OPERATIONS AND MAINTENANCE MANUAL

ASEP ELMAR ENVIRO SB/LW

MAN-10001536
ASSY

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OPERATIONS AND MAINTENANCE MANUAL
ASEP ELMAR ENVIRO SB/LW
MAN-10001536
ASSY

This document is applicable to all ASEP Elmar Enviro combined stuffing box/line
wiper assemblies (and 15,000psi working pressure and below).

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Originally Prepared by P. Macdonald
Edited by S. Trevaskis
Approved by C Wade
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Publication MAN-10001536
© Copyright National Oilwell Varco, Inc. 2008
The information is correct at the time of print
First Published in March 2008 by Elmar Engineering
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Approval and Issue

REV ECO PREPARED CHECKED APPROVED DATE COMMENTS

B 9750 S. Trevaskis P. Macdonald P. Macdonald 13/11/2012 ADDED

ARCTIC
SECTION

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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  ENVIRO STUFFING BOX/LINE WIPER ASSEMBLY....................................... 17 

3.2  SEAL KIT .......................................................................................................... 19 

3.3  LINE SIZE KIT .................................................................................................. 20 

4  SPECIFICATIONS AND FEATURES ............................................................... 21 

4.1  SPECIFICATIONS ............................................................................................ 22 

4.2  STANDARD FEATURES .................................................................................. 22 

4.3  DESIGN STANDARDS AND REQUIREMENTS............................................... 22 

4.4  HYDRAULIC SYSTEM - OPERATING REQUIREMENTS ............................... 24 

5  OPERATION .................................................................................................... 25 

5.1  FUNDAMENTAL RULES FOR PROPER OPERATION ................................... 26 

5.2  OPERATION .................................................................................................... 26 

6  ASSEMBLY INSTRUCTIONS .......................................................................... 28 

6.1  TOOL LIST ....................................................................................................... 29 

6.2  ASSEMBLY INSTRUCTIONS .......................................................................... 30 

7  MAINTENANCE AND TESTING ...................................................................... 35 

7.1  ROUTINE MAINTENANCE .............................................................................. 36 
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7.2  MAJOR MAINTENANCE .................................................................................. 38 

7.3  TESTING .......................................................................................................... 40 

7.4  TROUBLESHOOTING...................................................................................... 43 

7.5  MAINTENANCE RECORD SHEET .................................................................. 44 

8  TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL................ 45 

8.1  TRANSPORTATION......................................................................................... 46 

8.2  SPARES AND ACCESSORIES ........................................................................ 46 

8.3  DISPOSAL ........................................................................................................ 47 

9  DRAWINGS AND BILLS OF MATERIAL ........................................................ 48 

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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 ASEP 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

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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):

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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ASEP Elmar recommends 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.

ASEP Elmar recommends that personnel involved in wellhead pressure operations

have been formally trained. ASEP 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).

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 5) Body Protection.

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 risk assessment it should be possible to

document that:

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  All hazards have been identified;

 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.

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

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 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.

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  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.

 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 are available to cover the tool and allow
3ft (1 metre) clearance. This applies to fixed structures, not semi-
submersible 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.

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  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.

 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 ASEP 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 Enviro Combination Stuffing Box and Line Wiper is mounted immediately above
the Grease Injection Head. Unlike the conventional set-up, the Enviro stuffing box is
located above the line wiper, which helps to increase line wiper efficiency and reduce
grease spillage, resulting in cleaner wire, less grease escaping from the assembly
and a cleaner worksite/derrick. The stuffing box section is used to seal around the
cable in an emergency or when the cable will be stationary for an extended period of
time. The device remains open during normal operation.

Directly below the stuffing box is the line wiper which removes excess grease from
the surface of the moving cable. As the grease is wiped off the cable, it passes down
inside the lower body. A manifold fitted to the base of the line wiper is used to return
the grease back to the control module.

The ASEP Elmar Enviro Stuffing Box and Line Wiper can be dressed for use with
braided wire from 0.188" to 0.468" diameter and can be supplied for use with
concentric (2"-10 TPI) or solid (2"-6-60º) type flow tubes.

The ASEP Elmar Enviro Combination Stuffing Box and Line Wiper incorporates the
following features as standard:-

 API 6A and NACE compliant.

 Third Party Design Approval.

 Compact size, allowing shorter rig-up heights.

 Range of line size kits available to allow redress for different cable size.

 Slotted rubbers available for increased line wiping efficiency.

 Arctic versions available upon request, for operation between API 6A

temperature classes L to V (-46ºC to 121ºC).

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3 EQUIPMENT DESCRIPTION
3.1 ENVIRO STUFFING BOX/LINE WIPER ASSEMBLY

3.2 SEAL KIT

3.3 LINE SIZE KIT

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3.1 ENVIRO STUFFING BOX/LINE WIPER ASSEMBLY

Fig. 1 Section view of typical Enviro SB/LW assy

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The stuffing box section consists of a brass upper gland which fits around the cable
and is mounted under a spring loaded piston. In its non-energised state the upper
gland fits loosely around the cable and presents little resistance to the movement of
the cable. The stuffing box rubber packing is positioned between the upper gland and
a brass spacer gland. When hydraulic fluid is pumped into the upper hydraulic
chamber, the piston is forced down onto the packing which causes the rubber to
compress and seal around the stationary wireline. The brass upper gland and
spacer gland, along with the upper bush are replaceable parts which are designed to
wear with use.

The line wiper also consists of a rubber element which closes around the moving
cable by means of a hydraulically activated piston. When operated, the piston is
forced upwards against the outer sleeve (rubber coated spring element) which in turn
compresses and squeezes the line wiper rubber around the moving cable. The line
wiper rubber is larger than the stuffing box packing and requires a much lower
hydraulic pressure to operate. This prevents the rubber crushing/stripping the
moving cable, and instead is sufficient to remove excess grease from the surface of
the wire. As the grease is wiped from the cable, it gathers in the cavity under the
lower gland and then travels down the return line back to the control module via a
hose. A slotted version of the line wiper rubber is also available at extra cost, which
can improve the wiping efficiency of the assembly.

Refer to section 6.21 or 6.22 for relevant assembly instructions.

CAUTION!
The cable is not free to move when the stuffing box packings are activated. Any attempt to
close the stuffing box packing around a moving cable could cause the outer strands to 'bird
cage' or break.

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3.2 SEAL KIT
The seal kit, usually designated by a 'K' suffix, contains all o-rings and back up rings
required to redress the Enviro assembly. Elmar supply nitrile elastomers as standard
on our seal kits. Other elastomer compounds are available upon request. See
specific assembly drawing for appropriate reorder code. Part numbers exist also for
seal kits which include not only the o-rings and back up rings required for re-dress,
but also the line sized wiper rubber. Again, full details for these kits can be found on
the appropriate assembly drawing.

Kits containing the slotted line wiper rubbers are also available on request.

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3.3 LINE SIZE KIT
The line size kit enables the client to change out the line sized components without
incurring the costs of a new Enviro SB/LW assembly. The components included in
the kit are indicated in figure 1 by red asterisks and as follows:

 Upper Bush

 Upper Gland

 Stuffing Box Packing

 Spacer Gland

 Line Wiper Rubber

 Lower Gland

See specific assembly drawing for relevant line size kit ordering codes.

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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 Enviro Combined Stuffing Box/Line Wiper will vary
depending on the customer’s individual requirements.

4.2 STANDARD FEATURES

ASEP Elmar Enviro Combined Stuffing Box/Line Wiper assemblies all have the
standard following features:

 All components in contact with well fluid are rated for H2S service.

 Hydraulics are supplied via quick connect style joints and incorrect
supply line connection is avoided by ensuring the stuffing box and line
wiper hydraulic connections are different (i.e. one is a coupling and the
other is a nipple).

 Fully certified to API 6A latest edition

 Fully certified to NACE MR0175 latest edition (for H2S service only).

 Replaceable line sized components are available for a wide range of

wireline diameters.

4.3 DESIGN STANDARDS AND REQUIREMENTS

4.3.1 DESIGN STANDARDS

The ASEP Elmar Enviro Combined Stuffing Box/Line Wiper 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) – for H2S service only

 Norwegian Petroleum Directorate, the Facilities Regulations, Sept 2001

 Schlumberger, Pressure Operations Manual

 SI 289, 1974

 SI 913, 1996
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  SI 2306, 1998 - PUWER

As standard each Enviro Combined Stuffing Box/Line Wiper is designed to comply

with the following requirements within API 6A:

 Working Pressure Refer to relevant assembly drawing for details

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

 Manufacturing standards PSL 3 and PR1.

 Material Class Refer to relevant assembly drawing for details.

All ASEP Elmar Enviro Combined Stuffing Box/Line Wipers are supplied as standard
with Nitrile elastomers for all sealing elements. The o-rings in contact with both the
hydraulic pistons are made from a 70 Duro compound to provide reduced resistance
to movement. Other grades are available in seal kit form on request.

ASEP Elmar Enviro Combined Stuffing Box/Line Wiper assemblies can also be
designed to API 6A service temperature class L (-46C).

4.3.2 SPECIFICATIONS FOR ARCTIC USE

Our standard PCE range is designed to operate at a minimum temperature limit of -
29ºC (-20ºF) in accordance with API 6A temperature classes P to V. We can also
offer the option of arctic service assemblies which are designed for operation over a
wider range to include API 6A temperature classes L or K where required. The
associated lower limits for this arctic equipment are as follows:

 API 6A temperature class L has a minimum temperature limit of -46ºC

(-50ºF)

 API 6A temperature class K has a minimum temperature limit of -60ºC

(-75ºF)

All pressure containing bodies and elastomers are made from materials specifically
selected for use in low temperature environments. Raw materials for metallic
pressure containing elements have undergone appropriate impact testing at the
lowest limit for the temperature class required, and HNBR o-rings are used in seal
kits.

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Arctic assemblies are identified by an ‘ARC’ suffix, and associated seal kits have a
‘KA’ suffix.

4.4 HYDRAULIC SYSTEM - OPERATING REQUIREMENTS

For 15Kpsi WP Enviro SB/LW Assy (with Dual Stuffing Box)

Line wiper normal operating pressure 200 - 500 psi

Line wiper maximum working pressure 3000 psi

Stuffing box maximum working pressure 3000 psi

For 10Kpsi WP Enviro SB/LW Assy

Line wiper normal operating pressure 200 - 500 psi

Line wiper maximum working pressure 3000 psi

Stuffing box normal operating pressure 3000 psi

Stuffing box maximum working pressure 5000 psi

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5 OPERATION
5.1 FUNDAMENTAL RULES FOR PROPER OPERATION

5.2 OPERATION

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 ASEP Elmar Enviro Combined Stuffing Box/Line Wiper 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.

 Ensure that the hydraulic lines for the stuffing box (upper) and line wiper
(lower) are connected to the appropriate control module connections.

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  Check the hydraulic circuit on the hydraulic control module is fully
functional with no leaks.

 Check that the grease return hose has been fitted to the grease return
manifold and back to the Control Module.

 For operation of the stuffing box, ensure the cable is stationary before
applying the required hydraulic pressure. Please refer to specific
assembly drawing for details on the maximum operating pressure.

 To release the seal at the stuffing box, dump hydraulic pressure to the
stuffing box line. The cable should only be moved once all hydraulic
pressure is dumped.

 For operation of the line wiper, apply pressure to the lower hydraulic
connection until the desired operating pressure is achieved. Monitor
the pressure being applied to the line wiper and apply just enough to
achieve removal of excess grease. There should not be any need to
apply the maximum hydraulic operating pressure unless the line wiper
element is particularly worn.

CAUTION
The operator must ensure they are aware of the maximum hydraulic operating pressures for
both the stuffing box and the line wiper before using the equipment.
The line wiper requires a much lower hydraulic pressure to operate. Failure to observe the
maximum hydraulic pressure operating limits for the stuffing box and the line wiper could result
in damage to the cable. Refer to section 4.4 along with the appropriate assembly drawing for
allowable pressure limits.

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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

 Adjustable spanner (pressure fittings)

 3/8” punch (for piston housing/coupling/lower body make up)

 Small flat screwdriver (for spacer gland)

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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.

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6.2.1 ASSEMBLY INSTRUCTIONS FOR ENVIRO COMBINED SB/LW

Fig. 2 Enviro 10K Combined SB/LW Assembly

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STEP ACTION
1. O-Rings and Back-ups
To minimize damage to O-rings during installation:
Check all components for cleanliness before installation.
Tape all threads over which o-rings will pass. O-rings should never be forced over
unprotected sharp edges.
Use an O-ring lubricator.
Double check O-ring to ensure correct size.
Don’t over stretch the O-ring.
Prevent the O-ring from rolling or twisting during assembly.
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 and coat all threads and seal areas lightly
with grease before assembly.
Steps 8 and 9 (marked with *) will change for 15K dual stuffing box Enviro assemblies. The
procedure has been fully described following the next 'Note!'.

STEP ACTION
2. Fit all o-rings and back-up rings into their respective grooves.
3. Locate lower body with upper body and make up tight.
Install wiper piston, cage and sleeve into the upper body. Ensure that wiper
4.
piston comes to a positive stop on upper body shoulder.
Install lower bush along with line wiper rubber (from line size kit) into the
5.
sleeve housed in the upper body.
6. Assemble spacer gland and packing rubber (from line size kit) into coupling.
7. Locate coupling with upper body and make up tight.
8.* Install piston along with upper gland and spring into piston housing.
9.* Locate piston housing onto coupling and make up tight
Assemble upper bush with clip and install into piston housing. Make up
10.
tight with tulip.
11. Locate and secure grease nipple and all hydraulic fittings.
12. Use grease nipple to fill piston cavity with light grease.

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 NOTE!
For 15K working pressure dual Enviro assemblies, steps 8 and 9 will be extended to include the
following extra instructions (please refer to full details below figure 3).

Fig. 3 Enviro 15K Combined Dual SB/LW Assembly

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STEP ACTION
Secure the flotube insert from the line size kit into the base of the piston
8
with panhead screws.
Locate lower piston into piston housing.
Make up spring housing with piston housing.
Install lower spring retainer and spring onto coupling body.
9 Locate lowermost collar over spring housing and make up with upper body.
Install brass seat and uppermost packing rubber (from line size kit) into
lower piston housing. Repeat step 8 for upper piston.
Install spring retainer, spring and collar retainer with collar and assemble
onto upper piston housing with upper piston.
Make upper collar up tight with upper piston housing.
Continue with steps 10 to 12 as described in main assembly instructions.

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7 MAINTENANCE AND TESTING
7.1 ROUTINE MAINTENANCE

7.2 MAJOR MAINTENANCE

7.3 TESTING

7.4 TROUBLESHOOTING

7.5 MAINTENANCE RECORD SHEET

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7.1 ROUTINE MAINTENANCE

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

WARNING
This 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!
Enviro LW/SB assemblies 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.

 Where grease lubrication nipples exist, ensure grease is pumped until

full.

 After inspection and reassembly the equipment shall undergo a function

and pressure test to working pressure.

7.1.1 BEFORE EVERY JOB

 Check the equipment service record to ensure the equipment has been
fully serviced by competent personnel.
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  Check all threads, seals and sealing surfaces for damage that might
impair sealing. Repair or replace as necessary.

 Lubricate through all grease nipples.

 Check the hydraulic functions, to test that the stuffing box and line wiper
operate as intended.

 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.

 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, inspect 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 Enviro assembly,
replacing the seals that see well pressure.
Extended Exposure (> 48 hours)
H2S
High pressure gas

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  Reassemble as per the assembly instruction in Section 6.

 Lubricate line wiper piston cavity through grease nipple.

 Check that the correct line sized components have been fitted for the
intended wireline diameter.

 Test all hydraulic functions.

 Function test at working pressure.

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, 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.

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  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.
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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.
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 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 BODY PRESSURE TEST PROCEDURE (FOR 10K AND LOWER ENVIRO
ASSEMBLIES)
1) Locate the appropriate test fixture onto the bottom connection.

2) Locate test plug L-972201 in place of upper gland, and L-972241 in

place of wiper sleeve.

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 BODY PRESSURE TEST PROCEDURE (FOR 15K ENVIRO ASSEMBLIES)

1) Locate the appropriate test fixture onto the bottom connection.

2) Locate test plug L-980088 in place of upper line rubber.

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.

7.3.3 FUNCTION TEST PROCEDURE (ALL ENVIRO ASSEMBLIES)

1) Replace stuffing box packing with L-980088 and apply hydraulic test
pressure to stuffing box and hold for 5 minutes.

2) Bleed to zero.

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 3) For dual stuffing box designs, repeat steps 1 and 2 for the second
stuffing box.

4) Replace line wiper rubber and sleeve with L-975102, apply hydraulic
test pressure to line wiper and hold for 5 minutes.

5) Bleed to zero.

No Leakage acceptable.

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7.4 TROUBLESHOOTING

Problem Possible Cause Corrective Action

Leakage at the (a) Damage to the O-Rings and/or (a) Replace faulty parts.
connections. seal surfaces.
(a) Insufficient hydraulic pressure (a) Increase pressure in small
applied to the stuffing box increments up to a maximum of
packing. 3,000psi.

Grease leakage (b) Spacer gland/brass seat not (b) Check and install as
through the fitted. necessary.
stuffing box (c) Worn stuffing box packing. (c) Inspect and replace as
necessary.
(d) Incorrect line size kit fitted. (d) Check and replace as
necessary.
(a) Insufficient hydraulic pressure (a) Increase pressure in small
applied to line rubber. increments up to a maximum of
500 psi.
Wireline still
coated in grease (b) Worn line rubber. (b) Inspect and replace as
having passed necessary.
through the line (c) Lower gland missing. (c) Inspect and replace as
wiper. necessary.
(d) Incorrect line size kit fitted. (d) Check and replace as
necessary.

Leaking hydraulic (a) O-ring damaged/missing or (a) Inspect and replace as

fluid seal surface damaged. necessary.

Cable not fitting (a) Incorrect line size kit fitted to (a) Check and replace as
through bore assembly. necessary.
(a) Blockage in hose or in piston (a) Strip and clean parts
housing

Cable gripped by (b) Damaged piston spring (b) Inspect and replace as
pack-off even necessary
when there is no
hydraulic (c) Cable damaged below pack off (c) Strip and check for damaged
pressure applied wire
(d) Packing is damaged (d) Inspect and replace as
necessary

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

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8 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL
8.1 TRANSPORTATION

8.2 SPARES AND ACCESSORIES

8.3 DISPOSAL

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8.1 TRANSPORTATION
The ASEP Elmar Enviro Combined Stuffing Box and Line Wiper assembly should
always be stored with:

 the assembly disconnected from the hydraulic lines;

 any residual hydraulic fluid and grease drained;

 top and bottom quick union threads protected;

 protection from moisture ingress.

Whenever possible, the assembly should be enclosed in a transport frame when not
in use. Care should be taken to ensure that the hydraulic fitting is left unobstructed
and not subjected to any loads or impacts.

8.2 SPARES AND ACCESSORIES

8.2.1 SPARES
Use only ASEP Elmar recommended spares.

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

All ASEP Elmar Enviro SB/LW 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 ASEP Elmar Sales
Department for details.

Recommended spares:

 Seal Kit

 Line size Kit

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

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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

 Quick Union Test Stump/Cap

 Test Stump Mounting Table

 Male thread protector (steel or plastic)

 ‘C’ Spanner

 Non-Marking Strap Wrench (ASEP Elmar Part No L-840957)

 Grease (ASEP Elmar Part No L-881720)

 Grease Anti-seize – Copperslip (ASEP Elmar Part No L-882940)

 L-980088 - Test plug for stuffing box (used in function test)

 L-975102 - Test plug for line wiper (used in function test)

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. ASEP Elmar can assist if required.

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9 DRAWINGS AND BILLS OF MATERIAL
For drawings specific to purchased equipment, refer to the drawing package supplied
with the equipment

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