP PISTON SECTION PAGE FOR PACKING
PUMP BODY AND PISTON ASSEMBLY.
SEE PUMP CHECK VALVE PAGE FOR PARTS

2
INCLUDED IN INLET AND OUTLET CHECK VALVES.
THIS ITEM(S) AND THE PUMP BODY ARE

PERMANENTLY LOCTITED TOGETHER AT
ASSEMBLY.
THESE ITEMS ARE LOCKWIRED TOGETHER WITH

.032 DIAMETER STAINLESS STEEL WIRE AT
ASSEMBLY.
RELUBE W/HASKEL LUBE P/N 28442.
TORQUE TO 16-18 FT. LBS.
PUMP AIR DRIVE SECTION SEAL KIT L-664140

MODELS AWB-10, AWB-32
SEAL KIT L-664150

Figure 8-2H
ITEM QTY/
DESCRIPTION
NO ASSY
*1 UPPER CAP 1
2 NAME PLATE 1
*3 NAME PLATE 1
*&**4 PLUG 2
*5 PLUG 1
6 BOLT 2
7 BOLT 2
8 NUT 4
9 LOCKWASHER 4
10 WASHER 8
*&**11 PLUG 2
*&**12 O-RING 2
5/8" ODx1/16"
*&**13 SPRING 2
*&**14 PILOT STEM 2
*&**15 O-RING 2
1/4" ODx1/16"
*&**16 SPACER 2
*&**17 RETAINER 2
18 O-RING 2
3/8"ODx1/16"
19 O-RING 2
5/8"ODx1/16"
20 PILOT TUBE 1
21 FLOW TUBE 1
**22 LOWER CAP 1
**23 PLUG 1
**24 FITTING 1
**25 SPACER 1
**26 SLEEVE 1
**27 O-RING 5
1"ODx1/16"
**28 SPOOL 1
**29 O-RING 8
13/16"ODx1/16"
**30 RETAINER 1
**31 O-RING 1
11/16"ODx1/16"
32 O-RING 2
5-3/8"ODx1/16"
33 BARREL 1
34 O-RING 1
35 DECAL,LUBE 1
36 DECAL,PATENT 1
37 O-RING 1
1-5/8"ODx1/16"
53 NUT 1
54 LOCK NUT 1
55 MTG. BRACKET 1
* UPPER CAP ASSY

** LOWER CAP ASSY
NOTES:
SEE PUMP CHECK VALVE PAGE FOR PARTS

2
INCLUDED IN INLET AND OUTLET CHECK VALVES.
THIS ITEM(S) AND THE PUMP BODY ARE

PERMANENTLY LOCTITED TOGETHER AT
ASSEMBLY.
RELUBE W/HASKEL LUBE P/N 28442.
TORQUE TO 16-18 FT. LBS.
PUMP AIR DRIVE SECTION SEAL KIT L-664140

MODELS AW-25, AW-35, AW-60, AW-100, AW-150
SEAL KIT L-664150

Figure 8-2I
* PARTS INCLUDED IN SEAL KITS SHOWN ON

PISTON SECTION PAGE.
NOTES:
SEE PUMP AIR DRIVE PAGE FOR PARTS

2
INCLUDED IN AIR DRIVE SECTION.
USE TOOL P/N 28407 TO ASSEMBLE AND

DISASSEMBLE PARTS.

DISASSEMBLE PARTS.
PUMP CHECK VALVES

MODELS AWB-10, AWB-32

Figure 8-2J
* PARTS INCLUDED IN SEAL KITS SHOWN ON

PISTON SECTION PAGE.
NOTES:
SEE PUMP PISTON SECTION PAGE FOR PACKING
1
SEE PUMP AIR DRIVE PAGE FOR PARTS

2 INCLUDED IN AIR DRIVE SECTION.

DISASSEMBLE PARTS.
THESE ITEMS ARE LOCKWIRED TOGETHER WITH

.032 DIAMETER STAINLESS STEEL WIRE AT
ASSEMBLY.
PUMP CHECK VALVES

MODELS AW-25, AW-35, AW-60, AW-100, AW-150

Figure 8-2K

3.4 SC10-500-1 HYDRAULIC PUMP SPECIFICATIONS
Air Consumption: When operating from 0 to 1,000 psi, air consumption will be
approximately 28 CFM of free air at 100 psi input. At lower air pressures and
higher hydraulic pressures (see Table 2) air consumption will be reduced
proportionally to flow rates indicated.
Hydraulic piston diameter: 1.1875 in
Hydraulic piston area: 1.107 sq in
Volume per stroke: 1.384 cu in
Air Pressure - PSI 10 20 30 40 50 60 70 80 90 100

Hydraulic Pressure 145 330 525 700 925 1,100 1,300 1,500 1,700 1,900
Table 1: Approximate air to hydraulic pressure ratios under static conditions.
Hydraulic Pressure 0 250 500 750 1000 1250 1500 1750 2000
60 561 403 336 278 180 0
Air Pressure 80 659 488 409 357 270 223 63 0
100 708 549 476 403 354 305 256 153 0
Table 2: Approximate rate of discharge in cubic inches per minute.
MAINTENANCE
• Do not exceed 150 psi input air pressure maximum

• Lubrication of the air input is required. Check that the unit either contains
Killfrost L-880000, or turbine #9 Gargoyle DTE light weight oil or equivalent
• Check that the air outlet filter is not blocked if the pump refuses to start by
unscrewing it. Change filter every year
• Pump priming can only be achieved if pump outlet pressure is zero. Pump
valve must be open when priming pump
• Inlet filter. This is located in the hydraulic tank and must be removed and
cleaned every year. Access to the filter is by removing the hydraulic tank top
plate

• Air cylinder bolt torque (10-12 ft lbs). If the air head is opened great care must
be taken when reassembling. The 8 bolts must be tightened evenly - do not
over-tighten initially. Bolts should be secured lightly at first and then drawn up
in sequence until uniform torque has been applied to all 8 bolts around the air
head
• Do not run the pump with an empty hydraulic tank.
3.5 SERVICING INSTRUCTIONS FOR SC HYDRAULIC PUMP

- MODEL N°10 500-1
1. To Disassemble the Motor
Refer to cross-section of the pump (Figure 8-3).
a) Remove the eight 5/16" bolts that clamp the air cylinder, between the
head casting and the air cylinder end. Remove the head by tapping
on a fitting screwed into either the 'Air In' or 'Air Out' ports with a soft
hammer.
b) Remove the retaining ring, item 7, from the bottom of the air piston,
item 26, and remove the hydraulic piston. The pilot valve assembly¸ L-
834610 may then be pushed out through the bottom of the air piston.
c) Remove the retaining ring, item 10, from the head assembly. Remove
the bearing assembly, item 23, by lifting or prying it out with a hammer
handle or similar tool. The air piston actuating valve (part of item 20,
valve assembly) may also be removed at this time. The bearing
assembly has a moulded rubber seat and should be replaced if worn
or damaged. The 'O' ring, item 4, in the bearing assembly, the 'O' ring,
item 14, in the upper part of the air piston actuating valve, and the 'O'
ring* on the pilot valve assembly head should be replaced as a routine
matter while the pump is disassembled as they are especially
important for maximum performance.
* (This 'O' ring is part L-834216, see pilot valve assembly L- 834610).

d) The head has a rubber bumper, item 19, inserted in the upper portion
of the body. This acts as an air seal and also as a cushion for the air
piston actuating valve. If worn or damaged it should be replaced.
Note: When worn or damaged the air piston actuating valve and the sleeve
in which it operates are supplied as a valve assembly, part L-834340 (see
parts list). The sleeve may be removed from the head casting by means of
an internal puller engaging the slots in the sleeve. Install a new set of 'O'
rings, part L-834090, item 12, (4 required and included with valve assembly
when ordering as a replacement part). Also coat the 'O' rings and the
sleeve OD with Vaseline or other suitable lubricant to avoid possibility of
damage to the 'O' rings when installing the new sleeve.

SC 10-500-1 Pump Assembly FIGURE 8-3
16
8
5
13
15
23 22
9 21
7 19
11
32
12
10
4
14
27
17
26
3
18
28
33
20
31
24 25
29 30

SC10-500-1 PUMP ASSEMBLY PART NUMBERS
ITEM PART NUMBER DESCRIPTION

1 L-834340 Valve Assembly
2 L-834140 Bumper
3 L-834280 End
4 10-450-48 Piston
5 L-834410 Spring
6 L-834007 Cylinder
7 L-834500 Bearing Assembly
8 L-834610 Air Pilot Valve
9 L-834440 O Ring
10 L-834010 O Ring 6230-1
11 L-834020 O Ring 6230-9
12 L-834030 O Ring 6230-30
13 L-834040 O Ring 6227-19
14 L-834000 O Ring 6227-56
15 L-834300 Bumper Valve
16 10-450-112 Head
17 L-834290 Retaining Ring
18 L-813200 Nut 5/16"-UNC
19 L-813510 Bolt 5/16"-UNCx4”
20 Flat Point Set Screw ¼-20
21 L-834090 O Ring
22 Air Inlet ½" Pipe Thread
23 Air Exhaust 3/4" Pipe Thread
24 L-834170 Outlet Valve Assembly
25 L-834220 Inlet Valve Assembly
26 L-834240 Bumper-Piston
27 L-834150 Retainer-Bumper
28 L-835209 Washer
29 L-834130 O Ring
30 L-834200 Back Up Ring
31 L-834012 Piston & Cylinder Assembly
32 L-834310 Retaining Ring
33 10-450-28 Gasket

Caution: Do not remove the sleeve from the head casting unless replacement is to
be made. The valve assembly is precision ground and honed to very close
tolerances and the sleeve may be damaged when removed from the head
casting.
2. Repairing the Pilot Valve Assembly (Figure 8-4)
The pilot valve assembly, L-834610, has an air check assembly, part L-
834250, located in the lower end. Remove the retaining ring, part L-
834420, which locks the valve seat, part L-834550, in place and remove the
valve seat with a spanner wrench. The air check assembly and the spring,
part L-834620, will then drop out and may be inspected for wear or damage.
Replace the springs and worn parts as required. When installing the spring,
part L-834600, in the air check assembly, the assembly should be screwed
together until the component parts are drawn up just snugly with no travel in
the bolt assembly and then the nut should be backed off one complete turn
for proper adjustment. When the assembly adjustment has been done
correctly, the valve will open approximately 1/32” when the bolt assembly is
depressed to open the valve. Deform the threads on the end of the bolt
after completion of assembly to ensure the self-locking nut being held in
proper position.
Note: Both the OD and the ID of the stem of the air piston, item 4, must be
free from wear, scoring or other damage as they must make a perfect seal
with the contacting 'O' rings. While the pump will run under these
conditions, satisfactory performance will not be obtained where air leakage
may occur between the piston stem and the 'O' rings. The 'O' ring, item 14,
may also be inspected at this time. Replace if necessary.
3. To Replace the Packing in the Hydraulic Cylinder
It is not necessary to dismantle the air motor. Proceed as follows:

Disconnect the air supply line, remove the muffler if necessary and loosen
the set screw in the air cylinder end, item 20. Unscrew the air motor from
the hydraulic cylinder. The hydraulic piston will be removed with the air
motor, permitting convenient replacement of the packing in the hydraulic
cylinder. Replace the backup rings and the 'O' rings. The parts list will give
the size and kind of packing required and when installing the new packings,
be sure that the backup rings are properly in place. If they are damaged or

not installed correctly, the 'O' ring will malfunction, with resultant loss of
pressure and packing failure. When replacing the air motor, install a new
gasket, part #10-450-28, item 33 and see that the hydraulic piston is in
proper alignment before screwing the air motor down into position. Tighten
the air motor securely and also the set screw, item 20, in the air cylinder
end.
Pilot Valve Assembly L-834610 Figure 8-4
Valve Body
Retainer Ring L-834008
L-834420
Seat
L-834550
"O" Ring "O" Ring

L-834216 L-834214
Air Check Spring

Assembly L-834620
L-834250
Air Check Valve Assembly L-834250 Figure 8-4a
Bolt
L-834510 Washer
L-834259
Washer
Spring "O" Ring

L-834600 L-873400
Valve Retainer
L-834540 L-834530
Self Locking Nut

4. The Hydraulic Piston
The hydraulic piston has a rubber bumper, part L-834240, in the head. If
replacement is required remove the retainer, part L-834150, with a spanner
wrench and install a new rubber bumper and washer, part L-835209. Apply
'Loctite' sealant to the retainer threads when replacing and tighten securely,
but not to exceed four foot-pounds of torque.
Note: The piston stem is chrome plated and honed and lapped to a very
close tolerance with the hydraulic cylinder. Should it show indications of
wear or being scored (usually due to foreign matter being present in the
hydraulic fluid), the entire hydraulic piston and cylinder assembly, part L-
834012, should be returned to Elmar, for repair or replacement as required.
5. Repairing or Replacing the Hydraulic Check Valves (Items 24 & 25)
These valves should not give any trouble unless foreign matter such as dirt
or grit is present in the fluid supply. If a leak develops remove the check
valves from the hydraulic cylinder. Remove the 'O' ring and replace with a
new one. Inspect the ball seat in the valve while the 'O' ring is removed. If
it shows any indication of wear or damage, the entire valve assembly
should be replaced. Refer to parts list for part numbers and cross section of
the valves.
Note: There are several different model pumps. When ordering parts, give
the part number, the pump model number and serial number.
6. When operations described in paragraphs 1 to 5 inclusive have been

completed, the entire unit will have been dismantled and all parts inspected
for wear and damage. It is especially important that all parts that operate in
'O' rings or packing be free from pits, scoring or any other defects that may
cause excessively rapid wear of 'O' rings and packing, since leaks will
develop almost immediately under these conditions and satisfactory
performance will not result.

7. Reassembling the Pump
Reverse the procedure used for dismantling, making sure that all retaining
rings are properly in place and that no 'O' rings have been damaged in
reassembly.
Important: When reassembling the air motor be sure that the air cylinder,
part L-834007, is in proper position against the flanges on the pump head
and the air cylinder end before tightening the bolts that clamp the air motor
together. Use a soft hammer to position the flanges tightly against the air
cylinder ends before tightening the bolts. Failure to do this can result in
over-tightening the bolts initially and when the bolts on the opposite side are
drawn up this may result in the bolt lugs being broken or twisted off when
the assembly is drawn down into position. Bolts should be secured lightly at
first then drawn up in sequence until uniform torque has been applied to all
of the bolts around the perimeter of the pump (10-12 ft lbs).
8. Pump Not Running Properly
If for any reason the pump does not run properly, look for one of the
following causes:
a) If the pump appears to be short stroking and running too fast without
pumping properly, it usually indicates that the air check assembly is
not working as it should be (see paragraph 2 for correction procedure).
b) Loss of pressure may be caused by one of two reasons, the hydraulic

check valves have developed a leaky condition or the hydraulic fluid is
bleeding past the packing in the hydraulic cylinder (see paragraphs 3,
4 and 5 for repair instructions). Also check air pressure at pump inlet if
hydraulic pressures fluctuate.
c) Should the pump commence to run erratically and in a jerky manner

after a period of time, it is usually an indication that a seizing action is
taking place in the hydraulic piston and cylinder assembly (see
paragraphs 1 and 3 for disassembly instructions). This is usually
caused by foreign matter such as alkali, dirt, grit or chemicals that do
not have sufficient lubrication qualities being present in the fluid

supply. If the hydraulic piston and cylinder have not been damaged, a
thorough cleaning will normally place the pump in operation again.
d) For maximum volume of flow, make sure that a sufficient flow of air is
supplied to the pump. Hooking the pump up to a smaller pipe size
than the 'Air In’ port on the pump (1/2") will not allow it to run at its full
rated capacity. Long runs of relatively small pipe supplying air to the
pump will have the same effect.
e) If an excessive amount of oil or water is coming through the pump air

exhaust, check the following:
1. Lubricating unit in the air supply is delivering too much oil. Adjust to
about one drop of oil for every 20 strokes of the pump.
2. The filtering unit in the air supply is not functioning properly. The bowl
should be cleaned periodically to assure delivery of clean air to the
pump.
3. The hydraulic fluid being pumped (oil or water) may be leaking past
the packing in the hydraulic cylinder into the air motor (see paragraph
3 for correction procedure).

4.0 BACK-UP HAND PUMP CHECK
• Set Wireline Valve and tool trap valves to off and tool catcher valve to catch
• Close the three dump valves for the hydraulic system
• Turn off the accumulator isolating valve, located beside the accumulator
pressure gauge
• Insert the pump handle into the back-up hand pump and pressure up to 3,000
psi. Check for leaks
• Open the dump valve, located to the right of the hydraulic pump pressure
gauge, to release pressure
• Close the dump valve.
See Figure 8-5 for pump details.
4.1 HIGH PRESSURE HAND PUMP CHECK
• Close the stuffing box dump valve, located to the right of the stuffing box
pressure gauge
• Position the selector valve, located at the top right of the control panel, to
stuffing box
• Insert the pump handle into the high pressure hand pump and pressure up to
10,000 psi. Check for leaks
• Dump pressure by opening the stuffing box dump valve, located to the right of
the stuffing box pressure gauge
• Close the dump valve.
See Figure 8-6 for pump details.

Hand Pump Assembly 3,000 PSI WP

Figure 8-5
2 19 8
12
7 21
18 14
3
10 17
15 5
11 Check Valve Detail

4
6
20
9 16
13
Item Part No. QTY Description Item Part No. QTY Description
1 L-792100 1 Handle casting 12 L-870800 1 O-Ring
2 L-812030 3 Nyloc nut 13 L-870890 1 O-Ring
3 L-792300 2 Link lever 14 L-872100 1 O-Ring
4 L-792400 1 Pivot 15 L-872340 1 O-Ring
5 L-790004 1 Check valve liner 16 L-871070 1 O-Ring
6 L-875250 1 Check valve body 17 L-874600 1 Spring
7 L-792900 1 Cylinder 18 L-875210 1 Polypak seal
8 L-793100 1 Piston 19 L-813310 3 Hex bolt
9 L-680267 1 Manifold block 20 L-875250 1 Ball, 1/4"
10 L-813000 1 Washer flat M8 Stain 21 L-875260 1 Ball, 3/16"
11 L-813290 1 SH Screw

Hand Pump Assembly 10,000 PSI WP
Figure 8-6
2 18 8
12
7 20
17 13
3
10 16
14 5
4 Check Valve Detail

6
19
9 15
11
1 L-792100 1 Handle lever 12 L-871800 1 O-Ring
2 L-812030 3 Nut 13 L-872100 1 O-Ring
3 L-792300 2 Lever link 14 L-872340 1 O-Ring
4 L-792400 1 Pivot block 15 L-871070 1 O-Ring
5 L-790004 1 Check valve liner 16 L-874600 1 Spring
6 L-680266 1 Check valve body 17 L-875200 1 Polypak seal
7 L-792800 1 Cylinder 18 L-813310 3 Hex bolt
8 L-793000 1 Piston 19 L-875250 1 1/4’’ Dia. Ball
9 L-680267 1 Manifold block 20 L-875260 1 3/16’’ Dia. Ball
10 L-810200 1 PH Screw 21 L-875270 1 Circlip
11 L-870890 1 O-Ring

5.0 HYDRAULIC ACCUMULATOR (See Figure 8-7 and 8-7a)
The hydro-pneumatic accumulator used in Elmar Hydraulic Modules is a fluid

pressure storage chamber, connected into a hydraulic circuit by a single
inlet/outlet port.
The accumulator's chief function is to store fluid from the circuit under pressure.
The fluid's potential energy is converted into useful work by the dynamic force
provided within the accumulator by the gas pressurised bladder.
A hydro-pneumatic accumulator delivers its stored fluid power into the circuit as a
back-up to pump output.
Main construction features of an accumulator are illustrated in figure 8-7.
Protective Cap - protects high pressure gas valve assembly.
Non-return pre-charge valve - high pressure gas valve assembly backed-up

with 'O' ring in sealing cap.
Nameplate - maximum working pressure (usually 3,000 psi), capacity (usually

2½ or 5 gallon) and manufacturer.
Poppet valve - forged steel, spring-loaded valve. Prevents extrusion of the

separator bag through the fluid port.
Bleed valve - for controlled bleeding of fluid or gas.
Inlet/Outlet port - provides maximum area for unrestricted flow.
Anti-extrusion ring - provides smooth contour to prevent bladder damaged.
Bladder - fully enclosed for positive separation.
Steel shell - no seams, welds or joints, treated to prevent corrosion.

SAFETY FEATURES
1. Should the shell test pressure be exceeded, the mouth of the shell spreads,
allowing the 'O' ring seal to extrude outwards with immediate loss of
pressure. Extrusion takes place long before burst pressure.
2. Poppet valve ensures that accumulator cannot be dismantled without first

releasing gas pressure.
Accumulators supplied in Elmar units are normally pre-charged to between 900 -

1,000 psi. Pre-charge pressure should never be below 20% of maximum working
pressure. To find out the pre-charge pressure follow these steps:
1. Turn air regulator off.
2. Close hydraulic dump.
3. Open accumulator ON/OFF valve.
4. Turn on air and increase regulator. (System hydraulic and regulator

pressure will increase but pump will not stroke continually - no fluid is being
pumped into accumulator).
5. Continue increasing regulator until pump strokes continually. This is the

pre-charge pressure. Pre-charge pressure has now been overcome and
fluid is being pumped into the accumulator.
5.1 ACCUMULATOR OPERATION
To charge the accumulator (refer to Figure 8-1):
• Turn the hydraulic pump air regulator (1) fully anti-clockwise

• Close the dump valve (2), located above the hydraulic pump pressure gauge
• Turn on the hydraulic pump air on/off valve (4)
• Adjust regulator for hydraulic pump clockwise until the hydraulic system
pressure gauge indicates 2,000 psi

• Turn on accumulator isolating valve (3), located beside the accumulator

pressure gauge. The pump will stroke for several minutes until the
accumulator pressure gauge indicates 2,000 psi
• Turn off accumulator isolating valve, located beside accumulator pressure
gauge
• Turn off the hydraulic pump air on/off valve
• Open the dump valve, located above the hydraulic pump pressure gauge.
To operate the hydraulic functions using the accumulator:
• Close the dump valve (2), located to the right of the hydraulic pump pressure
gauge
• Turn on accumulator isolating valve (3), located beside the accumulator
pressure gauge. All the hydraulic functions can now be operated by
positioning the relevant valves in the required positions
• The accumulator pressure can now be dumped by turning on the accumulator
isolating valve, located beside the accumulator pressure gauge and opening
the dump valve, located to the right of the hydraulic pump pressure gauge.
The accumulator should be dumped after every job.
5.2 ACCUMULATOR CHECK (Refer to Figure 8-1)
• Turn on accumulator isolating valve (3), located beside accumulator pressure

gauge
• Turn on air supply valve (4) to hydraulic pump. Adjust regulator (1) for
hydraulic pump to 3,000 psi maximum
• Check for leaks
• Dump accumulator pressure, using the dump valve (2) located above the
hydraulic pump pressure gauge.

Hydraulic Accumulator
Figure 8-7
Protective Cap
Non-Return
Pre-Charge Valve
Name Plate
NITROGEN
Steel Shell
FLUID
Bladder
Anti-Extrusion
Poppet Valve
Anti-Extrusion
Ring
Bleed Valve
Inlet/Outlet Port

Accumulator Assembly, 10L, Vertical, 1/4” tube
Figure 8-7a
11 5
7 8 9
10
14 13 12
16
15 17 18 19
3 2
1 L-830000 1 Accumulator 11 L-830020 1 Clamp Rubber
2 L-874000 1 Dowty Seal 12 L-814400 2 SHCS
3 L-681000 1 Red Adapter 13 L-814200 2 Washer
4 L-120600 1 Male Elbow 14 L-814100 2 Washer
5 L-830300 1 Saddle 15 L-671610 1 Support Bracket
6 L-830030 1 Saddle Rubber 16 L-830010 1 Seat Cushion
7 L-816000 2 Nut 17 L-816990 4 Nut
8 L-816100 2 Washer 18 L-816970 4 Washer
9 L-816300 2 Washer 19 L-816980 4 Washer
10 L-830200 1 Clamp

6.0 TO OPERATE THE GREASE CIRCUIT
The following procedure is for circuit number one. To operate circuit number two,
follow the same procedure using the corresponding valves for circuit number two
(refer to Figure 8-1).
• Turn regulator for pump N° 1 fully anti-clockwise

• Turn on air supply valve for pump N° 1
• Turn regulator for pump N° 1 clockwise until pressure gauge for pump N° 1
indicates the desired grease injection pressure
• Open the grease supply valve, located directly above pump N° 1 pressure
gauge
• To stop injecting grease, turn off air supply valve for pump N° 1
• Dump grease pressure by opening the crossover valve and the dump valve,
both of which are located above pump N° 2 pressure gauge.
Caution: do not bleed the lubricator pressure using the grease dump valve.
Always use the drain valve provided.
To operate N° 2 injection line using pump N° 1:
• Adjust pump N° 1 to desired injection pressure

• Close N° 1 grease supply valve, located directly above pump N° 1 pressure
gauge
• Open crossover valve
• Open N° 2 grease supply valve, located directly above pump N° 2 pressure
gauge.
To operate N° 1 injection line using pump N° 2:
• Adjust pump N° 2 to desired injection pressure

• Close N° 2 grease supply valve, located directly above pump N° 2 pressure
gauge
• Open crossover valve

• Open N° 1 grease supply valve, located directly above pump N° 1 pressure

gauge.
6.1 PRESSURE TEST PROCEDURE FOR GREASE CIRCUIT
NOTE: Fully unspool all hoses. Do not rotate reels with pressure in the hoses.
This will reduce 'O' ring seal life.
6.2 GREASE INJECTION SYSTEM CHECK
• Fully unspool grease hose and fit blanking plugs

• Turn grease pump air regulators fully anti-clockwise
• Close all grease valves
• Turn on pump N° 1 air supply valve
• Open the grease supply valve, located directly above pump N° 1 pressure
gauge
• Turn the air regulator for pump N° 1 clockwise. The pump will start to stroke
as it pressures up the grease injection line. Keep adjusting until 10,000 psi is
reached on the gauge. Check for leaks behind the panel, at hose reel centre
and at hose end
• If the air supply valve is turned off the pressure will drop slowly until check
valve closes
• Open the crossover valve, located above the two pressure gauges; the
pressure should now also register on pump N° 2 pressure gauge
• Open the grease supply valve located directly above pump N° 2 pressure
gauge. Check for leaks
• Turn off pump N° 1 air supply valve
• Turn on pump N° 2 air supply valve
• Turn the air regulator for pump N° 2 clockwise. Keep adjusting until 10,000
psi is reached on gauge. Check for leaks

• Turn off pump N° 2 air supply valve

• Open grease dump valve to release pressure.
• Pump flow rate and pressure can be checked with an Elmar grease pump flow
tester. Part No. L-690207
6.3 DRAIN LINE CHECK
• Disconnect the drain hose and one grease inject hose

• Connect the drain hose to the inject hose
• Open the grease drain valve, located top centre of the control panel
• Pump grease through drain hose until it comes out of the drain point. Use a
length of hose to direct the waste fluids to a convenient disposal point
• Close the grease drain valve, pump to 10,000 psi and check for leaks
• Close the air supply valve and open the grease dump valve
• If possible test the drain line with water to avoid filling it with thick oil.

7.0 MAINTENANCE AND SERVICING OF WIWA 175:1 PUMPS
THE SYSTEM
A high pressure pump (see Figure 8-8), consisting of a reciprocating air drive (air
motor, Figure 8-9) and a fluid pump (fluid end, Figures 8-10, 8-11) forms the
heart of the system. Infinitely variable control of the air motor and thus the
displacement speed (cycle) of the fluid pump is obtained using a pressure
reducing valve (air regulator), governing the fluid output and stall pressure.
The pressure ratio (pump ratio) of the high pressure pump is equal to the ratio of
the area of the air motor piston versus the area of the displacement piston in the
fluid end. (Notice that the ratio of areas is equal to the square of the OD ratio).
The pressure of the fluid outlet is equal to the pressure of the compressed air
feed, multiplied by the pump ratio.
Example: Pump ratio 175:1
Compressed air pressure reading 5 bar (73 psi)

at air motor control
Maximum fluid pressure build-up 875 bar (12,690 psi)
7.1 THE AIR MOTOR
WIWA reciprocating motors are specifically designed for use with high pressure
pumps and paint spray pumps. They are designed for easy serviceability and low
noise (Figure 8-9).
7.2 GENERAL MAINTENANCE
1. Daily - if compressed air is wet at least twice daily - drain oil and water
separator with line pressure on and blow out water.
2. Check fog oiler for correct adjustment (droplet metering) and oil level, refill if
required.

NOTE: Severe operating conditions may cause frosting of air motor.

To prevent, fill fog oiler with mixture of 50:50 regular SAE 10 Oil and Glycol.
3. Check or top level of specially formulated lubricant in pump lube chamber or

wet-cup of packing take-up nut.
WIWA 175:1, grease injection pump Figure 8-8
5 4
2 8
1 L-840750 1 Pump Wiwa 175:1 8 L-100080 1 Male Connector
2 L-861400 1 Gasket F
3 L-812590 8 SHC Screw
4 L-201900 1 Nipple
5 L-851120 1 Air Line Lubricator
6 L-301700 1 Male Elbow
7 L-460610 1 Hose End

Re-order WIWA specially formulated packing lubricant under part number

16 333 3.
Note: Exchange specially formulated packing lubricant every 50 hours of

operation, earlier in wet-cup pumps. Discoloration of lubricant indicates
packing wear or failure affecting pump performance.
4. Do not kink or bend high pressure fluid hose into less than a four inch
radius.
7.3 THE FLUID END
The WIWA high pressure pumps installed in the 10 series module are of a closed
design. The closed design features an integrated lube chamber having a small
vent hole only. This lube chamber connects between the air motor and the fluid
end and the travel of the displacement piston cannot be viewed. A specially
formulated lubricant filled into the lube chamber allows for wetting of the
displacement plunger on each upstroke preventing drying up or hardening of
deposits on the fluid piston.
Fluid pumps of the closed design feature the piston guided between two sets of
fixed packings constantly readjusted by a pressure spring which results in extra
long packing life.
The displacement piston has been given an approximate 0.3 mm (0.012") layer
of hard chrome to protect against wear; both the upper and lower ball valves
have tungsten carbide seats, reversible for wear, depending on the pump model
selected.
Leather and Teflon "V"-packings are installed as packing sets. They must be
arranged in sequence, leather/Teflon "only", i.e. "mixed". WIWA Teflon "V"-
packings are graphite filled and the leather packings Thiokol impregnated.

WIWA Air Motor D 200/120 - HD 42.175

Figure 8-9
Seal Kit L-660770

Repair Kit L-660340
Parts of Seal kit
Parts of Repair kit
Engineering Adhesive 50ml
Lubrication Grease (Acid-Free)

AIR MOTOR 175:1
ITEM PIECES PART N° DESCRIPTION

(1) 1 L-838080 Ring Screw Assembly
2 1 L-838090 Cover
3 1 L-838110 Muffler Assembly
4 1 Perf Metal Housing
5 4 L-838120 Retaining Nut
6 4 L-838130 Washer
7 1 L-838140 Cap
8 1 L-838150 Control Cylinder
9 4 L-838160 O Ring
10 4 L-838170 Threaded Bolt
11 2 L-838180 Nut
12 1 L-838190 Control Piston Assembly
13 1 L-838200 Control Housing
14 1 L-838210 Gasket
15 1 L-838220 Cylinder Head Assembly
(16) 1 Safety Valve
17 8 L-838230 Dome Nut
18 8 L-838240 Spring Ring
19 8 L-838250 Washer
20 2 L-838260 Retaining Screw
21 2 L-838270 Spring
22 2 L-838280 Bearing Bush
23 2 L-838290 Toggle Bearing
24 2 L-838300 Toggle
25 1 L-838310 Cylindrical Pin
26 1 L-838360 Sintered Bearing
27 1 L-838370 Retaining Ring
28 1 L-838320 Cover Assembly
29 2 L-838330 Screw
30 2 L-838340 Screw
31 2 L-838350 Washer
32 1 L-838380 Control Axle
33 1 L-838390 Dampening Spacer
34 1 L-838400 Carrier


37 1 L-838430 Sintered Bearing
38 2 L-838440 O Ring
39 1 L-838450 Plate
40 1 L-838460 U Seal
42 1 L-838470 O Ring
43 1 L-838480 O Ring
44 1 L-838490 Piston Plate
45 1 L-838500 Guide Ring
46 1 L-838510 O Ring
47 1 L-838520 Spacer
48 1 L-838530 Stop Guide
49 1 L-838540 Spring
50 1 L-838550 Guide Axle Assembly
51 1 L-838560 Cylinder
52 1 L-838470 O Ring
54 1 L-837001 Guide Bush Assembly
55 4 L-838610 O Ring
56 2 L-838620 Air Inlet Pipe
58 8 L-838250 Washer
59 8 L-838240 Spring Ring
60 8 L-838230 Dome Nut
61 1 L-838630 Bottom Assembly
62 1 L-838540 Spring
63 1 L-838640 Motor Axle
(64) 1 L-838650 Coupling
1 L-660770 Seal Kit
1 L-660340 Repair Kit

Section of a WIWA 175:1, Fluid End (Rev A)
Figure 8-10

ED 4 (A)
ELMAR SERVICES LTD No: TI-840553-E
TITLE: PUMP WIWA 85:1 & 175:1 FLUID SECTION >
Figure 8-11

PAGE 1 OF 1
E 3940 R. LARGUE 25/03/99

7.4: WIWA 85:1 PUMP
The 85:1 pump (Figure 8-12) is built the same way as the 175:1 pump. The only
differences are in the size of the air motor (see Figure 8-13). The fluid ends are
exactly the same.
4
5
2 8
WIWA 85:1, grease injection pump
Figure 8-12
1 L-840880 1 Pump 5 L-851120 1 Lubricator
2 L-861400 1 Gasket 6 L-301700 1 Male Elbow
3 L-812590 8 SHCS 7 L-460610 1 Hose End
4 L-201900 1 M-Hex Nipple 8 L-120160 1 Male Elbow

WIWA Air Motor D 140/120 - HDP 42.85

Figure 8-13
Seal Kit L-661430

Repair Kit L-661440
* Wear Parts
Parts of Seal kit

Parts of Repair kit

AIR MOTOR 85:1

(1) 1 L-837002 Ring Screw Assembly
2 3 L-837003 Dome Nut
3 3 L-837053 Washer
4 1 L-837004 Cover Assembly
5 1 L-837005 Air Muffler Assembly
6 1 L-837006 Spacer
7 2 L-837007 Threaded Bolt Assembly
8 2 L-837053 Washer
9 4 L-837008 O Ring
10 1 L-837007 Threaded Bolt Assembly
11 1 L-837009 Safety Plate
12 1 L-837010 Control Cylinder
13 1 L-837011 Control Housing Assembly
14 2 L-837012 Nut
16 1 L-837014 Control Axle
17 1 L-837015 Alignment, Insert
18 1 L-837016 Dampening spacer
19 2 L-837017 Spacer
20 1 L-837018 Carrier Assembly
23 1 L-837020 Spacer
24 3 L-837021 O Ring
25 4 Dome Nut
26 4 Washer
(27) 1 L-837022 Safety Valve
(28) 1 L-837023 Reducing Nipple for Air Regulator
(28) 1 Union Pipe for Air Maintenance
30 1 L-837025 U Seal
32 2 L-837026 Toggle


34 2 L-837028 Spring
36 2 L-837030 Threaded Pin
37 2 L-837031 Nut
38 1 L-837032 O Ring
41 1 L-837035 O Ring
42 1 L-837036 Spacer
45 1 L-837039 O Ring
48 1 L-837042 O Ring
49 1 L-837043 O Ring
50 2 L-837044 O Ring
52 1 L-837046 Bush Assembly
53 1 L-837047 Spacer
(55) 1 L-837049 Coupling
(56) 1 L-837050 Split Pin
(57) 1 L-837051 Tension Pin
59 4 L-837053 Washer
60 4 L-837054 Screw

7.5 FLUID END CHECK VALVE
There have been a few reports of randomly occurring problems experienced with
L-840750 WIWA Pumps installed in Elmar Grease skids.
Refer to drawing TI-840553-E, page 8-51 showing the fluid end.
Owing to corrosion created by poor quality seal grease or accumulation of
moisture in the grease tanks, the lower ball valve (item 20) can get stuck in its
seat (item 21). This causes the pump to stop pumping, even if the air motor
continues to cycle.
This problem can be fixed by replacing the steel ball part L-838900, with a
ceramic ball, part number L-830039, which resists corrosion, and has a higher
surface hardness than the steel ball.
The ceramic ball is a drop-in replacement for the steel ball.

TROUBLE PROBABLE CAUSE REMEDY
Pump will not operate. 1. Air supply closed. 1. Open.
2. Fluid end ball valves blocked. 2. Dismantle, clean. Check ball for
damage. Replace with Ceramic ball if
corroded (see para 7.5, section 8)
3. Air motor blocked. 3. Service/replace air motor.
Pump cycles regularly, but will not prime. 1. Fluid end ball valve sticking. 1. Loosen, clean. Check ball for damage.
Replace with Ceramic ball if corroded
(see para 7.5, section 8)
2. Suction tube or hose not properly installed (pump 2. Check for air leaks on hose and tube
pulls air). connections on fluid supply side and
seal or tighten.
3. Material too viscous. 3. Reduce viscosity
Pump works erratic, fluid flow pulsates 1. Pump pressure too low. 1. Increase air pressure setting.
2. Material too viscous. 2. Reduce viscosity
3. Fluid end ball valves sticking. 3. Loosen, clean, dissolve any

accumulation of gelled grease. Check ball
for damage. Replace with Ceramic ball if
corroded (see para 7.5, section 8).
4. Ball valves, packings or piston worn. 4. Replace.

TROUBLE PROBABLE CAUSE REMEDY
Fluid flow stops or becomes sluggish. 1. Fluid supply empty. 1. Refill.
2. Foreign matter lodged in foot valve. 2. Dismantle, clean.
3. Packings worn. 3. Replace.
4. Pumping rate too high. 4. Reduce air pressure and pump

speed.
5. Air motor leaks. 5. Replace O-rings.
Air motor freezes 1. Pump cycling rate too high. 1. Reduce air pressure.
2. Compressed air moisture content too high. 2. Install oil and water separator and
drain in shorter intervals.
3. Unfavourable operating conditions, high humidity, 3. Fill fog oiler with Kilfrost or
inadequate piping, fog, temperature around antifreeze/oil mixture and adjust droplet
freezing point. metering (Refer to section 8 page 92).

8.0 ARO PUMPS
The ARO 100:1 grease pump is fitted with a 6" air motor, part number
L- 840000 (Figure 8-15). The corresponding pump tube is the L-832430 (Figure
8-16). The maximum outlet pressure obtainable is 15,000 psi at 150 psi air inlet
pressure.
Notice that ARO Pumps have been discontinued in Elmar Modules. Elmar
recommends replacing them with WIWA pumps at the time of a major overhaul of
the modules.
8.1 OPERATION 100:1 RATIO PUMP (Refer to Figure 8-14 & 8-14a)
The ARO pumps are fitted with quick-connect couplers for the air supply. Either
or both pumps may be used by connecting the air supply at the pump. The pump
should then be operated from the control panel using the air supply valve and
regulator.
8.2 MAINTENANCE 100:1 RATIO PUMP
After use the grease pressure should be dumped and the air supply turned off. If
disassembly is necessary, consult the drawings for parts identification. During
reassembly, lubricate all parts, taking care with 'O' rings and 'O' ring surfaces.
Threaded sections of the lower pump tube should be degreased and assembled
using Loctite Studlock 270.

ARO: Double acting extrusion pump, up stroke
Figure 8-14

ARO: Double acting extrusion pump, down stroke
Figure 8-14a

ARO 6” Air Motor
Figure 8-15

AIR MOTOR PARTS LIST
REF PART N° DESCRIPTION

1 L-810230 Screw
2 L-832590 Deflector
3 L-810260 Screw
4 L-810240 Screw
5 L-832800 Washer
6 L-833490 Screw
7 L-833590 Washer
8 L-832510 Air Motor Cap
9 L-833450 Valve Guide
10 L-832260 Gasket
11 L-833250 Valve Plate & Pin Assembly
12 L-832270 Insert Spring Assembly
13 L-832630 Insert Valve
14 L-832830 Valve Plate Gasket
15 L-871760 O Ring
16 L-832280 Washer
17 L-870800 O Ring
18 L-832880 Air Motor Hd Assembly
19 L-833060 U Cup Packing
20 L-871750 O Ring
21 L-817360 Mach Screw
22 L-832910 Adapter
23 L-832120 Piston Assembly
24 L-832210 O Ring
25 L-833440 Nut
26 L-832900 Rod Assembly
27 L-832680 Air Cylinder
28 L-833460 Tube
29 L-832200 O Ring
30 L-832890 Air Motor Base & Bearing Assembly
31 L-833120 Valve Piston
32 L-832290 Valve Plate Gasket
33 L-832440 Valve Plate
34 L-832640 Insert

REF PART N° DESCRIPTION

35 L-833010 Valve Guide
36 L-832300 Washer
37 L-833470 Gland
38 L-832090 Seal
39 L-832150 O Ring
40 L-833000 Ext Rod
41 L-832460 Nut
42 L-833130 Piston Adapter
43 L-832110 Gland
44 L-832840 Washer
45 L-871740 O Ring
46 L-688020 Connecting Rod
47 Snap Ring
48 Guide Washer
49 L-832240 U Cup Packing
50 L-832450 Nut
51 Washer
52 L-833020 Rod & Ball Assembly

Disassembly



ARO: 100:1 pump, fluid end
Figure 8-16
TUBE
EXTENSION ROD
Adapter L-832410
Pin L-832760
Ball Guide L-832770
Ball L-832030
Piston and Cylinder

L-832390
Gasket L-832140
Tube L-832570
Washer L-832310
Primer Rod L-832040
Foot Valve Sleeve L-832070
Foot Valve L-832080 Washer L-832320
Washer L-832370
Washer L-832060 Foot Valve Seat L-832360
Primer Tube L-832580
Elastic Stop Nut L-832050

8.3 TROUBLE SHOOTING 100:1 RATIO PUMP
Caution: Always disconnect air supply and relieve material pressure before
attempting to service.
No grease at outlet Cause Empty grease tank.

(Pump continuously cycles)
Solution Disconnect the air, replenish the
grease supply.
Cause Foreign matter is holding foot

valve seats open in lower pump
tube assembly.
Solution Remove lower pump tube

assembly and clean valve seats.
Pump operates sluggishly, Cause Air motor is dirty or lacks

tends to stick when air is lubrication.
applied or control is opened
Solution Clean air motor.
Cause Insufficient air supply or volume of

air.
Solution Check air supply.
Air bypasses through the Cause Foreign matter is holding air valve
exhaust port open or lacks lubrication.
Solution Consult factory for nearest service

centre.
Motor stalls Cause Foreign matter in pump, hose,

control valve or spray tip
obstructing grease flow.
Solution Check grease supply hose and

control valve or tip.
Cause Air not getting to pump.

Solution Check air supply.

9.0 WIWA LOW PRESSURE TRANSFER PUMP
1. SYSTEM DESCRIPTION
The WIWA low-pressure pump comprises a compressed-air motor and a

fluid pump.
The fluid pressure is continuously variable with the regulator (pressure

reducer) attached to the air motor.
The transmission ratio of the low-pressure pumps is determined by the

square of the ratio of the diameter of the air motor piston and the diameter
of the fluid end piston rod.
The pressure is derived from by the transmission ratio (stated on the type
plate) multiplied by the air supply pressure. Example: pump pressure ratio
5:1 x air supply pressure 5 bar = Material pressure 25 bar.
The Air Motor (Figure 8-17)
WIWA air motors are designed specifically for driving high and low-pressure
pumps.
The Fluid End (Figure 8-18)
The "open" design of WIWA low-pressure pumps is delivered as standard.
The air motor and pump are connected only by spacer bolts with this
configuration, so that operation of the pump can be observed and
monitored.
The pump is equipped with Teflon packings as standard. Specially

impregnated leather packings are available for special purposes, e.g. use
with abrasive and coarsely pigmented materials.
The top packing can be adjusted manually by means of the packing nut in
the form of an oil cup while the pump is running. (Caution: maximum air
supply pressure 1 bar).

In order to utilise the advantages of a packing lubricant, the top packing of

the pump takes the form of a "flushing agent" cup. The piston rod is wetted
with the lubricant on each upward stroke, thus preventing the delivery
medium from becoming encrusted on the piston rod. This protects the
packings and minimises wear.
A hard chrome coating of above-average thickness guarantees the piston

rod a long service life.
Both ball valves have carbide seats. The pump is also available with nylon
valve seats on request. With the "open" configuration, the packing pressure
exerted on the piston must be readjusted manually by turning the top
packing nut, which takes the form of an oil cup, while the pump is running.
3. STARTING UP
1. Once installed, check that the pump is operated entirely properly (test
medium: oily emulsion). In order to avoid impairing the delivery
medium, thoroughly flush the pump with a solvent before using for the
first time.
2. Add packing lubricant almost up to the edge of the flushing agent cup
of the packing nut. Make sure that the piston rod of the material pump
is facing downwards and completely inserted in the flushing agent cup.
4. MAINTENANCE
1. Open the water trap under pressure every day (several times a day if
the compressed air is moist) and blow out the condensate.
2. Check the correct setting (batching) and filling of the mist oiler. We
recommend one drop about every 5 to 10 double strokes.
3. Check the amount of packing lubricant in the flushing agent cup.
Note: The packing lubricant must be renewed after approximately 50

operating hours.

Caution: Changes in the colour of the lubricant indicate faulty packings

accompanied by impaired performance of the system. In this event, adjust
the packing. The packing must be renewed if it still fails to achieve a tight
seal (wear).

WIWA Air Motor D 70/42 - 02
Figure 8-17
Seal Kit L-837174

Repair Kit L-662050
* Wear Parts
Parts of Seal kit

Parts of Repair kit


1 2 L-837216 Screw
2 2 L-837215 Screw
1 L-837214 Cover Assembly
3 1 L-837213 Cover not illustrated
1 L-837212 Bush
5 1 L-837210 Washer Serrated
7 1 L-837208 Bolt
8 1 L-837207 Spacer
9 1 L-837206 Carrier Assembly
12 4 L-837203 Screw
13 2 L-837202 Cylindrical Pin
14 4 L-837201 Washer
15 1 L-837200 Dampening Plate
(16) 1 L-837199 Handle
17 2 L-837031 Nut
20 1 L-837196 Male Adapter only for water pump
(20) 1 L-688010 Male Adapter
21 1 L-837195 Air Inlet Pipe
22 2 L-837194 O Ring
(23) 1 Safety Valve
24 1 L-837193 Shoulder Bush
26 1 L-837191 Spacer
27 1 L-837190 U Seal
28 1 L-837189 O Ring
30 1 L-837187 O Ring
32 1 L-837185 Spacer
33 2 L-837026 Toggle
35 2 L-837184 Spring
39 1 L-837180 O Ring
41 1 L-837178 O Ring
43 1 L-837176 Guide Bush Assembly
1 L-837174 Seal Kit

WIWA Fluid End ND 40/42
Figure 8-18
Seal Kit L-837217

Repair Kit L-662060
* Wear Parts
Parts of Seal kit

Parts of Repair kit

FLUID END

(2) 4 L-837237 Screw
3 1 L-837236 Connecting Ring
4 1 L-837235 Pump Head
5 1 L-837234 Gasket
6 1 L-837233 Male Adapter
7 1 L-837232 Spacer
8 1 L-837231 U Seal
(10) 1 L-837230 Tension Pin
11 1 L-837229 Piston Rod
12 1 L-837071 Nut
13 1 L-837228 Cylinder Head
15 1 L-837226 U Seal
16 1 L-837225 Ball
17 1 L-837224 Valve Housing
18 1 L-837223 Tube
1 L-837222 Bottom Valve Assembly
19 1 L-837221 O Ring
20 1 L-837220 Ball Stop
21 1 L-837219 Ball
22 1 L-837218 Valve Housing
1 L-837217 Seal Kit

10.0 ARO 4:1 RATIO TRANSFER PUMP
An ARO transfer pump may be part of the grease skid. This is the 4:1 ratio L-
840600 model (see Figure 8-19).
OPERATION/MAINTENANCE
Should pump operate but dispense little or no grease, check for:
1. Inadequate supply of grease or possible malfunctioning of the foot valve,

which would prevent grease from feeding into suction tube.
2. Dirt or foreign matter in the foot valve or other cause, which may be
preventing it from closing on downstroke of piston.
If unit should fail to operate, the following procedure will be helpful in determining
the cause:
1. Check air pressure at pump to ensure air line is not obstructed and air is
being supplied to pump.
2. If insufficient air is not the trouble, disconnect the quick coupler at pump and
then detach check valve by loosening swivel nut. Remove slowly as
pressure may be built up in pump. Hold rag at this point and apply air to
pump. If pump now operates, there is obstruction in material line, reel, or
control handle. If, however, pump will still not operate, Q-check the pump.
Consult Elmar if trouble cannot be located.

POTENTIAL OPERATING FAULTS AND REMEDIES
Potential Operating Fault Possible Cause Remedy

Material line blocked Carefully clean material line.
Ball valves blocked Dismantle and clean pump.

Pump fails to run
Filter blocked Carefully clean filter.
Control jammed Contact Elmar Services.

Ball sticking in foot valve (dried Lift the ball in the foot valve
material) through the inlet bore to release
it.
Suction hose or pipe in union Tighten suction hose or pipe
leaking and reseal threaded unions if
Pump runs regularly but does
necessary.
not take in any material
Suction filter contaminated Clean suction filter.
Viscosity of delivery medium too Thin the delivery medium or

high select a more powerful pump.
Valves contaminated Clean system and allow to
stand in a solvent if necessary.
Valves, packings or piston rod Renew worn parts.

worn
Delivery pressure too low Increase air supply pressure.

Irregular pump operation and
Delivery medium viscosity too Thin the delivery medium or
decrease in delivery rate
high select a more powerful pump.
Suction and/or paint filter Clean filter.

blocked
Contact Elmar Services.
Air motor control faulty
A more powerful pump has to
System being overloaded be used.
Pump operates even when Valve, packings or piston rod
Renew worn parts.
discharge stations are closed worn
Decrease air supply pressure.
Number of strokes too high
It may be necessary to use a
more powerful pump.
Install a maintenance unit if not

Supply air contains too much
already provided. Empty water
Air motor freezes condensate.
trap more frequently.
Add anti-freeze to the oiler of

Highly unfavourable operating
the maintenance unit and set for
conditions (high humidity or
one drop every 5 to 10 double
temperatures near freezing)
strokes.

4:1 ratio transfer pump, L-840600
Figure 8-19
ARO
Air Motor
Air Motor
Fluid End

11.0 AIR REGULATORS
Air regulators used on Elmar skids all have the same operating principles and
similar construction. Care must be taken when carrying out maintenance as
some parts are manufactured in moulded plastic and therefore are prone to
break under excessive force and cross-thread easily.
In most applications we have a supply air pressure of approximately 100 psi and
we wish to supply a pump with a regulated air pressure.
Turning the control knob compresses the large coil spring, which in turn pushes
upon the diaphragm, closes the needle valve and unseats the shut-off valve.
When the shut-off valve is unseated, air is able to flow and the regulated air
increases in pressure.
The regulated air pressure increases and the resultant force upon the diaphragm,
due to the air pressure, approaches and eventually overcomes the spring force.
The diaphragm will then move and further increase the spring compression. The
shut-off valve will follow the travel of the diaphragm and will eventually seal,
preventing any more air to flow through the regulator.
As the regulated air pressure decreases, the spring extends and moves the shut-
off valve. This movement will unseat the shut-off valve allowing air to flow freely.
Once again the regulated air pressure will increase to that determined by the
compression of the large spring.
There are two types of regulator used on Elmar control modules and they both
work in the same way (refer to Figure 8-20).
1. WILKERSON REGULATOR N° L-851710
This regulator is easily recognised by the green colour of the body and by
the transparent dial with digits behind it.
The specifications for the Wilkerson are:
Primary Pressure: 300 psi maximum

Adjusted Pressure: 160 psi maximum
Temperature Range: 0 - 170 degrees F (-18 - 79 degrees C)
Seal Kit Part N°: L-660390

2. ARO REGULATOR N° L-680224
Easily recognised by its all black appearance.
The specifications for the ARO are:
Primary Pressure: 250 psi maximum

Adjusted Pressure: 250 psi maximum
Temperature Range: 0 - 180 degrees F (-18 - 82 degrees C)
Seal Kit Part N°: L-660300
For trouble free operation proper lubrication of the regulator is essential. When
any of the following symptoms occur, lubricate with the recommended lubricant
according to the manual.
1. Excessive relief venting.
2. Inability to attain high secondary pressure.
3. Erratic secondary pressure.
Clean all parts in the valve assembly and valve seat and lubricate with Dow
Corning 55M. If this is not available use a heavy grease such as Parker 'O' Ring
Lube, Lubriplate or Molykote.
Note: Do not use oil as lubricant.

Regulator valve
Figure 8-20
Control Knob
Coil Spring
Diaphragm
Needle Valve
REGULATED AIR AIR INLET
Shut Off Valve
Coil Spring

12.0 HOSE REELS
WHE integrated grease skids designed by Elmar include reel-mounted hoses.

Wet-centre reels are advantageous since the hoses are permanently connected
to pumps and control systems and are less prone to damage.
1. GENERAL
All reels employ a gland system to maintain hydraulic communication with

the controls. This allows any length of hose to be unwound. A 3:1 ratio
hand gear drive is used on all reels (see Figure 8-21 & 8-21a).
Note: Reels must not be rotated with pressure in the hoses. This will
reduce ‘O’ ring seal life.
2. MAINTENANCE
The reels are designed for easy maintenance. The ‘O’ ring and back-up
rings should be changed periodically (suggested every 12 months
depending on severity of use).
3. GREASING
Each hub has two grease nipples accessible when the hose is unwound.
Warning: Only one slow pump of the grease gun is necessary otherwise
the bushings and ‘O’ ring dust seal could be pumped out.
4. BRONZE BUSHINGS
These are designed to centralise the piston within the hub and also to act
as a bearing surface. These may wear slightly over a period of time.

5. BACK-UP RINGS
‘O’ rings, size 224, on the pistons have a back-up ring to aid the life of the
‘O’ ring and to ensure the high pressure rating.
Always install the back-up ring on the side of the ‘O’ ring away from the
pressure with the curved side facing the ‘O’-ring.
6. DISMANTLING
The whole assembly can be removed from the frame after unbolting the
manifold and support blocks. If desired the manifold block can be left in the
frame by removing the socket head screws in the block side - if this is done
care should be taken with the ‘O’ ring seal between the piston and manifold.
The piston can now be removed from the hub by pushing it from the
manifold end. On double port reels, you must mark the position of the
piston to be able to reposition it in the same position. (See paragraph 7)
7. REASSEMBLY
This is the reverse of the dismantling process. Care should be taken not to
damage the ‘O’ rings on the piston. They should be lubricated with Castrol
Spheerol LMM grease or similar to ease reassembly of the piston and hub.
On double port reels it is important when bolting the manifold block to the
piston to ensure that the piston is placed exactly as it was when
disassembled and not rotated through 180 degrees. This is to ensure that
on moving a BOP valve to open that the BOP does in fact open and not
close. This applies similarly to tool trap, tool catcher and line wiper/stuffing
box reels.
Due to continuous development the exact specification of reels may have

changed over a period of time. The 'O' ring seal kits for the reels may
therefore contain extra 'O' rings.

Typical E-Lite Series reel layout
Figure 8-21

Typical Wet Centre Reel
Figure 8-21a
"O" Ring with

Back-Up Ring
Bevel Gear
Hydraulic/
Grease Line
Grease Nipples

13.0 HOSES
1. GREASE HOSES
High pressure grease hoses are made of a rubber or synthetic body,

reinforced by steel braiding. End fittings are swaged on both ends and
union connections screwed onto them.
Rubber/steel hoses are suitable for 10,000 psi working pressure in liquids.
For higher pressures or gas operations polyflex hoses with Nylon/Kevlar

lining and stainless steel braiding are recommended. These hoses, rated
13,000 or 26,000 psi WP are impervious to gas, corrosion resistant and are
not affected by H2S or CO2.
The ratings of assembled hoses is limited by the rating of the union

connectors. Autoclave unions must be used for working pressures above
10,000 psi. Titanium hose ends are recommended when CO2 or H2S are
present.
To avoid excessive pressures losses in the hoses, ID should be 1/2" or

larger.
2. HYDRAULIC HOSES
Hoses used for hydraulic fluids, water, glycol, or air, use rubber/steel
construction and have a variety of end fittings. They come with IDs from
1/4" to 1" and ratings of 1,000, 3,000, 5000 or 10,000 psi.
3. MAINTENANCE
1 - GENERAL
Hose ends are designed to be stronger than the hose, so that the hose
bursts before the end blows off. This is verified periodically at the factory.
Depending on the usage of the hose several failures can occur:

a) Outer cover cut/damage allowing corrosion of the high tensile steel

wires.
b) Mechanical damage to the hose at the crimped end due to excessive

sideways pull.
c) Mechanical damage to the hose insert between the crimped end and
the fittings due to excessive side loads, e.g. pulling on a hydraulic
hose to move the pressure equipment in the derrick.
d) Hose "kinking".
2 - PROCEDURE
a) To avoid problems following any damage the hoses should be

pressure tested to 50% above the expected working pressure before
every job for 5 minutes and inspected for damage when being
rewound onto the reels, after the job.
b) If corrosion of the end fittings is a problem they should be replaced

every year. Corrosion can be avoided by spraying "Control 450"
Elmar Part N° L-880710.

14.0 MAINTENANCE SCHEDULE CONTROL MODULE
Refer to relevant section in manual for parts identification and

disassembly/assembly instructions.
INTERVAL OPERATION
Daily Top up Airline Lubricator. Check air line filter is kept clean
and is working correctly.
12 Monthly Disassemble all pumps. Check for corrosion and wear.
Disassemble hose reels. Renew 'O' ring seals and back-

up rings.
Note: If required Elmar, Aberdeen, UK, will undertake all 12 month servicing.
Please contact the servicing department for further details. All spare parts are
available. See relevant section in manual for parts lists.
Service telephone number +(44) 1224 740261.

15.0 FACTORS AFFECTING GREASE INJECTION PERFORMANCE

FACTORS AFFECTING GREASE INJECTION PER
The ability of a grease injection system to maintain a good seal depends on
several factors:
1. Grease type and viscosity in relation to ambient temperature

2. Clearance between wireline and flowtube ID
3. Number of flowtubes
4. Wireline speed
5. Pump performance characteristic
6. Grease hose length and inside diameter
7. Air pressure available at the grease pump.
Points 1-4 have been discussed elsewhere.
• Pump performance: To obtain and maintain a seal, it is important not only to

inject grease at a pressure 20% higher than the well pressure, but also to
supply enough volume of grease to replace the volume carried out by the
wireline or lost in the well bore. Grease pumps have a characteristic
deliverability curve: flow-rate vs. output pressure. As shown by experimental
results (Figure 8-22), the flow rate drops considerably with increasing
pressure. The best pump is the one delivering the highest flow-rate at the
chosen operating pressure. If the pump is unable to deliver the flow rate
required to maintain seal at a given wireline speed, it might be necessary to
have two pumps in parallel and dual injection points. This is recommended for
high pressure gas wells
• Grease hose length and ID: The length and ID of the grease hose govern
the drop of pressure between the output of the pump and the input to the
grease head. Practical experiments have shown (see Figure 8-23):
• High pressure hoses act as a choke.

• The longer the hose, the higher the pressure drop, or the smaller the flow
at a given pressure.
• The smaller the ID the higher the pressure drop
So, to achieve a flow of 0.2 gallons per minute into a 10,000 psi well with a 150 ft
long 0.4” ID hose, it will require 15,000 psi at the pump, well above the
conventional 12,000 psi.

Grease pump performance curves
Figure 8-22
16,000
EXPERIMENTAL RESULTS USING THE THREE MOST
15,000 COMMON AIRDRIVEN GREASE PUMPS
AIR SUPPLY: 100 psi (6.9bar)

HOSE: 120ft (36.5m) 1/2” ID (12.7mm)
14,000 GREASE: Polybutane Multigrade (L-88280
ELMAR 175:1 TEMPERATURE: 14˚C
L-840750
13,000 P IN PRESSURE AT PUMP OUTPUT
P OUT PRESSURE AT END OF 120FT HOSE
12,000
LINCOLN 140:1
L-840810
11,000
10,000
ARO 100:1
L-840000
9,000
8,000
7,000
6,000
5,000
4,000
P OUT
3,000
2,000
P IN
1,000
PRESSURE
(PSI)
1 2 3 4 5 6 7
FLOW RATE (LITRES PER MINUTE)

Pump Pressure v Grease Flowrate
Figure 8-23
HOSE: .50 ID HOSE: .50 ID

.40 ID .40 ID
.30 ID .30 ID
25 25
20 20
PUMP PSI 1,000
PUMP PSI 1,000

15 15
10 10
5 5
.50 1.00 1.50 .50 1.00 1.50

GMP GMP
PRESSURE VS. FLOW 100' HOSE 5,000 PSI WELL PRESSURE VS. FLOW 150' HOSE 5,000 PSI WELL
HOSE: .50 ID HOSE: .50 ID

.40 ID .40 ID
.30 ID .30 ID
25 25
20 20
PUMP PSI 1,000
PUMP PSI 1,000
15 15
10 10
5 5
.50 1.00 1.50 .50 1.00 1.50

GMP GMP
PRESSURE VS. FLOW 100' HOSE 10,000 PSI WELL PRESSURE VS. FLOW 150' HOSE 10,000 PSI WELL
• Air pressure: The grease pump output pressure is directly proportional to

the input air pressure. It is important to have available an air supply that
can maintain constant air pressure at the pump irrespective of the flow
rate. Air supply lines from the compressor’s tank should be kept as short
as possible, and have a large ID.
CONCLUSIONS
• Choose a pump that can deliver a reasonable flow-rate at the pressure you
require to operate at
• Adjust grease injection pressure taking into account the pressure drop in
the grease hoses.

16.0 WELLSITE OPERATION
1. RIG UP
• Place the skid with reels facing the rig

• Connect hose to pressure equipment as it is rigged up
• When opening BOPs manually set air on/off valve on control panel to off, set
BOP valve handle to open and open the dump valve, located to the right of
the main hydraulic pressure gauge
• Caution: Always check for correct operation of tool catcher and BOPs before
rig up, i.e. open and not close.
• Pump up the accumulator (3,000 psi maximum) and turn the accumulator
valve off
• Set hydraulic pressure to 1,200 psi
• Set BOP, tool trap and tool catcher valves to the desired position
• One grease pump should be sufficient to run the job, but remember that with
120 ft of hose the pressure losses along the grease line are high. It may be
necessary to pump 2,000 psi - 3,000 psi above well pressure to regain a lost
seal or to keep up with excessive grease consumption if the flowtubes are
worn.
2. RIG DOWN
• When closing BOPs manually set air on/off valve on control panel to off, set
BOP valve handle to close and open the dump valve, located to the right of
the main pressure gauge
• Ensure that all pressure including accumulator pressure is dumped. All
pressure must be removed from the hoses before reeling up by moving the
BOP, tool trap and tool catcher valves from open to close twice.

17.0 FREEZING OF AIR-OPERATED PUMPS
In cold temperatures, air operated grease and hydraulic oil pumps can freeze up.
A pump stroking at a very high rate will have more tendency to freeze-up,
another reason to keep the size of your flowtubes close to the wireline ID.
Aggravating conditions are high moisture content in the air supply, high ambient
humidity (fog), and ambient temperature near freezing. In such conditions it is
imperative to have a water separator system on the air supply, which must be
purged frequently (3-4 hour's interval). In addition an Air Line Lubricator (Fog
Oiler) must be used at, or close to, the pump input. The lubricator must use
Kilfrost, (Elmar Part N° L-880000) a specially formulated lubricant/antifreeze
mixture that absorbs humidity. If Kilfrost is not available you can use a mixture of
glycol (neat antifreeze) and SAE 10 Oil, or other thin lubricating oil. Use a 50-50
mixture. Mineral oil will not absorb water so it will be less effective at preventing
icing.
Notice that Haskel pump air motors are lubricated at assembly and should not
use the oil/glycol mixture that has a tendency to wash away the lubricant. In
exceptional circumstances you might be obliged to use the antifreeze mixture. In
this case you should continue to use a fog oiler with the Haskel pump, as the
original lubricant will have been washed away.
With WIWA, ARO, and Lincoln pumps, a fog oiler is always recommended, and
Kilfrost or a mixture of Glycol and SAE 10 oil must be used in it whenever
temperature is low and/or ambient humidity is high.

18.0 HYDRAULICALLY DRIVEN GREASE PUMPS
Hydraulically driven grease pumps also called “Intensifiers” use hydraulic

pressure to generate high pressure grease for the control head.
Grease intensifiers use a variable rate hydraulic pump powered by a dedicated

diesel engine or electric motor. Alternatively the hydraulic pump can be driven by
a mast/ crane truck engine through a PTO.
Grease intensifiers can generate grease flow rates at high pressure (15K and
above) larger than air driven pumps.
They are used for 20K pressure control equipment, and sometimes for 15K
equipment when a reliable air supply is not available.
They are also often used in very cold artic conditions when a dry air supply is
not available and humidity in the air causes the air-operated pumps to freeze-up.
Maximum output pressure is a function of the intensifier ratio and of the hydraulic
pump output pressure. Commonly available intensifiers have ratios varying from
1:7 to 1:12, with hydraulic oil inputs from 2,000 to 3,000 psi the available
maximum grease pressure is in the range 21,000 to 30,000 psi.
18.1 THE “HYDROLEX” INTENSIFIER
This unit (see fig.8-24) has the capability to pump up to 21,000 PSI and a rated
output of 1.5 gallons per minute at 20,000 PSI working pressure. The unit can be
rated to 30,000 PSI. The unit is driven by a 3 cylinder water cooled diesel engine
driving a remote compensated hydraulic pump which drives the intensifier pump.
The remote compensator controls the hydraulic pressure usually between 0-
3,000 PSI which varies the Intensifier pump grease pressure. The intensifier
pump is a double end reciprocating type pump, powered and controlled by a
unique hydraulic system.

Figure 8-24: Intensifier Skid
Figure 8-25: Intensifier Skid Control Panel

18.1.1 SAFETY
SAFETY IS EVERYONE'S RESPONSIBILITY
CAUTION
• Read the service manual before operating

• Observe all safety precautions and ensure other crew members have been
made aware of them
• This system is capable of producing high pressure
• To avoid component rupture and possible injury, regulate inlet air pressure so
outlet pressure does not exceed the maximum working pressure of any
component in the set up
• Check pressure rating and compatibility of all connections
• Clear area of unnecessary personnel
• Make sure valves and regulators are in correct position throughout the
operation
• Do not try to tighten or loosen connections under pressure
• Do not weld, file or use metal stamps on the pressure equipment - these can
start cracks
• Do not overtighten any control valves (hand tight only)
• Do not attach anything to this equipment unless you are sure of its pressure
rating
• Watch for trapped pressure. Bleed off fully before breaking down unions, etc.
Warning: High Pressure
Never allow any part of the human body to come in front of or in direct
contact with the material outlet. Accidental operation of the pump could
cause an injection into the flesh. If injection occurs, medical aid must be
immediately obtained from a physician.
Servicing: Before servicing, cleaning or removing any component, always

disconnect or shut-off power source and carefully relieve all fluid pressure from
the system.

18.1.2 GENERAL CHECK OF UNIT PRIOR TO OPERATIONS
Walk around the unit and check:

• Hydraulic Oil level
• Diesel fuel level
• Ensure all valves that supply grease, oil and fuel are open
• Back out pressure compensator
• Open re-circulate valve
18.1.3 UNIT OPERATION
• Turn diesel engine on.

• Compensator by-pass to the “OFF” position.
• Carefully turn the compensator valve clockwise, intensifier should begin to
stroke.
• Grease pressure gauge on control panel will indicate intensifier is stroking.
• Close re-circulate valve slowly to increase grease pressure while turning
compensator control valve.
• Once pressure is reached the compensator by-pass can be switched to the
“ON” position.
• To stop the unit Fluid On/Off valve should be in the down position. Turn
engine off and adjust the compensator valve counter clockwise until tension is
off.

SECTION 9 - PRESSURE TIGHT SEALS AND FITTINGS

Obviously our pressure equipment requires pressure tight connections. One way of
achieving this is to use threaded connections with a metal-to-metal seal. Another
method is to use a seal or 'O' ring. A third method is to use a flanged connection and a
fourth method is to use a grease seal as is done in the GIH. A quick summary of the
different methods is given below.
9.1 THREADED METAL TO METAL SEAL
Figure 9-1 shows a butted connection where the seal is made on the shoulder of
the pin connection. High torque is required to make the seal. This method is not
very satisfactory as any imperfection in the surface of the shoulder can easily
lead to a leaky joint, especially if insufficient torque has been applied. Drill pipes
tool joints use this type of seal.
Figure 9-2 shows an alternative method. The threads of the pin and box section
are tapered. When screwed together the threads themselves make the seal.
This has the advantage over the previous method of having a larger sealing area
and thus less chance of a leak - even if one thread happened to be damaged.
As an emergency procedure (and only in emergency!) the threads could be
coated with Teflon tape or a thick grease (e.g. pipe dope). This method also
requires high torque to make up the joint.
The tapered thread is used on casing, tubing and line pipe connections.
Standard thread profiles are defined by API and these threaded connections are
generally called “API Threads”. Line pipe threads have a sharp “V” profile,
while casing and tubing threads have rounded crests and troughs. (See Figure
9-3).
Butted Connection Figure 9-1
Seal at Shoulder

Tapered Thread Joint
Figure 9-2
Seal on Threads
These seals will only seal if made-up tight
Figure 9-3
Line Pipe, V THD Form
Casing and Tubing, 8RD THD Form

Maximum acceptable working pressure for API threaded connections depend on

the pipe size, as specified in Table 9-1.
TABLE 9-1: PRESSURE RATING FOR API THREADED CONNECTIONS
Size range Max. Working Pressure

API Thread Type Inches psi
1/2 10,000
3/4 to 2 5,000
Line pipe
2 1/2 to 6 3,000
Tubing Round Thread 1.050 to 4 1/2 5,000
4 1/2 to 10 3/4 5,000
Casing, 8 Round 11 3/4 to 13 3/8 3,000

and Buttress Thread 16 to 20 2,000
Remember that API tubing connections rely on torque to seal properly. API
values of torque are given in Table 9-2.
TABLE 9-2: RECOMMENDED TORQUE FOR TUBING CONNECTIONS
Tubing Size Grade API Thread Torque

2 3/8” J-55 8 RD 1200 lbs.ft
2 3/8” N-80 8 RD 1500 lbs.ft
2 7/8” J-55 8 RD 1500 lbs.ft
2 7/8” N-80 8 RD 1800 lbs.ft
Tapered threads are also used to join the pieces which make-up BOP manifolds
of the equalising hose type. In this case NPT (National Pipe Taper) threads are
used. NPT threads are also used extensively for nipples and fittings in the
petroleum industry, and have a profile similar to Line Pipe. The half inch threads
are easily damaged, and time consuming to make up.
In all API Threaded connections the threads have a dual function: they ensure
the mechanical connection (therefore bear the loads), and make the seal. API
threads used in a well completion or in WHE are therefore partially exposed to
the well fluids. They can suffer corrosion and H2S attack, and therefore cause
catastrophic failures. For this reason API Threads are banned by most users of
Pressure Control Equipment, except for 1/2” NPT fittings.

9.2 PREMIUM SEAL CONNECTIONS
“Premium Seal” connections have a thread-independent sealing mechanism,

either a metal-to-metal seal or an O-Ring seal. The threads are not exposed to
well fluid, but only ensure the mechanical connection.
“Premium” threaded connections with metal-to-metal seal have been developed
for tubing and casing and are certified to seal in gas under pressures as high as
15,000 psi. (Vallourec VAM, Mannesman TDS, Hydril PH, CFJ, CS, etc). These
connections have special thread and shoulder profiles and specified torque
values for sealing.
ACME threads are rugged and easy to make-up. They are extensively used in
oilfield equipment for any connection that is to be made up and broken out
quickly and repetitively. ACME threads do not seal and must be coupled with an
O-ring type seal. (See Figure 9-4).
Figure 9-4: Acme Threads
o
29
Elmar Light Weight Lubricators use a proprietary improved Premium Seal

connection between the tube and the unions. The primary seal is a metal-to-
metal seal designed to be effective at low torque (500 lbs.ft). This is backed-up
by an O-Ring. The O-Ring and the connecting threads sees pressure and well
fluids only in case the primary metal-to-metal seal fails. Therefore the O-Ring
requires replacement only once a year or whenever the metal-to-metal seal is
broken.

9.3 O-RING SEALS
9.3.1 END FACE O-RING SEALS
This type of seal was used to connect up the obsolete Yale (Wing) Union of WHE
and is used for grease hose unions. The O-Ring is seated in the face of one half
of the joint. The force needed to keep the two halves of the joint against each
other is provided by means of a nut (Figure 9-5). The joint needs to be made up
fairly tightly to keep the O-Ring compressed, ensuring a seal. A small amount of
‘unscrewing’ will reduce the sealing ability. Does not require as much torque as a
metal-to-metal type seal.
“O” Ring Seal - End Face Figure 9-5
Ring Seal
Thread Seal
9.3.2 INTERNAL O-RING SEAL
This type of seal, shown in (Figures 9-6 & 9-7) has the advantage that the
connection does not need to be tightly joined: The threads are used only to keep
the two ends together, and not to compress the O-Ring - therefore these type of
connections need to be only hand tight. It is used in situations where relative
movement of the two components is necessary, e.g. between the ram stems and
the body of the Wireline Valves. It is also employed in connections requiring fast
and easy coupling such as the quick unions used to join the major WHE
components (Lubricators, Wireline Valves, etc).

Internal seal - “O” Ring in Pin
Figure 9-6
Internal seal - “O” Ring in Box
Figure 9-7
Will seal even if thread is loose

9.3.3 PROBLEMS WITH O-RING TYPE SEALS
The immediate problem faced in the field is that of keeping the 'O' rings and the
sealing surfaces free from dirt. The very nature of the WHE, with its grease seal
mechanism, means that everything is invariably coated with a sticky layer of
grease. Particles of dirt, sand, grit, etc, are easily trapped in the grease and can
prevent an effective seal and damage the rings. All 'O' rings should be cleaned
before making up a joint. A thin layer of grease is useful for helping to maintain
the seal.
A longer-term problem is damage or corrosion of the sealing surfaces. These

need to be smooth to perform their required function. If they are scored or
heavily corroded, a seal cannot be maintained. Hence it is very important to
remove all 'O' rings at the scheduled maintenance intervals, and inspect the
seats. 'O' rings exposed to a corrosive environment, e.g. drilling mud, should be
removed frequently so that the seats can be properly cleaned. A thin layer of
grease will help to prevent the corrosive elements coming in contact with the
seat.
9.3.4 THE THREE RING SYSTEM
O-Ring seals provide a way of making a rapid, pressure tight connection.

However, there are limitations to the conditions in which the O-Ring can retain
the seal.
The old style WHE risers used a connection of the type shown in Figure 9-6.
These connections can be made and broken repeatedly. In addition risers often
have to be connected when not perfectly aligned. To allow the joints to be made
up easily the difference between the pin OD and box ID is relatively large. This
means that the seal ring must be elastic and extend a long way beyond the seat.
When stabbing the pin into the box the 'O' rings become deformed especially if
the risers are not aligned, the O-Ring is also deformed when the system is
pressurised. Moderate deformation (Figure 9-8a) occurs at low pressures (this is
the "normal way for an O-Ring to seal) and severe deformation (Figure 9-8b)
occurs at high pressures.

The constant mechanical stress imposed on the 'O' rings either during the
connection of the joint or when under pressure, can weaken the 'O' ring,
particularly if the ring is in contact with a corrosive environment (drilling mud, gas,
etc). In severe cases the O-Ring will no longer seal and can rupture under very
high pressures (Figure 9-8c).
a) Low Pressure - Moderate Deformation

"O" Ring
P Seal Protector
b) High Pressure - Severe Deformation Anti-Extrusion Ring
FIGURE 9-9
!!!! The Three Ring System
!!
!!
RUPTURE
P
c) "O" Ring Stressed - Damage Occurs

P
“O” Ring Rupturing Under Stress The Three Ring System Sealing Against
Pressure
Figure 9-8 Figure 9-10
"O" Ring "O" Ring

Seal Protector Ring Seal Protector Ring
Split Ring with Split Ring with
Bevelled Edge Bevelled Edge
Three Ring System Three Ring System Sealing

Against Pressure
Figure 9-11a Figure 9-11b

To surmount this problem, a multiple ring system has been developed and is
extensively used throughout the pressure equipment manufactured. The three
rings are the 'O' ring, seal protector ring and anti-extrusion ring as shown in
Figure 9-9. The anti-extrusion ring is made of steel or a hard plastic material and
is chamfered on one side. The chamfered edge faces away from the 'O' ring.
When pushed back, due to the pressure acting on the 'O' ring, the anti-extrusion
ring is forced to expand as the chamfered edge slides up the matching bevelled
edge of the seat. The anti-extrusion ring is a split ring and the two ends overlap
as shown in Figure 9-11a. The seal protector ring is composed of elastomer. It
is used to protect the O-Ring from possible damage due to the expansion and
contraction of the anti-extrusion ring. Finally the O-Ring itself makes the seal
against pressure (Figures 9-10 & 9-11b).
Elmar equipment uses a two-ring system for "up to" 10,000 psi WP and a 3-ring
system (with Teflon non-extrusion ring) in 15,000 psi equipment. The Elmar
system uses a glass-filled PTFE back-up ring, maintain in place by a small O-
Ring (Figure 9-12). Elmar does not use the chamfered groove system due to
damage sometimes caused by the metal non-extrusion ring.
Figure 9-12
PTFE Back-Up Ring

"O" Ring
In some parts of the WHE, where the connection is never broken, e.g. the
internal seals of the Wireline Valve, the 3-ring system may be replaced by a one-
piece Buna plastic seal ring (Figure 9-13). This was done to try and prevent
damage to the equipment if steel rings were improperly installed.
Notice:
In a three-ring system, the seal protector and non-extrusion rings are always
installed on the low pressure side, with the O-Ring on the high pressure side
(Figure 9-9). If high pressure is on both sides a double set is required.

Integrated ring system
Figure 9-13
Non - Extrusion Ring Non - Extrusion Ring

(2 Req)
Seal Protector Ring Seal Protector Ring
(2 Req)
"O" Ring "O" Ring
o o
30 30
Buna N Ring "CP" Hard Plastic Split

Ring "TK" (2 Req)
Soft Buna N Double

Lip Seal "TL"
o o
30 30
BOP End Cap Seals Piston Seal

(Pressure on one side) (Pressure on both sides)

9.4 FLANGE SEAL
API flanges are sealed by means of a steel ring. The ring is placed between the
flanges and located in the seal ring grooves. A metal-to-metal seal is formed
(Figure 9-14). The pressure required to make the seal is supplied by means of a
series of bolts, distributed around the outer part of the flange. The number and
size of bolt and the size of the flange varies according to the pressure rating of
the equipment.
Flange connections tend to be time consuming to make up and are usually

employed for permanent or semi-permanent connections.
Flange connection
Figure 9-14
OUTSIDE DIAMETER
Inside
Bore
Seal
Ring
Groove

9.5 FITTINGS
There are different types of fittings rated for various pressures. Only forged steel
fittings are to be used and never cast iron. The most common with our pressure
control equipment are NPT, Autoclave Engineer, BSP, CPI and JIC. NPT
threaded fittings may be used up to 10,000 psi working pressure. Above 5,000
psi working pressure fittings shall be ½" nominal or smaller. Above 10,000 psi
working pressure only suitably rated Autoclave Engineer or similar fittings
corresponding to API 6A, section 100 should be used. Use only stamped
approved fittings, if its not stamped or you are in doubt, do not use it. Never use
cast iron fittings for oil and gas applications.
1) NPT (National Pipe Tapered) fittings (Figure 9-15): threads must be

machined from a conical shaped material, or a hole drilled with a twist drill.
Cheaper fittings are cut in cylindrical material and have less strength. Threads
are cut at 60° angle; taper is 1° 47'. There must be at least 7 perfectly cut
threads, not over-flattened. When assembling, the fitting should be hand-tight
after 4 to 4.5 turns. Normal wrench-tightening is another three turns, giving a
minimum of 7 turns for a good seal. Teflon tape (3 wraps max) or a liquid sealant
can be used on the male thread, but use sparingly. Do not use Teflon tape on
fittings connected to the input of hydraulic pumps: Teflon tape shreds can clog
the filters. In the range 1/16" to 1/2" the maximum acceptable flat is 1/10th mm;
this can be evaluated with the naked eye (Figure 9-16).
Figure 9-15
NPT Hex coupling NPT Hex nipple

Figure 9-16: NPT Fittings
F Female
Male
F
Vanish Plugs
Threads +1
OK! Plain OK
"Vanish" Threads
GOOD
BAD
Female Male

Caution is needed when replacing high pressure NPT fittings with blind plugs.
Use only solid machined plugs, never a hollow plug. A few useful numbers are
given in Table 9.3.
TABLE 9.3
No of turns No of
Nominal Number Width of No of turns OD of
Wrench Vanish
Size of TPI Flat F Hand-tight Male thread
make-up threads
1/16 27 0.0014" to 0.3125"
1/8 27 0.0041" 0.405"
1/4 18 0.0021" to 4 to 4.5 3 3.5 0.540"
3/8 18 0.0057" 0.675"
1/2 14 0.0027" to 0.840"
3/4 14 0.0064" 1.050"
Be careful not to replace high pressure fittings with low-pressure water-pipe

fittings. A way to visually check is to measure the ID of the fittings. For a 5,000
psi rated fitting:
1/4" nominal size, the ID should be 7/32" maximum

2) Autoclave fittings are made up of three parts (Figure 9-17):
1) The piece of pipe or tubing you are going to make-up

2) The gland or nut, to allow the connection to be tightened
3) The collar.
The end of the tubing on an Autoclave engineer fitting has to be prepared with a
special tool. The tool threads the pipe and shapes the end into a cone. The seal
is made across the cone, which has been cut to 59°. Once the tubing is threaded
and cut, you slip over the gland and screw the collar on until 1 to 2 threads are
exposed. You then apply thread sealant onto the threads of the gland, make-up
connection by hand and tighten to a set torque specified by manufacturers.
3) JIC fittings (Figure 9-18): are also a cone type seal. The angle of the cone is
37° for both male and female connectors. Thread sealant should be used on
threads during make-up. For example, used on control module.

Figure 9-17
Assembled high pressure Autoclave fitting
Completed AE medium pressure Completed AE high pressure

connection connection
Figure 9-18: JIC Fittings
JIC 37° female swivel JIC 37° male

4) CPI Ultra Seal fittings (Figure 9-19): have an end to end O-Ring seal that is
designed for a system that needs regular removal and replacement, for example,
grease injection hoses.
CPI Ultra Seal
Figure 9-19
5) CPI single ferrule tube fitting: consist of three parts. Requires only two
metal-to-metal seal points to secure a pressure tight seal. These seals are to the
fitting body and to the tubing for example, the piping behind the panel of the
control module.
9.5.1 THREADS FOR FITTINGS
BSPP and BSP taper threads have a thread angle of 55°. BSPP - British
Standard Pipe Parallel threads are used for tubes and fittings where pressure-
tight joints are not made on the threads.
BSP Taper - British Standard Pipe Taper threads are used for tubes and fittings
where pressure-tight joints are made across the threads.
Almost all tube fittings and valves use screw threads for fittings, valve stems, lock
nuts, end threads etc. They are straight, not tapered threads.

Unified screw threads:

American Standard Unified Screw Thread (UN, UNC, UNF)
• 60° thread angle

• Pitch measured in inches
• Truncation of root and crest are flat
• Diameter measured in inches
Threads are named UN (standard) UNC (coarse) or UNF (fine) when describing
the relationship of threads per inch to thread diameter. For example UNF, ‘F’
stands for fine pitch.
Metric Screw Threads (ISO262):

International Organisation For Standards (ISO Metric)
• 60° Thread angle

• Pitch measured in millimetres
• Truncation of root and crest are flat and of a different width
• Diameter measured in millimetres
• Metric screw threads are straight and not tapered and use either a
gasket or O-Ring to seal male screw threaded components to a female
component.

9.6 VALVES
Various types of valves are used in wellhead equipment. The most commonly
used valves are needle valves, ball valves, check valves and metering valves.
Needle valves (Figures 9-20 & 9-21): used for controlling high pressures. The
valves are designed to shut-off pressure from 1 main direction. An arrow on the
valve body usually marks the direction, or you can tell by looking into the entry
ports of the valve. The high pressure should always enter the valve from below
the valve seat. Needle valves can be found on the end of the high pressure
grease return line, equalising hose type Wireline Valves manifolds and on the
pressure control grease injection module. Various pressure ratings are available
from 0 to 15,000 psi. Needle valves using a replaceable cartridge seat are used
in Elmar's integral manifolds; see Figure 9-22.
Regulating needle valve with CPI fitting
Figure 9-20
INLET OUTLET

Lorimer valve 10,000 psi Working Pressure Figure 9-21
Cartridge valve manifold block Figure 9-22
Teflon Seal
Valve Stem Valve Seat
Valve Gland
"O" Ring and

Stem Retaining Screw Back-Up Rings

Ball Valves (Figure 9-23): used in the control modules for directing the flow of
hydraulic fluid for line wiper and stuffing box etc. Also used for air supply shut off
on control module. Ball valves are available as 2 or 3 way valves with operating
pressures up to 10,000 psi.
3-way ball valve Figure 9-23
Bottom - Loaded,
Blowout - Proof Stem
Directional Handle Panel Mounting
Spring - Loaded
PEEK Seats
INLET

Check Valves (Figure 9-24): used in the grease injection line and in some of the
hydraulic lines. The check valve prevents back flow of the substance that is being
pumped. It is very important that the check valve on the grease injection line is
operating correctly to prevent well fluids from coming back to the grease tank and
contaminating the grease. It could also cause an explosion if the tank is filled
with high pressure gas. Always check the direction of flow on a check valve
when installing.
10,000 PSI check valve Figure 9-24
Direction
Of Flow
Metering Valves: used to control the hydraulic oil pressure being applied to the
WHE components, for example, line wiper, stuffing box etc. Working pressure
rating of up to 6,000 psi.

SECTION 10 - USING THE CASED HOLE PRESSURE

EQUIPMENT
10.1 PRE-JOB
Pre-job planning is an essential element of any successful operation.

No pressure job can be considered routine and Murphy's Law* will always apply.
When receiving a call from a client, the supervisor in charge needs to know
certain basic information:
• Type of wireline services to be performed
• Well depth and deviation profile
• Type of wellhead connection, size and pressure rating.
• Maximum expected wellhead pressure.
• Is H2S present? What is the concentration? Other hazardous gases or well

chemicals may also require the use of specialised equipment.
• Size of tubing/casing in hole and minimum ID.
• Type of fluid in hole, e.g. gas, oil, diesel or water.
Using this information the supervisor can select the correct type of WHE.
• Never exceed the rated working pressure of the equipment. Always use H2S
proof equipment if H2S is present
• Double check that the cable length, temperature rating and H2S resistance
are suitable for the job
• Check the auxiliary equipment. Make sure there are enough weights
available to overcome the pressure. Calculate the theoretical weight needed
for the pressure (Figure 10.1) and add 20%. The theoretical weight is the
weight to just balance the upthrust on the cable due to well pressure. Extra
weight is needed to overcome friction effects and to ensure the tool will

descend easily. Note that if you are operating in a producing well, there will
be an additional up-thrust due to frictional effects of the well fluid on the
wireline. The up-force can be quite large and extra weights are required to
balance it. Refer to service company operating instructions to estimate the
amount
• Double check the correct wellhead adapters are available
• Check that there are sufficient lubricators to cover the tool. Calculate the
total length of the tool string including weights, centralisers, adapters, head,
etc and add 3 feet. This will be minimum length of riser to be used
• Ensure the correct number and type of Wireline Valves are available for the
job
• Check that Pressure Control Equipment string ID is adequate for the tool
string to be run in the well. Take into account swelling of guns after firing
• Check that the Wireline Valve inner seal is the correct size for the wireline
OD or use Elmar Multiline Seals
• Check that the grease supply system has a correctly rated pump and
sufficient grease of a suitable type for the job. Take into account variations
of ambient temperature during the job. Allow for repeated or unforecasted
runs
• Ensure that you have a glycol injection pump and glycol if you are dealing
with H.P. gas
• Check that the stuffing box has the correct wireline-size components
• Make sure there are enough flow tubes in the GIH and enough hi-pressure
grease hoses are available
• Check all valves and fittings are complete
• Check that there is an adequate number of hydraulic hoses and pumps
• Check an adequate supply of spare parts and hand tools are available to
repair equipment damaged during transport/rig up, etc and to provide items
which may be needed in case problems occur or in case there is a change in
well conditions.
The supervisor in charge that may be new to WHE operations should make
careful checks that the equipment is complete. Too many engineers have
*
Murphy's Law - If anything can possibly go wrong, it will - at the worst possible moment.

arrived at the wellsite with insufficient risers or grease hose or with the wrong
wellhead adapter. Most experienced production engineers have developed a
"ready box" system to ensure equipment is not forgotten. This may take many
forms. For example, a land operation may have a special truck assigned to
production operations. Equipment is assigned to tool bays and the hardware is
permanently mounted on top. Offshore operations utilise specially designed
skids for transporting the equipment and spare parts. The experienced
supervisor can quickly glance at the ready boxes and skids and ensure all the
equipment is correct for the job and ready to go. Much pre-planning is involved
in the design of a ready box/skid system but it will save time and possible
disaster jobs in the future.

Figure 10-1
10,000
I
PS
00
9,000
/10
I
PS
BS
00
6L
10
S/
27.
E
8,000
I
PS
LB
E-
00
7.6
10
BL
3 L
S/
-
CA
LB
WELLHEAD PRESSURE IN PSI
E
7,000
1
B
IA.
9.
CA
-4 P
8) D
I
PS
A.
LE
00
DI
(.18
AB
6,000 10
S/
)
.C
19
LB
6"
IA
(.2
M
6.7
3/1
)D
-7
2"
50
E I
7/3
5,000 BL PS
(.2
A 0 00
A
C /1
4"
A. BS
1/
) DI 0 .4L
3 11 I
4,000 .31 E- 00
PS
"( BL
X
6 A S /10
5/1 .C
150
LB
DIA E- I
7 5) BL 0 PS
(.3 CA /100
E
3,000 " A . B S
3/8 I 3L
8) D - 17
6" (.43 C A BLE PSI
.
7 /1 DIA /1000
" ( .469) - 2 4 9 LBS
2 ABLE
2,000 15/3 IA. C
" ( .563) D
9/16
1,000
0 100 200 300 400 500 600
TOOL WEIGHT (IN LBS) REQUIRED TO COUNTER BALANCE

WELLHEAD PRESSURE

10.2 RIG UP PROCEDURES
Providing enough forethought has been put into the pre-job planning, the
supervisor and crew will arrive at the wellsite secure in the knowledge that most
contingencies have been adequately covered and that the equipment is clean,
serviced and in first class operating condition.
The most critical portion of the operation is the rig up. The supervisor should
carefully supervise his crew to ensure wellhead equipment make up and system
testing are carried out safely and efficiently. The wellsite should be inspected for
possible safety hazards and escape routes planned if necessary. A spot safety
meeting should be held with the crew and client.
Before removing the well cap some preparation work needs to be carried out first.
The following procedure applies mainly to braided line pressure jobs on a drilling
rig or a permanent derrick with a raised drill floor.
Variations to this procedure are needed for slickline jobs, and for jobs on a
workover hoist or rigless job with a Mast or Crane Truck
• Function and pressure test BOPs (working pressure only) (Figure 10-2)
• Function test tool traps, tool catchers, stuffing box and line wiper
• Function test control module
• Spool out wireline into a figure of eight in front of the winch and cut a neat
end to allow easy feeding through GIH. Pass the wireline through the
sheave wheels if required as some wheels frame are solid
• Clean wireline with a diesel soaked rag to remove any dirt and feed through
line wiper and stuffing box (it might be necessary to remove the inners from
the stuffing box to allow the wireline to pass through), then through the
correct number of flow tubes, ball valve and tool catcher
• Once the wireline has been fed through the GIH you need to make a rope
socket and attach the cable head with the correct weak point
• Connect two lengths of lubricator together and feed the cable head with a
weight bar into them
• Connect the GIH to the two lengths of lubricators taking care not to damage
the wireline and pull the head up into the catcher
• Fit a set of dolly wheels to the bottom of the lubricator to aid in the rig up. If
no dolly available then use a thread protector as a safety barrier to prevent

the weight falling out the end as you lift the lubricator. Fit the lubricator lifting
clamp to the top of the uppermost riser
• The next stage of the operation is on the rig floor or at the wellhead. Position
the control module where you have easy access to the panel and with the
hose reels facing the well you are about to rig up on. Choose a position
upwind from the wellhead whenever possible.
• Move all the WHE you require for the job to the rig floor by crane and
position it where a catline can be attached to rig it up.
• The wellhead preparation is critical. Remember the wellhead belongs to the
client. High pressure wellheads are expensive and the wrong sequence of
valve operations can cause loss of well control and damage the valves
beyond repair. If possible, the client should be encouraged to operate his
own wellhead control valves, or provide information on the preferred valve he
wants closed. However, we should know the correct operating procedures.
o Close the Master Valve or the uppermost master valve if two valves
are installed (Figure 10-3). Count the number of turns needed. Do not
touch the lower master valve.
A high pressure wellhead showing various valves Figure 10-3
IIIII IIIII
II I I I I I
II I
I I
I I I I
II
I
II
I
I
II
I I
IIIIII IIII
I
I IIIII IIIII
I I
I I I I
I
I I I
I I
I
I I
II I
II
I
I
II
II
II I
Gauge Valve
Top Connection
Swab Valve
Choke Choke
Wing Valve Wing Valve
(Flowline Valve) (Flowline Valve)
Master Valve
Tubing Head Adapter

o Close both the innermost wing valves. (Note points 1 and 2 may not
apply if you operate on a flowing well. Additional precautions are
necessary in this case).
o Close the swab valve. Count and record the number of turns needed
for full closure.
o If a gauge is mounted on the wellhead, ensure the valve reads zero

pressure, close the gauge valve, remove the gauge and open the
gauge valve to bleed off residual pressure.
Caution: If the gauge still reads pressure after the tree valves are closed,
stop. The company man needs to be informed.
o Remove wellhead cap. Beware of trapped pressure.
o Attach the wellhead adapter. Threads should be clean and coated

with pipe dope. Flanges should be clean and lightly oiled. Hammer
flange bolts up tight. To obtain the full pressure rating from API
threaded joints, they should be tightened correctly. The API
specifications for clean, lubricated threads, state that the connection
should be made up hand tight and then 'X' more turns where 'X' is
shown below.
Type of Pipe X Turns

4-1/2" - 7" API 8 round casing 3
7-5/8" - 20" API 8 round casing 3-1/2
All API round form tubing 2
1/8" - 2" API line pipe (V-thread) 3
2-1/2" - 20" API line pipe (V-thread) 2
This chart does not apply when Teflon tape is used. Feeling the hand
tight position is difficult. A joint not made up enough will leak and the
threads can jump out when pressure is applied. Making the joints up
tight requires considerable torque especially on larger threads.

Pre-Job function and pressure testing Figure 10-2
I II I I I I I I I
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II I I
I
I
I
I II
I
I
I I
I I
I III
I II
I II I
I II I I I I I I I I
I
I
II
II I I I I I I I I
I
I
II
I
I
II I

• Place the BOPs on the adapter after checking that the rams can be opened
and closed. If necessary and the rig-up height allows it, use risers as
spacers, so that the BOP is at easy reach on the rig floor (Figure 10-4)
• Making up lubricators (risers) - depending on the quantity of risers required it
might not be advisable to pick up the whole string in one go. In this case
three or four risers can be connected together, picked up and placed in the
mouse hole (if available) ready to be connected to the GIH vertically.
Alternatively, make them up one at a time
• Lift the GIH with the head and weight inside the lubricator to the drill floor
using a crane. Be careful that the wireline is not damaged. Connect a
catline to the GIH lifting clamp and slowly pick-up on the catlines air hoist as
you lower the crane down and let the GIH sit in the 'V' door. Rest the bottom
of he lubricator attached to the GIH at the bottom of the 'V' door. All the
weight of the GIH should now be on the catline. Remove the crane (Figure
10-5).
• Connect all the hydraulic and grease hoses to the GIH. Warning: Take care
that the correct hoses are being attached at the correct places. Fix two
ropes on to the bottom of the GIH to assist rig up
• Loop wireline on to upper sheave wheel and raise the sheave up to the
necessary height you need for the operation. The upper sheave is usually
held in the elevators of a drilling derrick or fixed to a rated pad eye at the top
of a wireline mast. If using a mast, connect top sheave with the wireline over
it to the pad eye before raising the mast. This saves a lot of trouble trying to
put it up once the mast is raised. Remember that the top sheave can be left
hanging from the utility winch hook only if the utility line is rated twice the
maximum breaking strength of the wireline. Notice some Mast Trucks have a
Sheave Lock system. This allows using one of the utility winches to be used
to lift the sheave and lock it in place after the mast has been rigged-up.
• Pick up the GIH and stab it on to the lubricators in the mouse hole. Make up
the quick connect union. (Quick connect unions only need to be made up
hand tight)
• Pick up the whole GIH and lubricator and lift up to a height just above the
BOPs. Take care not to bend severely the lubricators, use ropes to assist
• Fix the lower sheave tie down chain and tension device to the appropriate tie
down point. Loop the wireline over the sheave

• Pick up the excess slack in the wireline using the winch. Take care not to
pull the weak point. Leave a small amount of slack in the wireline and hold it
down while the tool catcher is released
• Once the head and weight is released from the catcher, lower them down to
a height at which you can connect the wireline tools. Depending on the set
up of the rig you are working with, it might be easier to make up the tools in
the well you are about to enter. This depends on the distance between your
BOPs and the swab valve
• Now that the tools are all made up you are ready to lower down your
lubricator and make up the quick union. Always ensure there is sufficient
distance between the head and the tool catcher to allow this operation,
otherwise a cablehead pullout may occur
• After connection, lubricators should be straight and vertical, otherwise the
pressure rating of the equipment may need to be down rated
• For safety reasons, the grease return hoses must be fixed with a needle
valve and a high pressure tee, then securely chained down to a fixed
structure. This prevents the hose from "whipping" due to well fluids escaping
if the grease seal is lost
• It is now best to pull the downhole tool into the catcher before pressure
testing. This prevents the tool from being pushed-up during pressure testing,
and eliminates the chance of the wireline being kinked
• You are now ready to pressure test.

Rig-up stage 1 Figure 10-4

Rig-up stage 2
Figure 10-5

10.3 PRESSURE TEST PRIOR TO RUN IN HOLE
To carry out the pressure test, fill the assembled WHE with the appropriate test
liquid, e.g. Glycol/water mix, making sure all air is bled from the system. After
water/fluid appears at the top of the greasehead, the pressure test can then
commence. It is recommended to conduct the test with the stuffing box closed
and no grease in the flow tubes so that the grease return line and needle valve
and the check valve on the grease injection line are tested. The test should be
held for a minimum of 3 minutes, bled off then pressure up for another 15
minutes.
It is advisable to also check that the grease injection system is fully operational,
i.e. there are no leaks or blockages in the injection line and that the one way
check valve will pass grease. This can be checked at the end of the test by
pumping grease into the flow tubes, opening the return line valve and the stuffing
box and observing that there is no loss in test pressure on the WHE.
The pressure test proves that the equipment is capable of withstanding the
anticipated pressures. If leaks occur the pressure must be bled off, fault rectified
and equipment retested.
Whenever WHE equipment is used at the wellsite for pressure control operation,
it shall be pressure tested after it has been rigged up on the wellhead, before
opening the well for the first trip. On long duration project work, equipment
should normally be tested once per 24-hour period or to an agreed schedule.
For pressure build-up work longer than 24 hours, test the equipment whenever
the cable head is returned to surface

10.4 BASIC WELLSITE PRESSURE TEST RULES
• All components of the WHE equipment used shall have a WP and TP rating.
The overall WP rating of the assembled equipment shall be equal to the rating
of the weakest component. All components used shall have a validated level 1
service, including a hydrostatic body test to test pressure TP. Equipment
lacking a current test record shall not be used
• The wellsite working pressure rating or MAWP (Maximum Allowable Working
Pressure) shall be equal to the wellsite test pressure. The wellsite test
pressure shall never exceed the equipment WP rating, or the client wellhead
WP rating, whichever is lower
• Wellsite test pressure shall be 1.2 times the expected maximum shut-in
wellhead pressure. If the client does not want his wellhead subject to this
pressure, the test pressure shall be equal to the maximum wellhead pressure
or the maximum specified by the client whichever is greater. If no wellhead
pressure is expected the equipment shall be tested at 25% of its WP rating
• WHE equipment shall never be pressurised with high-volume pumps such as
mud pumps or other piston pumps, due to the risk of over-pressuring the
system in one pump cycle. Dedicated low-volume/high-pressure test pumps
and equipment should be used to introduce the test pressure after the
equipment has been filled-up with high-volume pumps while allowing all air to
escape
• When pressure testing, low pressure lines shall be kept open ended to
prevent over-pressuring of the low pressure lines in case of a leak
• Pressure testing shall be carried out with a non-volatile, non-compressible
liquid such as ethylene glycol or water. Use of flammable liquid or gas, or of
well fluid is forbidden. Testing with diesel for example is not allowed due to
the risk of explosion (Diesel engine effect)
• The occurrence of a wellsite pressure test and the wellsite pressure test value
shall be noted on the service report. It is recommended to use a pressure
recorder (chart or film) during wellsite pressure testing
• Adequate warning signs should be displayed and all unnecessary personnel
cleared from the vicinity of the test.

Special pump units are available for pressure testing, such as the Elmar testing
skid (Figure 10-6). This L-696700 pressure test unit is designed to test WHE in
the shop and eventually on the wellsite. It measures 0.95 m x 0.85 m x 1.45 m
and is mounted on wheels.
It includes:
• 1 water pump high volume low pressure

• 1 water pump low volume high pressure (20,000 psi)
• 1 chart recorder
• 1 hydraulic hand pump for opening and closing BOP, etc
• 12 gallon oil tank
• 20,000 psi pressure gauge.
Note that both pumps are water pumps. Hence no grease is pumped and the
test should not cause any mess. All that is required is a water (or water/glycol
mixture) and air supply.
Elmar testing unit designed to test WHE in the shop and on the wellsite
Figure 10-6

Many supervisors prefer to conduct the pressure test with just weights and a
bottom nose in the riser (note that tool thread protectors are not pressure rated),
just in case something goes wrong. However, standard procedure requires the
complete tool assembly in the riser for the test, since a joint will have to be
broken after the test in order to connect the tool and this joint should then be
pressure tested again before the job can proceed.
The use of a Quick Test Sub or of a Wireline Safety Valve allows pressure-
testing the broken connection only, avoiding to pressure-up again the whole
lubricator string.
A risk assessment should be performed to weigh up the possible consequences

of each course of action. Any deviations from standard procedure should be
written down and agreed with the customer.
10.5 PROCEDURES FOR PRESSURE TESTING WITH A LOADED GUN IN THE

RISER WITHOUT QUICK TEST SUB OR WIRELINE SAFETY VALVE
• First pressure test the wellhead equipment to the requested wellsite pressure
test value with a dummy gun or no gun
• Bleed off pressure, break off riser and rig up gun
• Make up and pressure test riser with armed gun to wellsite pressure test
value, or to 80% of the gun rating, which ever is lower
• Equalise pressure across wellhead, open master valve and swab valve and
proceed with operations.

10.6 RUNNING THE JOB
Only after the wellsite hydrostatic test has proven that the equipment is pressure
tight can the well be opened. The process that began with the initial client
request can now be brought to fruition. It only remains to lower the tool string
into the well, perform the service and retrieve the tool. However, problems
caused by human error failures abound, so it is worthwhile reiterating some
operating points.
a) Safety
Pressure jobs are inherently dangerous. As far as possible, pressure jobs

should only be conducted during daylight hours. If the client insists upon
night-time operations, the supervisor should satisfy himself that adequate
lighting is available so that small leaks can be detected early and escape
routes are clearly visible in case of catastrophic failures. Ensure that all
hoses for the BOP, Tool Trap, Tool Catcher, Stuffing Box and Line Wiper
are connected, and that the control module is easily accessible and clearly
visible.
b) Running in Hole
At the conclusion of the pressure test, the pressure in the risers is bled
down, equalised to that of wellhead pressure and the grease injection
pressure at the GIH set to 20% above well pressure. The pump will pump
extremely slowly when the wireline is stationary. The pump will stroke
quickly if the grease hoses and grease tubes are not filled with grease. If
there is zero pressure on the well the grease pump should be set to
minimum pump pressure. Grease must always be injected to lubricate the
wireline and reduce wear on the flow tubes.
Lower the cable head a few inches before opening the master valve. This
will prevent the tool sticking against the bottom of the GIH adapter or ball
valve (or accidentally being caught by the tool catcher). Newer GIH
adapters are supplied with an eccentered groove to prevent differential
sticking of the fishing head.
The master valve should be opened slowly. Count the turns needed to fully
open the valve. Hang a sign on the valve indicating that wireline operations

are in progress and the number of turns needed to open the valve. If more
than one master valve is closed, then open the lower-most valves first.
Note: The tool trap should remain CLOSED (ready-to-catch) until the tool is
ready to be run in the hole. Run in hole slowly until the tool is below the
Christmas tree valves or other obstructions. Cable movement may be very
slow for the first few hundred feet depending on well pressure and the
number of weights used. If possible use large tungsten weights to
maximise the total weight of the tool assembly and to minimise its length
(and hence that of the risers). Try not to allow slack wireline to come in
contact with the ground. Clean the wireline with a diesel saturated rag to
remove dirt, sand, etc. If the monocable has not been used for a long time
it may be necessary to clean the wireline on the top layer of the drum before
running in the hole. Double check that the line wiper and stuffing box have
not been activated.
Maintain positive depth control. This cannot be emphasised enough. Put

extra magnetic marks on the cable when the tool is 100 ft or so below the
BOP. Note the depth at which the cable leaves the drum at the end of each
layer (i.e. at each flange, see Figure 10-7). Note also the position of the last
turn of the cable on the drum before running in the hole. This will ensure
accurate depth control on the way out of the well even if the cable has no
magnetic marks (H2S proof multiphase cable cannot be marked) or if the
marks have been erased due to a magnetised tubing string.
Be extremely careful of any restrictions in the hole especially if the well is

flowing. Fluid velocities can be extremely high as the tool passes through a
nipple. Make sure the winchman has a good well sketch with depths noted
(Figure 10-8). Check CCL's are appearing when expected - roughly every
30 feet in tubing and every 40 feet in casing.
Cable depth diagram Figure 10-7
Measure Distances A & B
A
B 613'
1363' 2104'
2834' 3551'
4262' 4965'
5663' 6357'
Tubing Shoe
TD

Typical well sketch
Figure 10-8
Seabed DHSV
Liner Hanger
Deviation 50˚
Packer
Restriction
(eg nipple)
Tubing Shoe
Perforations
TD
10.7 OPERATIONS
Once you are down hole the main problem becomes sticking your tool in the
nipples/restrictions, or in the sump at TD, or pulling back into the tubing shoe too
quickly. If you have been depth correlating all the way into the hole there should
be no surprises. Outline to the winch driver these two boundary points, allow a
good safety margin (if possible), check your pull-on-line-safety and remind
everybody to watch the tension device.

CASED HOLE
"Safe Winch Driving With Small Cables"
WELL SKETCH DRUM

(MARK YOUR START POSITION
OF CABLE)
A
Liner Measure
Hanger = Distance
Top of
Flange to
Packer = First Wrap
A = _____
Packer =
Restriction =
(eg Nipple)
Tubing
Shoe =
Bell at ____
COMING OUT SHOT DEPTHS
STOP
1.
2.
3.
4.
AT 200FT 5.

Tool jammed in tubing due to fluid velocity - cannot break weak point
Figure 10-9
Cable
Packer
Nipple
Tubing
Casing
Wireline Entry
Guide
Fluid Flow
Wireline Tool
On injector wells if you do pull into the tubing you have a large piston effect trying
to break your weak point. On producers, the tool can be rammed past the cable,
wedging the tool and cable in the tubing and you cannot break the weak point
because the cable becomes wrapped around the tool (Figure 10-9). Charts are
available to calculate these effects for high flowrate wells.
If possible, shut in the well before pulling back into the tubing. Customers are
often reluctant to shut in the wells. If this is a problem, ask them at the very least
if they could choke back production. Make sure the right valve is closed, if it is
your responsibility, supervise it yourself.

Damaged cable
Figure 10-10
Knotted Cable Birdcage Broken Armour

Wire

Debris in well
Figure 10-11
Debris and scale in a cased well is quite common. Milling, cementing, perforating and
drilling can all cause debris. Sand entering from the perforations can also cause a tool
to stick.
Tool Wedged by Debris Tool Stuck by Sandfill

10.8 PULLING OUT OF HOLE
When pulling out of hole the wireline speed is limited by the volume of grease
that the pump can output and the clearance between wireline and flowtubes.
Beware of loosing grease seal due to cable speed.
After performing the service conditions can change. Guns swell after being fired,
calliper and flowmeter arms bend or break, so plan on the unexpected. Devote
all your attention and keep the speed down when pulling back into the shoe and
through any restrictions in the tubing. Keep the cable speed very low near
surface and watch your tension and your CCL response. Make sure the tool trap
is closed and tool catcher ready-to-catch. If you do get stuck, you need to be
able to determine exactly where and what part of the tool is hanging up. Do not
immediately pull to the full safe limit because you could wedge the tool or wireline
much harder into the flow tubes. Stop, drop down and try again. If you see slack
immediately when running in hole, you are probably hanging the wireline in the
flow tubes. The pull on line safety is set close to the normal logging tension and
this should be adjusted all the way out of the hole. If you have been logging in a
producing well, shut off production when pulling out, otherwise the wireline can
be sucked into the wing valve by the fluid flow.
Coming out of the hole new problems arise (Figure 10-10 and 10-11):
• Bad spooling
• Wireline stranding
• Spooler depth slipping.
Wireline stranding is the subtlest, but has dire results if not detected. You and
your operator need to be watching the tension device for any irregular movement
or unexplained shift.
Each time the tension differential is manually adjusted inform each other of the
shift. If a cable armour wire does strand, the differential tension will start shaking
and very slowly build up. Accurate tension devices are a must.
Spooler depth slipping should be easy to detect with the magnetic marks. If the
bell is not constant you know something is wrong. As you get near the surface
you check your cable diagram to be sure that everything is correct. The cable
diagram also helps if you have had to change depth because of a workover rig or

Mast truck having a different depth reference from the tie-in logs. Make sure your
winch driver spooled the cable carefully to prevent cable stranding and insulation
failures in the future.
When 200 ft from surface the supervisor takes the winch. A rope is thrown over
the cable, the lower sheave held down, the POL (pull-on-line) safety checked and
if perforating, everything else shut off. Proceed carefully but confidently to pull
out. The operator holding the rope is the one to watch (see Figure 10-12).
If you are pulling out at 1,800 ft/hr (30 ft/min) and your rope operator has given
15 ft of slack to the wireline, you have a full 30 secs to react. In this same
situation if you push down on the lower sheave with only 2 ft of slack there is only
4 seconds reaction time.
Be careful! It is possible to break a weak point by pushing on the wireline. If

your tool is stuck somewhere close to surface, there is very little stretch in the
wireline. With both ends of the wireline fixed and a couple of operators pushing
down very hard on the middle of the wireline, the weak point will break.
When the tool reaches the stuffing box, the rope induced slack starts to
straighten out. BEWARE! This also occurs if the tool gets stuck in the
Christmas tree.
The next step is to set the tool down on the closed tool trap. This confirms that
you are in the riser. If the tool and wireline will not go down or if they do not stop,
something has gone wrong.
With a manual tool trap or external indicator trap, you can see the handle of the
tool trap move when the tool enters the riser. One operator should be holding
the handle. He should signal when the head enters the riser and when the
bottom of the tool clears the tool trap.
If you have pulled into the tool catcher, run some slack, once you are positive
that the tool is in the riser, you can have the SWAB valve closed slowly. Count
the number of turns and, if any resistance is felt before the valve has completely
closed, stop and recheck that your tool is in the riser. If it takes 16 turns to
normally close, and if the valve stops after 10 or 11 turns, the tool or wireline may
be across the valve. The wireline is easily damaged. Open the valve at the first
sign of resistance. Only close the master valve after the swab valve is closed.

Once the master valve is closed the pressure can be bled off. The quickest way
to bleed-off is through a wing flowline, whenever possible. If this is not possible
bleed off through the lower BOP manifold. Ideally the bleed off valve should be
connected via a high pressure grease hose to the client or well testing company
flowline. If this is not possible the hose should drain off fluids downwind and be
securely fastened to a fixed structure. As soon as the pressure is bled off the
grease pump can be switched off and the pressure gauges and manifolds
removed to prevent damage during rig down.
When bleeding off high pressure gas, crack the manifold valve slowly to avoid
freezing the valve or the whole high pressure drain hose. You might have to drain
the lubricator in stages by closing a valve at the end of the drain, filling the hose
with gas, closing the manifold valve, emptying the hose.....etc.
At the end of the drain hose connect a ‘T’ junction to balance out the side-way
reaction of the high pressure fluid being drained.
Remember that, after bleeding off the pressure, it is highly likely that there will
still be fluid in the riser since the grease seal in the GIH will not allow air into the
system. Be careful when the risers are lifted. Fluid will pour out once the risers
are disconnected. The tool can be lifted off the tool trap and cleaned and
disassembled.

10.9 RIG DOWN
Caution
Remember to take care when rigging down, the job is not over until all the WHE
is packed away and you have tidied up. Do not take short cuts. Take your time
and remember that WHE is heavy and awkward to handle. Ensure all pressure is
bled off before you start.
Rig down procedures are the reverse of the rig up procedures. Remember to
give slack to the wireline when rigging down the lubricators so that the GIH does
not end up resting on the head and breaking the weak point.
POH procedures
Figure 10-12
Operator 1 stands on
the tie down chain
Operator 2 holds down

the cable with a rope

SECTION 11 - PROBLEM SITUATIONS
1. REGAINING LOST SEAL
A lost grease seal is first noticed by fluid escaping at the top of the stuffing box,
and/or by the grease pump increasing its rate. If the grease seal is lost, stop the
cable and increase the grease pump pressure to regain the seal. If this is not
effective, close the stuffing box and the high pressure return flowline valve in that
order. If seal still cannot be regained, close the Wireline Valves. If in a gas well
with twin or triple Wireline Valve, close first the lower set of rams (inverted) and
while pumping grease into the BOP∗ - close the top most rams (normal). The
middle set of rams (normal rams) is for back-up and must only be closed if the
others fail. Increase grease pump pressure to 1.5 times well pressure. When
the seal is regained equalise pressure across the BOPs, open the flowline valve
and the stuffing box, open BOPs and carry on with the operation.
Continuous Loss of Grease Seal
If the seal is lost continually, the wireline run may need to be abandoned. The
tool and cable should be returned to surface as slow as necessary to maintain
the seal. Before you pull out of hole check the following:
1. Is the pump working?
Check the pump is stroking, if it is not try to increase the pressure at the
regulator to hear if it strokes.
2. Have you a sufficient air supply?
Check your air supply. If pump does not stroke change over and use the
other grease pump.
3. Is there grease in the tank?
The grease tank should be clean, full and no water present in the sump.
∗
Notice that in this chapter the terms “BOP” and “riser” are often used for the more accurate “Wireline Valve “ and
“lubricator” to conform to field people’s practice.

4. Have you chosen the correct size of flow tube?
Check your cable OD using a micrometer and the size of flow tube you're
using. If flow tubes are too large you may have to pull out of hole and
change them out.
5. Pumps appear to be working but no grease is getting to the GIH.
If this happens it will be necessary to close the Wireline Valves and bleed
down the lubricator. Once the lubricator has been bled down you will have
to put on a riding belt or harness and go up to the GIH and remove the
grease injection hose. Once hose has been disconnected try to pump
grease through it to determine if the hose is faulty or the check valve on the
GIH. If check valve is faulty then replace it. If the hose is blocked then you
can change it with the hose for injecting grease to the Wireline Valves.
Once repairs have been made, equalise pressure across BOPs, open the
BOPs and carry on with the operation.
2. PUMP AIR PRESSURE/VOLUME
Adequate air pressure and air volume is a must. If the rig air supply is not
adequate, then a second source must be secured.
3. HOSE LENGTH/DIAMETER
Hose length and diameter are often overlooked as a problem. The importance of
using short, large diameter hoses cannot be over emphasised.
4. NEW CABLE Vs OLD CABLE
Using a new cable on a gas well may permit gas to escape through the spaces
between the cable armour. Once a cable is used a few times these spaces
become filled with grease and residue and this decreases the problem. If you
must use a new cable in a gas well, the cable must be prepared in the shop by
running it through a cable grease injector.

5. STRANDED CABLE
Stranding of a cable is one of the worst problems encountered in pressure work.

Prevention is much better than the cure. Keep running-in and pulling-out speeds
at a reasonable rate to prevent torque imbalance in the cable and consequent
bird-caging. ALWAYS, use an H2S inhibitor in the grease if H2S is present, even
in traces. Cut the cable often so the cable does not become worn or flattened.
A stranded cable is first noticed when cable tension increases for no apparent
reason or the operator notices the missing strand or strands as the cable comes
on the drum or over the sheave wheels.
Stop the cable, close the Wireline Valves and bleed the pressure off the
lubricator. Monitor lubricator pressure for at least 15 minutes. Ensure that the
BOPs are holding the pressure before removing the lubricator. Pump grease
between the Wireline Valves if you are on a gas well.
Raise the lubricator a few feet and attach a cable clamp to the cable on top of the
Wireline Valve. Do not allow the cable to slip through the Wireline Valves as this
may damage the seals. (For added safety you can use a "flow diverter" which
can be installed on top of the Wireline Valve and includes a cable clamp). Slack
off the cable and check that the clamp is holding. Pull the cable down through
the control head and inspect the damage. Notice that if you have a single lift rig-
up on a workover/mast job, or if you are using a turn-around sheave, special
procedures or special equipment must be used to be able to open the lubricators
and slack the cable.
There will be a ball of stranded cable caught under the control head. This ball
will have to be removed from the lubricator and cut away with a sharp pair of wire
cutters.
Pick up the excess slack until the cable just begins to come under tension. Very
carefully unwrap each of the damaged strands 3 or 4 turns. Do not bend strands
back from the cable. Make a clean cut and, with a fine file, taper the end of the
strand and lay it back in the cable. If necessary, a very slight bend can be given
to the tip of the strand to ensure that it remains pointed towards the cable core.
Use a fine file to smooth down any small excess of cable that may be protruding.
If more than one strand is damaged, ensure that the strands are terminated at
widely spaced intervals. Instant glue often works to hold the strand in place.

Pick up the full tension. Remove the cable clamp, reconnect the lubricators,
pressure up the control head and equalise pressure in the lubricators through the
Wireline Valve equaliser manifold. Once the lubricators are at well pressure the
Wireline Valve can be opened and the cable slowly pulled up. Monitor tension
and watch the cable coming out of the control head to check that the strands
pass through the flow tubes. The whole process may need to be repeated
several times until successful.
If the damage is too extensive, it may not be practical to adopt the above
approach or the strength of the cable may be considerably reduced.
The cable will then have to be cut at a point as high above the Wireline Valves as
possible. There must be enough cable to feed through the flowtubes as
described in the next step. Taper the end of the cable to allow it to pass through
the flow tubes. Cut off the damaged cable on the winch side also.
Remove one or more sections of lubricator, lay down the pressure control
equipment and thread the cable through the control head from the bottom. Tie a
reef knot outside the control head so that the winch can again pull the cable.
Pick up the remaining lubricator and reconnect following the same procedures as
before. The cable is spooled back on the winch until the knot reaches the
topmost sheave wheel. The knot may or may not pass over the sheave
depending on the size sheave you are using.
If the knot cannot pass over the sheave, close the Wireline Valve, bleed off the
pressure, lift the lubricators and clamp the cable as before. Lower the block - or
the hoist holding the top sheave - slacking cable so that the knot can be
repositioned on the winch side of the sheave. Undo the cable clamp, reconnect
the lubricator string, and pull out. When close to surface, go through the same
procedure, open the knot, reconnect the lubricators that were previously
removed, pass the cable back through the GIH, retie the knot and continue to pull
out of hole after removing the clamp and reconnecting the lubricator string. This
step may be eliminated if excess risers were used in the initial rig up and
sufficient lubricators remain to cover the tool length. If only one lubricator length
remains after eliminating the first cable damage, it is advisable to add again
lubricators after a few hundred feet, to allow for the cable to strand again.
An alternative solution is to use a T clamp with the small cable inserts. When the
knot reaches the upper or lower sheave the cable may be clamped with a T
clamp suspended from an air hoist while the travelling block is again lowered to
allow the knot to be repositioned on the winch side of the sheave. Remember to
raise the block to its original position once the knot is spooled on the drum. This
eliminates one series of opening and closing the risers.

6. KNOTTED OR SEVERELY KINKED CABLE
Generally these problems occur when passing through a restriction in a flowing

well. The fluids act as a piston against the tool forcing it upward faster than the
cable is moving. Should the tool pass the cable, called "over-running", the tool
may become stuck, depending of course on the tubing size. "Over-running" can
also happen when you are entering a well if the cable movement is faster than
the tool is travelling. If a knot or kinked cable is all one gets from an over run,
consider yourself lucky. Normally the cable is stuck beside the tool and must be
broken because you are not pulling on the weak point.
Particular attention is needed when running in a flowing well. The client should be
convinced to stop production while the tool passes through the wellhead and the
cable is 4-500 ft in the well, otherwise the wireline can be sucked into the flow
line.
These problems should be handled the same as a stranded cable as generally

these knots and kinks will not pass through the flow tubes.
7. FREEZE-UP WITH HYDRATES
Under certain conditions of temperature and pressure, some constituents of

natural gas will combine with the water vapour to form hydrocarbon hydrates.
These hydrates have the appearance of snow or ice and form in the valves, flow
lines or even several hundred feet below surface in the tubing. This can block
the passage of tools or fluid flow. Hydrates are particularly dangerous as they
can obstruct the BOPs, preventing them from closing or causing the wireline
equipment to get stuck.
Hydrates formation is a function of gas composition. In some cases, hydrates can

form at temperatures as high as 122 oF, although generally the problem appears
at temperatures below 70 oF. In general, the higher the gas pressure, the higher
the temperature at which they can form though above some critical temperatures
they cannot form regardless of the pressure.
Cure: Keep a good grease seal as some gas expansion is needed for these
hydrates to form. Fluid flow or leakage can induce hydrate formation as both
temperature and pressure drop.
Since hydrates usually form when water is produced with the gas, water used in
filling the lubricator for pressure testing will only aggravate the problem. On gas

wells always use ethylene glycol (anti-freeze) to fill the lubricator during testing.
Glycol can also be used to prevent formation of hydrates and injected
continuously during the job through the Wireline Valve or through purpose
designed chemical injection subs, or glycol injection valves at the top of the
lubricator string. Methanol can also be used and in fact has a chemical
advantage over glycol (see next paragraph). When using methanol, use caution
and make sure these flammable liquids are pressured slowly so the vapour and
air in the lubricator will not be heated and cause a diesel type explosion. Do not
pressure the lubricator with a large pump.
Methanol mixed with the wet gas reduces the maximum temperature at which
hydrates can form. For example, a natural gas hydrate that normally forms up to
42oF can be altered so it will not form above 25°F by adding methanol. Methanol
injected on top of hydrates will cause them to melt.
Caution: methanol is poisonous and should be used with care; it also attacks ‘o’
rings if left a long time. Should only be injected with a dedicated methanol pump.
Therefore, use glycol to prevent hydrates formation, use methanol to dissolve
hydrates if they form.
8. TOOL STUCK IN CHRISTMAS TREE
Guns swell and get bent when fired and may cause problems when entering the
Christmas tree. When stuck in the Christmas tree, try to work the tool loose. Go
down a few feet and make another pass. Be sure that the valves are fully open.
If you have to pull off, have the client present. In certain situations, it helps to put
the well into production, if it is shut in. Do this only as a last resort before pulling-
off. Only the client can take this decision and open the wing valve.
9. BROKEN WEAK POINT
When tools are lost in the well the cable will have a tendency to be blown out of
the control head as the weight becomes less than needed to counter balance the
well pressure. When this happens the cable is pushed out of the control head
faster than it can be spooled on the winch. Cable everywhere!
Before pulling out of the hole, stop and have a safety meeting with everyone on
location, clear the area of unnecessary personnel. Be sure all flow hoses are
chained down.

Compute the approximate depth at which the cable will start moving out alone:
1) Compute weight to balance pressure from (Figure 10-1) ∴ ‘W’
2) Divide ‘W’ by the weight/ ft of your cable to obtain the approximate depth
Notice: this is only an approximation because of buoyancy and friction effects.
Cure: Watch your weight indicator and as the tension nears zero increase the
grease pump pressure. This will add some drag to the cable. Next increase the
pressure on the line wiper or packoff if a line wiper is not available. This pressure
must be steadily increased as more and more cable is pulled out of the well.
One must be careful in applying just the amount of tension necessary to slow
down the cable. Too much tension will milk the cable and cause it to become
stuck in the flowtubes.
If everything works right and your depth control is good, the cable can be stopped
with the end between the BOPs and the control head.
If not, and you have a ball check valve in the string it will seal after the cable has
passed and prevent a mess on the location. Have an operator at the master
valve to shut well in as soon as cable passes.
10. TOOLS WON'T GO DOWN
This can usually be attributed to insufficient tool weight to overcome well

pressure, dirty or kinked cable, or trying to flow the well.
Cure: Add extra weight and more lubricators if needed. Always clean the cable
that has come in contact with the ground with a diesel soaked rag. If there is a
kink, the cable will have to be cut and a new head made. If the well is flowing
and you can't get down ask the client to close the well in until you can get down a
couple hundred feet.
11. LUBRICATOR O-RING - EMERGENCY REPLACEMENT
Should a lubricator O-ring be damaged during cable repair, it cannot be replaced

by a new one due to the presence of the cable. However, a new O-ring can be

cut diagonally and the ends glued together with”instant" glue. Be sure and
replace the O-ring before the next job.

SECTION 12 – LARGE DIAMETER PRESSURE EQUIPMENT

FOR OPEN HOLE AND CASED HOLE
OPERATIONS
1.0 PRESSURE CONTROL USING MUD SYSTEMS IN OPEN HOLE
The drilling fluid, known as mud, is the first barrier against formation pressure. It
is usually a mixture of water, oils, clay, weighting material and chemicals. Drilling
mud serves several functions:
• It raises the cuttings made by the bit

• It cools and lubricates the bit
• It forms a mud cake to prevent loss of mud into the formation
• It exerts hydrostatic pressure which counteracts the formation pressure.
Weighting materials, usually barite, are added to the mud to raise the specific
gravity (mud weight) to a level that is needed to contain formation pressure. It is
the job of the mud engineer to continuously monitor the condition of the mud to
make sure that the mud weight is sufficient to overcome the expected formation
pressures. Usually the mud weight maintained is such that the hydrostatic
downhole pressure is a few hundred psi in excess of the formation pressure. The
mud engineer also monitors the level of mud in the well bore and mud tanks.
1.1 EFFECTS OF LOST MUD
A hole full of mud that weighs the right amount should not blow out. Sometimes
the unexpected occurs either because of human error or because geological
predictions of formation pressure may have been inaccurate. If formation fluids
enter the hole, a "kick" is said to have taken place. This is due to the mud weight
being too low resulting in formation pressure being greater than the hydrostatic
pressure of mud. An experienced rig crew can recognise certain symptoms such
as the level of mud in the pits rising above the normal level, or mud continuing to
flow out of the well after the pumps have been stopped, and take action
accordingly (usually by weighting up the mud).

Of course the opposite can happen and the formation can "suck". If the mud
weight is too high, the mud is forced into the formation. This is known as lost
circulation. If the well is not topped up the level will drop until the hydrostatic
column of fluid is no longer sufficient to force the mud into the formation. This
can be dangerous since other zones in the well may have a higher pressure than
the lost circulation zone (after taking into account the difference of the hydrostatic
pressure due to the different depths of the zones). These high pressure zones
may become underbalanced due to the drop of hydrostatic pressure of mud and
formation fluids can enter the borehole.
Why is a "kick" dangerous? If the rig crew do not take immediate steps to
contain the kick, a blowout can occur.
What causes the blowout? The initial seepage of formation fluids into the hole
serves to lighten the mud, since the specific gravity of hydrocarbons is likely to be
considerably less than that of the mud. As the mud is circulated, the average
weight drops as more and more formation fluids enter the system. As the mud
weight drops the formation fluids come in faster due to a lower mud pressure and
the process keeps accelerating until the mud is "blown out" of the hole mixed with
the incoming formation fluid. If the incoming fluids are hydrocarbons, there is a
danger of fire. Gas kicks are especially dangerous as the gas expands and fills
the hole very quickly. Gas can ignite easily as cuttings and formation particles,
blown out of the hole, create sparks when hitting the rig metal structure.
1.2 CONTROLLING A KICK
If a crew detects a kick a second line of defence is possible. Since well pressure
is now greater than the mud hydrostatic pressure the rig needs to create
additional surface pressure to contain the kick. This is done by first closing the
rig annular blowout preventers (BOPs) around the drill pipe. Hydril is the most
common amongst annular BOPs. The BOPs form a pressure-tight seal at the top
of the well and prevent the escape of fluids (Figure 12-1). In order to resume
drilling, the kick must be "circulated out" by pumping mud, properly weighted, at a
higher pressure that the surface pressure. It is not always an easy matter to
circulate out the kick and various techniques such as the addition of very viscous
materials to create a "viscous pill" may be necessary before the well is once
more under control.
In order to circulate the kick out of the well, a choke manifold is necessary. A
choke is a valve which can restrict fluid flow by having its size infinitely variable

from fully closed (zero flow) to fully open (full flow). As the kick starts moving up
the hole, the choke opening is reduced in size by an amount that creates just
enough back-pressure to allow the mud and kick out, but prevent further entry of
formation fluid. When the kick is circulated out, heavy mud is circulated into the
well and the choke fully opened.

A typical Drilling Rig pressure control system
Figure 12-1
Rotary
Bell Nipple Flowline
Annular BOP (Hydril)
Pipe Rams
Double BOP
Blind Rams
Kill Line Drilling Spool
Pipe Rams
Casing Flange
Well

2.0 CONNECTION OF WIRELINE AND DRILLING RIG PRESSURE EQUIPMENT
To have control of the well while running down hole tools, we need to be able to
connect our Wireline Valve to the drilling rig stack.
It is recommended that the wireline BOP be easily accessible, i.e. at waist height
when connected to the client equipment. This facilitates the easy and rapid
operation of the BOP rams should the need ever arise. It also makes it much
easier to guide the tools in and out of the well and to do a vertical make-up of the
tools if no mouse or rat-hole is conveniently available. Since the rig floor is
usually much higher than the stack, a riser is needed. The riser is attached to
the stack or Christmas tree at its lower end and extends through the rotary table
to just above the rig floor where it is connected to the wireline BOP.
If the riser is too long and the Wireline Valve is too high above the rig floor then a
work platform has to be constructed to allow easy and safe access to the BOP.
2.1 HOLD-DOWN ADAPTER (“SHOOTING NIPPLE”) IN THE RIG HYDRIL
One of the most common methods to connect the Wireline Valve (“BOP”) to the
rig stack was --in the past-- to use a Hydril Hold-Down Adapter, commonly called
“Shooting Nipple”.
In the most simple and most unsafe configuration this used to be a length of
casing, (usually 7”) connected on one end to the Wireline BOP with a Casing
Collar thread. The lower end of the casing was held in the Hydril by closing the
annular pack-off around it.
Because of the large cross-section area of the casing, there is a very large
upward thrust with this configuration: with 1,000 psi, the shooting nipple will be
subject to a 38,500 lbs upward thrust.
To contain this very large upward thrust the Hydril Adapter must have a system
to retain it (“hold-down”). If not properly positioned it is quite common to see the
shooting nipple move up out of the stack as the pressure increases during a
pressure test until retained by a stop.
“Home” made hold-down systems have a welded flange or upset at the bottom,
or ear-lugs in the body to connect chains secured to the rig floor.
Both systems are not acceptable: a locally made weld does not normally have
the proper heat treatment to withstand the very high tensile stress created when

retaining the adapter in the Hydril. Chains under such high tensions present a
very high risk, as it is possible to have an unbalanced system not loading evenly
the legs; if a chain breaks on the rig floor links can be projected with the same
speed as a bullet, and create fatal injuries.
Therefore the only acceptable Hydril Adapters are the ones designed and
manufactured, specifically for this use, by approved vendors.
Usually they are available with an ID of 4.89”, 7.62” and 8.53”. The lower end has
a specially designed flange screwed onto the riser body, with a certified thread.
(Figure 12-2 and 12-5). Slim-line quick union connections are used to split the
length in manageable section (6, 8 or 10 ft.)
In operations, the flange must be located directly under the Hydril packing
element, in contact with the packing metal fingers, to avoid any movement when
pressure increases.
Some major Service Companies prefer to have the Hydril Adapter held in the
pipe rams of the drilling BOP instead of the Hydril. This requires a longer riser
length, and also may require changing the drilling BOP rams to suit the size of
the Hydril Adapter.
For this reasons the Hydril Adapter solution is not recommended, except in cases
where the pressure is induced and controlled on the rig and by the rig personnel.

Advantages to the Hydril Hold-down Adapter System
• Usually quick to rig up

• Normally one on every rig therefore:
o It is dimensioned to the correct length since the distance from the rig floor
to the wellhead is usually fairly constant for most wells for one particular
rig.
o Service Company does not have to transport and store bulky risers.
Open hole pressure control with shooting nipple inside Hydril
Figure 12-2
Disadvantages
• The Hydril is disabled and cannot be used in an emergency.

• Unsafe when locally-made equipment is used.
• There is no visual control of the mud level in the well.

Flange adapter
Figure 12-3
2.2 QUICK UNION SHOOTING NIPPLE
This is a preferred arrangement. A flanged shooting nipple is bolted to the top of

the Hydril using a quick union adapter. The flange is held down by several bolts
and seals against pressure by means of a metal ring. The flange is screwed to
the bottom of the shooting nipple by means of an appropriate quick union adapter
(Figure 12-3 and 12-5).
Advantages to Quick Union System
• Hydril remains operational

• Safe arrangement within the limits of the pressure rating of the flange.
Safety Note
All flange bolts must be used and properly tightened. Flanges are only designed
to seal against pressure when the seal ring is uniformly clamped. Using the
example of 1,000 lbs pressure and a 3,000 lb rated series 900, size 6 flange with
a ring gasket of inside diameter 7-7/8", the force exerted on the flange is F =
48,700 lbs.
This flange has 12 bolts. Thus a force of over 4,000 lbs is exerted on each bolt.
The force on each bolt is correspondingly much greater if one or more bolts are
missing and the bending stresses which exist within the flange due to the missing
bolts make matters worse.

2.3 PERMANENT FLANGE HYDRIL ADAPTER
Pressure control equipment manufacturers have designed "permanent flange

Hydril adapters" (Figure 12-4 and 12-5). This flange is permanently bolted on top
of the annular preventer (Hydril). The top of the flange is the box part of a high
pressure quick union. Two options are possible:
Drilling mode: the rig bell nipple adapter (riser for mud return) is directly
connected to the flange via the high pressure quick union.
Wireline mode: the riser is connected to a riser adapter that fits the high pressure
quick union from the flange.
The main advantages with this system is that the Hydril remains operational
during wireline operations and the rig up of the pressure equipment is speeded
up by the use of the quick union client riser and the wireline companies riser
Permanent annular BOP flange adapter for WHE
Figure 12-4
Bell Nipple Adapter
Weld
Riser Adapter
WIRELINE DRILLING MODE
Annular BOP

Riser arrangements for OH WHE Figure 12-5
Bell Bell
Nipple Nipple
Removed Removed
Bell Nipple Pipe Rams

Remains Closed on
in Place Riser Flange
Below Valves Riser
Quick Weld
Union
Adapter
Bell Nipple
Adapter
Hydril Element
1b
Closed to Seal
on Riser 1a-1b - Fast
- Immobilizes Hydril
Riser Adapter and Pipe Ram BOP
Flange to be
1a 2 3
Engaged Below 2 - Time Consuming
Steel Back-Up - High Degree of Safety
Fingers Rams Closed on Pipe Rams Closed on Riser Screwed into Quick Union Adapter
Riser Adapter Riser Adapter Hydril Top Flange Flange on Top of Hydril 3 - Faster Than Threaded Flange
- High Degree of Safety
- Preferred Solution

3.0 OPEN HOLE PRESSURE CONTROL EQUIPMENT WITH SHOOTING NIPPLE
The standard open hole pressure equipment is usually a single, manual or

hydraulic Wireline Valve with a stuffing box or an annular wireline BOP mounted
on top. It should have a minimum safe working pressure of 3,000 psi and is
designed for working with large diameter logging tools and large multi-conductors
cables, (normally 15/32" OD).
3.1 WIRELINE VALVE
Elmar manufacture a manually operated single BOP with a 5-1/2" ID and a safe
working pressure of 5,000 psi for open hole logging. This along with a hydraulic
line wiper and stuffing box L-971780 gives protection against pressure in open
hole situations (Figure 12-6).
The manually operated BOP can only be mechanically opened and closed by
turning handles that are connected to a threaded shaft which screws into the
body of the BOP. At the end of the shaft is a plate that locks into the back of the
ram body and pushes and pulls the ram depending on the direction you turn the
handles.
Manual single ram BOPs are to be found in service with working pressure ratings
up to 5,000 psi, and have an ACME threaded body with O-ring seal. Older
models with 8 round casing threads are not recommended, and are banned by a
majority of major operators.
Figure 12-6
Large Bore Safety-While-Logging Wireline Valve

3.2 HYDRAULIC LINE WIPER AND STUFFING BOX
The hydraulic line wiper and stuffing box is designed to seal on a moving cable
under pressure. Positioned above the wireline valve, the internal parts are
removed before the wireline tools are lowered into the well. Once the tools are in
the well the internal parts can then be replaced.
The hydraulic line wiper and stuffing box works by operating a hydraulic hand
pump which in turn applies pressure to a rubber element that is wrapped around
the wireline and therefore provides the seal.
The hydraulic line wiper and stuffing box L-971780 has a safe working pressure
of 5,000 psi and is suitable for H2S service (Figure 12-7).
Figure 12-7 Hydraulic Line Wiper and Stuffing Box
3.3 CONNECTION OF BOP TO SHOOTING NIPPLE
The majority of shooting nipples have either ACME or STUB ACME threads with
‘O’- ring seals. The BOP-M and HLW-B stuffing box have the same type of
threads and seals. If API connections are used, pressure ratings will only be
valid if the connection is made up to the recommended torque, it is therefore

recommended to use quick couplings with O-ring seals and have the API
connection made-up well before the job.
Notice that most operators are now banning API connections, and accept only
“premium” threaded unions or Quick Unions.
3.4 USE OF WHE WITH LARGE BRAIDED WIRELINE AND ARMOURED

CABLES
When using wireline valves and stuffing boxes it is important to remember that
the elastomeres seals are effectively sealing against the outer armour, but cannot
shut-off all the passages (Refer to Section 7, page 17) in-between the armour
strands and the electrical conductors.
With mud or viscous fluids in the well, leakage through the armour will be
minimal, but leakage will increase if light fluid or gas is present.
Leakage will also be a function of how tightly packed is the cable. Some cables
are pre-packed at manufacturing to reduce the amount of void. Cables also tend
to become “seasoned” with use through accumulation of mud solids particles or
grease. It is also possible to pre-treat cables injecting high-viscosity grease to fill
the armour voids. Special equipment is required for this purpose.
Taking into account what stated above the function of the Wireline Valve/ Stuffing
box combination is to allow a minimal, controlled leak, until the downhole tool is
brought to a position in the well where well control procedures can be initiated
safely.
Primary control of the well is always assured by the mud system, and by
well killing procedures in case of a kick with cable and down-hole tools in
the well.
If total control of the well by the pressure control equipment is required,

than a Grease Injection Head must be installed.

3.5 HYDRAULIC WIRELINE ANNULAR BOP
The Elmar Hydraulic Wireline Annular BOP (sometimes called “BOP-V”) is

designed to seal on a moving cable under pressure. It is meant to be used for
“Safety while Logging” applications and for Perforations with large guns when no
pressure is expected after perforation. (See Figures 12-8 and 12-9)
The annular BOP is rated 3,000 psi STD Service.
The Hydraulic Wireline Annular BOP seals by squeezing a split rubber element,
which is wrapped around the wire. This element effectively seals against well
pressure, as well as wiping the wire free of fluid.
Positioned above the drilling BOP, or a “shooting nipple”, it offers a clean bore of
6” to 6.5” (depending on connection type) to run a tool through. It is lighter and
easier to install than a Wireline Valve. Bottom connection has an ACME Thread
with O-Ring seal, either pin or box depending on Customer’s request.
The cable and rope socket are initially threaded through the top section and
connected to the head. Several elements are split or slotted for ease of
assembly. In subsequent runs the top section is lifted with the logging head that
engages in the overshot, and remains around the cable while tools are laid down.
The funnel on the top has the same profile, and replaces a gooseneck.
In the funnel there are optional quick connections for compressed air, to clean
any remaining mud on the cable.
The rubber packoff can be easily replaced, even midway through a run if no
pressure is present. A Hydraulic hand pump is required to operate the pack-off.
Part No. Wire Size Working Pressure Service Bottom Connection

L - 971618 0.46”-0.52” * 3,000 psi STD 7 9/16” - 5thd Stub Acme Box
L - 971619 0.46”-0.52” * 3,000 psi STD 7” - 5thd Stub Acme Pin
* Other line sizes available on request
AIR HOSE ASSEMBLY

L-690541 Air Hose Assembly 1/4 ” ID ARO Hose
STUFFING BOX OR PACK-OFF HAND PUMP (STEEL) HYDRAULIC HOSE ASSEMBLY

Part Number Part Number Description
L-691080 25ft Hose Assembly
1
/4” ID 100 R2AT Hose with 1/4” NPT
L-690730 L-690760 50ft
Male Hose Ends and Snaptite
L-690740 100ft Male and Female Connectors

Figure 12-8
Typical Elmar Hydraulic Wireline Annular BOP
3,000 psi Working Pressure (STD Service)
L-690551 Sling and

Spreader Beam Assembly
Casing Joint

Figure 12-9
Typical Elmar Hydraulic Wireline Annular BOP
Quick Union
Minimum Passage 1.75" Quick Union
ID 2.40"
ID 6" to 6.5" *
Overshot
Logging Head
*Depending upon bottom connection

The function of the BOP-V is to allow controlling well pressure while moving the
tool to a safe position before initiating well control procedures.
It is important to have in the rig-up the possibility of connecting a pump to bull-

head the well as needed. Use a pump-in sub if no other facility is available.
Some operators do not allow use of a single pack-off when Well Head Pressure
is expected. Make sure to know your Company’s and the well operator’s policy
before starting a job.
If required, the Annular BOP can be replaced with a dual Pack Off
3.6 COMPACT DUAL PACK-OFF
The Enviro Dual Compact Packoff (see fig 12-10) consists of two rubber
packoffs in series. It can be used to wipe the line and contain pressure on a
moving wireline in situations where full control of the well is assured and well
killing facilities are available. The tool is rated 5,000 psi, H2S service.
Two separate hand pumps and hoses are required to operate each pack-off
independently.
One specific application of the Compact Dual Packoff is to offer enhanced well
control during operations through drill-pipes, for instance, Back-Off or pipe
severing applications. In this case the Compact Dual Pack-off can be connected
to a pump-in sub, which is in turn connected on top of the pipe string.
The Compact Dual Pack Off has a clean ID of 1.74” when the split packing
rubber and brass bushings are removed. This allow passing through small (1
11/16” heads. For larger heads the cable and rope socket are threaded through,
and the head assembled with the Pack-off over the cable.

Figure 12-10
Dual Pack Off with Pump-in Sub

M3000 - DUAL HYDRAULIC ANNULAR WIRELINE BOP
The Elmar Dual Hydraulic Annular Wireline BOP (M3000) (See fig 12-11 and 12-
12) is a two-piece tool, which is designed to seal on a moving cable under
pressure and which if necessary, allows the introduction of extra lubricator
sections to the wireline rig-up if the operating conditions necessitate this step. It
is to be used for “Safety While Logging” applications, perforating with large guns
and other similar wireline intervention work.
Positioned above the drilling BOP, or a “shooting nipple”, the M3000 Lower
Assembly comprises a lower body and a lower packing assembly that can be
easily disassembled for ease of rig-up. The M3000 Lower Assembly offers a
through bore of 6.5” ID maximum (depending on connection type). Several
elements of the lower packing assembly are either slotted or split in order that the
cable head with rope socket can remain intact.
In the course of the wireline intervention it may be necessary to add lubricator

sections with the Upper Assembly installed to overcome a wireline problem e.g.
birdcage or a well “kick”. A two-step procedure will allow the birdcage to be
removed from the well and the wireline tool to be raised above the drilling BOP in
order that it may be closed.
Figure 12-12-1 (Section 12 page 21): Illustrates the rig-up as wireline intervention
work commences.
Figure 12-12-2: Illustrates the position where the wireline crew have clamped the
wire above the Lower Assembly, they have cut the wire and threaded the wire
through the M3000 Upper Assembly and the extra lubricator section(s) and/or
pump-in sub, they have tied the two loose ends of wire together and have taken
the tool weight on the winch, they have removed the wireline clamp and have
lowered the extra lubricator and M3000 Upper Assembly to make-up to the
M3000 Lower Assembly.
Figure 12-12-3: Illustrates the position after equalisation across the M3000 lower
packing element and slacking off the lower packing lock-down screws to allow
the lower packing to be raised with the wire/tool.
The M3000 upper and lower packing assemblies seal by squeezing a split rubber
element, which is wrapped around the wire. These elements effectively seal
against well pressure, as well as wiping the wire free of fluid.

The M3000 is designed so that the rubber element, which is in direct contact with
the wire, can be easily replaced.
An Air Cleaner is integral to the upper and lower assembly.
A Hydraulic hand pump is required to operate the packing element.
Figure 12-11 Typical Elmar Dual Hydraulic Annular Wireline BOP

Upper
Assembly
Lower Tulip Wire

Assembly Guide
Air Cleaner
Lock-Down Lower
Screws Packing
Assembly
Pump-in/
Equalisation
Lower Body
Port
Overshot

Figure 12-12: Elmar Dual Hydraulic Annular Wireline BOP

M3000 Upper Assembly
Lower
Packing
Assembly
Lubricator Section (s) Wireline

Logging
Tool
Pump-In Sub
Lock-down
Lock-down
Screws
Screws
Released
Lower Body
M3000
Lower
Assembly
Figure 1 Figure 2 Figure 3
Description Part No. Wire Size Working Pressure Service Bottom Connection
Upper Assembly L - 971472 0.46”-0.52” * 3,000 psi STD 9”-4thd (7.500”) Slimline EØ5
Lower Assembly L - 971473 0.46”-0.52” * 3,000 psi STD 9”-4thd (7.500”) Slimline EØ5
Note: 1. Other line sizes available on request 2. Seal Kits comprise O-Rings and BURs only
AIR HOSE ASSEMBLY

L-690541 Air Hose Assembly 1/4 ” ID ARO Hose
STUFFING BOX OR PACK-OFF HAND PUMP (STEEL) HYDRAULIC HOSE ASSEMBLY

Part Number Part Number Description
L-691080 25ft Hose Assembly
1
/4” ID 100 R2AT Hose with 1/4” NPT
L-690730 L-690760 50ft
Male Hose Ends and Snaptite
L-690740 100ft Male and Female Connectors

4.0 SLIMLINE AND SLIMLITE EQUIPMENT
The “Slimline” and SLIMLITE equipment (fig 12-13 and 12-14) is a range of large
bore equipment available in H2S and STD service typically used during “Open
Hole” wireline intervention work, or for perforating operations with large casing
guns.
Figure 12-13: Slimline and SLIMLITE Lubricators
The “Slimline” family of WHE Equipment uses lubricators made out of L-80 or P-
110 casing tubes, with quick union adapters screwed-on the body of the tubes.
Because of this and because of the "slim" union, the test pressure TP for such
equipment is
Test Pressure =1.5 X Working Pressure in the 3,000 psi and 5,000 psi WP
range.
This is not in compliance with API6A, which dictates for pressure vessels rated
3Kpsi or 5Kpsi TP = 2.0 x WP.

Taking advantage of the new high strength alloys available for Oilfield Tubular
applications, ELMAR has recently developed a new "SLIMLITE" line of large bore
lubricators, which fully comply with API6A.
The SLIMLITE equipment has a 2.0 safety factor with:
Test Pressure = 2.0 X Working Pressure
ELMAR SLIMLINE/SLIMLITE IDENTIFICATION CHART

Slimline Size ID Thread Details Working Pressure Test Pressure Service
5 1/2" 4.89" 6 3/4" - 4THD (5.375") Slimline 5,000 psi 7,500 psi STD
7 5/8" 6.76" 8 1/2" - 4THD (7.250") Slimline 3,000 psi 4,500 psi STD
7 5/8" 6.76" 9" - 4THD (7.500") Slimline 5,000 psi 7,500 psi STD
7 5/8" 6.62" 9 1/2" - 4THD (7.500") Slimline 5,000 psi 7,500 psi H2S
5 1/2" 4.89" 6 3/4" - 4THD (5.375") SLIMLITE 5,000 psi 10,000 psi H2S
7 5/8" 6.62" 9 1/2" - 4THD (7.500") SLIMLITE 5,000 psi 10,000 psi H2S

Figure 12-14: Typical Slimline Equipment

NOTES
NOTES
NOTES
NOTES
NOTES
NOTES

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2. Whilst Elmar will attempt to exercise reasonable care in the running of

3. Any safety policies, procedures or instructions of the employers or the

4. Copyright in this manual is vested in Elmar. No copying in whole or in part is

Commercial Confidential Copyright © Elmar 2002, not to be copied without permission

July 2002 Revision: 2 Important Notices

SECTION TABLE OF CONTENTS

1 Introduction to Elmar and Elmar Customer Services

2 Training School Outline

4 Introduction to Wireline Pressure Control Equipment

5 Pressure Control Safety

6 Relevant Design, Manufacturing and Certification Standards

Wireline Pressure Control Equipment – Hardware

8 Grease and Hydraulic Control Module

9 Pressure Tight Seals & Fittings

10 Using the Cased Hole Pressure Equipment

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Contents - Page 1

SECTION 1 - ELMAR SERVICES

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 1 - Page 1

SECTION 2 - OUTLINE OF THE COURSE

• Equipment - Wireline Valves (BOPs)

• Divide into groups, dismantle, inspect, assemble and test equipment

• Quick re-cap of day 1.

• Equipment - Grease seal flow tubes

• Divide into groups, dismantle, inspect, assemble and test equipment.

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 2 - Page 1

SECTION 2 – OUTLINE CONTINUED

• Quick re-cap of day 2

• Using cased hole logging equipment

Move Outside to Well Site

• Quick re-cap of day 3

• Discuss operational problems

Move Outside to Well Site

• Simulate stranded cable

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 2 - Page 2

SECTION 3 - ASSESSMENT SYSTEM

A total of 65 questions, 35 are written answers, 30 are multiple choice.

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 3 - Page 1

SECTION 4 - INTRODUCTION TO WIRELINE PRESSURE

The mechanical strength of a smaller OD wireline is considerably less than that of a

Pressure Control Equipment, often referred to as wellhead equipment (WHE) normally

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 4 - Page 1

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 4 - Page 2

SECTION 5 - PRESSURE CONTROL SAFETY

• Pressure control equipment is used to safely perform operations when

• Never heat or weld any part of the pressure control equipment

• Detailed, advanced planning of a job is essential to ensure safe operations

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 5 - Page 1

Wellhead pressure and temperature

• Select proper equipment depending on pressure and type of service.

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 5 - Page 2

• Clear area of all unnecessary personnel

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 5 - Page 3

PRESSURE EQUIPMENT - THE DO'S AND DON'TS