Operating and Service Manual

For

10K Super Choke
2-9/16" and 3-1/16"






















Swaco, A Division of M-I L.L.C.
A Smith/Schlumberger Company
5950 North Course Drive
Houston, Texas 77072

Tel: 281-988-1868
Fax: 281-988-1888


MANUAL PART #90-90-080 (REV. A)




DISCLAIMER

Recommendations made by Swaco are advisory only. Swaco shall not be liable
under any guarantees or warranties, expressed or implied, in any manner or form,
AND ALL WARRANTIES, EXPRESSED OR IMPLIED, ARE HEREBY
SPECIFICALLY EXCLUDED, and Swaco shall not be liable for the failure to
obtain any particular results from the use of any recommendation made by it or
from the use of this material. In no event shall Swaco be liable for incidental or
consequential damages.






i
Table of Contents

Section 1: Introduction 1
1.1: Notes and symbols 1
1.2: General precautions 1

Section 2: General information 2
2.1: Choke valve 2
2.2: Control console 3

Section 3: Installation 6
3.1: Choke valve 6
3.1.1: Installing the choke valve 6
3.1.2: Repositioning the actuator assembly 8
3.1.3 Control lines 8
3.1.4 Choke disc position transmitter 8
3.2: Control console 9
3.2.1: Installing the control console 9
3.2.2: Air supply 10
3.2.3: Stroke / Rate meter 11
3.2.4: Gauge protector 11
3.3: Multiple choke installation 12
3.3.1: Dual control console assembly 12
3.3.2: Auxiliary control panel 13
3.3.3: Multiple control console installation 13

Section 4: Operation 13
4.1: Procedures 14
4.1.1: Normal operating method (fast) 14
4.1.2: Alternate operating method (slow) 14
4.1.3: Emergency operation 14

Section 5: Service and maintenance 16
5.1: Procedures 16
5.1.1: Routine inspection 16
5.1.2: Daily visual checks 17
5.1.3: Daily operational checks 17
5.1.4: Removing the choke valve from the manifold 17
5.1.5: Changing the disc assemblies 18
5.1.6: Bonnet end disassembly 21
5.1.7: Gauge protector 22
5.1.8: Gauge protector repair 22
5.1.9: Filling gauge protector lines 24

ii
5.1.10: Position indicator system 25
5.1.11: Calibration and adjustment 25
5.1.12: Digital stroke / Rate meter 27
5.1.13: Actuator assembly 27

Section 6: Pressure testing 27
6.1: Procedures 27
6.1.1: Shell hydrostatic test procedure 27
6.1.2: Hydrostatic disc test procedure 29

Section 7: Troubleshooting 29
7.1: Diagnostic guides 29
7.1.1: Choke discs will not open or close 29
7.1.2: Choke opens and closes too slowly 31
7.1.3: Choke valve leaks 32
7.1.4: Choke discs leak 32
7.1.5: Digital stroke / Rate meter 32
7.1.6: Pressure gauge not reading correctly 33
7.1.7: Position indicator not working 33

Section 8: Drawings and Parts lists 36

Appendix 111

A. Barksdale 111
B. SC Hydraulic 112
C. Pine pump 117
D. Flo-tork 120



1
Section 1: Introduction

The remotely operated Swaco Super Choke has been proven by experience to be a
reliable choke for the drilling industry. Like all mechanical equipment there are
certain fundamental rules that operators should observe.

The basic mechanical operation of the Swaco Super Choke is quite simple. However,
the applications for which this type of equipment is used may be complicated enough
to require specific training and experience to complete an operation successfully.

NOTE: For this reason, the Swaco Super Choke should be operated only by, or
under the supervision of qualified operators.

All mechanical equipment is subject to wear caused by either use or abuse. For this
reason, the Swaco Super Choke and Control Console should be inspected on a regular
basis by qualified personnel. Repairs should be made before undertaking any
operations involving the Swaco Super Choke.

In the event of any problems with the Super Choke, contact your nearest Swaco
service center.

1.1: Notes and symbols

Symbols in the operating instructions which concern operating safety are emphasized
as follows:

This symbol draws attention to the safety measures which must be observed to
prevent personal injury.

ATTENTION! This symbol draw attention to the safety measures which must
be observed to prevent damage to the equipment.

NOTE: This symbol draws attention to general operating notes which
should be especially observed.

1.2: General precautions
THIS DEVISE OPERATES UNDER HIGH PRESSURE. NEVER
ATTEMPT TO DISASSEMBLE UNTIL ALL PRESSURE HAS BEEN
RELEASED.


2

PROPER MAINTENANCE TOOLS SHOULD BE USED AND NO
UNAUTHORIZED MODIFICATIONS ARE TO BE MADE. USE ONLY
AUTHORIZED REPLACEMENT PARTS.

WHILE PRESSURE TESTING, ASSURE THAT ALL AIR HAS BEEN
PURGED FROM THE SYSTEM, APPROACH THE UNIT ONLY AFTER
THE DESIRED PRESSURE HAS BEEN OBTAINED AND STABILIZED.
EYE PROTECTION IS REQUIRED WHILE PERFORMING
MAINTENANCE AND PRESSURE TESTING.

ALWAYS USE PROPER SAFETY PRECAUTIONS WHERE H2S GAS
MAY BE TRAPPED IN THE CHOKE OR MANIFOLD.

Section 2: General information

2.1: Choke Valve

The Super Choke is a hydraulically operated valve providing an adjustable orifice
size from a maximum area of 1.9 square inches (12 cm) to complete shutoff. The
working pressure of this choke is 10,000 psi (68950 kPa). The size of the choke
orifice is determined by the overlapping portion of two off-center half-moon openings
in two highly polished tungsten carbide discs. The downstream disc is fixed while
the upstream disc may be rotated up to 180 by a hydraulically driven rotary actuator
(See Figure 1)


Figure 1

The Super Choke was designed primarily to control high pressure gas kicks and salt
water flows during drilling operations. However, because of its long life, high
capacity, ease and simplicity of operation the Super Choke is commonly used in a


3
Number of applications such as the following:

Stripping-in under pressure (controlled displacement)
Spotting light fluids, particularly in freeing stuck pipe
Volume "calipering" specific hole sections
Spotting heavy slugs (barite, cement, etc.)
Drilling under pressure
Displacing fluids in wells before and after workover
Testing and clean up of new completion's where sand, lost circulation material, or
perforating debris are present.

2.2: Control console

The Super Choke in normally operated from the Control Console located on the rig
floor. However, the Control Console may be placed in a remote location or any safe
working area designated by the customer. In special installations, several Control
Consoles may be placed at different locations, where any Control Console can
provide full control.

The Control Console panel has a control lever, master air supply valve, choke disc
position indicator, drill pipe gauge, casing pressure gauge and a pump stroke counter
with rate meter. Mounted below the Control Console panel is the air-operated
hydraulic pump, hydraulic fluid reservoir and a manually operated hydraulic pump to
be used in case the air supply fails (See Figure 2).

The control lever normally remains in the HOLD position, and is rotated to the OPEN
or CLOSE position to open or close the choke, respectively. The control lever is
spring loaded to return to the HOLD position when released.

A needle valve, labeled HYDRAULIC REGULATOR, can be adjusted to control the
opening and closing speed of the choke discs. The hydraulic regulator valve should
normally be rotated at least 1-1/2 turns to provide a suitable speed for the choke discs
during operation.

The AIR SUPPLY valve controls the air supply to the air-operated hydraulic pump
and the position indicator system. The recommended air pressure is 50-125 psi (342-
862 kPa).



4


Figure 2

For multiple choke installations, Swaco has a Dual Choke Control Console (See
Figure 3). Two chokes can be operated with this console without the need for an
auxiliary panel or two single consoles.

The Dual Control Console panel consists of two choke control levers, two choke disc
position indicators and two hydraulic regulators. The are also pressure gauges and a
master air supply valve for use in operation of either or both choke valves.

The operation of the Dual Control Console is identical to that of a single Control
Console. Located below the panel is a hydraulic reservoir, which supplies both
systems with the required hydraulic fluid. Each system has a separate air-operated
hydraulic pump and a manually operated hydraulic pump to be used in case the air
supply fails.


5


Figure 3


6
Section 3: Installation

3.1: Choke valve

3.1.1: Installing the choke valve

The standard inlet and outlet flanges are AIP Type 6BX, 2-9/16, 10,000 psi
(68950 kPa), 3-9/16, 10,000 psi is also available.

ATTENTION! Most common bolts, studs and nuts available do not
meet the requirements for H2S service and will fail
from hydrogen embrittlement. Replace bolts, studs and
nuts with authorized replacement parts.

ATTENTION! All Swaco Super Chokes contain a tungsten carbide
wear sleeve which extends 1/8 inch (4 mm) beyond the
face of the outlet flange. This protects the ring gasket
from erosion. Because of this feature, the internal
diameter of the companion flange or adapter must have
a minimum 2-9/16 inch bore; otherwise the wear sleeve
will crush the back choke disc when the flange is
installed.


7
Before installation, the flange studs and nuts should be
checked for cracks, damage, wear and thread distortion.
When any of these conditions are detected the part
should be replaced.

Companion flanges and adapter flanges can be furnished with the choke and
must be made from specially heat treated material. Zinc plated BX ring
gaskets suitable for H2S service is also available.

New ring gaskets should be used on each installation and each time the
flanges are reconnected. Use gaskets will be deformed and may not seal
properly. (Refer to API Specification 6A, Specification for Wellhead and
Christmas tree Equipment).

The nuts should be evenly torqued. The nut threads must be fully engaged
with the stud threads. It is recommended that the stud be exposed by at least
three or four threads to permit more even stress loading.

When the nuts are fully torqued, the faces of the choke flanges should be
parallel to the companion or adapter flanges. The material used to fabricate
the choke is relatively soft, therefore, when fitting the choke to the manifold
care should be taken not to damage the flanges.

The choke manifold should have at least two positive shutoff valves between
the blowout preventer and Super Choke. There should also be one valve
downstream of the Super choke to permit isolation for servicing of the choke
while other sections of the manifold are in use. (Refer to API Bulletin RP 53,
Blowout Prevention Equipment Systems).

The discharge line from the choke must be securely anchored according to
API Specifications. (Refer to API Bulletin RP 53)

The Super Choke valve should be pressure tested after installation and
notation made on the drilling report. This test may be done when the choke
manifold is being tested. Refer to Section 6 of this manual for pressure test
procedures.




8
3.1.2: Repositioning the actuator assembly

When installing the Swaco Super Choke in the manifold, the actuator
assembly should be installed with the open area facing down or to one side
(See Figure 4). If the actuator assembly is not positioned properly, the
following procedures should be followed to rotate it to the correct position.

NOTE: Do not rotate the indicator head when removing and turning the
actuator assembly because this will cause misalignment of the
choke discs. Also make sure the actuator assembly shaft is not
rotated. When the actuator assembly is reinstalled the position
indicator cam must be in the same position as it was when the
actuator assembly was removed or the choke will not operate
properly.

Remove the four bolts, which fasten the actuator assembly to the
mounting adapter.
Pull the actuator assembly away from the adapter until the square shaft
is clear of the indicator head.
Turn the actuator assembly 90 to 180 to the desired position.
Push the actuator assembly shaft into the indicator head. A light
application of grease on the actuator assembly shaft is recommended
to ease installation and future changes.
Replace the four bolts and tighten them to 27 ft-lbs. (366 Nm).

3.1.3: Control lines

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

3.1.4: Choke disc position transmitter

Connect 1/4 inch O.D. vinyl tubing from fittings on the position transmitter,
located on the choke valve to the corresponding fittings on the control console
(See Figure 5).

The two (2) fittings on the control console manifold are labeled "Air to
Transmitter" and "Air Return from Transmitter".


9
The fittings on the position transmitter are not labeled. Check the arrow
located on the position transmitter regulator to determine the direction of the
air flow.

3.2: Control console

3.2.1: Installing the control console

Place the control console in the desired location on the rig floor or in a safe
working area designated by the customer. Normally, the best location for the
control console is against the hand rail nearest the mud tanks and the choke
manifold. This location provides the choke operator with a view of the fluid
level in the mud tanks and other equipment related to a well killing operation.


Figure 5



10
3.2.2: Air supply

Connect the air supply hose from the manifold on the control console to the
rig air supply (See Figure 5). The air hose should be connected to an outlet
where clean, dry air may be obtained. Trash or moisture in the air supply can
cause a malfunction of the air-operated hydraulic pump. This air outlet should
not be sued for any other purpose which might cause the supply to be
disconnected from the control console. Install the air hose to avoid crimping
or cutting and excessive heat from other equipment.

The recommended air supply pressure for the control console is 50-125 psi
(345-862 kPa). For a hose length to 50 feet (15 m) a 1/2 inch diameter hose is
adequate. For longer lengths a 3/4 inch diameter hose is desirable. The air
hose supplied with the control console has 1/2 inch NPT male connection
which can be adapted to the air outlet on the rig.

Turn the master air supply valve on the control console to the ON position.
The pointer of the position indicator gauge should show OPEN (assuming the
choke was installed in the open position). If it shows CLOSED or partially
closed, check to determine if the super choke valve is fully closed or if the
position transmitter is properly calibrated.

NOTE: The control console and super choke valve should be calibrated
together at the service center. Refer to section 5.1.10 of this
manual for proper calibration procedures.

Push the control lever to the right toward the choke CLOSE label. The
Hydraulic pump should start stroking and the needle of the position indicator
gauge should begin moving. Hold the lever in this position until the choke is
fully closed and the hydraulic pump stops stroking; then release the lever.
The control valve should open.

Push the control lever to the left toward the choke OPEN label until the choke
is fully open.

If there is any problem with any of these operations, refer to Section 5.1.10 of
this manual.




11
3.2.3: Stroke / Rate Meter

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

- Limit switch: Each pump Stroke switch assembly mounts to the mud pump frame
near the exposed pump rods. Position each switch assembly so the switch
actuator rod moves when contacted by the pump rod collar or splash guard. There
should be one full deflection and release of the actuator rod for each pump stroke
to assure proper operation of the stroke counter and to avoid double counting.
- Magnetic switch: Find a large mass of metal on the pump and position switch so
that it can sense off of it. Be sure not to allow the mass to pass completely past
the sensor or it will double count.
Route the cable from the Digital Pump Stroke/Rater Meter to the junction box and connect
the wires. Use wire nuts to connect the wires inside the junction box. The strain relief
connections on the meter, junction box and pump switches should be used to avoid wire
damage. Shielded cable is recommended between the Stroke/Rate Meter and the limit switch
assembly. Ground the shielding on one end of the cable. This will prevent electrical noise
from the power cables adjacent to the Stroke/Rate Meter from causing an inaccurate count.

Operate each pump stroke assembly by hand to determine Pump 1, 2, or 3. The pump select
switch is located on the bottom of the Stroke/Rate Meter is used to display the desired pump
stroke count and rate being displayed.

3.2.4 GAUGE PROTECTOR

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


12
3.3 MULTIPLE CHOKE INSTALLATION

3.2.1 DUAL CONTROL CONSOLE ASSEMBLY

If two Super Choke valves are to be used in the choke manifold, they may both be
controlled from the dual control console assembly (figure 6). On the rear manifold of
the dual control console (drawing 20) there are OPEN and CLOSE lines for each
choke, also air to and air return lines for each choke. It is important not to
interchange the lines for Choke A with the lines from Choke B. Improperly installed
lines will cause choke B to operate when choke A controls are actuated and vice
versa. Therefore, it is recommended to install one set of lines (choke A or choke B)
at a time. The OPEN and CLOSE lines for Choke A are located next to the drill pipe
pressure fitting. The open and close lines for choke bare are located next to the
casing pressure fitting. Facing the back of the dual control console, the air lines for
choke A are the right pair and the air lines for Choke B are the left pair.

The supply air and gauge protector assemblies are installed in the same manner as
they are for the Single Control Console.




13
3.3.2 AUXILIARY CONTROL PANEL

If a SWACO Dual Control Console is not available, the Auxiliary control panel may be used
with the single control console for the operation of the two super chokes.

The Auxiliary Control Panel is mounted on the right side of the Control Console. There are
two hose connections that tie the Auxiliary control panel into the control console hydraulic
system. One connection is located at the output of the air operated hydraulic pump. The
connection will supply the necessary hydraulic pressure for operating the auxiliary choke.
Use high pressure hose and fittings (minimum 3,000 psi 20685 kPa) to make this
connection. The second connection is located between the return port on the auxiliary
control panel control valve and the hydraulic reservoir on the control console.

To complete the installation, connect the air supply to the position transmitter on the second
choke. This can be done by installing a tubing tee in the Air to Transmitter line
between the Control Console and the primary choke. Connect this air supply to the position
transmitter on the second choke. The return line from the second choke position transmitter
connects directly to the position indicator gauge on the auxiliary control panel.

3.3.3 MULTIPLE CONTROL CONSOLE INSTALLATION

When using two Super Chokes it may be desirable to have more than one Control console in
order to operate the chokes from different areas around the drilling site. Drawing 36 is a
schematic for installing two chokes and three control consoles with auxiliary control panels
on each control console. Full operation of each choke valve is possible from any of the three
control locations. For two console operation use consoles at Master Station 1 and Station 2
only.

The control line hoses may be replaced by Schedule 40 pipe for underground routing to
remote locations. This change will improve the choke response time and prevent the lines
from being crushed by vehicle traffic around the rig.

When making these special installations, 1/8 copper or stainless steel tubing should be used
for the gauge lines if the total distance between the control console and the gauge protectors
exceeds 100 ft. (30m).

For multiple panel installations with the Dual Control console, the same steps can be
followed as for the single control console with an auxiliary control panel.

4 OPERATION

The choke discs should remain in the fill OPEN position when the choke is not in use.
Operation of the SWACO Super Choke should always begin with the choke in the OPEN
position. (Closed choke discs may result in hydraulic shock on the well bore and if the mud
pumps are running can result in lost returns and a down hole blowout). For example: at the
start of a well control procedure, the choke should not be closed until after the blowout

14
preventer has been closed and drilling fluid is flowing through the manifold and Super
Choke. This helps to seat the discs and prevents mud particles from getting between the
discs. The choke should be closed slowly to avoid hydraulic shock on the surface pressure
control equipment and the casing seat.

4.1 PROCEDURES

4.1.1 NORMAL OPERATING METHOD (fast)

- Move faster AIR SUPPLY valve to the ON position (see figure 2).
- Open the HYDRAULIC REGULATOR all the way.
- The control console displays the following information that is typically used in
well control procedures
- Drill pipe pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 kPa
increments)
- Casing pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 Kpa
increments)
- Choke position (full OPEN to full CLOSE)
- Rig pumps stroke rate and stroke count
- Be prepared to shift the CONTROL LEVER in either direction to maintain the
desired casing or drill pipe pressure.
- When the well control operation is complete, open the choke and turn master AIR
SUPPLY valve OFF to remove all pressure on the hydraulic system

NOTE: A PLUGGED CHOKE MAY RESULT IN EXCESS PRESSURE BUILD-UP IN
THE SYSTEM WHICH MAY EXCEED THE CASING PRESSURE LIMIT. IN CASE OF
CHOKE PLUGGING, SHIFT THE MAIN CONTROL LEVER TO OPEN, AND OPEN
THE HYDRAULIC REGULATOR FOR FAST RESPONSE. AS SOON AS THE PLUG IS
CLEARED, THE CONTROL LEVER MUST BE SHIFTED TO CLOSE LONG ENOUGH
TO RETURN TO THE DESIRED PRESSURE. THE HYDRAULIC REGULATOR
VALVE MAY THEN BE ADJ USTED FOR A SLOWER RESPONSE.

4.1.2 ALTERNATE OPERATING METHOD (slow)

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

4.1.3 EMERGENCY OPERATION
FAILURE OF AIR SUPPLY OR AIR PUMP


15
- Install PUMP HANDLE on the HAND PUMP which is mounted on the base of
the control console skid. (Be sure pump BLEED-OFF valve on the HAND
PUMP is closed).
- To change choke opening, hold the control lever in the desired position while
stroking the HAND PUMP.

RUPTURE IN HYDRAULIC LINE OR CONNECTION

- If either hydraulic line is cut or ruptures, cut both lines at the choke. The hoses
must be cut and NOT DISCONNECTED. If they are disconnected, check valves
in the fittings will prevent operation.
- Insert 5/8 (16mm) diameter rod into one of the holes in the INDICATOR HEAD
(figure 7) and manually position the choke as desired.















16
5 SERVICE AND MAINTENANCE

5.1 PROCEDURES

5.1.1 ROUTINE INSPECTION

The SWACO super Choke is a key element of the pressure control system used to
prevent rig blowouts. Therefore, it is important that the Super Choke and Control
Console be maintained in good operating condition at all times (see figure 8).



















17
5.1.2 DAILY VISUAL CHECKS

- Check the presence of a hand pump handle (item 9), a manual choke operating bar
and all panel labels
- Check fluid level in the hydraulic oil reservoir (item 1). Fill with the correct
hydraulic oil. Keep a supply of oil at the choke panel or close by.
- See that all connections fit tight. Make sure the hydraulic hoses, pump switch
cable and air lines are properly connected and not cut or pinched.
- Check the pump Stroke/Rate Meter (Item 8). Place the selector switch on
TEST, the meter should be counting and should show 128 SPM. Select Pump 1
or Pump 2 and observe counter and rate display. Reset counter to zero after test.
- See that the pump stroke counter switches (item 3) are properly attached to the
mud pump and counting the correct number of strokes.
- Check the air line lubricator (item 14); the bowl should be filled with the correct
hydraulic oil.

5.1.3 DAILY OPERATIONAL CHECKS

- Turn the master air supply valve (item 5) on. The hydraulic pressure gauge (item
12) should show 1500-1750 psi (10343-12066 kPa).
- Close the hydraulic regulator (item 11) and then open 1-1/2 turns. Operate the
control lever (item 6). Complete a full cycle of the choke discs from full OPEN,
to full CLOSE, back to full OPEN. The position indicator (item 10) should track
the choke disc movement according to the choke lever selection.
- While the hydraulic pump is stroking, check the sight glass located on top of the
air line lubricator (item 14). The lubricator should deliver approximately 1 drop
of oil for every 20 strokes of the hydraulic pump. The adjustment screw is
located on top of the lubricator.
- To operate the hand pump (item 2) to close or open the choke discs, shut the air
supply off. Hold the choke control lever in desired position and operate hand
pump. Make sure the bleed valve on the hand pump is closed. Leave the pump
piston in the DOWN position to avoid rust or corrosion.
- Observe the Drill Pipe and Casing Pressure gauges (item 7). The pressure valve
should be approximately the same as the rig gauges. Gauge faces should be clean
and visible.

5.1.4 REMOVING THE CHOKE VALVE FROM THE MANIFOLD

Before attempting to work on a Super Choke in a manifold, extreme caution should be
exercised to assure that there is no pressure trapped in the choke valve or choke manifold.
Always use proper safety precautions where H
2
S gas may be trapped in the choke valve or
manifold. Only personnel who have received instruction on the hazards of H
2
S may be
present should be permitted to work on the Super Choke. Failure to follow these instructions
could result in injury.


18
- Rotate the choke discs to the full OPEN position. Allow the pressure in the choke
valve to be relieved before continuing with this procedure.
- Carefully loosen the outlet flange nuts one turn each until seal or ring gasket is
broken but do not remove the nuts on the outlet flanges of the choke valve. After
all the nuts are loosened, break the seal on the ring gasket by separating the outlet
flange from the manifold flange. Stand on either side of the flange gap, never
over it, when breaking the seal to avoid possible severe personal injury. Once the
seal is broken and all pressure inside the choke is relieved, the nuts and studs may
be safely removed. Do not use a pry bar to remove flange because of possibly
damaging the extended wear sleeve.
- Provide some manner of support for the valve, and then carefully loosen the
upstream flange nuts one turn until seal is broken and any trapped pressure is
released, and then remove the nuts and studs on the inlet flange.
Refer to section 3.1.1 of this manual for reinstalling the choke in the manifold.

ATTENTION!

Because of the H
2
S rating for the SWACO Super Choke the steel used to fabricate the
flanges, nuts and studs are relatively soft and therefore, subject to surface distortion and dents
from poor work practices. Care should be exercised in the handling procedures and use of
tools when working on the Super Choke to avoid damaging these parts. Damaged parts will
adversely affect the structural integrity of the super choke which may result in injury.

5.1.5 CHANGING THE DISC ASSEMBLIES

This section describes the procedure for removing the super choke discs from the outlet end
of the valve body for inspection and/or replacement and removal of the wear sleeves. See
drawing 2 for part number information.

NOTE: Before attempting to work on a Super Choke, extreme caution should be exercised
to assure that there is no pressure trapped in the choke valve. Always use proper safety
precautions where H
2
S gas may be trapped in the choke valve. Only personnel who have
received instruction on the hazards of H
2
S, the proper safety equipment and procedures for
working in areas where H
2
S may be present should be permitted to work on the Super Choke.
Failure to follow these instructions could result in injury.

- Carefully loosen the outlet spool bolts one turn each. After all the bolts are
loosened, break the o-ring seal and unbolt the outlet spool, carefully separating it
from the body. The spool is fastened to the choke body with 7/8 ferry head cap
screws. Locating pins provide alignment between the body and the outlet spool.
- To remove the choke discs, first rotate the front disc to the full OPEN position if
this has not been previously done. Wash any sand, grit or weight material from
around the exposed portion of the back disc and the disc opening.
- Insert the hook end of the disc puller (Swaco part number 96-11-083) in the disc
opening as illustrated in Figure 9 and gently remove both discs using the sliding
weight on the puller.

19

NOTE: To avoid injury, caution should be taken to avoid getting any part of the hand
caught between the sliding weight and the stop on the end of the puller shaft.

- Maintain the position of the hook on the puller to avoid chipping the corners of
the disc orifice. Even if the discs are worn they may be repairable if not damaged
from this procedure. When the discs have been removed, locate and inspect the
stationary disc locking pin. Replace if damaged.
- Clean both disc assemblies thoroughly and inspect for wear or damage. The
primary criteria for determining whether or not the choke discs are reusable are
that they can provide a positive seal under pressure when installed in the choke.
See section 6.1.2 of this manual for the Hydrostatic disc test procedure.
- Wash out and clean the interior of the choke body and the o-ring sealing surfaces.
- Remove the o-rings on the back disc carrier and the choke body flange and
replace these o-rings.

NOTE: The o-rings used in the Super Choke are made of a special H
2
S resistant material.
Use only the o-rings specified in drawing 2.

- Thoroughly clean the disc assemblies and apply a light film of silicone grease to
the o-ring groove on the rear disc carrier. Avoid getting grease on the polished
disc faces because this can cause the choke to leak when tested.
- Insert the front disc assembly into the body so that the half-moon opening side is
facing the choke inlet flange. Be sure that the turning fork fingers and the
locating pin in one of the fingers align properly with the slots and locating pin
hole in the front disc assembly. The front disc should fit loosely into the body
and into the turning fork fingers.
- Position the back disc locking pin in the groove on the inside diameter of the
choke body. Align the matching pin groove in the back disc assembly and insert
the back disc.

20
NOTE: The moon-shaped opening must be facing the inlet flange of the choke valve. See
figure 10.

- To remove the outlet spool wear sleeves carefully press them out through the end
which bolts to the body. There are three identical large internal diameter wear
sleeves and one with a smaller opening that protects the outlet flange seal.
- Inspect the wear sleeves for wear and replace as necessary.
- Before reinserting the wear sleeves, clean and inspect the bore of the spool. Be
especially careful to remove any dirt, rust or debris from the shoulder where the
extended wear sleeve makes contact. Failure to do so may cause the wear sleeves
to break the choke discs when the spool is bolted to the valve body.


- Remove any dirt, rust or debris from the ends of the wear sleeves and the shoulder
on the extended wear sleeve. Apply a light film of silicone grease on the outside
of the wear sleeves and insert them into the spool.
- Reassemble the outlet spool to the valve body using the alignment pins and the
ferry head cap screws. Check to be sure the o-rings are properly positioned. Use
only the screws and bolts specified in drawing 2 to assemble. Discard and replace
any damaged screws. Tighten these screws uniformly. The bolts should be
torqued to 165 ft/lb (224 Nm). Over torquing the bolts will cause them to stretch
and reduce their strength which, can result in premature failure.
- Clean and inspect the inlet and outlet flange faces and ring grooves. Apply a light
film of general purpose grease or a rust inhibitor to the face and ring groove for
corrosion protection.




21

5.1.6 BONNET END DISASSEMBLY

This section describes the procedure for removal of the actuator assembly and bonnet from
choke valve. It also covers the removal and inspection of the turning fork. These procedures
may be done with the super choke either installed in the manifold or removed.

NOTE: Before attempting to work on a Super Choke in a manifold, extreme caution should
be exercised to assure that there is not pressure trapped in the choke valve or choke manifold.
Always use proper safety precautions where H
2
S gas may be trapped in the choke valve or
manifold. Only personnel who have received instruction on the hazards of H
2
S, the proper
safety equipment and procedures for working in areas where H
2
S may be present should be
permitted to work on the Super Choke. Failure to follow these instructions could result in
injury.

- The first step is disassembling the Bonnet from the Choke is to remove the
Actuator Assembly. Before doing this, position the choke discs in the full OPEN
position. To remove the Actuator Assembly from the choke valve, remove the
four bolts that attach the adapter to the choke valve. Remove these bolts and
proceed to the next step.
- Remove the cap screw attaching the indicator head to the turning fork. Remove
the indicator head from the turning fork shaft.
- Before removing the Bonnet, mark the valve body and bonnet so they can be
reassembled with the same orientation. Remove the remaining ferry head cap
screws attaching the bonnet to the body. Inspect these screws for damage or
distortion and replace as necessary. Use only bolts specified in Drawing 2.
Remove the bonnet from the valve body.

NOTE: Most common bolts, studs and nuts available do not meet the requirements for H
2
S
service and will fail from hydrogen embrittlement. Replace bolts, studs, and nuts with
authorized replacement parts.

- Push the turning fork out of the bonnet being careful not to damage the shaft
surfaces that rotate inside the bonnet.
- Clean the turning fork and inspect for wear or damage. The thrust bearing and o-
ring seal areas should be smooth. The hex should not be rounded, cracked or
deformed. Replace the turning fork if any of these conditions exist. Lubricate the
turning fork shaft with a light application of silicone grease before reassembly.
- Replace the thrust bearing, shaft bushing, all o-rings and backup rings on the
bonnet. Refer to drawing 2 for the proper location of these parts. The parts that
are used in the super choke are made of special material for exposure to H
2
S gas.
Use only parts specified in drawing 2 to replace components in the super choke.
- Reinsert the turning fork in the bonnet being careful not to damage the o-rings or
bushing. The bonnet should be clean and have a light application of silicone
grease on the surfaces where there is contact or close proximity to the valve body
and turning fork.

22
- If the outlet spool is not to be removed from the body, the front disc assembly
must be properly positioned on the turning fork prior to installation. Be sure to
properly align the locating pin in the turning fork finger with the alignment hole
in the front disc assembly. The polished surfaces on both the front and back disc
must be completely clean, dry and free of grease to assure proper seating.
- Clean the indicator head and apply a light film of grease to the square and hex
sockets. Check that the indicator head socket will fit freely on the actuator
assembly shaft. This will eliminate problems when assembling the actuator
assembly to the valve.
- When inserting the bonnet assembly into the valve body, position the half moon
opening on the front disc toward the inlet flange and align the marks described in
step 3 on the bonnet and valve body.
- Reinsert and uniformly tighten the bolts securing the bonnet to the valve body and
the actuator assembly to the bonnet. Note: four of the bolts are longer than the
rest. The longer bolts are used to attach the actuator assembly to the bonnet. The
actuator assembly may be positioned in three possible positions, but never upside
down. Care should be exercised to assure that both the actuator assembly shaft
and the choke discs are in the OPEN position when these two components are
reassembled. Evenly torque these bolts to 165 ft/lbs (224Nm). Over-torquing the
bolts will cause them to stretch and reduce their strength, which can result in
premature failure.

5.1.7 GAUGE PROTECTOR

The purpose of the Gauge protector (figure 11) is to transmit fluid pressure from the drill
pipe or the casing to the control console and isolate the gauges from the drilling mud.

5.1.8 GAUGE PROTECTOR REPAIR

- If the hydraulic hose is to remain attached to the gauge protector, remove the plug
from the side of the body. This will permit air to enter the body when the piston
is removed.
- Remove the body from the female hub by removing the wing nut.
- Remove the stainless steel internal snap ring from the bore of the gauge protector
body.
- Insert a -13NC bolt in the tapped hole at the bottom of the piston. Use the bolt
as a handle to extract the piston.
- Clean the piston and replace the o-rings on the piston. Use only the size and type
o-ring called for in drawing 26.


23


NOTE: The o-rings used in the gauge protector are made of a special H
2
S resistant material.
Use only the o-rings specified in drawing 26.

- Clean and inspect the bore of the gauge protector body for corrosion, wear and
pitting. Replace the body if these conditions exist.
- Before reinstalling the piston apply an ample film of silicone grease on the piston
and o-rings. Manually insert the piston all the way into the body. The piston
should move in the body with only moderate physical effort. If the piston sticks,
replace the piston. Do not file or grind the bore of the gauge protection body, or
o.d. of the piston.

24
- Reinstall the stainless steel internal snap ring. Refer to section 5.1.9 of this
manual for refilling the gauge protector with hydraulic fluid. The body plug is
replaced during the line filling procedure.

5.1.9 FILLING GAUGE PROTECTOR LINES

After assembly, the gauge protector, signal line and gauge lines on the control console should
be filled with hydraulic oil and purged of air. A few drops of oil will be lost each time the
line is coupled or uncoupled. It is therefore advisable to avoid disconnecting these lines once
the system has been purged. Loss of hydraulic fluid in the lines may cause the gauge to read
incorrectly. The hydraulic fluid in the system must be free of air or full pressure cannot be
transmitted to the gauge.

- Place the gauge protector in a vertical position near the control console. The
signal line should be connected tightly to the gauge protector and the control
console manifold.
- Remove the check valve cap on the back of the control console manifold and
attach the hand pump loosely to the check valve (figure 12). Do not tighten this
connection yet.


- Slide the cover of the hand pump to one side and fill the reservoir with hydraulic
fluid. While pumping, keep the hand pump reservoir at least full to avoid
pumping air into the line.
- Pump slowly, purging air from the pump at the loose connection. When the pump
is purged of air, tighten the connection between the pump and the check valve.
- Turn the damper valve on the gauge counterclockwise several turns to relieve the
dampening effect.

25
- Remove the pipe plug on top of the gauge to allow air to bleed from the system.
Pump fluid into the system until no air bubbles appear at the plug on the gauge.
Tighten the plug and push the damper valve in, turning clockwise to engage the
threads.
- Lay the hydraulic hose out as straight and flat as possible, below the level of the
gauge.
- Remove the plug from the gauge protector body.
- Pump hydraulic fluid into the system to purge all air from the signal line and the
gauge protector. Bleed air out at the gauge protector plug opening.
- When the signal line and gauge protector appear to be purged of air, continue
pumping slowly and rock the gauge protector slightly to help pass any remaining
air through the vent holes. Rotate the gauge protector plug end up, to displace
any air from the passage.
- When all the air has been purged from the system, replace the plug on the gauge
protector and tighten.
- Once the plug in the gauge protector is replaced, continue to pump hydraulic fluid
into the system until the piston contacts the internal snap ring in the bore of the
gauge protector.
- Close the hand pump cover and remove the pump from the check valve.
- Replace the check valve cap.

5.1.10 POSITION INDICATOR SYSTEM

This system utilizes a 3 to 15 psi (21 to 103 kPa) air signal to operate an indicator gauge on
the control console. The signal comes from a plunger type regulator. As the choke is rotated
toward the CLOSE position, a cam connected to the control console shaft moves the pivot
arm assembly. The pivot arm assembly pushes on the regulator plunger and increases the air
signal. At the full OPEN position, the signal is 3 psi (21 kPA), at the full CLOSED position
the signal is 15psi (103 kPa). The position indicator gauge is labeled OPEN and CLOSE
with a mark at the middle position to indicate or 50% open. (The graph in drawing 35 can
be used to convert the choke position to an approximate equivalent diameter opening or
choke bean size). The position indicator serves as an aid in observing the direction and speed
of changes being made in the choke opening.

5.1.11 CALIBRATION AND ADJUSTMENT

Connect the supply air from the control console to the left hand tubing fitting, and connect
the signal return air to the right hand tubing fitting (figure 13). Turn the air supply on.


26

TO ZERO THE POSITION INDICATOR GAUGE

- completely OPEN the choke
- Loosen the nut and set screws on the camshaft so the cam turns on the shaft.
- Rotate the cam shaft so the scribe mark on the short side of the cam lines up with
the cam follower.
- Tighten shaft nut and set screws.
- Loosen the pivot block locking screw on rear of mounting plate and turn the
zero adjustment screw until signal output is 3 psi (21 kPa) on a test gauge, or
OPEN on the position indicator gauge.
- Tighten pivot block locking screws.
- Be sure the output is 3 psi (21 kPa) when the locking screw is tight. Movement
during tightening may slightly change the setting. This can result in inaccurate
readings of the position indicator. If output is not 3psi (21 kPa), adjust block as
indicated in Step 5 above the required 3 psi (21kPa).
- Completely CLOSE the choke. The test gauge should read about 15psi (103 kPa),
or CLOSED on the position indicator gauge.

TO ZERO THE SPAN OF THE INDICATOR GAUGE

- Completely CLOSE the choke. This puts the scribe mark on the long side of the
cam at the cam follower. Output should be near 15 psi (103 kPa) on the test
gauge, or CLOSED on the position indicator gauge.

27
- If less than 15 psi (103 kPa), loosen both socket head cap screws and move
regulator bracket slightly away from the pivot block. If more than 15 psi (103
kPa), move regulator bracket slightly toward the pivot block.
- Tighten both socket head cap screws.
- Completely OPEN the choke. If output is not 3 psi (21 kPa), re-adjust the pivot
block as in Section 5.1.12 to 3 psi (21 kPa).
- Completely close the choke and check 15 psi (103 kPa) signals
- Repeat steps 1 through 5 until 3 and 15 psi (21 and 103 kPa) outputs are obtained.

NOTE: If it is not convenient to use the control panel to rotate the choke, use a short adapter
connection between the open and closed connectors, and rotate the choke by hand.
However, it is best to check the control console and choke valve together.

5.1.12 DIGITAL STROKE / RATE METER

The digital stroke / rate meter is designed for simple maintenance. The meter contains three
interconnected modules; a display module, a switch module and a battery pack. Should any
one of these modules fail, they are not repairable and must be replaced. Refer to the
troubleshooting guide in section 7.1.5. Parts information is given in Drawings 31 and 32.

5.1.13 ACTUATOR ASSEMBLY

See the appendix for the manufacturers instructions for repair and maintenance of the
actuator assembly.

6 PRESSURE TESTING

This section describes how to perform a shell and disc hydrostatic test on the SWACO Super
Choke. This test is not intended to supersede or duplicate the standard API specification 6A
shell and leak tests, but provide a routing procedure to verify that the seals and discs are not
leaking and to verify the integrity of the pressure containing parts.

6.1 PROCEDURES

6.1.1 SHELL HYDROSTATIC TEST PROCEDURE

- Completely OPEN the choke discs.
- Connect test flanges with the pressure manifold as shown in figure 14 to the inlet
and outlet flanges of the super choke.
- Place the super choke with the side of the actuator assembly housing and the
outlet flange resting on the ground. The inlet flange is pointing upward (see
figure 14).


28

- With the isolation valves on the inlet and outlet flanges open, fill the choke with
water from the outlet end. When the choke appears to be full, raise the outlet end
until the centerline of the valve is parallel to the ground (see figure 15).


- Continue filling choke with water. When all of the air has been purged from the
choke, close the isolation valve on the outlet flange and disconnect the water line.
Lower the choke outlet to ground level. (See figure 14).

29
- Open the hydraulic inlet valve and purge any air that may be trapped in the
hydraulic feed line.
- It may be necessary to purge air from the hydraulic line to the pressure gauge.
Open the bleed fitting for the pressure gauge and close the isolation valve on the
inlet test flange. Pump hydraulic oil through the gauge line until all air is
removed. Close the bleed fitting for the gauge.
- With the inlet isolation valves closed and the hydraulic inlet valve open, slowly
raise the pressure on the choke shell to 10,000 psi (68950 kPa). Check the valve
and test flanges for leaks. If leaks occur, stop the test, take appropriate steps to
correct the problem and repeat this test procedure.
- If no leaks are evident at this point, close the hydraulic valve on the inlet test
flange and observe the pressure gauge for three (3) minutes. If the pressure
begins to bleed down before three minutes inspect the choke and test flange for
leaks. Repair leaks as required and repeat this test procedure.
- Open the isolation valve on the outlet test flange and remove the test flange.

NOTE: Do not block the discharge opening for the isolation valves. When the valves are
opened under pressure a small quantity of water will shoot out of the opening.

6.1.2 HYDROSTATIC DISC TEST PROCEDURE

- To prepare the choke for the hydrostatic disc test, fill the valve with water and
remove all of the trapped air as described in Section 6.1.1. Steps 1-7.
- With the isolation valves on the inlet and outlet test flanges closed, slowly raise
the pressure in the choke to approximately 2,500 psi (17238 kPa).
- With the hydraulic valve open and pump on, close the choke discs. Open the
isolation valve on the outlet test flange. This should seat the choke discs. Slowly
raise the pressure in the choke to 10,000 psi (68950 kPa) leaving the outlet
isolation valve open.
- Watch the test gauge for three (3) minutes. If the pressure bleeds down,
disassemble the choke to determine the cause for the leakage. Replace the discs
or seals as required and repeat this test procedure.

7 TROUBLESHOOTING

7.1 DIAGNOSTIC GUIDES

7.1.1 CHOKE DISCS WILL NOT OPEN OR CLOSE

Before disconnecting air or hydraulic lines, turn the system off and make absolutely sure that
all pressure in the lines has been relieved. Failure to do so may result in injury.

- To locate the problem when the control console will not operate the super choke,
turn the mater air supply valve ON. The control lever should be in neutral
HOLD position. Fully open the hydraulic regulator by turning the knob

30
counterclockwise several turns. If the hydraulic pump continues to cycle, proceed
with the following steps in the order listed (see figure 16).


- Check the hydraulic fluid level in the reservoir. If less than half full, add the
correct hydraulic fluid, SWACO part number LSF00003-103. Do not use diesel
oil because this will cause some valve seals and hydraulic hoses to deteriorate.
- Check the low pressure suction hose between the reservoir and the hydraulic
pump for leaks, collapse or crimping. This condition will cause the pump to lose
prime and not pump fluid. Replace this hose as needed.
- Check the high pressure hose from the output manifold on the hydraulic pump to
the hydraulic regulator and from the hydraulic regulator to the control valve for
leaks. Replace these hoses as needed.
- Disconnect the return line on the hydraulic relief valve. This hose must
temporarily be plugged to prevent hydraulic fluid in the reservoir from leaking
out. Make certain to remove this plug before reinstalling the hydraulic relief
valve return line. If hydraulic oil is leaking form the discharge of the relief valve
when the pump is cycling, slowly tighten the pressure adjustment screw on the
relief valve while observing the pressure gauge on the output manifold on the
hydraulic pump. When the maximum reading on the pressure gauge reaches 1800
psi (12411 kPa) stop tightening the adjustment screw on the relief valve and lower
the air pressure on the air regulator feeding the hydraulic pump until the hydraulic

31
pressure drops to 1500 psi (10342 kPa). At this point, the pump should stop
cycling and the relief valve should stop leaking from the return connection. If the
relief valve continues to leak, replace it.
- Remove the return line from the control valve. Start the hydraulic pump and
check the return connection for leakage. If hydraulic fluid leaks from this
connection, repair or replace the control valve. Refer to the appendix A for the
manufacturers instructions for the control lever.
- Remove the pump suction and discharge check valves. Check for debris or a
frozen value. Repair or replace as needed.
- Inspect the open and close hydraulic lines to the choke for crimps, pinching and
damage. Replace as needed.
- Connect the choke open hydraulic line to the choke close hydraulic line using
the quick-connect hose couplings on the actuator assembly.
- Operate the control lever to both the OPEN and CLOSE positions. If the
hydraulic pump begins to cycle when the control lever is moved to the OPEN and
CLOSE positions, check the hydraulic lines for the leakage. Reconnect the
hydraulic lines to the actuator assembly.
- Turn off the air supply to the hydraulic pump and bleed the hydraulic system to
relieve the pressure in the lines between the hydraulic pump and the rear manifold
on the console.
- Remove the high pressure hose between the hydraulic regulator and the control
lever. Make sure the hydraulic regulator is open. Turn on the air supply to the
hydraulic pump. If little or no fluid flows through the hydraulic regulator, then it
is plugged and must be repaired or replaced.
- At this point if the control console will still not operate the choke, the problem has
been isolated to either the actuator assembly or the choke valve. Remove the
actuator assembly (see section 3.1.2) and rotate the actuator using the control
console. If the actuator does not rotate, check the routing of hydraulic lines inside
the actuator cover (see drawing 5), repair or replace as needed. If the actuator still
does not rotate, replace the actuator. (see appendix D for manufacturers
instructions)
- If the actuator rotates when the control lever is operated then problem has been
isolated to the choke valve. Remove the bonnet end of the choke using the
procedure beginning with section 5.1.6. Clear debris from the valve or repair the
choke and reassemble.

7.1.2 CHOKE OPENS AND CLOSES TOO SLOWLY

- Check for partial plugging in the hydraulic regulator needle valve and in the
check valves of the quick disconnect hose couplings
- If faster choke response is desired replace the standard 3/16 ID high pressure
hose with ID hose or hard piping. DO NOT EXCEED 1500 psi (10342 kPa)
hydraulic pressure. If the turning fork becomes locked, hydraulic pressure greater
than 1500 psi (10342 kPa) could result in over-torquing and twisting off the end
of the turning fork. This condition would make it impossible to control the
position of the choke discs.

32
7.1.3 CHOKE VALVE LEAKS

- Determine the location of the leak. If the leak is at the bonnet end of the valve,
remove the bonnet and turning fork from the body as described in section 5.1.6 of
this manual. Clean and inspect the sealing surfaces for damage and wear.
Replace the seals as required and reassemble the valve as described in section
5.1.6.
- If the choke valve leaks between the body and outlet spool, remove the super
choke from the manifold and repair the outlet spool end of the valve as described
in section 5.1.4.
- If the inlet or outlet flanges leak, remove the valve and replace the seals as
described in sections 5.1.4 and 5.1.5.

7.1.4 CHOKE DISCS LEAK

There are several conditions that will cause the choke discs to leak. The repair procedure to
stop the discs from leaking is to determine the cause for the leak. Section 5.1.5 describes the
proper disassembly and inspection procedure. Below is a list of conditions to be checked that
will cause the choke discs to leak.

- Dirt, rust or other debris between the discs.
- Worn or cracked discs.
- Damaged or improperly sized o-ring around the back disc.
- Damaged dirty or corroded sealing in surfaces contacting the o-ring around eh
back dis.
- Missing or damaged back disc locking pin.
- Front disc frozen to the turning fork.
- Improper alignment of the front disc on the turning fork. Alignment pin may be
damaged or missing.
- Improper orientation of the indicator head on the turning fork.
- Improper alignment of the actuator shaft on the indicator head.
- Worn or damaged thrust bearing between the bonnet and turning fork.

7.1.5 DIGITAL STROKE / RATE METER

The rate meter contains three modules, which are not field repairable; however, they were
designed for easy field replacement. Before replacing any of the modules, make the
following check: place the selector switch in the test SPM position. If the rate is 128 and
the counter counts, the problem is probably with the wiring or the pump stroke switches. The
rate meter is working properly. If neither the wiring nor the pump switches are bad, replace
the switch module and repeat this test.

If the meter does not indicate in the test position, replace the logic module.




33
A troubleshooting symptom-cure table follows:


PROBLEM / SYMPTOM CURE / REMEDY
Display flashing Low or bad batteries
No display Replace batteries or check connection to
battery pack. If okay, then replace logic
module.
Display on but is not counting or displaying
rate, including the test mode
Replace logic module
Display is on but does not count or indicate
correct rate, but works correctly in test
mode or for only one pump.
Check wiring and pump stroke switches
Only one input (p1 or p2) works, but okay in
test mode
Check wiring and pump stroke switches
Count display does not display all digits Replace logic module
Erratic count and stroke rate display Cable to the pump switches are not properly
shielded or grounded.


7.1.6 PRESSURE GAUGE NOT READING CORRECTLY

The pressure gauges located on the super choke control console will, in almost all cases, be
the gauges which are used to determine drill pipe pressure and casing pressure during
operations involving the use of the SWACO super choke. If these gauges are not working
properly, repairs should be made before operations involving the super choke are undertaken.

- Check that the dampening valve on the gauge is not closed.
- Check the hydraulic hose to the gauge protector for damage or crimping
- If the gauge fails to register correctly at higher pressures, check for air in the
hydraulic lines or improperly charged lines to the gauge protectors. See section
5.1.9 of this manual.
- If the hydraulic lines to the gauge protector are longer than 100 ft. (30 meters)
hard piping or special steel braided hose will be required.

7.1.7 POSITION INDICATOR NOT WORKING

- Check the air supply gauge on air regulator attached to the hydraulic pump for a
positive reading of 3-35 psi (27-241 kPa).
- Check air supply and signal lines for leaks and crimping.
- Make sure the cam is tight on the cam shaft connected to the actuator unit is tight
and straight. The cam should turn a full 180
0
when the choke position is changed
from OPEN to CLOSED or from CLOSED to OPEN.
- Check choke position, 3 psi (21 kPa) applied directly to the gauge should indicate
OPEN of the gauge, and 15 psi (103 kPa) should indicate CLOSED, if the
gauge is in good condition.

34
- If the position gauge does not agree with the calibration band on the choke, see
section 5.1.10 for the correct installation and adjustment.













































35
















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36
8 DRAWINGS AND PARTS LIST














































37











38

DRAWING 1, 2-9/16 SUPER CHOKE ASSY. 96-11-630
ITEM
NO.
QTY. PART
NO.
DESCRIPTION
1 4 13-45-295 WASHER, LOCK IN
2 4 14-04-164 SCREW FERRY -10NC X 3-1/1 IN
3 4 14-08-562 SCREW SOC HD GRD 8 -10NC X 1-3/4 IN
4 4 14-92-031 SCREW DRIVE #4 X 3/16 IN
5 2 39-19-153 GASKET RING API BX153 (NOT SHOWN)
6 1 84-20-200 DECAL SWACO 6 X 2-1/2 IN
7 1 96-11-376 ADAPTER ACTUATOR
8 1 96-11-421 CHOKE ASSY. 10K 2-9/16 IN
9 1 96-11-631 ACTUATOR
10 1 96-50-384 NAMEPLATE
2 96-11-431 FLANGE COMPANION 2-9/16 IN (NOT SHOWN)
































39






40


41
DRAWING 2, 2-9/16 CHOKE VALVE 96-11-421
ITEM
NO.
QTY. PART
NUMBER
DESCRIPTION
1 4 13-05-043 NUT HEX 7/8-9 NC
2 4 13-45-127 WASHER FLAT 7/8 IN
3 12 14-04-163 SCREW FERRY HD -10 NC X 2-1/2 IN
4 16 14-04-183 SCREW FERRY HD 7/8-9 NC X 3 IN
5 2 14-92-031 SCREW DRIVE SS # 4 X 3/16 IN
6 1 14-92-250 SCREW SOC HD 3/8-16 NC X 5/8 IN
7 1 15-73-243 PIN ROLL SS 3/16 DIA X IN
8 2 15-73-273 PIN ROLL SS 3/8 DIA X 1-1/2 IN
10 1 39-66-338 O-RING BUNA-N 90
11 1 39-67-149 O-RING VITON 90
12 1 39-67-151 O-RING VITON 90
13 1 39-67-216 O-RING VITON 90
14 2 39-67-237 O-RING VITON 90
15 1 39-67-342 O-RING VITON 90
16 1 39-67-348 O-RING VITON 90
17 1 39-67-915 O-RING TEFLON
18 2 39-67-916 O-RING BACKUP TEFLON
19 1 58-67-261 PIN DOWWL SS SS DIA X IN
20 1 58-67-430 PLUG CAP 1-5/8 IN
21 1 58-67-436 PLUG CAP 2-9/16 IN
22 1 58-67-521 PROTECTOR 9 IN
23 6 80-87-264 TIE CABLE 8 IN (NOT SHOWN)
24 1 93-60-904 SPRING WAVE
25 1 94-36-145 HANDLE CHOKE MANUAL (NOT SHOWN)
26 3 96-11-111 SLEEVE WEAR 2-9/16
27 1 96-11-214 DISC FRONT
28 1 96-11-215 DISC BACK
29 1 96-11-216 SLEEVE WEAR FLANGE PROTECTOR
30 1 96-11-352 RING PROTECTOR 4 IN
31 1 96-11-354 RING PROTECTOR 5-1/4 IN
32 1 96-11-360 PROTECTOR, BODY OUTLET
33 1 96-11-422 BODY, CHOKE 2-9/16 IN
34 1 96-11-423 SPOOL,OUTLET 2-9/16 IN
35 1 96-11-425 FORK TURNING
36 1 96-11-427 BUSHING SHAFT
37 1 96-11-428 RING THRUST
38 1 96-11-429 BAND CALIBRATION
39 1 96-11-432 INDICATOR HEAD
40 1 96-11-439 BONNET
41 1 96-11-556 COLLAR



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DRAWING 9 PANEL ASSY. SINGLE 96-11-155
ITEM
NO.
QTY. PART NO. DESCRIPTION
1 2 13-05-236 NUT HEX SS 10-32
2 1 13-45-241 WASHER FLAT SS ID X 1 IN OD
3 6 13-45-338 WASHER LOCK IN
4 4 13-45-339 WASHER LOCK 5/16 IN
5 2 13-45-489 WASHER LOCK # 10
6 4 14-06-649 SCREW HEX HD 10-32 NF X IN
7 6 14-07-051 SCREW HEX HD -20 NC X 5/8 IN
8 4 14-07-472 SCREW HEX HD SS 5/16-18 NC X IN
9 1 20-32-544 HOSE ASSY, 10K 3/16 ID X 18 IN
10 2 24-22-244 GAUGE 0-10,000 PSI 0-70 KPA 6 IN
11 REF 34-91-100 HANDLE PUMP
12 4 50-05-096 NIPPLE BRSPUSH LOC ID X NPT
13 1 50-30-196 ELBOW 90D 150 PSI NPT
14 2 50-30-352 ELBOW STR 150 PSI NPT
15 1 50-30-449 ELBOW 90D 3,000 PSI IN
16 2 54-17-526 CONNECOTR FLARED 37D 7/16 NC X NPT
17 4 54-17-567 ELBOW MALE 37D X NPT
18 1 56-03-156 VALVE BALL NPT
19 1 56-03-292 VALVE 4 WAY 3 POS NPT
20 1 56-03-368 VALVE REGULATING FPT
21 1 96-11-052 BRACKET PUMP HANDLE
22 1 96-11-143 GAUGE POSITION INDICATOR IN
23 1 96-11-398 BOX CONTROL PANEL





















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DRAWING 27, METER 2 PUMP W/LIMIT
SWITCH 96-11-626
ITEM
NO.
QTY. PART NO. DESCRIPTION
1 1 60-07-124 BOX CONDUIT EP 3 PRT NPT
2 3 65-60-049 CONNECTOR CABLE NYLON .250-.375 DIA
NPT
3 5 80-62-680 NUT WIRE WING 12-18 AWG
4 2 96-11-049 SWITCH LIMIT ASSY. PUMP STROKE
5 1 96-11-321 METER ASSY, DIGITAL 2 PUMP

























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DRAWING 28, METER 3 PUMP W/LIMIT
SWITCH 96-11-625
ITEM
NO.
QTY. PART NO. DESCRIPTION
1 1 60-07-125 BOX CONDUIT EP 4 PRT NPT
2 4 65-60-049 CONNECTOR CABLE NYLON .250-.375 DIA
NPT
3 6 80-62-680 NUT WIRE WING 12-18 AWG
4 3 96-11-049 SWITCH LIMIT ASSY PUMP STROKE
5 1 96-11-612 METER ASSY DIGITAL 3 PUMP





























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DRAWING 29, METER 2 PUMP W/MAG SWITCH
96-11-641
ITEM
NO.
QTY. PART NO. DESCRIPTION
1 1 60-07-124 BOX CONDUIT EP 3 PRT NPT
2 2 65-60-042 CONNECOTR, CABLE NYLON .187-.250 DIA NPT
3 1 65-60-049 CONNECTOR CABLE NYLON .250-.375 DIA NPT
4 4 80-62-680 NUT WIRE WING 12-18 AWG
5 1 96-11-321 METER ASSY DIGITAL 2 PUMP
6 2 96-11-635 SWITCH ASSY PROXIMITY MAGNETIC





























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DRAWING 30, METER 3 PUMP W/MAG SWITCH
96-11-633
ITEM
NO.
QTY. PART NO. DESCRIPTION
1 1 60-07-125 BOX CONDUIT EP 4 PRT NPT
2 3 65-60-042 CONNECOTR CABLE NYLON .187-.250 DIA
NPT
3 1 65-60-049 CONNECTOR CABLE NYLON .250-.375 DIA
NPT
4 6 80-62-680 NUT WIRE WING 12-18 AWG
5 1 96-11-612 METER ASSY DIGITAL 3 PUMP
6 3 96-11-635 SWITCH ASSY PROXIMITY MAGNETIC
























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9 APPENDIX

9.1 BARKSDALE






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9.2 SC HYDRAULIC







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9.3 PINE PUMP







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9.4 FLO-TORK







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