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3.1.

3: Control lines
Connect the two 3/16 inch, low pressure hydraulic hoses from the Super Choke Valve to the
rear manifold on the control console (See Figure 5).These two (2) hoses are provided with
quick disconnect fittings that are matched with male and female ends in such a manner that is
impossible to reverse and install the two (2) hoses incorrectly. Route the hydraulic hose's in
such a manner as to avoid damage and hazards for rig personnel.

3.1.4: Choke disc position transmitter


Connect 1/4 inch O.D. vinyl tubing from fittings on the position transmitter, located on the
choke valve to the corresponding fittings on the control console(See Figure 5).The two (2)
fittings on the control console manifold are labeled "Air toTransmitter" and "Air Return from
Transmitter".

The fittings on the position transmitter are not labeled. Check the arrow located on the
position transmitter regulator to determine the direction of the air flow.
3.2: Control console3.2.1: Installing the control console
Place the control console in the desired location on the rig floor or in a safe working area
designated by the customer. Normally, the best location for the control console is against the
hand rail nearest the mud tanks and the choke manifold. This location provides the choke
operator with a view of the fluid level in the mud tanks and other equipment related to a well
killing operation. Figure 5
3.2.2: Air supply
Connect the air supply hose from the manifold on the control console to the rig air supply
(See Figure 5). The air hose should be connected to an outlet where clean, dry air may be
obtained. Trash or moisture in the air supply can cause a malfunction of the air-operated
hydraulic pump. This air outlet should not be sued for any other purpose which might cause
the supply to be disconnected from the control console. Install the air hose to avoid crimping
or cutting and excessive heat from other equipment. The recommended air supply pressure
for the control console is 50-125 psi(345-862 kPa). For a hose length to 50 feet (15 m) a 1/2
inch diameter hose is adequate. For longer lengths a 3/4 inch diameter hose is desirable. The
air hose supplied with the control console has 1/2 inch NPT male connection which can be
adapted to the air outlet on the rig. Turn the master air supply valve on the control console to
the ON position. The pointer of the position indicator gauge should show OPEN (assuming
the choke was installed in the open position). If it shows CLOSED or partially closed, check
to determine if the super choke valve is fully closed or if the position transmitter is properly
calibrated.
NOTE:
The control console and super choke valve should be calibrated together at the service center.
Refer to section 5.1.10 of this manual for proper calibration procedures. Push the control
lever to the right toward the choke CLOSE label. The Hydraulic pump should start stroking
and the needle of the position indicator gauge should begin moving. Hold the lever in this
position until the choke is fully closed and the hydraulic pump stops stroking; then release
the lever. The control valve should open. Push the control lever to the left toward the choke
OPEN label until the choke is fully open. If there is any problem with any of these
operations, refer to Section 5.1.10 of this manual.

3.2.3: Stroke / Rate Meter The Swaco Digital Pump Stroke / Rate Meter, located on the
control console, is powered by a built-in battery pack. No outside source of power is
required. The meter comes with either limit or magnetic proximity switches.-

Limit switch: Each pump Stroke switch assembly mounts to the mud pump frame near the
exposed pump rods. Position each switch assembly so the switch actuator rod moves when
contacted by the pump rod collar or splash guard. There should be one full deflection and
release of the actuator rod for each pump stroke to assure proper operation of the stroke
counter and to avoid double counting.-

Magnetic switch: Find a large mass of metal on the pump and position switch so that it can
sense off of it. Be sure not to allow the mass to pass completely past the sensor or it will
double count. Route the cable from the Digital Pump Stroke/Rater Meter to the junction box
and connect the wires. Use wire nuts to connect the wires inside the junction box. The strain
relief connections on the meter, junction box and pump switches should be used to avoid
wire damage. Shielded cable is recommended between the Stroke/Rate Meter and the limit
switch assembly. Ground the shielding on one end of the cable. This will prevent electrical
noise from the power cables adjacent to the Stroke/Rate Meter from causing an inaccurate
count. Operate each pump stroke assembly by hand to determine Pump 1, 2, or 3. The pump
select switch is located on the bottom of the Stroke/Rate Meter is used to display the desired
pump stroke count and rate being displayed.
3.2.4 GAUGE PROTECTOR
-

Connect the drill pipe pressure gauge protector assembly (figure 5) to the rig stand pipe. The
assembly should be mounted in an upright position to allow mud to drain when there is no
pressure in the standpipe. The hydraulic hose is connected to the drill pipe pressure gauge
connection located on the control console manifold. Make sure the hose is run in a manner
which will not interfere with pedestrian or vehicle traffic or be cut, crimped, worn by rig
structures or burned by other equipment.-
Connect the casing pressure gauge protector assembly (figure 5) to a suitable place on the
choke manifold. This assembly should be mounted upright and have a valve below it that
can be closed off to allow repair of the gauge protector. The hydraulic hose is connected to
the casing pressure gauge connection located on the control console manifold. Make sure the
hose is routed in the same manner as described above. The gauge protectors are rated for
10,000 psi (68950 kPa) working pressure and may be mounted to a 2” female hammer union
hub, a 2” npt male or female connection on the standpipe and choke manifold. The gauge
protector lines should be filled with hydraulic fluid at the service center prior to the control
console being delivered to the rig site. If this is not possible, refer to section 5.1.9 of this
manual for the hydraulic line filling procedure.

4.1 PROCEDURES4.1.1 NORMAL OPERATING METHOD (fast)


-

Move faster AIR SUPPLY valve to the ON position (see figure 2).-

Open the HYDRAULIC REGULATOR all the way.-

The control console displays the following information that is typically used in well control
procedures-

Drill pipe pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 kPa increments)-

Casing pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 Kpa increments)-

Choke position (full OPEN to full CLOSE)-

Rig pumps stroke rate and stroke count-

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

When the well control operation is complete, open the choke and turn master AIRSUPPLY
valve OFF to remove all pressure on the hydraulic system
NOTE:
A PLUGGED CHOKE MAY RESULT IN EXCESS PRESSURE BUILD-UP INTHE
SYSTEM WHICH MAY EXCEED THE CASING PRESSURE LIMIT. IN CASE
OFCHOKE PLUGGING, SHIFT THE MAIN CONTROL LEVER TO OPEN, AND
OPENTHE HYDRAULIC REGULATOR FOR FAST RESPONSE. AS SOON AS THE
PLUG ISCLEARED, THE CONTROL LEVER MUST BE SHIFTED TO CLOSE
LONG ENOUGHTO RETURN TO THE DESIRED PRESSURE. THE HYDRAULIC
REGULATORVALVE MAY THEN BE ADJUSTED FOR A SLOWER RESPONSE.
4.1.2 ALTERNATE OPERATING METHOD (slow)
-

If slow operation is desired, close the HYDRAULIC REGULATOR all the way. Then to
adjust the choke disc speed, hold the CONTROL LEVER in the CLOSE position and
slowly open the HYDRAULIC REGULATOR valve. This allows only a very slow
movement of the choke discs. When the desired pressure is reached, the CONTROL
LEVER should be released.-

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


4.1.3 EMERGENCY OPERATIONFAILURE OF AIR SUPPLY OR AIR PUMP

Install PUMP HANDLE on the HAND PUMP which is mounted on the base of the control
console skid. (Be sure pump BLEED-OFF valve on the HANDPUMP is closed).-

To change choke opening, hold the control lever in the desired position while stroking the
HAND PUMP.
RUPTURE IN HYDRAULIC LINE OR CONNECTION
-

If either hydraulic line is cut or rupture’s, cut both lines at the choke. The hoses must be cut
and NOT DISCONNECTED. If they are disconnected, check valves in the fittings will
prevent operation.-

Insert 5/8” (16mm) diameter rod into one of the holes in the INDICATOR HEAD(figure 7)
and manually position the choke as desired.
SERVICE AND MAINTENANCE5.1 PROCEDURES5.1.1 ROUTINE INSPECTION
The SWACO super Choke is a key element of the pressure control system used to prevent
rig blowouts. Therefore, it is important that the Super Choke and Control Console be
maintained in good operating condition at all times (see figure 8).
5.1.2 DAILY VISUAL CHECKS
-

Check the presence of a hand pump handle (item 9), a manual choke operating bar and all
panel labels-

Check fluid level in the hydraulic oil reservoir (item 1). Fill with the correct hydraulic oil.
Keep a supply of oil at the choke panel or close by.-

See that all connections fit tight. Make sure the hydraulic hoses, pump switch cable and air
lines are properly connected and not cut or pinched.-

Check the pump Stroke/Rate Meter (Item 8). Place the selector switch on “TEST”, the meter
should be counting and should show 128 SPM. Select Pump 1or Pump 2 and observe
counter and rate display. Reset counter to zero after test.-

See that the pump stroke counter switches (item 3) are properly attached to the mud pump
and counting the correct number of strokes.-
Check the air line lubricator (item 14); the bowl should be filled with the correct hydraulic
oil.
5.1.3 DAILY OPERATIONAL CHECKS
-

Turn the master air supply valve (item 5) on. The hydraulic pressure gauge (item12) should
show 1500-1750 psi (10343-12066 kPa).-

Close the hydraulic regulator (item 11) and then open 1-1/2 turns. Operate the control lever
(item 6). Complete a full cycle of the choke discs from full OPEN, to full CLOSE, back to
full OPEN. The position indicator (item 10) should track the choke disc movement
according to the choke lever selection.-

While the hydraulic pump is stroking, check the sight glass located on top of the air line
lubricator (item 14). The lubricator should deliver approximately 1 drop of oil for every 20
strokes of the hydraulic pump. The adjustment screw is located on top of the lubricator.-

To operate the hand pump (item 2) to close or open the choke discs, shut the air supply off.
Hold the choke control lever in desired position and operate hand pump. Make sure the bleed
valve on the hand pump is closed. Leave the pump piston in the DOWN position to avoid
rust or corrosion.-

Observe the Drill Pipe and Casing Pressure gauges (item 7). The pressure valve should be
approximately the same as the rig gauges. Gauge faces should be clean and visible.
5.1.4 REMOVING THE CHOKE VALVE FROM THE MANIFOLD
Before attempting to work on a Super Choke in a manifold, extreme caution should be
exercised to assure that there is no pressure trapped in the choke valve or choke manifold.
Always use proper safety precautions where H
2
S gas may be trapped in the choke valve or manifold. Only personnel who have received
instruction on the hazards of H2S may be present should be permitted to work on the Super
Choke. Failure to follow these instructions could result in injury.

Rotate the choke discs to the full OPEN position. Allow the pressure in the choke valve to be
relieved before continuing with this procedure.-

Carefully loosen the outlet flange nuts one turn each until seal or ring gasket is broken but do
not remove the nuts on the outlet flanges of the choke valve. After all the nuts are loosened,
break the seal on the ring gasket by separating the outlet flange from the manifold flange.
Stand on either side of the flange gap, never over it, when breaking the seal to avoid possible
severe personal injury. Once the seal is broken and all pressure inside the choke is relieved,
the nuts and studs maybe safely removed. Do not use a pry bar to remove flange because of
possibly damaging the extended wear sleeve.-

Provide some manner of support for the valve, and then carefully loosen the upstream flange
nuts one turn until seal is broken and any trapped pressure is released, and then remove the
nuts and studs on the inlet flange. Refer to section 3.1.1 of this manual for reinstalling the
choke in the manifold.
ATTENTION!
Because of the H
2
S rating for the SWACO Super Choke the steel used to fabricate the flanges, nuts and studs
are relatively soft and therefore, subject to surface distortion and dents from poor work
practices. Care should be exercised in the handling procedures and use of tools when
working on the Super Choke to avoid damaging these parts. Damaged parts will adversely
affect the structural integrity of the super choke which may result in injury.
5.1.5 CHANGING THE DISC ASSEMBLIES
This section describes the procedure for removing the super choke discs from the outlet end
of the valve body for inspection and/or replacement and removal of the wear sleeves. See
drawing 2 for part number information.
NOTE:
Before attempting to work on a Super Choke, extreme caution should be exercised to assure
that there is no pressure trapped in the choke valve. Always use proper safety precautions
where H
2
S gas may be trapped in the choke valve. Only personnel who have received instruction on
the hazards of H
2
S, the proper safety equipment and procedures for working in areas where H
2
S may be present should be permitted to work on the Super Choke. Failure to follow these
instructions could result in injury.-

Carefully loosen the outlet spool bolts one turn each. After all the bolts are loosened, break
the o-ring seal and unbolt the outlet spool, carefully separating it from the body. The spool is
fastened to the choke body with 7/8” ferry head cap screws. Locating pins provide alignment
between the body and the outlet spool.-
To remove the choke discs, first rotate the front disc to the full OPEN position if this has not
been previously done. Wash any sand, grit or weight material from around the exposed
portion of the back disc and the disc opening.-

Insert the hook end of the disc puller (Swaco part number 96-11-083) in the disc opening as
illustrated in Figure 9 and gently remove both discs using the sliding weight on the puller.