OPERATIONS AND MAINTENANCE MANUAL

NOV ASEP ELMAR DUAL

MAN-10001480 "COMPACT" PACK-OFF
ASSEMBLY

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OPERATIONS AND MAINTENANCE MANUAL
NOV ASEP ELMAR DUAL
MAN-10001480 "COMPACT" PACK-OFF
ASSEMBLY

This document is applicable to all NOV ASEP Elmar dual "compact" pack-off
assemblies with a working pressure of 5,000 psi or below and a temperature rating of
P, R, S, T, U & V as defined in API 6A.

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Originally Prepared by V. Moorthy
Edited by S. Trevaskis
Approved by C. Wade
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Publication MAN-10001480
© 2010 Copyright National Oilwell Varco, Inc.
The information is correct at the time of print
First Published in November 2010 by Elmar Engineering
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Approval and Issue

REV ECO PREPARED CHECKED APPROVED DATE COMMENTS

A V. Moorthy C. Wade C. Wade 22/11/2010 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 ............................................................................................... 17

3.2 LINE SIZE KIT .................................................................................................. 18

3.3 SEAL KIT .......................................................................................................... 18

4 SPECIFICATIONS AND FEATURES ............................................................... 19

4.1 SPECIFICATIONS ............................................................................................ 20

4.2 STANDARD FEATURES .................................................................................. 20

4.3 DESIGN STANDARDS AND REQUIREMENTS............................................... 20

4.4 OPERATING REQUIREMENTS ....................................................................... 21

5 OPERATION .................................................................................................... 22
5.1 FUNDAMENTAL RULES FOR PROPER OPERATION ................................... 23

5.2 OPERATION .................................................................................................... 23

6 ASSEMBLY INSTRUCTIONS .......................................................................... 25

6.1 TOOL LIST ....................................................................................................... 26

6.2 ASSEMBLY INSTRUCTIONS .......................................................................... 26

7 MAINTENANCE AND TESTING ...................................................................... 31

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7.1 ROUTINE MAINTENANCE .............................................................................. 32

7.2 MAJOR MAINTENANCE .................................................................................. 34

7.3 TESTING .......................................................................................................... 36

7.4 TROUBLESHOOTING...................................................................................... 38

7.5 MAINTENANCE RECORD SHEET .................................................................. 39

8 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL................ 40

8.1 TRANSPORTATION......................................................................................... 41

8.2 SPARES AND ACCESSORIES ........................................................................ 41

8.3 DISPOSAL ........................................................................................................ 42

9 DRAWINGS AND BILLS OF MATERIAL ........................................................ 43

9.1 GUIDE TO USE OF NOV ASEP ELMAR DRAWINGS ..................................... 44

9.2 IDENTIFICATION OF COMPONENTS WITHIN AN ASSEMBLY ..................... 44

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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 NOV 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
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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NOV ASEP 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.

NOV ASEP Elmar recommend that personnel involved in wellhead pressure

operations have been formally trained. NOV 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.

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 3) Hearing Protection.

4) Respiratory Protection (where conditions deem necessary).

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

2) The knowledge of experienced staff provides a sound basis for hazard

identification and assessment.

3) Checklists

4) 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.

5) Hazards are assessed using any combination of:

6) Engineering judgement, or.

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 − Comparison with good practice in the field.

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

document that:

− 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.

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 • 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.

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;

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 − 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.

• 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.

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 • 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.

• 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 NOV ASEP Elmar Enviro™ Dual "Compact" Pack-Off is designed to wipe clean
moving cable under pressure.

Positioned above the tubing/casing, the Dual "Compact" Pack-Off is built around the
wire before the wireline tool is lowered into the well.

The Dual "Compact" Pack-Off works by squeezing each of the two independent
rubber elements which are wrapped around the wire. Each element seals on the
cable outer armour against well pressure, as well as wiping the wire free of fluid. The
sealing element will seal on the static cable, although the ideal cable to seal on is a
seasoned cable.

WARNING!
When determining the safe line tension the strength of the complete string/rig-up must be
considered.

The NOV ASEP Elmar Dual "Compact" Pack-Off is designed so that the rubber
element in direct contact with the wire is easily replaced.

The Dual Pack-Off is designed to be hydraulically operated and (2)x 3,000 psi hand
pumps and hoses are required for operation.

Various quick union connections can be provided for the lower connection..

The NOV ASEP Elmar Enviro™ Dual "Compact" Pack-Off incorporates the following
features as standard:-

• API 6A and NACE compliant (for H2S service versions only).

• Third Party Design Approval and material traceablity.

• Lightweight, allowing easier handling.

• Line size kits (for sealing on various braided cable sizes).

• 1/4" Quick connect hydraulic fittings.

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3 EQUIPMENT DESCRIPTION
3.1 STUFFING BOX

3.2 LINE SIZE KIT

3.3 SEAL KIT

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3.1 STUFFING BOX

Fig. 1 Upper Pack-Off Assembly

The upper section consists of a rubber element which closes around the cable by
means of a hydraulically actuated piston. When operated, the piston is forced
upwards against the outer sleeve (rubber coated spring element) which causes the
rubber to compress and squeeze the line rubber which seals around the wireline.
The brass upper bush and lower bush are replaceable wear parts which are
designed to centralise the wire. The lower pack off operates in a similar manner.

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When the hydraulic pressure is released, the spring within the sleeve returns the
piston to its original position removing the squeeze on the packing.

Refer to section 6.2 for assembly instructions.

CAUTION!
Excessive hydraulic pressure in the packing may result in the outer strands of the wire from
breaking or to "bird cage".

3.2 LINE SIZE KIT

The line size kit enables the client to redress the dual pack-off with line rubber and
bushings for sealing on the wire sizes ranging from 3/16" up to 9/16". The
components included in the line size kit are as follows:

• Upper Bushing x 2

• Lower Bushing x 2

• Line Rubber x 2

Refer to the ASEP Elmar assembly drawing for part numbers for line size kits.

3.3 SEAL KIT

The seal kit can includes the following:

• O-rings (NBR typically supplied as standard).

• Back-Up Rings (NBR typically supplied as standard).

NOTE!
O-rings and back-up rings can be supplied in a variety of materials to suit a range of different
applications. Please consult NOV ASEP Elmar Sales Team for details.

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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 NOV ASEP Elmar assembly drawing states the working pressure, test pressure
and service (either H2S/STD) for your specific assembly number.

4.2 STANDARD FEATURES

NOV ASEP Elmar Dual "Compact" Pack-Off assemblies have the following features
as standard:

• All pressure retaining components on H2S service assemblies are

manufactured using NACE compliant materials.

• On STD service assemblies, all pressure retaining components,

excluding lower body and standard collar are suitable for H2S Service.

• The upper body has a shoulder to allow lifting clamp to be fitted. (Lift
clamp part number L-6901022172 for 2,200lb SWL)

• The lower body is typically supplied with a quick union connection but
other connections are also available.

• Thread protector supplied for connector on lower body.

• Tulip guide on upper connection.

4.3 DESIGN STANDARDS AND REQUIREMENTS

The NOV ASEP Elmar Dual "Compact" Pack-Off 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.

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 • SI 913, 1996.

• SI 2306, 1998 - PUWER.

As standard each Dual Pack-Off is designed to comply with the following

requirements within API 6A:

• Pressure Rating (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 DD (for H2S service assemblies), AA (for STD

service assemblies).

All hydraulic Dual "Compact" Pack-Off are supplied as standard with Nitrile
elastomers. Alternative compounds are available in seal kit form on request.

NOV ASEP Elmar Dual "Compact" Pack-Off assemblies can also be designed to
service temperature classes L (-46°C) and X (180°C).

4.4 OPERATING REQUIREMENTS

• Hydraulic Pressure: 300 - 500 psi (on moving wire)

5000 psi (on static wire only)

• Volume of oil to operate piston: 2 in³ (0.03 litre).

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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.

• The safe line tension of the assembly must never be exceeded.

Consideration must be given to the strength of the string/rig-up as a
whole when determining the safe line tension.

• All WHE components holding pressure or used for lifting must have
valid certification.

• All WHE components holding pressure or used for lifting 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.

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Before operation of the Dual "Compact" Pack-Off 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.

To operate pack-off:

• Ensure that the hydraulic lines to the 1/4" quick connectors are made up
securely.

• Check the hydraulic circuits on the Hydraulic Control Module or hand

pumps are fully functional with no leaks.

In use, hydraulic pressure should be applied to the piston in the Pack-Off, which will
cause the packings to compress and seal around the wireline. When the wire is
moving, the hydraulic pressure should be approximately 300-500 psi. If this pressure
is exceeded on moving cable there is a danger of damaging the cable strands. When
the wire is stopped the hydraulic pressure can be increased to a maximum of 5000
psi.

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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;

• Piston Removal tool (ASEP Elmar part no. L-980916)

• Plastic hammer;

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

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

• Grease (ASEP Elmar Part No L-881720);

• Anti-seize protective compound;

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

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

• Hydraulic Oil;

• Punch (for making up components), Recommended set of following

sizes 1/2", 7/16", 13/32" & 3/8"

• 12” adjustable spanner (for hydraulic fittings);

• Strap wrench (ASEP Elmar part no. L-840957)

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.

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• 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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Fig. 2 Dual Pack-Off Assembly

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STEP ACTION
1. O-Rings and Back-ups - Install seals prior to assembling parts
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
Locate the piston into the lower pack-off body. (Apply grease L-881720
2.
prior to installation)
Insert the cage and the lower bushing into the piston. (Apply grease L-
3.
881720 prior to installation)
Locate the standard collar around the lower pack-off body. Apply grease L-
4.
881720 to the collar female threads.
Make-up the lower wiper housing with the lower body. (apply anti-seize
5.
compound to thread prior to making up).
6. Insert the sleeve and the line rubber into the lower wiper body.
7. Locate the upper bushing and clip into the bottom end of the connector.
Apply anti-seize compound to the connector threads and make up with the
8.
lower wiper housing.

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 Insert the upper piston, cage and the lower bushing into the connector.
9.
(apply grease L-881720 prior to installation)
Make-up the upper wiper body with the connector. (apply anti-seize
10.
compound to threads prior to making up)
11. Insert the sleeve and the line rubber into the upper wiper body.
Insert the upper bushing and clip into the top retainer and make up with the
12. upper wiper housing (apply anti-seize compound to thread prior to making
up).
Locate the tulip onto the top retainer (apply anti-seize compound to thread
13.
prior to making up).
Apply loctite (577) to male thread hex plug and fit to connector body. (If port
14.
exists. Leave 1st thread free of sealant)
Apply loctite (577) to male thread elbow and fit to body assembly (Leave 1st
15.
thread free of sealant).
Apply loctite (577) to quick connector male thread. (Leave 1st thread free of
16.
sealant)

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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
The Dual Pack-Off 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!
Dual Pack-Off 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 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.

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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.

• Lubricate through all grease nipples (if applicable).

• Check the hydraulic functions, to test that the piston assembly opens
and closes.

• 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 rig-up.

• Check that Seal Kits and line size 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, back-up rings and line rubbers

• Check all threads for damage or corrosion.

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

• Reassemble as per the assembly instruction in Section 6.

• Lubricate through all grease nipples (if applicable)

• 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.

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

• 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.

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

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.

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 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.

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

1) Replace the top line rubber with test plug L-975102.

2) Locate appropriate test stump/cap on to lower pack-off body.

3) Bleed all air from within 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 holding for 15 minutes

minimum.

7) Replace top line rubber into its location.

No Leakage acceptable.

7.3.2 HYDRAULIC TEST PROCEDURE

1) Insert test rod (Test rod diameter should match line rubber size fitted)

2) Fill with water & bleed off all air within the assembly.

3) Ensure all external surfaces are dry.

4) Apply 5,000 psi hydraulic pressure to energise the upper line rubber
only.

5) Pressure test to working pressure for 10 minutes.

6) Repeat steps 2 to 5 but only energise the lower line rubber.

No Leakage acceptable.

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 NOTES!
Test Rods Available:
L-973431 (Test Rods for 3/16" and 5/16" Diameter)
L-9701021667 (Test Rod for 1/2" Diameter)

7.4 TROUBLESHOOTING

Problem Possible Cause Corrective Action

Leakage at body
(a) Damage to the O-Rings
or housing
and/or seal surfaces
connections
(a) Insufficient hydraulic
pressure applied.
Not sealing on a
moving/static
cable.
(b) Worn line rubbers.
(c) Damaged spring sleeve
(d) Excessive wire speed
(e) Cable not seasoned
(a) Damage to O-rings / sealing
surfaces on piston and/or lower
body and/or middle connector.
Leaking hydraulic
(b) Leakage from quick
pressure.
connector fittings.
(c) Damaged hydraulic pump
seals.
(a) Excessive wire speed
(b) Inadequate Lubrication
Packings wearing
out quickly (c) Worn wear bushings
(d) Damaged spring sleeve
resulting in spring not returning
(a) Inspect and replace as
necessary.
(a) For Static Wire:
Increase pressure in stages up to
5,000 psi maximum.
For Moving Wire:
Maintain hydraulic pressure
between 300 - 500 psi.
(b) Replace line rubbers.
(c) Replace spring sleeve.
(d) Reduce wire speed.
(e) Replace wire with seasoned
cable.
(a) Inspect and replace as
necessary.
(b) Strip and re-fit with suitable
thread sealant. Replace if
corroded or damaged.
(c) Replace pump
(a) Reduce wire speed
(b) Lubricate wire
(c) Replace upper & lower
bushings
(d) Replace spring sleeve.

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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 NOV ASEP Elmar Dual "Compact" Pack-Off assembly should always be stored
with:

• The assembly disconnected from the hydraulic lines;

• Any residual hydraulic fluid drained;

• All internals flushed clean and coated with grease to prevent corrosion;

• 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 fittings are left unobstructed
and not subjected to any loads or impacts.

8.2 SPARES AND ACCESSORIES

8.2.1 SPARES
Use only NOV ASEP Elmar recommended spares.

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

All pack-offs are supplied as standard with Nitrile o-rings and back-up rings. A wide
range of alternative compounds, for various service conditions, are available on
request. Contact the NOV ASEP Elmar Sales Department for details.

Recommended spares:

• Seal Kit;

• Line Size Kit.

8.2.2 ACCESSORIES
NOV ASEP Elmar can supply a range of accessories for handling, testing and
assembling the Dual Pack-Off. 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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NOV ASEP Elmar can supply end adapters for various quick union sizes. Contact the
Sales Department for details

For accessories that do not have part numbers stated contact the NOV ASEP Elmar
Sales Department. The part numbers for these accessories change depending on the
quick union being used.

Recommended Accessories

• Test Plug for top pack off (NOV ASEP Elmar Part No L-975102);

• Quick Union Test Stump/Cap;

• Lifting clamp, 1000 kg SWL (NOV ASEP Elmar part no. L-6901022172)

• Test Stump Mounting Table;

• Female Thread Protector (steel or plastic);

• Punches (1/2", 7/16", 13/32" & 3/8");

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

• Grease (ASEP Elmar Part No L-881720);

• Anti-seize compound (NOV ASEP Elmar part no. for each region)

L-8831028751 (USA)

L-8831028752 (North America)

L-8831028753 (Middle East)

L-8831028754 (Far East)

L-8831028755 (Europe)

• Test Rods (for working pressure function test):

L-973431 supplied with 3/16" & 5/16" test rods

L-9701021667 supplied with 1/2" test rod.

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. NOV ASEP Elmar can assist if required.

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9 DRAWINGS AND BILLS OF MATERIAL
9.1 GUIDE TO USE OF NOV ASEP ELMAR DRAWINGS

9.2 IDENTIFICATION OF COMPONENTS WITHIN AN ASSEMBLY

For drawings specific to purchased equipment, refer to the drawing package supplied
with the equipment

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9.1 GUIDE TO USE OF NOV ASEP ELMAR DRAWINGS
IDENTIFICATION OF AN ASSEMBLY PART NUMBER

All NOV ASEP Elmar assemblies are identified by a number stamped on the
equipment and beginning with L-9, e.g. L-9701004884.

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

Assembly numbers and serial numbers can usually be found stamped on the main
components e.g. Upper body, Lower body, collar, etc.

9.2 IDENTIFICATION OF COMPONENTS WITHIN AN ASSEMBLY

• Identify equipment assembly part number as described above, e.g. L-

9701004884.

• Look at the drawing with the same number, e.g. L-9701004884.

• The Bill of Material for this drawing will consist of part numbers beginning
with L-9, L-8, L-6, L-5 or L-2 e.g. L-981452.

• Look at the drawing with the same number, e.g. L-981452.

Page 44 of 44