OPERATIONS AND MAINTENANCE MANUAL

ELMAR GREASE INJECTION

MAN-10000946
EQUIPMENT ASSEMBLY

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OPERATIONS AND MAINTENANCE MANUAL
ELMAR GREASE INJECTION
MAN-10000946
EQUIPMENT ASSEMBLY

Document covering the following Elmar assemblies:

L-979470

L-978385

L-970635

L-971229

L-971218

L-9701013485

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Originally Prepared by G. Reid
Edited by S. Trevaskis
Approved by C Wade
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Publication MAN-10000946
© Copyright National Oilwell Varco, Inc. 2007
The information is correct at the time of print
First Published in January 2007 by Elmar Engineering
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Approval and Issue

REV ECO PREPARED CHECKED APPROVED DATE COMMENTS

A G. Reid C. Wade C. Wade 17/01/2007 1st Issue

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

1.1 GENERAL ......................................................................................................6

1.2 SAFETY PRECAUTIONS AND WARNINGS..................................................6

1.3 COMPETENCY OF PERSONNEL .................................................................7

1.4 PERSONAL PROTECTIVE EQUIPMENT ......................................................8

1.5 PREPARATION OF THE WORKSITE............................................................9

1.6 PRESSURE CONTROL SAFETY................................................................. 10

2 DESCRIPTION ............................................................................................. 14

2.1 GENERAL DESCRIPTION ........................................................................... 15

3 EQUIPMENT DESCRIPTION ....................................................................... 16

3.1 STUFFING BOX ASSEMBLY ....................................................................... 17

3.2 GREASE INJECTION EQUIPMENT ASSEMBLY ........................................ 20

4 SPECIFICATIONS AND FEATURES........................................................... 25

4.1 SPECIFICATIONS........................................................................................ 26

4.2 STANDARD FEATURES.............................................................................. 26

4.3 DESIGN STANDARDS AND REQUIREMENTS........................................... 26

4.4 OPERATING REQUIREMENTS................................................................... 27

5 OPERATION ................................................................................................ 28

5.1 FUNDAMENTAL RULES FOR PROPER OPERATION ............................... 29

5.2 OPERATION ................................................................................................ 29

6 ASSEMBLY INSTRUCTIONS ...................................................................... 31

6.1 TOOL LIST ................................................................................................... 32

6.2 ASSEMBLY INSTRUCTIONS ...................................................................... 33

7 MAINTENANCE AND TESTING .................................................................. 38

7.1 ROUTINE MAINTENANCE .......................................................................... 39

7.2 MAJOR MAINTENANCE .............................................................................. 41

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7.3 TESTING ...................................................................................................... 43

7.4 TROUBLESHOOTING.................................................................................. 45

7.5 MAINTENANCE RECORD SHEET .............................................................. 46

8 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL............ 47

8.1 TRANSPORTATION..................................................................................... 48

8.2 SPARES AND ACCESSORIES....................................................................48

8.3 DISPOSAL.................................................................................................... 52

9 DRAWINGS AND BILLS OF MATERIAL .................................................... 53

9.1 GUIDE TO USE OF ELMAR DRAWINGS .................................................... 54

9.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT .............................. 54

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1 HEALTH AND SAFETY
1.1 GENERAL

1.2 SAFETY PRECAUTIONS AND WARNINGS

1.3 COMPETENCY OF PERSONNEL

1.4 PERSONAL PROTECTIVE EQUIPMENT

1.5 PREPARATION OF THE WORKSITE

1.6 PRESSURE CONTROL AND SAFETY

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 SAFETY IS EVERYONE'S RESPONSIBILITY

1.1 GENERAL
This manual should be consulted as a minimum requirement by all persons involved
in work on Wellhead Pressure Control Equipment. All other documents such as
assembly drawings, bill of materials etc, should be made available at the worksite.
Failure to consult the manual could result in a lack of knowledge that could result in
accidents involving injury to personnel or lead to damage to property and equipment.

This manual documents Elmar's recommendations, but should not be assumed to

satisfy the requirements of legal regulations governing the region in which the
equipment is being used or additional company policy of the owner/user.

Additional measures must be put in place by owner/user to ensure that:

• the required competency of operators is defined, and that only competent

operators are permitted to operate the equipment;

• suitable additional workplace measures are defined, and adhered to, to

further reduce the residual risks associated with the use of the equipment;

• a suitable program for regular maintenance of the equipment is defined,

adhered to and recorded;

• a suitable program for periodic inspection, testing and examination of the

equipment is defined, adhered to and recorded.

1.2 SAFETY PRECAUTIONS AND WARNINGS

Operation and maintenance of wellhead pressure control equipment involves residual
risks which cannot be reduced by design lower than is reasonably practical. General
hazards and additional information to reduce these risks are provided in the form of
additional notes, cautions or warnings.

The following nomenclature is used throughout the manual. Its purpose is to make
the user aware of the potential hazards related to using pressure containing
equipment in general, and to allow the operator to minimise these risks by employing
safe working practices (refer also to 1.5, Preparation of the Worksite):
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 TIP!
An instruction with this indicator is a tip to make a task easier to carry out.

NOTE!
An instruction with this indicator is extra information that can prevent minor problems.

CAUTION!
An instruction FOLLOWED by this CAUTION highlights a hazard which could cause damage to
equipment or its components. Follow the instructions carefully.

WARNING!
An instruction FOLLOWED by this WARNING highlights a danger or injury to the OPERATOR
or other PERSONNEL, or danger of serious damage to the equipment or other objects. Follow
the instructions carefully.

1.3 COMPETENCY OF PERSONNEL

All operation and maintenance of the Wellhead Pressure Control Equipment (WHE)
should be planned and supervised by a competent person. The competent person
will normally be the person in charge of the worksite who should consider the safety
aspects of the work and the competency of the persons carrying out the operations.

WARNING!
Any persons who feel sick, tired, or are under the influence of medicines, alcohol, or other
drugs should not be allowed to operate WHE.

The legal requirements and owner/user requirements for operator competency may
vary between regions and between owner/users. The definition of operator
competency should, therefore, be defined and controlled by the equipment
owner/user.

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Elmar recommend that the competent person must have, as a minimum:

• Sufficient practical and theoretical knowledge of wellhead pressure control

equipment at that particular location.

• Sufficient experience of the operation of wellhead pressure control

equipment in the environment in which it is used.

• The ability to detect deficiencies and to assess their criticality in relation to

strength and performance, and to recommend remedial action to ensure
that conditions are appropriate for safe use.

• Understand and comply with Emergency Procedures and Instructions.

• Be able to describe the nature of principal hazards that could occur at the
particular location including the appropriate worksite precautions, test
methods and means of safe handling.

• Be able to locate, identify, describe functionality and operate all fixed and
portable fire fighting and life support equipment at the location.

• Other personnel involved in the operations should have a sound

knowledge of their part of the operation and have received instructions
from the competent person.

Elmar recommend that personnel involved in wellhead pressure operations have

been formally trained. Elmar can provide formal training courses which should be
attended as part of the achievement of operator competency.

1.4 PERSONAL PROTECTIVE EQUIPMENT

Appropriate PPE should be worn specific to the job. As a minimum standard the
following is recommended:

1) Safety Helmets.

2) Eye Protection.

3) Hearing Protection.

4) Respiratory Protection (where conditions deem necessary).

5) Body Protection.
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 6) Hand Protection i.e. wearing of gloves or use a barrier cream if necessary.

7) Foot Protection.

1.5 PREPARATION OF THE WORKSITE

The competent person should not allow work to proceed until the thorough
examination and risk assessment of the work site and equipment has been carried
out, and that he is satisfied that it is safe to proceed. The risk assessment should be
carried out to identify hazards and assess their threat. This risk assessment should
be cascaded to all other persons involved in carrying out the work.

The examination should assess (as a minimum) the condition of the equipment
structure, the condition of all critical components, and ensure that the WHE shows no
signs of excessive damage or wear which may affect the safety of the equipment
during use. (Refer to Section 7 for inspection, examination and testing for WHE
details).

Hazards are identified and assessed through:

1) Experience/Judgement

− The knowledge of experienced staff provides a sound basis for

hazard identification and assessment.

2) Checklists

− These are a useful way of ensuring that known hazards have been
identified and assessed. They are normally drawn up from
operational experience and focus on areas where the potential for
mistakes is high or where problems have occurred in the past.

3) Hazards are assessed using any combination of:

− Engineering judgement, or.

− Comparison with good practice in the field.

4) At the completion of the of the risk assessment it should be possible to

document that:

− All hazards have been identified;

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 − The controls to manage potential causes are in place.

− The prepared measures to mitigate potential consequences have

been taken.

Remember….

• Do use eye protection when using power tools.

• Do wear gloves or use barrier cream to protect your hands.

• Do wear protective footwear.

• Keep loose clothing and long hair well out of the way of moving
mechanical parts.

• Do remove rings, wristwatch etc, before working.

• Do change out of oil-soaked clothes and do not keep oily rags in your
pocket.

• Do ensure that any lifting or jacking equipment has a safe working load
rating adequate for the job.

• Do get someone to check periodically that all is well if working alone.

1.6 PRESSURE CONTROL SAFETY

1.6.1 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 hats and overalls.

• Special precautions are necessary if H2S may be present at the well site.

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1.6.2 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
well site.

1.6.3 BASIC SAFETY

• 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 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 equipment that does not have a Working Pressure
Rating.

1.6.4 PRE-DEPARTURE

• Detailed, advanced Detailed, advanced planning of a job is essential to

ensure safe operations.

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

− Wellhead Pressure and Temperature;

− Production: gas, oil, H2S, CO2, chlorides, hydrates;

− Inhibitors, corrosive fluids, chemical injection;

− Rig: Height – BOP adapter flanges;

− Tubing, casing, restrictions, deviation;

− Wellhead crossover connection;

− Lifting equipment, cat lines, 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 pressure. Check the rating and
compatibility of all connections.
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 • 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 fittings, needle valves, gauges, etc.

• Ensure that enough lubricators is available to cover the tool and allow 3ft
(1metre) clearance. This applies to fixed structures- not semi-submersible
rigs drilling rigs.

• Check spare parts box.

1.6.5 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 riser or pressure test with diesel oil. Air in the riser can be
compressed and mixed with diesel vapour to cause a diesel explosion.

• Drill floors are dangerous places. Be more alert and take care of
necessary precautions when working on a rig floor.

1.6.6 RIGGING UP

• Clear area of unnecessary personnel.

• Ensure drill floor is free of mud and dirt.

• Rig up wellhead adapter, BOP and tool trap first.

• Secure all flow lines.

• Ensure drain lines are coupled to closed drain system or environmental

secure area.

• Pressure test the complete set up 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.

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 • Client representative controls the Christmas Tree master valves.

• 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 grease head
and lubricator with the wellhead.

1.6.7 RIGGING DOWN

• Be aware that trapped pressure may exist in 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.

1.6.8 AFTER JOB

• Perform maintenance. The time between the end of the job and
maintenance is when the equipment is most at risk from corrosion.

• Concentration is often low after the job is complete and this leads to
accidents. Please remember that the equipment is heavy and should still
be treated with care and attention.

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2 DESCRIPTION
2.1 GENERAL DESCRIPTION

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2.1 GENERAL DESCRIPTION
The Elmar Grease Injection Control Head have been designed for use as part of a
complete wireline intervention string. The primary purpose is to create a seal around
a moving wireline, allowing intervention access to wells under pressure.

Positioned at the uppermost point of the pressure control equipment string, the Elmar
Grease Injection Control Head comprises two major sub-assemblies, the stuffing box
(also known as the pack-off) and the flotube assembly.

The stuffing box is designed to pack-off on a stationary wireline by means of a pack-

off rubber energised by hydraulic pressure.

Two types of flotube assemblies are available, the “solid” type and the “concentric”
type. This manual covers the concentric flotube assemblies. These are made up of
an inner flotube sized to fit tightly around the wireline and an outer sleeve to support
the assembly. The outer sleeve ensures the mechanical strength of the assembly,
while the flotube contains the grease around the wireline.

To prepare for operations, the wireline is threaded through the components of the
Elmar 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
flotubes at a pressure minimum 20% greater than the existing well pressure. The
grease fills the annular space between the inner wall of the flotube and the outside
surface of the wireline, forming a liquid seal that contains the well fluids while
allowing wireline movement.

The Elmar Grease Injection Control Head incorporate the following features as
standard:-

• API 6A and NACE compliant

• Line Size Flotubes (standard connections for all line sizes)

• Line size kits (standard rubbers/wear parts for the range of line sizes)

• 2” Line pipe threaded connection (for adding a line wiper above the
stuffing box)

• Hydraulically actuated stuffing box maximum hydraulic working pressure

6,500 psi

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3 EQUIPMENT DESCRIPTION
3.1 THE STUFFING BOX ASSEMBLY

3.2 THE GREASE INJECTION EQUIPMENT ASSEMBLY

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3.1 STUFFING BOX ASSEMBLY

Fig. 1 Stuffing Box Assembly

CAUTION!
The stuffing box is not designed to be used as a line wiper. The braided cable must not be
pulled through the stuffing box when closed. 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 flotubes

The function of the stuffing box is 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.

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The Stuffing box assembly comprises of three line sized components – a rubber
element, an upper and a lower gland (also know as a brass seat). The upper gland
fits loosely around the braided cable and is mounted under a spring loaded piston.
This gland presents little resistance to the movement of the cable. The line rubber
sits between the upper gland and the lower gland. When hydraulic fluid is pumped
into a chamber above the piston it pushes the piston down against the force of the
spring squeezing the line rubber between the two glands. The glands are line sized
to maintain the right OD of the cable and avoid ‘bird-caging’, which could happen if
the cable was pulled through partially closed rubbers.

CAUTION!
The cable is not free to move when the stuffing box is closed. It is possible for the stuffing box
line rubber to grip the cable tight enough so that the outer strands of the cable will ‘bird-cage’ or
even break if sufficient pull is applied.

When hydraulic pressure is released the spring pushes up the piston and the rubber
will then expand to release the cable.

Normally a line wiper is mounted above the stuffing box, this wipes grease from a
moving cable and grease is drained off at the stuffing box upper return manifold (low
pressure side). A further return manifold is fitted to the bottom of the stuffing box
(high pressure side) and is used to return the grease to a drain valve via the control
module.

Fig. 2 Line Size Kit Coding

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The line size kit enables the client to change the size of braided cable without
incurring the costs of a new stuffing box assembly. The components included in the
kit are as follows:

• Upper Gland;

• Lower Gland (Brass Seat);

• Line Rubber.

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3.2 GREASE INJECTION EQUIPMENT ASSEMBLY

Fig. 3 Grease Injection Equipment Assembly

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The function of the Grease Injection Equipment is to control the well pressure while
allowing free movement of the wireline.

Grease Injection Equipment consists of a set of flotubes and couplings which are
mounted below the stuffing box.

There are two different types of flotube in common use, solid type flotubes and
concentric flotubes. Both types do the same job and work in the same way but are of
a different construction. This manual covers the concentric flotube type.

The concentric type flotube is made up of flotubes and flotube sleeves. The flow tube
is slightly longer than the sleeve and is sealed with an o-ring at both ends of the GIE
coupling. The flow tube sleeve fits over the flotube and also seals by an o-ring at
either end of the GIE coupling. With the concentric design it is possible to change the
flotube more often, thus maintaining optimum clearance.

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.
The supervisor must decide what size tubes are most appropriate for the cable. For
example, a brand new 7/32” cable will probably require flotubes that have an ID of
0.226”. After the first five to ten jobs the cable will stretch and become slightly worn.
The cable will then possibly pass through the 0.222” flotubes. As the cable
approaches the end of its life, the outer strands may become very worn and flattened
and the 0.219” flotubes may be used.

NOTE!
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.

Below is the recommended number of total flotubes suggested – including the tube
below the grease injection coupling. It is safer to have too many than too few. In gas
more flotubes must be used, as it is easier for gas to break through the grease, and
push it out as the gas expands. If the flotube length is not adequate, grease
consumption increase and it is difficult or impossible to establish a seal.

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 Number of Concentric
Well Pressure Type Number of Solid Flotubes
Flotubes
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+

Fig. 4 Table of Flotubes Required

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
strands slightly flattened – this requires smaller ID flotubes. 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
flotubes and the job cannot proceed.
Remember: The cable diameter should be consistent all along its length.

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 Maximum Tube ID
Use for Range of Actual
Nominal Line Size Including wear - do not
(Average) Line Size
(in.) Use when greater
(in.)
(in.)
.124 - .125 .134
1/8
.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
.206 - .208 .216
7/32
.211 - .213 .221
.214 - .216 .224
.216 - .219 .226
.219 - .221 .229
.222 - .225 .232
.224 - .228 .234
.227 - .229 .237
.231 - .233 .241
1/4
.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
.406 - .408 .418
7/16
.410 - .413 .422
.417 - .420 .429
.425 - .430 .437
15/32 .462 - .464 .477
17/32 .524 - .526 .539

Fig. 5 Table of Flotube Data

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Remember to measure your wireline with a micrometer at the cable head end, half
way in the hole and at the TD. Record these measurements in the cable record book.
This will greatly help in the correct selection of flotubes. The wireline OD should be
measured from two directions in case it is oval.

The pressure seal is maintained by a flow of thick, viscous grease which is pumped
into the small annular space between the cable and the inner wall of the flotube. The
annular space is very small, ie between +0.002” and +0.008” difference in the
diameter. In practice, small amounts of grease are lost at both ends, particularly
when the cable is moving, while well fluids are contained.

Well pressure maintains the grease in the tube. The grease flows upward through the
flow tubes to exit through a port in the upper flotube. A return manifold fitted to the
bottom of the stuffing box (high pressure side) is used to return the grease lost at the
upper end of the flow tubes to a drain valve via the control module.

A check valve is located at the grease injection point in case a grease seal is lost. If
the well fluid was to reach the grease pump through the grease injection line there
would be the potential for a catastrophic situation.

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4 SPECIFICATIONS AND FEATURES
4.1 SPECIFICATIONS

4.2 STANDARD FEATURES

4.3 DESIGN STANDARDS AND REQUIREMENTS

4.4 OPERATING REQUIREMENTS

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4.1 SPECIFICATIONS
The exact specification of each Grease Injection Equipment Assembly will vary
depending on the customer’s individual requirements.

4.2 STANDARD FEATURES

Elmar Grease Injection Equipment assemblies have all the standard following
features:

• All components are rated for H2S service.

• Integral check valve on the grease injection ports.

• Grease return port.

• See Section 3 for specific features that relate to each sub-assembly.

4.3 DESIGN STANDARDS AND REQUIREMENTS

The Elmar Hydraulic Wireline Tool Catcher assemblies have been designed in
accordance with the following standards and given third party approval by Bureau
Veritas:

• API 6A (Latest Edition)

• NACE MR 01 75 (Latest Edition)

• Norwegian Petroleum Directorate, the Facilities Regulations, Sept 2001

• Schlumberger, Pressure Operations Manual

• SI 289, 1974

• SI 913, 1996

• SI 2306, 1998 - PUWER

Each Grease Injection Equipment assembly is designed to comply with the following
requirements within API 6A:

• Service Temperature Classes P, R, S, T, U & V (-29°C to 121°C)

• Manufacturing standards PSL 3 and PR1.

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 • Material Class EE-Sour Service.

All Grease Injection Equipment assemblies are supplied as standard with Nitrile
elastomers. Other grades are available in seal kit form on request.

Line rubbers can be provided specifically for arctic service conditions (-46°C).

Elmar Grease Injection Equipment assemblies can also be designed to service

temperature classes L (-46°C) and X (180°C).

4.4 OPERATING REQUIREMENTS

• Hydraulic Pressure 6,500 psi maximum

• Volume to CLOSE 6.5 in³ (0.10 litre)

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5 OPERATION
5.1 FUNDAMENTAL RULES FOR PROPER OPERATION

5.2 OPERATION

5.3 SEALING ON BRAIDED LINE

THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH

THE APPROPRIATE ASSEMBLY DRAWINGS BEFORE CARRYING OUT
ANY OF THE FOLLOWING ACTIONS

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5.1 FUNDAMENTAL RULES FOR PROPER OPERATION
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, or 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 operation check at WP.

• A well-site pressure test must be carried out after set-up and before
opening the well on each job. The Maximum Allowable Working Pressure
during the job equals the well-site test pressure.

• All crews operating WHE equipment must be qualified to carry out

pressure operations.

5.2 OPERATION
Observe all safety considerations (Refer to Section 1 for general safety information)
and site rules.

Before operation of the grease injection equipment assemblies refer to Section 7,

Maintenance and Testing to ensure the equipment has been fully serviced and the
necessary ‘Before Job Checks’ have been carried out. Do not assume that
serviceable equipment on the last job will be serviceable again.

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

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connection and the 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 flotubes, 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, which will cause the line
rubber to be compressed around the wire.

CAUTION!
The cable is not free to move when the stuffing box is closed.

5.3 SEALING ON BRAIDED LINE

The line rubber effectively seals around the outer surface of a wire line by
displacement of the rubber which flows into the crevices of the outer strands.

CAUTION!
Unseasoned or new cable is particularly difficult to obtain a reliable seal with and every care
should be taken to avoid the equipment to seal on a new or clean cable.

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6 ASSEMBLY INSTRUCTIONS
6.1 TOOL LIST

6.2 ASSEMBLY INSTRUCTIONS

THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH

THE APPROPRIATE ASSEMBLY DRAWINGS BEFORE CARRYING OUT
ANY OF THE FOLLOWING ACTIONS

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6.1 TOOL LIST

• Clean work surface;

• Airline;

• Clean rags;

• Vice;

• O-ring pick;

• Grease brush;

• Plastic hammer;

• 3M Scotchbrite (Elmar Part No L-893000);

• WD40 (Elmar Part No L-881740 – 5 litres);

• Grease (Elmar Part No L-881720);

• Anti-seize protective compound (Copperslip) (Elmar Part No L-882940);

• PTFE thread tape (Elmar Part No L-861900);

• Loctite 577 thread sealant (Elmar Part No L-862200);

• Hydraulic Oil

• Tool – Check Valve Locator (Elmar Part Number L-981053)

• 5/16” Allan Key – (for manifold block screws)

• 12” adjustable spanner (pressure fittings)

• -Piston Removal Tool (Elmar Part No L-980447)

Page 32 of 54
6.2 ASSEMBLY INSTRUCTIONS
Remember….

• Do use eye protection when using power tools.

• Do wear gloves or use barrier cream to protect your hands.

• Do wear protective footwear.

• Keep loose clothing and long hair well out of the way of moving
mechanical parts.

• Do remove rings, wristwatch etc, before working.

• Do change out of oil-soaked clothes and do not keep oily rags in your
pocket.

• Do ensure that any lifting or jacking equipment has a safe working load
rating adequate for the job.

• Do get someone to check periodically that all is well when working alone.

Page 33 of 54
6.2.1 ASSEMBLY INSTRUCTIONS FOR GREASE INJECTION ASSEMBLY

Fig. 3 Standard Tool Catcher Assembly (Shown with BCV)

Page 34 of 54
STEP ACTION
1. O-Rings and Back-ups
To minimize damage to O-rings during installation:
1) Check all components for cleanliness before installation.
2) Tape all threads over which o-rings will pass. O-rings should never be
forced over unprotected sharp edges.
3) Use an O-ring lubricator.
4) Double check O-ring to ensure correct size.
5) Don’t over stretch the O-ring.
6) Prevent the O-ring from rolling or twisting during assembly.
7) Where only one back-up ring is used, it must be placed between the O-
ring and the pressure face.

BACK-UP RING O-RING

PRESSURE DIRECTION

PRESSURE FACE

NOTE!
Clean all parts thoroughly before beginning assembly.

STEP ACTION
2. Thoroughly clean packing nut and the lower body.
3. Fit o-ring and back-up ring in packing bore nut.
4. Insert internal o-rings in grooves of lower body.
5. Fit o-ring and back-up ring in piston.
6. Grease bore and o-rings of packing nut.
7. Grease o-ring and back-up ring of piston.
Invert packing nut and stand vertically on flat surface (wood packing to
8. protect bore) and insert the piston. Hammer down piston using plastic drift
(L-980447) until piston locates internal shoulder.
9. Insert piston spring into piston stem in packing nut.
10. Fit appropriate line sized upper gland to piston.

Page 35 of 54
11. Fit appropriate line sized rubber and brass seat on upper gland.
12. Thoroughly clean and grease threads of lower body.
Screw lower body to packing nut, ensuring line rubber and brass seat
13.
locate.
14. Secure assembly horizontally in vice.
15. Fit o-rings and back-up rings to check valve housing.

NOTE!
Check the orientation of the back-up rings in relation to the orientation of the housing, ie the
larger the OD of the housing fits into the check valve port in the coupling.

STEP ACTION
16. Fit the check valve housing into the lower body.
17. Tap the check valve housing down into the lower body until it bottoms out.
18. Grease the port on the manifold block.
Assemble the block to the lower body ensuring that the grease return port
19.
faces downwards and the check valve housing locates in the port.
Put thread sealant on manifold block 5/16” screws and screw the manifold
20.
block to the lower body.
Tape and loctite (577) hex nipple to QC Huber assembly. Ensure that the
QC Huber is assembled with the internal o-ring facing down. Tighten down
21.
the hex plug while holding the QC Huber. Tape and loctite (577) assembly
into manifold block.
22. Tape and loctite (577) elbow to packing nut.
Tape and loctite (577) hex nipple to elbow and tape and loctite (577) QC
23.
Huber assembly to nipple.
24. Tape and loctite (577) hex plug to QC Huber.
25. Tape and loctite (577) elbow for hydraulic fitting and fit to packing nut.
26. Tape and loctite (577) male snaptite and fit to elbow.
27. Tape and loctite (577) relief valve to packing nut.
Thoroughly clean and grease couplings and flotubes (See section 3.2 Fig 4
28.
table for quantity required).
29. Fit o-rings in flotube couplings.
Insert injection coupling (bottom coupling) in vice and coat threads with
30.
grease.
Page 36 of 54
31. Coat first flotube sleeve thread with grease and screw into lower coupling.
32. Fit o-rings and back-up rings into check valve housing.

NOTE!
Check the orientation of the back-up rings in relation to the orientation of the housing, ie the
larger the OD of the housing fits into the check valve port in the coupling.

STEP ACTION
Fit the check valve into the leading edge of the check valve housing
33. ensuring that the arrow stamped on the check valve points into the port in
the coupling.
Use the 1/8” NPT adapter on the tool L-981053 to drive the check valve
34.
down into the check valve housing until the end faces are flush.
Grease the coupling check valve port and fit the check valve housing
35. assembly into the injection coupling ensuring the 1/8” NPT threaded end
faces into the bore, see figure 6.
36. Grease the check valve port on the manifold block.
Assemble the block to the coupling ensuring that the hydraulic coupling port
37.
faces downwards and that the check valve is located.
Put thread sealant on manifold block 5/16” cap screws and screw manifold
38.
block to coupling.
Tape and loctite (577) hex nipple to QC Huber. Ensure that the QC Huber
is assembled with the internal o-ring facing down. Tighten down the hex
39.
plug while holding the QC Huber. Tape and loctite (577) assembly into
manifold block.
40. Connect Remaining flotubes and couplings.
41. Connect Flotube assembly with stuffing box assembly.

Page 37 of 54
7 MAINTENANCE AND TESTING
7.1 ROUTINE MAINTENANCE

7.2 MAJOR MAINTENANCE

7.3 TESTING

7.4 TROUBLESHOOTING

7.5 MAINTENANCE RECORD SHEET

Page 38 of 54
7.1 ROUTINE MAINTENANCE

NOTE!
Refer to Section 1 for general safety information before carrying out any maintenance and
testing routines.

WARNING
The Grease Injection Equipment assembly is heavy; check that the lifting and handling
equipment can support this load. Never position yourself under the suspended equipment.

NOTE!
Refer to build specific assembly drawings for equipment details, e.g seal kit part numbers and
service details.

NOTE!
The BOP’s will need to be carefully maintained to perform properly.

General rules for routine inspections:

• All components shall be thoroughly cleaned.

• All assemblies shall be disassembled and components inspected for

damage or corrosion.

• All threads and sealing surfaces shall be checked for damage.

• All grease injection and hydraulic hoses shall be unreeled and carefully
inspected over their entire length.

• Any elements showing cracks or surface defects shall be replaced.

• After inspection and reassembly the equipment shall undergo a pressure

test.

7.1.1 BEFORE EVERY JOB

• Check the equipment service record to ensure the equipment has been
fully serviced by competent personnel.

• Check all threads, seals and sealing surfaces for damage that might
impair sealing. Repair or replace as necessary.

• Check that the line sized parts are dressed for the correct braided wire.
Page 39 of 54
 • Check the hydraulic functions, to test that the line rubber can close round
the cable and release.

• Function and pressure test to Working Pressure.

• Verify that the well site test pressure does not exceed the Working
Pressure rating of that of the equipment and that sufficient margin exists to
allow grease injection.

• Pressure test the complete hook-up.

• Check that Seal Kits are available.

7.1.2 AFTER EVERY JOB

NOTE!
Fully dismantling and cleaning all parts that have seen well fluids and debris will extend the life
of the product. The time between the end of the job and maintenance is when the equipment is
most at risk from corrosion.

NOTE!
Avoid steam cleaning any internal bores that have corrosion resistant coatings. Grease the
internal bores using a cloth/swab.
These coatings are sacrificial and may need re-applied periodically.

• Dismantle and clean all parts.

• Check condition of piston and piston seals. Replace if excessively worn or

damaged.

• Inspect all seals and sealing surfaces. Replace any damaged sealing rings
and back-up rings.

• Check all threads.

NOTE!
If the job contained any of the following, then it is advisable to strip the entire assembly,
replacing the seals that see well pressure.
Extended Exposure (> 48 hours)
H2S
High pressure gas

• Reassemble as per the assembly instruction in Section 6.

Page 40 of 54
 • Test all hydraulic functions.

• Function test at working pressure.

7.1.3 Every 3 months

• Check flotubes for wear. This is difficult to accomplish but can be

attempted with a calibrated short cylinder gauge at the end of a 25” rod.
As a narrow gap between the flotube ID and the wireline OD is essential
for proper operations, the flotube must be replaced if internal wear is
detected, see figure 5 for relevant sizes.

7.2 MAJOR MAINTENANCE

All WHE shall be surveyed at regular intervals and at least once per year. An annual
survey usually consists of a visual inspection and dimensional checks for ovality of
tubulars and threads. For all jobs over 5,000 psi, the hydrostatic body test and
operational test shall not be older than 3 months. A verification procedure should also
be carried out after every job where the WHE has been subjected to extraordinary
conditions, such as rough handling, bending, accidental drops, corrosive fluids,
unexpected H2S or CO2 during standard service, or replacement of major parts.

All surveys and tests must be recorded in the equipment service record.

Renewal of certification requires a detailed survey and performance verification

carried out under the control of a certification agency. The need and frequency of
such certification renewal shall be determined by local regulations, but typically every
five years. All WHE pressure containing equipment should undergo a major re-
certification every five years based on the following general procedures:

• Visual inspection.

• Random thickness tests on risers, flotube sleeves, BOP, tool trap, ball
check valve, tool catcher and general bodies using direct measurements,
ultrasonic or X-ray.

TIP!
Refer to Elmar Technical Bulletin TB-735
Procedure for finding minimum acceptable wall thickness on pressure control equipment.

Page 41 of 54
 • Dye penetration or MPI examination on threads or any damaged area
determined at visual inspection.

• Hydrostatic body test to Test Pressure.

• Function tests at Working Pressure.

• Review of Quality Files.

All WHE having undergone three 5 year major re-certification should be retired
before the fourth re-certification is due (Refer to section 8.30).

7.2.1 TO BE CARRIED OUT ONCE A YEAR

1) Carry out Routine Maintenance procedure.

2) Discard all O-rings, inspecting all components and sealing surfaces for
corrosion or damage along the way.

3) Rebuild using seal kit and pressure test to Test Pressure.

4) Function test at Working Pressure.

5) Complete maintenance record sheet and affix dated chart. Refer to

Section 7.50 for example Maintenance Record Sheet

6) Third party agency to witness pressure test and function test.

7.2.2 TO BE CARRIED OUT EVERY 5 YEARS

1) Carry out Routine Maintenance procedure tasks.

2) Strip all component parts. Discard all O-rings and back-up rings.

3) Dimensional and thickness test.

4) Magnetic Particle Inspection (MPI) of all parts.

5) Rebuild using seal kit and any necessary new parts.

6) Hydrostatic body test to Test Pressure.

7) Function test at Working Pressure.

8) Third party certificate of final test and inspection and certificate of

conformity.

Page 42 of 54
7.3 TESTING
The pressure rating of any item is expressed in pounds per square inch (psi) and it is
shown as a test pressure (TP) rating and a working pressure (WP) rating.

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 never 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 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.

The overall WP rating of the assembled equipment shall be equal to the rating of the
weakest component. All components used shall have a valid dated test record;
including a hydrostatic body test to TP. Equipment lacking a current test record shall
not be used. The well site TP shall never exceed the equipment WP rating.

The well site TP shall be 1.2 times maximum potential wellhead pressure (MPWHP).
If no wellhead pressure is expected, the equipment shall be tested at 25% of its WP
rating. All well site pressure testing and the pressure test values obtained shall be
noted on the equipment service report. The use of a pressure recorder (chart or film)
is recommended during well site pressure testing.

All adapters, flanges etc., shall be tested. It is recommended to test as much of the
equipment assembled together as possible. Valves must be in the partially open
position during the body test. Test plugs with a pressure rating equal to or higher
than the equipment that is being tested shall be used to cap open ended
components.

Adequate warning signs shall be displayed and all unnecessary personnel cleared
from the pressure testing location during the pressure test.

WARNING!
Trapped air requires considerable time to compress and when it is compressed is highly
dangerous. It has enough stored energy to separate parts with considerable force.

Page 43 of 54
 WARNING!
Clear the area of unnecessary personnel and ensure procedures are in force to prevent
personnel from entering the test area. Pressure testing should only be performed by competent
personnel.

7.3.1 ASSEMBLY PRESSURE TEST PROCEDURE (TEST WITH AND WITHOUT

FLOTUBES)
1) Remove the upper gland and replace with test plug L-972410 and locate
test cap L-972264 on to their appropriate end.

2) Remove check valve from injection coupling and re-assemble with hex
plug in huber.

3) Bleed off all air within the assembly.

4) Ensure all external surfaces are dry.

5) Pressure test to test pressure for 3 minutes.

6) Reduce pressure to zero and repeat test for 15 minutes minimum.

No Leakage acceptable.

7.3.2 FUNCTION TEST PROCEDURE

1) Install the appropriate line size kit into the stuffing box.

2) Ensure the check valve in the injection coupling(s) is in the correct position
and the hex plug in the Huber is removed.

3) Locate test plug L-971281 at upper connection.

4) Locate test cap L-972264 onto the lower connection.

5) Ensure all external surfaces are dry.

6) Apply 6,500 psi of hydraulic pressure.

7) Pressure test to working pressure for 3 minutes.

8) Reduce pressure to zero and repeat test for 15 minutes minimum.

No Leakage acceptable.

Page 44 of 54
7.4 TROUBLESHOOTING

Problem Possible Cause Corrective Action

(a) Damage to the seal (a) Inspect and replace as

Leakage at the necessary.
surfaces or damage to the
connections.
O-Rings

(a) Insufficient hydraulic (a) Increase pressure in stages up to

pressure applied. 6,500 psi.

(b) Worn Line rubber. (b) Replace line rubber.

Leakage through
the stuffing box:
(c) Worn flotubes, resulting (c) Replace flotubes, see figure 5 for
in loss of seal. relevant sizes.

(d) Insufficient no. of (d) Add extra flotubes, see figure 4

flotubes for well pressure. for guidance.

(a) Damage to o-rings on (a) Inspect and replace as

piston and/or packing nut. necessary.
Leaking hydraulic
pressure:
(b) Corroded sealing (b) Inspect and replace corroded
surfaces. parts.
(a) Seals/damaged or (a) Inspect and replace as
missing. necessary.

Injection check
(b) Metal surface (b) Inspect and replace as
valves do not seal
damaged/corroded on valve necessary.
or leaks:

(c) Valve installed the wrong (c) Turn valve around, see figure 6
way round. for correct orientation.
(a) Worn flotubes requiring
(a) Replace flotubes, see figure 5 for
higher grease flow to
relevant sizes.
maintain seal.
Excessive grease
consumption:
(b) Add extra flotubes, see figure 4
(b) Insufficient number of
for guidance.
flotubes for well pressure.

Page 45 of 54
7.5 MAINTENANCE RECORD SHEET
Date Type of Performed Verified
Comments
Peformed maintenance by by

Page 46 of 54
8 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL
8.1 TRANSPORTATION

8.2 SPARES AND ACCESSORIES

8.3 DISPOSAL

Page 47 of 54
8.1 TRANSPORTATION
The assembly should always be stored with:

• The assembly disconnected from the hydraulic and grease lines;

• Top and bottom threads protected;

• Protection from moisture ingress.

• Any residual hydraulic fluid drained;

• Lying horizontally and secured in wooden packing.

Whenever possible, the assembly should be enclosed in a protective frame or

packing during transportation and stored in the frame when not in use. Care should
be taken to ensure that the hydraulic fittings and injection couplings are left
unobstructed and not subjected to any loads or impacts.

8.2 SPARES AND ACCESSORIES

8.2.1 SPARES
Use only Elmar recommended spares.

For seal kit part numbers and spares parts, refer to the relevant Technical Illustration
supplied with the equipment.

All Grease Injection equipment assemblies are supplied as standard with Nitrile
elastomers for all sealing elements. A wide range of alternative compounds, for
various service conditions, are available on request. Contact the Elmar Sales
Department for details.

Recommended spares:

• Seal Kit;

• Line Size Kit;

• Replacement Flotubes, see following table for part numbers.

Page 48 of 54
CONCENTRIC STYLE FLOTUBE SELECTION AND PART NUMBERS

NOMINAL
ACTUAL TUBE ELMAR PART
LINE SIZE ACTUAL LINE SIZE
BORE NUMBER
(INCHES)
.124-.125 .127-.129
1/8"
.127-.129 .129-.131
.174-.176 .176-.178
.177-.180 .182-.184 L-976184
3/16" .181-.183 .185-.187 L-974570
.184-.186 .188-.190 L-972380
.188-.190 .192-.194 L-974571
.192-.193 .195-.197 L-976696
.194-.196 .198-.200 L-976650
.195-.198 .200-.202 L-977163
.199-.201 .203-.205 L-977167
.201-.205 .207-.209
.206-.208 .210-.212 .
7/32" .211-.213 .215-.217 L-975439
.214-.216 .218-.220 L-975440
.216-.219 .221-.223 L-974572
.219-.221 .223-.225 L-974538
.221-.223 .225-.227 L-971129
.222-.225 .227-.229 L-972370
.224-.228 .230-.232 L-972680
.227-.229 .231-.233 L-978002
.230-.232 .234-.236 L-980849
.231-.233 .235-.237 L-977887
.234-.236 .238-.240 L-977899
.235-.237 .239-.241 L-971130
1/4" .237-.240 .242-.244 L-977315
.242-.245 .247-.249 L-974573
.245-.247 .249-.251 L-980607
.247-.249 .251-.253 L-974246
.249-.251 .253-.255 L-972868
.251-.253 .255-.257 L-974507
Page 49 of 54
 .253-.255 .257-.259 L-972869
.255-.257 .259-.261 L-972871
.256-.258 .260-.262 L-973449
.257-.259 .261-.263 L-973571
.258-.260 .262-.264 L-980631
.259-.261 .263-.265 L-973572
.262-.264 .266-.268
.282-.284 .286-.288 L-978175
.284-.286 .288-.290 L-980759

9/32" .286-.288 .290-.292 L-980760

.287-.289 .291-.293 L-982517
.288-.290 .292-.294 L-980758
.290-.292 .294-.296 L-971312
.293-.295 .297-.299 L-971436
.300-.303 .305-.307 L-979643
.307-.309 .311-.313 L-976938
.310-.312 .314-.316 L-976538
.311-.313 .315-.317 L-976539
.314-.316 .318-.320 L-981937
.315-.318 .320-.322 L-976258
.319-.321 .323-.325 L-981959
5/16" .321-.323 .325-.327 L-976605
.323-.325 .327-.329 L-974225
.324-.326 .328-.330 L-973937
.327-.329 .331-.333 L-976606
.330-.332 .334-.336 L-973234
.332-.334 .336-.338 L-976607
.336-.338 .340-.342 L-980217
.360-.363 .365-.367 L-974159

3/8" .368-.370 .372-.374 L-974161

.371-.373 .375-.377 L-970429
.379-.381 .383-.385 L-978176
.389-.391 .393-.395 L-981228
7/16" .392-.394 .396-.398 L-981227
.394-.396 .398-.400 L-970946

Page 50 of 54
 .398-.401 .403-.405 L-980490
.402-.404 .406-.408 L-982438
.403-.405 .407-.409 L-980948
.405-.407 .409-.411 L-982439
.406-.408 .410-.412 L-974162
.408-.410 .412-.414 L-982440
.410-.413 .415-.417 L-974163
.417-.420 .422-.424 L-970571
.419-.422 .424-.426 L-970572
.421-.424 .426-.428 L-970573
.424-.427 .429-.431 L-982431
.425-.430 .432-.434 L-970106
.430-.433 .435-.437 L-971639
.434-.436 .438-.440 L-982348
.437-.439 .441-.443 L-982349
.460-.462 .464-.466 L-981229
.462-.464 .466-.468 L-972906
.465-.467 .469-.471 L-981230

15/32" .467-.469 .471-.473 L-979388

.472-.474 .476-.478 L-979088
.476-.478 .480-.482 L-980689
.483-.485 .487-.488 L-982525
.496-.498 .500-.502 L-982529
.518-.520 .522-.524 L-982143
.520-.522 .524-.526 L-982141
17/32" .522-.524 .526-.528 L-982142
.524-.526 .528-.530 L-982144
.532-.534 .536-.538 L-982450

8.2.2 ACCESSORIES
Elmar can supply a range of accessories for handling, testing and assembling the
Grease Injection Equipment. The use of any other accessories is NOT recommended
as this could lead to damage that may result in failure of the equipment.

Page 51 of 54
For accessories that do not have part numbers stated contact the Elmar Sales
Department for details. The part numbers for these accessories change depending
on the quick union being used.

Recommended Accessories

• Test Plugs and test caps;

• ‘C’ Spanner;

• Non-Marking Strap Wrench (Elmar Part No L-840957);

• Grease (Elmar Part No L-881720);

• Grease Anti-seize – Copperslip (Elmar Part No L-882940).

8.3 DISPOSAL
When the product approaches its twentieth service year it should be retired.

Ensure that the product is disposed of in a responsible manner and that any local
legislation is observed. Elmar can assist if required.

Page 52 of 54
9 DRAWINGS AND BILLS OF MATERIAL
9.1 GUIDE TO USE OF ELMAR DRAWINGS

9.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT

9.3 DRAWINGS AND BILLS OF MATERIAL

9.4 GIE ASSEMBLY 3BWN SB 10K H2S...........................................TI-979470-C

9.5 STUFFING BOX ASSEMBLY ..................................................... TI-971278-A4

9.6 GIE SUB ASSEMBLY 3BWN 10K H2S ...................................... TI-971273-A1

9.7 GIE INJ COUPLING ASSEMBLY BWN 10K H2S....................... TI-971466-A1

9.8 GIE ASSEMBLY 4BWN SB 10K H2S.........................................TI-978385-G1

9.9 GIE SUB ASSEMBLY 4BWN 10K H2S ...................................... TI-971274-B1

9.10 GIE ASSEMBLY 5BWN SB 10K H2S.........................................TI-970635-C1

9.11 GIE SUB ASSEMBLY 5BWN 10K H2S ...................................... TI-971275-A1

9.12 GIE ASSEMBLY 6BWN SB 10K H2S......................................... TI-971229-B1

9.13 GIE SUB ASSEMBLY 6BWN 10K H2S ...................................... TI-971276-B1

9.14 GIE INJ COUPLING ASSEMBLY 1BWN 10K H2S..................... TI-971218-B1

9.15 GIE ASSEMBLY 7BWN SB 10K H2S......................................DD9701013485

Page 53 of 54
9.1 GUIDE TO USE OF ELMAR DRAWINGS
IDENTIFICATION OF UNIT PART NUMBER

All Elmar units are identified by a part number beginning with L-69, e.g. L-
6901001234.

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

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

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

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

• engraved on the unit control panel.

9.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT

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

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

• The Bill of Material for this drawing will consist of sub-assembly numbers
beginning with L-65, e.g. L-6501009999.

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

• The Bill of Material for this drawing will show the part numbers for
individual components. (In some cases L-65 sub-assemblies reference
further L-65 sub-assemblies which then reference individual part
numbers).

Page 54 of 54