Wireline Mast Units

Elmar has extensive experience

in the design and manufacture
of Land and Offshore Mast Units
for use in both electric line and
slickline operations. Elmar Masts
are fully certified and can be
equipped with a variety of safety
features including DNV certified Elmar 70ft Wireline Mast is a compact,
Manrider winches. heavy duty unit capable of operating
in wind gusts of up to 60 mph at fully
variable operating heights from 27 feet
(8.23m) to 70 feet (21.3m). The hy-
Manrider Winch draulically operated mast sections are
easily erected by 2 operators in approxi-
mately 20 minutes. The SWL is rated at
20,000lbf column load.

The Elmar 95ft mast truck is designed for wireline

operations on land wells. The mast has DNV approval
Wellhead Pressure
Control Equipment

and is fully certified. The mast column

consists of three lattice work sections
with the top two hydraulically extend-
able to provide an operating height of 95
feet. Two sets of four hydraulic locking
dogs lock the mast in the fully extended
position. Aluminum Mast Section
Transport Frame

The Elmar 80ft lightweight aluminum lattice section mast is

a heliportable mast designed for use on either offshore or
land based wells. The mast column is modular in design
allowing the height of the mast to vary from 25 feet to 80
feet depending on the number of sections installed. This
simplifies the rigup process and
reduces rigup time for two operators to
15 minutes. The column SWL is rated
to 20,000lbs, operable in wind speeds
up to 60 mph.

Hydraulic Power Pack

Westhill Industrial Estate, Westhill, Aberdeen, AB32 6TQ, Scotland, United Kingdom
Telephone: +44 (0)1224 740261/748748 Fax: +44 (0)1224 743138 Sales E-mail: sales@[Link]
Website: [Link]
[Link] Page 1 Tuesday, April 13, 2004 11:03 AM

WELLHEAD PRESSURE
11
CONTROL EQUIPMENT

Wireline Valves .............................................................................. 5

Lubricators ................................................................................... 21
Measuring Line (Slickline) Stuffing Boxes ................................... 28
Grease Injection Control Heads ................................................... 29
Liquid Seal Slickline Control Head ............................................... 42
Large Casing and Openhole/Pack-offs ........................................ 43
Wellhead Adapters ...................................................................... 46
Shooting Nipple ........................................................................... 52
Accessory Equipment .................................................................. 56
Grease & Hydraulic Pressure Supply Systems ........................... 78
Pressure Test Units ..................................................................... 97
Quick Connect Couplings .......................................................... 102
Seals: Elastomers and Thermoplastics ..................................... 106
Maintenance .............................................................................. 138
Certifications & Major Surveys ................................................... 141
Cold Weather Operations Hints ................................................. 148

Copyright© 2004, Varco International

 [Link] Page 2 Tuesday, April 13, 2004 11:03 AM

Wireline pressure control equipment (usually referred to as WHE or well-

head equipment or PCE or pressure control equipment) is used to contain
well fluids while running wireline tools in and out of wells under pressure.
Its main applications are on oil and gas wells and sometimes on geother-
mal wells. Wireline pressure control equipment design has evolved over
the years to minimize well fluid spillage and to improve ease of opera-
tions, safety, and reliability.

Wireline pressure control equipment is manufactured according to API 6A

guidelines, and is normally defined by the following parameters:

• maximum working pressure

• service type
• equipment ID
• wireline type and size (OD)

Wireline pressure control equipment is available in two main configura-

tions:

• Braided/Electric Line
• Slickline

Usual pressure ratings as defined by API 6A are 3,000 - 5,000 - 10,000

and 15,000 psi Working Pressure (WP). Special hostile environment
equipment has working pressure ratings up to 20,000 psi WP.

Temperature rating is usually -20ºF to +250ºF. Special equipment for arc-

tic conditions is rated to -50ºF. High temperature equipment is available
with 350ºF or 500ºF (geothermal) ratings.

Service type is defined as "STD” or “standard” for non-corrosive fluids and

"H2S” or “sour service” for H2S and/or CO2 corrosive fluids.

2
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Pressure Control Equipment Strings

Electric Line / Braided Line PCE String Slickline PCE String

3
 [Link] Page 4 Tuesday, April 13, 2004 11:03 AM

Pressure control equipment ID varies from 2" to 9". For electric line cased
hole applications, 2.5", 3.0" and 4.06" ID are the sizes most frequently
used. Larger sizes with inside diameters from 4.5" up to 9" ID are mainly
used for low-pressure perforating and openhole applications. Slickline
equipment commonly used varies from 2.5" ID to 6-3/8" ID.

The most basic cased hole equipment set is composed of:

• A control head that seals around a moving wireline, containing
the well fluid.
• A lubricator, which is a length of tube that is connected with the
wellbore and contains the wireline tool to be lowered or retrieved
from the well. The control head is positioned above the lubricator.
• A wireline valve which is used to seal-off around a stationary
wireline in the event of operational problems.
• A wellhead adapter which is used to connect the equipment to
the wellbore.

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Wireline Valves
Manually Operated Wireline Valves

WIRELINE VALVES

The wireline valve (often improperly referred to as a BOP or a wireline

BOP) is used to contain well pressure by closing around the wireline
when the lubricator and control head are to be disconnected with wireline
equipment in the well.

The valves use the opposed ram type design that consists of two elas-
tomer-faced metal ram assemblies that are grooved to fit a particular size
of wireline. The opposed rams are closed manually or hydraulically to
compress the ram seals around the outer surface of the wireline. Wireline
valves are only closed on stationary wireline to prevent damage to the
wireline and to the rams.

Wireline valves are closed in order to:

• Retain well pressure to make repairs to the wireline or pressure

equipment above the wireline valve

• To be able to pump liquids into the well to "kill" excessive or unex-

pected well pressure (open or cased hole)

• To aid in an emergency well "shut-in", if the pressure equipment fails

above the wireline valve.

Manually Operated Wireline Valves

These valves are operated by physically turning handles on each end of

the arms, which turn a threaded shaft that closes and opens the ram.
Both sides are turned equally in order to guide the wireline into the ram
seals.

A manual wireline valve can be supplied as a single set or a dual ram set
configuration. Lighter in weight and more economical than a comparable
hydraulic valve, they are usually limited for use with lower well pressures
(5,000 psi and less). They are not recommended for hostile environments
(gas, H2S & C02) because, operating it, the operator will be placed in a
dangerous position close to the wellhead.

5
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Wireline Valves
Hydraulically Operated Wireline Valves

Manual wireline valves are normally equipped with a pressure equalizer

valve assembly, and can have an additional valved port to bleed-off the
lubricator string above a closed ram pair.

Notice that rams should not be opened unless pressure is fully equalized
across the rams.

Hydraulically Operated Wireline Valves

Hydraulic wireline valves are operated by applying hydraulic pressure to a

piston on each end of the rams to either close or open them. A hydraulic
hand pump with a directional valve is utilized to provide the open or close
pressure through a dual "Y" or "bridle" hydraulic hose arrangement to
assure equal closing and opening strokes. Hydraulic pressure can also be
supplied by more modern control panels like the air operated hydraulic
control panel designed by Elmar as part of the complete WHE control
skid.

An additional threaded shaft provides a manual back up and/or locking

closing system. As the shaft is not connected to the piston, it cannot open
the rams manually. Usually an external indicator provides a visual check
of the rams' position.

Hydraulic operating pressure is in the 1,200-3,000 psi range. The hydrau-

lic pressure on the piston has to overcome well pressure before starting to
compress the elastomer seals. The additional hydraulic pressure needed
to energize the seal around the wireline varies from 500 to 1,000 psi

Therefore for large size and higher pressure rating wireline valves it is dif-
ficult to close the rams by hand force alone, and the manual system is
used only to lock the rams in place once hydraulically closed.

Each nominal size of wireline valve has slightly differing requirements in

terms of the hydraulic supply pressure and volumes. The following table
gives significant values for a single pair of rams.

6
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Wireline Valves
Hydraulically Operated Wireline Valves

Wireline Valves Operating Parameters

Valve Maximum Hydraulic Operating Hydraulic Operating Volume Flow Rate
ID Hydraulic Pressure Pressure Pressure Pressure to Close for 30 sec
Operating to close @ 5,000psi to close @ 10,000psi closing
Pressure vs. vs.
5,000psi 10,000psi
(in) (psi) (psi) (psi) (psi) (psi) ([Link]) ([Link]/min)
Conventional Wireline Valves
2.5-3.0 3000 650 1200-1700 1295 1800-2200 35 70
4.0-4.5 3000 600 1200-1700 1200 1800-2200 72 145
5.0-5.5 3000 710 1400-1900 1420 2000-2500 125 250
6.0-6.7 3000 770 1400-2000 1550 2000-2600 205 410
Elmar Light Weight Wireline Valves
3 3000 50-100 2000 50-100 2000 16 32

Hydraulically operated wireline valves can be supplied as a single, dou-

ble, triple or quadruple ram set configuration in all sizes and with working
pressure ratings from 3,000 through 20,000 psi and for any type of well
service conditions.

Typical Single Ram Hydraulic Wireline Valve

All hydraulic wireline valves must be fitted with gas vented hydraulic cylin-
ders. They are recognized by the small hole in the adapter cylinder close
to the wireline valve body. In the event of O-ring failure on the stem of the
hydraulic cylinder the vent hole prevents gas and well fluids from reaching
and contaminating the hydraulic system.

7
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Wireline Valves
Light Weight Wireline Valve

Light Weight Wireline Valve

The lightweight wireline valve (patents pending) developed by Elmar has

an innovative design of the hydraulic cylinders actuating the rams. The
hydraulic pistons are pressure compensated with respect to well pres-
sure, and the full hydraulic pressure is used to energize the elastomeric
seals. This allows a reduction of the piston ratios and their sizes and
thereby lightweight wireline valves have smaller cylinders and require
less hydraulic volume and are quicker to close for the same hydraulic oil
flow rate.

Lightweight wireline valves are available in 3" and 4.06" ID, 10,000 psi
WP rating, for H2S Service.

The overall weight is less than 50% of the weight of a conventional wire-
line valve with similar ratings.

Wireline Valve Rams

In the wireline valve, two opposite rams shut-off the wellbore and seal
around the wireline.

Wireline rams are composed of four essential parts:

• The ram body

• The wireline guide(s)

• The inner seal

• The outer seal

8
[Link] Page 9 Tuesday, April 13, 2004 11:03 AM

Wireline Valves
Wireline Guides

Exploded View: Heavy Duty Ram

Wireline Guides

Ram bodies must have a fixed position with respect to the wireline, and
are prevented from turning using a key or a guide rod that maintains them
in a predetermined orientation.

The rams guide the wireline to the centre of the bore with V-shaped guide
profiles.

There have been two common designs:

Rams with Standard Guide Plates

9
 [Link] Page 10 Tuesday, April 13, 2004 11:03 AM

Wireline Valves
Inner Seals and Outer Seals

Rams with Integral Guides

In either design, the guides are only on one side of each ram body and do
not force the wireline to be parallel to the BOP bore axis before the inner
seals are engaged.

Elmar has developed the Q-GUIDE™ ram, a new proprietary design (pat-
ents pending) that provides a positive alignment for the wireline. V-
shaped flat guides on either side of the inner seal restrict the wireline so
that the section of line contacting the inner seal is always centered and
parallel to the wireline valve bore axis.

Q-Guide™ Ram Body

Inner Seals and Outer Seals

The sealing surface of the wireline valve ram is composed of an elas-

tomer strip,

10
[Link] Page 11 Tuesday, April 13, 2004 11:03 AM

Wireline Valves
Inner Seals and Outer Seals

or inner seal, which is inserted in the face of the ram body. Around the
upper part of the ram body is an outer seal in the shape of a horseshoe.
The two sealing elements join together on the side of the ram body. The
inner seal provides a seal around the wireline while the outer seal pre-
vents well fluids from by-passing the closed rams inside the main wireline
valve body

Because of the shape of the outer seal, the rams are directional and seal
only in one direction (pressure on the opposite side from the outer seal,
normally from below i.e. wellbore side). Rams must be inverted to seal
with pressure from above.

Inner Seals
Electric Line Inner Seal Slickline Inner Seal

The inner sealing elements are made up of a rubber element sandwiched

between two steel plates. Electric/braided line seals have a groove
through the ram body and the inner seal sized close to the line OD. A dif-
ferent ram body and inner seal is required for each line size.

Slickline rams have a rectangular slot in the inner seal steel plates, and
no groove in the rubber element.

Elmar has developed a new, universal, "multiline inner seal" where the
line groove in the ram body and the steel plates is sized for 5/16" line and
the rubber seal is able to expand and seal around any line from 0.092"
OD to 0.312" OD. The multiline inner seal allows switching between slick-
line, electric line and fishing operations without changing rams.

11
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Wireline Valves
Shear and Seal Rams

Shear and Seal Rams

Wireline shear and seal rams are used to cut the wireline running through
the wireline valve and seal off the through bore on completion of ram clo-
sure. They are interchangeable with normal wireline rams and are used
either to avoid damage to the well valves or when the option of cutting is
not provided by the well valves.

There are two common types of shear and seal rams; separate function
and combined function.

Separate Function

The separate function type has two main flaws; a standard inner seal is
used leaving the diameter available to house the cutting blade reduced to
such a point that the tips of the blade cannot cover the full bore of the
wireline valve. This makes it impossible to guarantee that the wire will
even be collected by the cutting blade. Secondly, under certain wire con-
ditions the face of the inner seal can trap the cut Wireline leading to a seal
failure.

Shear & Seal Rams - Separate Cutting & Sealing Functions

Combined Function

Elmar have developed a blade with combined cutting and sealing function
that overcomes these problems. The blades are housed in the middle of
the ram body, allowing maximum width for wire collection. This allows
this blade system to cut multiple strands and cope with 'bird nests'. The

12
[Link] Page 13 Tuesday, April 13, 2004 11:03 AM

Wireline Valves
Multiple Ram Wireline Valves

blade seals are housed on the blade in the same plane as the cut end of
the Wireline allowing the blades to seal off the well no matter what the
wireline conditions.

Shear & Seal Rams - Combined Cutting & Sealing Functions

Multiple Ram Wireline Valves

Multiple ram wireline valves can be supplied as a set of single ram valves
that are mounted one on top of the other or as multiple sets of rams
mounted in a single block body. The main usages for dual ram wireline
valves are:

• To provide a secondary or back-up set of ram seals in the event that

the primary set does not contain the well pressure adequately.

• To allow grease injection between two sets of closed rams. When a

single ram set is closed on braided cable, the well fluid will migrate in
the voids between the inner and outer amour of the cable and leak. To
contain pressure, the top ram set is closed. Then the lower ram set,
which is inverted, is closed and grease is injected at a pressure up to
20% over the well pressure between the two closed ram sets. The
high-pressure grease provides a seal between the inner and outer
armor and a dynamic pressure barrier that holds the well pressure
below the closed rams. Seasoned or sealed cables have the voids
pre-packed with grease or special sealing materials, making it easier
to obtain a perfect seal.

13
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Wireline Valves
Triple Ram Wireline Valves

Typical Twin Ram Hydraulic Wireline Valve

Elmar Light Weight Dual Hydraulic Wireline Valve

Triple Ram Wireline Valves

Triple wireline valves are generally used on wells with high wellhead pres-
sure (10,000 psi and greater) and higher content of H2S and/or C02. The
lower ram set is normally inverted while the top two are in the standard
position. This provides a backup set of rams and when all three sets are
closed, dual areas for high pressure grease injection between the ram
sets.

14
[Link] Page 15 Tuesday, April 13, 2004 11:03 AM

Wireline Valves
Rams orientation

Typical Triple Ram Hydraulic Wireline Valve

Rams orientation

Since the rams are directional, it is important to check that the wireline
valve is mounted properly. Some wireline valves have an arrow marked
on the outside of the body which points downwards towards the well, i.e.
towards the high pressure side. The surest check is to remove the ram
assembly from the wireline valve and verify the position of the alignment
key. It should be located on the lower side of the wireline valve body for a
ram sealing against well pressure, and on the upper side of the body for
sealing against grease pressure. The bleed off port should be above the
rams when the wireline valve is correctly mounted. The position is similar
for rams having a guide rod. Normally sealing rams have the rod and the
guide hole on the lower part of the body; inverted rams have the guide
hole and the rod on the upper part of the body. Notice that it is easy to
"invert" a normal ram by moving the position of the guide rod and turning
the ram body upside-down. For this purpose there are two threaded holes
180° apart in the hydraulic cylinder face in the Elmar compact wireline
valve.

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Wireline Valves
Equalizer Manifold

Equalizer Manifold

Hydraulic wireline valves are equipped with a valve assembly, which

allows equalization of pressure above and below a closed ram. This can
be a simple flush-mounted pressure equalizer assembly, or a more com-
plex one allowing to connect a pressure gauge, a bleed-off line, and pro-
vides grease injection and glycol injection ports. Modern design wireline
valves are supplied with a block type equalizer bleed off manifold valve
system.

Flush Type Equalizing Manifold

Hose Type Manifold

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Wireline Valves
Grease Pack* Hydraulic Wireline Valve

Block Type Manifold

The block-type manifold is more rugged and safer as it has no protruding

valves or hoses that can be damaged during rig-up. It includes built-in
check-valves for the grease and glycol injection ports. Elmar modern
manifolds have recessed needle valves with replaceable cartridge-type
seats, and soft seat check valves that can be easily replaced as a single
sub-assembly.

Grease Pack* Hydraulic Wireline Valve

The grease pack hydraulic wireline valve has a unique feature in that
each ram element has a double sealing surface that permits grease to be
injected between the closed ram seals into and around a cable via dual
channels within the wireline valve body.

Grease Pack Ram Assembly & Ram Cross-Section

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Wireline Valves
Grease Pack* Hydraulic Wireline Valve

With this system, and for pressures up to 5K psi, one set of rams, with
injected grease, will seal better than a single conventional set of rams.
Sealing efficiency will also be a function of the condition of the braided
cable being used.

Some versions exist where the rams have a fully circular outer seal and
are therefore "bi-directional", holding pressure from above and below.

Additionally, the wireline valve includes a special "ram lock" feature

whereby the high pressure grease that is injected, assists the hydraulic
pistons in holding the rams closed.

Grease pack wireline valves can be supplied as a single ram set or a dual
ram set. A dual ram set also provides grease injection between both sets
of rams. Injection between the rams is often needed for a complete seal in
gas above 5K psi.

An external manifold block system for pressure bleed-off, pressure equal-

ization and high-pressure grease injection, is standard.

Because the grease injection chamber created in the rams is longer for
large size wireline valves, the sealing efficiency tends to be better for 4"
and larger sizes.

Unique Grease Pack Hydraulic Wireline Valve

*US Patent #4,938.290 / European Patent #89.309600.9 / Canadian Patent

#2.00562.0

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Wireline Valves
Wireline Valve Pre-Departure Operational Checks and Operational Hints

Wireline Valve Pre-Departure Operational Checks and

Operational Hints

• Be sure the ram bodies and ram elements (inner seals) are properly
sized for the OD of the wireline that is used.

• Visually check the wireline valve by closing and opening the rams.

• Check to be sure that the pressure equalization system is working.

• Perform a pressure test to the maximum expected operating pres-

sure, first on an open valve, with both ends blanked-off, second with
the rams closed around a test rod.

• It is advisable to close the rams on a solid test rod of the correct size
rather than use a braided line. When closing on a braided line the
seal rubber extrudes into the voids between armor wires. Not all the
deformation is reversible and the rams will loose the ability to seal on
a different section of the line.

• During field operations, wireline valve rams are closed only when the
wireline is stationary

• Open the wireline valve only after the well pressure has been equal-
ized across the rams.

Note: After any pressure operation when a wireline

valve has been closed on a wireline, it should be disas-
sembled, cleaned, the ram elements carefully checked
for any damage and all O-ring seals checked and
replaced, if damaged.

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Wireline Valves
Transportation

Wireline Valve Test Rods

Special care should be taken in the design and operation of a test rod.
5,000 psi pressure test on a wireline valve fitted with rams for a 15/32''
cable would exert a force of over 800 lbs on the test rod.

• The rod has a handle to lift in and out of the wireline valve. A cross
piece is attached to prevent the rod from being dropped through the
wireline valve during a rig pressure test.
Wireline Valve Test Rod
• End plates are fitted at both ends.

• Sealing surface is smooth and machined to

match the diameter of the wireline.

• The end plate should be located just under the

rams during a pressure test to prevent the rod
being blown out.

Transportation

The wireline valves should

always be transported, rigged
up and rigged down, with the
ram stems screwed into the
body and handles removed.
This will prevent the stems
from being bent due to mis-
handling of the wireline valve.
Elmar Protective Cage

Protective cages are avail-

able to protect the wireline
valve during use and trans-
portation. Some frames are
also used for lifting the valve, and provide a work platform.

20
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Lubricators
Lubricators

LUBRICATORS

Lubricators (sometimes called risers) are a series of tubular sections with

connectors. They are used to contain the entire wireline downhole tool
equipment string above the wireline valve and the wellhead to allow
entering and exiting a well under pressure. As a part of the pressure con-
trol system, lubricators are subjected to full well pressure when the sys-
tem is in communication with the wellbore.

Lubricators can be supplied for maximum working pressures ranging from

3,000 psi to 20,000 psi, any type of well service condition and most inside
diameter sizes. Standard lengths of 4', 5', 6', 8', 10' and 12' provide the
means to custom select the correct amount of lubricator needed. The
length of the lubricator is calculated to be as long as the tools string plus
any additional weights, centralizers, etc., necessary for the job. The ID of
the lubricator should be 0.25" to 0.50" larger than the OD of the largest
tool being run. The length of the lubricator string should be a minimum of
2' longer than the longest tool string, cablehead included.

Electric line lubricator strings are normally of one single ID. Slickline lubri-
cator strings are often "tapered" with for instance the lowermost two joints
4-1/16" ID (above a 4-1/16" ID wireline valve) a crossover joint and two 2-
1/2" ID joints below the slickline stuffing box.

Lubricator construction generally determines its usage. The main types

are:
• Tubing Lubricator
• Welded Lubricator
• Threaded Union Dual Seal Lubricator
• Integral Union (one piece) Lubricator
• Casing (Slimline) Lubricator

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Lubricators
Tubing Lubricator

Tubing Lubricator

The tubing lubricator is usually made from a tubing PUP

joint with union connections torqued on each end. The
tubing joint threads are API pipe threads which are rated
for a maximum working pressure of 5,000 psi (refer to
API specifications 6A) available in 2", 2-½", or 3" ID. The
API threads must be torqued to a recommended value to
maintain their sealing ability. The threads carry the sepa-
ration force; any bending moments transmitted through
the string, and also maintain the pressure integrity.
Because of these multiple functions the combined
stresses are difficult to quantify and tubing lubricators
should be used for light duty, standard service only, and
are banned by most of the major service companies.

Welded Lubricator

This type has quick union connections that are first attached on each end
with threads and then it is butt-welded. With time due to corrosion and
overstressing, it is possible for small cracks to form at the welds present-
ing a possible safety hazard. For safety reasons, welded lubricators are
no longer recommended.

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Lubricators
Threaded Union Lubricators

Threaded Union Lubricators

Quick union connections are attached on each end of

an alloy steel tube using ACME threads.

The ACME thread is inherently stronger than the API

thread. An O-ring seal under the connection isolates
the thread from exposure to well fluids. This type of
lubricator can be rated for maximum working pressures
up to and including 10,000 psi and for any type of well
service and is available in most ID sizes ranging from 2-
3/8 through 7-5/8".

Integral Union (One Piece) Lubricators

The integral lubricator is manufactured from a single

piece of seamless alloy steel tube. The quick union con-
nections are integral machined onto the lubricator elimi-
nating the need for threaded connection joints with O-
ring seals. This premium type lubricator can be rated for
maximum working pressures up to and including 20,000
psi and any type of service. They are available in most
ID sizes ranging from 2.5" through 6.38".

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 [Link] Page 24 Tuesday, April 13, 2004 11:03 AM

Lubricators
Premium Threaded Union Dual Seal Lubricator

Premium Threaded Union Dual Seal Lubricator

The quick union connections are attached to the lubricator tube using a
"premium" thread that provides a metal-to metal seal. Controlled torque is
normally required to energize the metal-to-metal seal. This seal is
backed-up by an O-ring seal creating a double barrier. This type of lubri-
cator is available for working pressures up to 15,000 psi, for any service
conditions in ID sizes from 2-3/8" through 5.5"

Lightweight Dual Seal Lubricator

Lightweight lubricators available

from Elmar use high-yield
strength CRA tubes, and opti-
mized unions, achieving weight
savings up to 55% for compara-
ble pressure ratings.

The quick union adapters are

connected to the lubricator tube
by a premium-threaded connec-
tion with metal-to-metal seal,
backed up by an O-ring seal.

With this configuration the pri-

mary seal is the metal-to-metal
one, and the O-ring never sees
well fluid if the metal-to-metal seal remains active. The end adapters are
torqued-up with special tools and locked by a grub screw.

The optimized lightweight unions have the basic Bowen profile, but have
double-start threads to avoid inadvertent connection to other unions with
similar dimensions and lower ratings.

Lightweight lubricators are available with 10,000 psi WP rating, hostile

environment service (H2S and/or CO2). Lightweight lubricators are avail-
able in 3", 4-1/16" and 5-1/8” ID size.

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Lubricators
Casing (Slimline) Lubricators

Casing (Slimline) Lubricators

Made from sections of

large diameter high
grade API casing, this
provides larger diame-
ter lubricators for
openhole logging or
running casing guns,
wireline bridge plugs,
or packers in low pres-
sure wells. These
lubricators are avail-
able with specially
designed lightweight
union connections,
screwed onto the
tubes. This type of
lubricator can be rated
for maximum working pressures to 5,000 psi and either standard or H2S
well condition service. They are available in any length and in sizes rang-
ing from 5.5" OD to 9.625" OD.

As this lubricator uses standard API casing, its test pressure rating is
7,500 psi for a working pressure of 5,000 psi.

Slimlite Lubricators

By using high yield strength CRA alloy tubes, the slimlite lubricators avail-
able from Elmar achieve a full API 6A rating (5,000 psi working pressure,
10,000 psi test pressure) with very little weight increase with respect to
Slimline. Slimlite lubricators are available in 5.5" and 7-5/8" OD sizes.

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Lubricators
Lower Lubricators

Lower Lubricators

A lower lubricator section can be manufactured in most

types and sizes, except the slimline type. They are
made with small diameter outlet ports. A needle valve is
installed in the outlet along with a companion hose. This
provides a means for "bleeding-off" the lubricator system
pressure before disconnecting.

Lower lubricators are mostly used for slickline rig-ups.

They can be supplied for most working pressure ratings
and well condition services.

Note: For personnel safety, using this method to "bleed-

off" the pressure system when the wellhead pressure
exceeds 5,000 psi should be avoided. Care should be
taken to avoid knocking-off the protruding needle valve
when rigging up.

Bleed-Off Sub

An alternative to lower lubricators is provided by

short bleed-off Subs with quick unions top and
bottom. This allows all lubricators in the string to
be identical and to position the bleed-off point
where it is most convenient.

Most common configuration is with a ½" NPT

bleed-off port into which a suitable needle valve
can be connected. Bleed off subs are available in
all ID sizes, for pressure up to 10,000 psi WP, for
STD and H2S service.

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Lubricators
Lubricator Operation and Maintenance Notes

Lubricator Operation and Maintenance Notes

Lubricators should have a rated working pressure equal to or greater than

the working pressure of the other pressure control equipment used on an
operation.

• The ID of the lubricators should be a minimum of 0.25" to 0.50" larger

than the largest diameter of the wireline downhole equipment being
used.

• Always use thread protectors when storing or transporting lubricators.

Never climb on a lubricator string that contains pressure.

• O-ring grooves, sealing elements, and sealing surfaces should be

cleaned and lightly greased before the union connections are "made-
up".

• Sealing surfaces and seal grooves should be inspected regularly to

check for corrosion. Replace O-rings often and always after an opera-
tion on a gas well.

• The quick union connections on a tubing lubricator, a dual seal lubri-

cator or a casing lubricator must be removed periodically in order to
check the condition of the threads, metal-to-metal seals, and O-ring
seals. After cleaning and re-lubricating, the correct amount of torque
specified by the manufacturer must be applied when reassembling.

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Measuring Line (Slickline) Stuffing Boxes

Measuring Line (Slickline) Stuffing Boxes

MEASURING LINE (SLICKLINE) STUFFING

BOXES

Installed on top of the lubri-

cator string, the measuring
line stuffing boxes are used
for slickline operations to
prevent the loss of well liq-
uids and gas into the atmo-
sphere, by sealing around
the slickline moving in and
out of the well. Many slick-
line service units do not
employ a crane (hoist) unit;
therefore the top sheave
Hydraulically & Manually Operated
wheel is made integral with
Measuring Line Stuffing Boxes the top stuffing box.

Hydraulically and manually operated measuring line stuffing boxes con-

sist of a housing (body), and upper and lower packing gland, a series of
packing elements and a device for compressing the elements. Connected
to the body by means of two roller bearings is the sheave staff on which
the sheave wheel is mounted. A lower quick union connects the stuffing
box to the top of the lubricator string.

The measuring line stuffing box is available for most sizes of slickline with
the sheave wheel diameters sizes ranging from 7" to 18" and working
pressures of up to 20,000 psi. They are rated for standard service as well
as H2S well conditions. Hydraulic pressure is normally provided by a hand
pump through a reinforced hydraulic hose. Hydraulic operating pressure
varies from 3,000 to 6,500 psi. Hydraulic pressure can also be supplied
by more modern control panels like the air operated hydraulic and grease
control panel designed by Elmar as part of the complete WHE control
skid.

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Grease Injection Control Heads

Grease Injection Control Heads

GREASE INJECTION CONTROL HEADS

Packing elements alone cannot seal

around a moving braided line or
electric line under moderate to high
pressure. For this purpose a grease
injection control head (GIH or GICH)
is needed.

The grease injection control head

provides a pressure seal around
stationary or moving wireline that is
run into or out of high-pressure
wells to prevent the loss of well liq-
uids and gas to the environment
and the potential exposure of per-
sonnel to hazardous conditions.

Grease injection control heads

include a hydraulic pack-off assem-
bly and a multiple flotube assembly.

The flotube assembly consists of a

number of close fitting steel tubes
("flotubes") through which the wire-
line passes. Single flotubes are
assembled in a string by means of
threaded couplings, or collars.
Highly viscous grease is injected in
the annular space between the flo-
tubes and the wireline through an
injection port in the collar located
immediately above the lowermost
flotube. The grease, injected at a
pressure 20-25% higher than the
well pressure, creates a soft seal
through which the wireline can move but the well fluids remain contained.

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Grease Injection Control Heads

Grease Injection Control Heads

The inside diameter clearance of the flotubes to the outside diameter of

the wireline is critical for the grease control head to be effective. The aver-
age clearance should be between 0.003" and 0.008".

The injected grease will seal over irregular forms such as braided cable
and the lubrication that it provides, reduces friction and wear on the wire-
line and seals. The seal is a dynamic seal, and the grease flows into the
well and towards the top of the grease head. When the wireline is moving,
grease is also removed from the tubes by the moving wireline. The
grease injection pump must supply a flow rate to continuously replace the
grease exiting the flotubes’ stack. A second grease injection port should
be used on higher-pressure wells to maintain the volume of grease
required for an effective pressure seal.

In operations, the grease control head is installed on the top of the lubri-
cator stack using a quick union sub with the top threaded to fit the lower
flotube housing. An alternate method is to connect it to the top of a head
catcher and/or a velocity check valve, which in turn are installed on top of
the lubricators. Grease under pressure is provided by a dedicated grease
pump, through a suitable length of high-pressure hose. Most common
grease pumps are air-operated. Hydraulically operated intensifier pumps
are used for 15,000 - 20,000 psi applications. Grease pressure can also
be supplied by more modern control panels like the air operated grease
and hydraulic control panel designed by Elmar as part of a complete WHE
control skid.

Grease control heads can be supplied for maximum working pressure rat-
ings ranging from 5,000 psi to 15,000 psi (20,000 psi on special order)
and for any type of well service conditions.

In case of loss of grease seal, the well fluid could invade the flotubes and,
through the grease injection line, reach the grease pump. This is a poten-
tially catastrophic situation. To avoid it, a check valve must be installed at
the end of the grease hose.

The operational efficiency of the grease control head will depend on sev-
eral factors, the most important being the pulling-out speed of the wire-
line, and the correct match of flotubes ID to wireline actual OD.

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Grease Injection Control Heads

Grease Injection Control Heads

Other factors include wear on flotubes, type of grease used (viscosity at

the operating temperature), actual volume delivered by the grease pump
through the connecting hose and the number (length) of flotubes used.

Pressure gradient in a flotube system

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Grease Injection Control Heads

Grease Injection Control Heads

Couette’s Flow Equation

6 Lµ Q
P 2 − P1 =
Rc h3
where
P2 = Grease injection pressure at flotube (psi)
P1 = Grease outlet pressure at flotube (psi)
L = Length of flotube (in)
µ = Grease viscosity (lb / sec / in2)
h = Flotube ID minus wireline OD (in)
Rc = Wireline radius (in)
Q = Grease flow rate (in3/sec)

The pressure gradient that maintains a seal can be expressed mathemat-

ically by Couette's flow equation.

This equation indicates that the smaller the clearance between the cable
and the flotube (h), the greater the pressure drop. It also shows that the
pressure gradient is proportional to the length of the flotubes, grease vis-
cosity and injection rate.

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Grease Injection Control Heads

Grease Injection Control Heads

Schematic of a Typical Grease Control Head System

Two types of flotubes are commonly used: solid or concentric. Both types
do the same job and work in the same way but are of a different construc-
tion. The solid type flotubes are longer (24") than the concentric ones and
come in one piece with two small tungsten carbide inserts at either end.
Both pin ends are threaded with 2" -6-60° ACME threads for making -up

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Grease Injection Control Heads

Grease Injection Control Heads

to other flotubes through box-box coupling collars. The concentric type

has an outer flotube sleeve and an inner tube known as the flotube that is
14" long and snaps into the GIH couplings with O-ring seals. The flotube
sleeve has 2" 10-TPI threaded pins both ends (notice this thread is differ-
ent from the one normally used on the solid flotubes) and ensures the
mechanical strength of the assembly, while the flotube contains the
grease around the wireline. This design is easier to manufacture and less
expensive to maintain than the solid one.

Recommended Flotube Selection chart

#* of Concentric #* of Solid # of Injection
Well Pressure Fluid
Flotubes Flotubes Points
0-5000 psi Liquid 4 3 1
0-5000 psi Gas 5 4 1
5-10000 psi Liquid 6 5 1
5-10000 psi Gas 7-8 6 1
10-15000 psi Liquid 10 7 2
10-15000 psi Gas 11-12 9-10 2
15-20000 psi Liquid 12 10 2
15-20000 psi Gas 13-15 11-12 2
*including the one(s) below the grease injection port(s)

The tubes must be matched to the size of the wireline in use, taking into
account any wear on the wireline. Thus for each nominal wireline size
there is a choice of tubes. The supervisor must decide what size tubes
are most appropriate for the cable based on actual cable OD measure-
ments. The flotube ID should be selected to have 0.003" to 0.008" clear-
ance to wireline OD. It is good practice to run the whole length of a new
line through the smaller flotube that is planned to be used, before its first
wellsite operation.

Flotubes must be checked quarterly for internal wear. This is difficult to

accomplish as flotubes wear more towards their center, and can be
attempted with calibrated short cylindrical gauges at the end of a 25" rod.
As a narrow gap between the flotube ID and the wireline OD is essential
for proper operations, the flotube must be replaced if internal wear is
detected.

Wireline OD will change during its operating life. Remember to measure

your wireline with a micrometer at the cablehead end, half way in the hole
and at TD. Record these measurements in the cable record book. This
will greatly help in the correct selection of flotubes. The wireline OD

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Grease Injection Control Heads

Grease Injection Control Heads

should be measured from two directions in case it is oval. Notice that

wireline run in mud, and not properly conditioned beforehand, can swell
instead of wearing out, because of rust and mud solids build-up between
the armor layers. If a cable has been run in mud without grease injection,
it is important to check the OD over the whole length exposed to mud. If
the wireline is not cut regularly from the downhole end, the cable
becomes tapered with the outer armor strands flattened - this requires
smaller ID flotubes. However, if a slightly deeper well than normal is being
logged, new cable will be fed off the drum into the hole as the tool nears
the bottom of the well, the cable will not pass through the flotubes and the
job cannot proceed.

Concentric Flotube Selection & Wear Data

Maximum Tube ID
Range of Actual Including Wear
Nominal Line Actual Tube
(Avg) Line Size Do Not Use When
Size (in) Bore (in)
(in) Greater
(in)
1/8 .124 - .125 .128 .134
.127 - .129 .131 .137
3/16 .174 - .176 .178 .184
.177 - .180 .183 .184
.181 - .183 .186 .191
.184 - .186 .189 .194
.188 - .190 .193 .198
7/32 .192 - .193 .196 .202
.194 - .196 .199 .204
.195 - .198 .201 .205
.199 - .201 .204 .209
.201 - .205 .208 .211
.206 - .208 .211 .216
.211 - .213 .216 .221
.214 - .216 .219 .224
.216 - .219 .222 .226
.219 - .221 .224 .229
.221 - .223 .226 .231
.222 - .225 .228 .232
.224 - .228 .231 .234
1/4 .227 - .229 .232 .237
.231 - .233 .236 .241
.234 - .236 .239 .244
.235 - .237 .240 .245
.237 - .240 .243 .247
.242 - .245 .248 .252
.249 - .251 .254 .259
.251 - .253 .256 .261

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Grease Injection Control Heads

Grease Injection Control Heads

Maximum Tube ID
Range of Actual Including Wear
Nominal Line Actual Tube
(Avg) Line Size Do Not Use When
Size (in) Bore (in)
(in) Greater
(in)
9/32 .253 - .255 .258 .263
.255 - .257 .260 .265
.256 - .258 .261 .266
.257 - .259 .262 .267
.259 - .261 .264 .269
.262 - .264 .267 .272
.282 - .284 .287 .292
.290 - .292 .295 .300
.293 - .295 .298 .302
.300 - .303 .306 .310
5/16 .307 - .309 .312 .317
.310 - .312 .315 .320
.311 - .313 .316 .321
.315 - .318 .321 .326
.321 - .323 .326 .331
.327 - .329 .329 .337
.330 - .332 .335 .340
.332 - .334 .337 .342
.336 - .338 .341 .346
3/8 .360 - .363 .366 .371
.368 - .370 .373 .378
.371 - .373 .376 .382
.379 - .381 .384 .390
7/16 .394 - .396 .399 .404
.398 - .401 .404 .410
.406 - .408 .411 .417
.410 - .413 .416 .422
.417 - .420 .423 .429
.419 - .422 .425 .431
.421 - .424 .427 .433
.425 - .430 .433 .439
.430 - .433 .436 .442
15/32 .462 - .464 .467 .475
.467 - .469 .472 .480
.472 - .474 .477 .485
17/32 .524 - .526 .529 .540

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Grease Injection Control Heads

Hydraulic Pack-Offs/Stuffing Boxes

Hydraulic Pack-Offs/Stuffing Boxes

The pack-off (also called "stuffing box") is normally incorporated as an

integral part of the grease injection control head. It provides a seal around
a wireline cable or a slickline to prevent liquids and/or gas from escaping
into the atmosphere should the grease control head fail. It is very similar
in design to a line wiper, but has a very different function.

During normal operations, the pack-off packing element (line rubber) is

not compressed around the wireline. Only when the grease seal has been
lost and the wireline is stopped is the line rubber compressed around the
wireline to hold the well pressure.

Typical Hydraulic Line Wiper/Stuffing Box Combination

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Grease Injection Control Heads

Hydraulic Pack-Offs/Stuffing Boxes

A pack-off should not be used as a line wiper. This will wear the packing
element (line rubber) thus reducing its capability to close on a wireline
completely and "hold" the well pressure.

The pack-off consists of a housing (body), a packing element (line rubber)

that seals around the wireline, an upper bushing (brass line guide) and a
hydraulic pressure device for compressing the packing element.

The packing element (line rubber) is either slit down one side or cut into
halves length wise to allow it to be replaced quickly. The packing element
is housed inside the pack-off body in such a way that expansion or elon-
gation of the element is very limited. To compress the element, directional
force is applied to it by a hydraulically operated piston.

For operations with wellhead pressures up to 10,000 psi, a single packing

element type pack-off is used. The hydraulic pressure required to close
the packing element around the wireline is 5,000 to 6,500 psi.

When wellhead pressures exceed 10,000 psi and a high amount of H2S is
present, a tandem or dual packing element pack-off should be used.

The tandem pack-off is an assembly with two separate operating packing

elements that are one above the other in the same housing (body). Due to
the high pressure that the packing elements are required to hold, in some
models, hydraulic pressure required to close each packing element
around the wireline is up to 10,000 psi. A high-pressure (10,000 psi)
pump is used for this purpose along with companion high-pressure
hydraulic hoses. Elmar's dual pack-offs for 15,000 and 20,000 psi WP
string require 2,000 to 3,000 psi.

Hydraulic pressure is provided by a hand pump and a suitable length of

hose. Hydraulic pressure can also be supplied by more modern control
panels like the air operated hydraulic and grease control panel designed
by Elmar as part of the complete WHE control skid.

In order to test the hydraulic packoff, a test rod of appropriate size should
be inserted into the packing area of the assembly. It is important that the
test rod used has a larger diameter at one end and that this end fits below
the stuffing box bushing, in order that the test rod cannot be forced

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Grease Injection Control Heads

Line Wipers

through the stuffing box packing. With hydraulic pressure applied to the
stuffing box connection, apply WP Pressure to the assembly for 5 minutes.
Bleed to zero. No leakage acceptable.

Line Wipers

A line wiper provides a means to remove excessive liquids and/or grease

from the wireline when it is pulled out of the well in order to prevent it from
dispersing into the environment. Used to seal around stationary or moving
wireline cable and slickline, it is usually installed above the grease control
head assembly or the lubricator string. There are many different designs
and types of line wipers (sometimes referred to as "oil savers") but their
use and operating characteristics are similar.

Line wipers consist of a housing (body), a packing element (line rubber),

and a device for compressing the packing element. Some models employ
a top protector funnel that helps prevent damage to the wireline when
raising or lowering the pressure control string. The lower connection is
equipped with a quick union or it can be a threaded connection compati-
ble with most grease control head top connections. The packing element
(line rubber) is either slit down one side or cut into halves length-wise for
quick and easy replacement. It is shaped in such a way to allow move-
ment of the wireline even when compressed. It wears quite fast and must
be replaced often. On some operations, it may be necessary to replace it
after each run in the well. Upper and lower bushings (brass) guide the
wireline through the packing element and are supplied in halves for easy
replacement.

Available for most sizes of wireline, the packing element (line rubber) and
upper and lower bushings (brass) are line size dependent. Some models
are rated for a maximum working pressure of up to 5,000 psi and for stan-
dard service or H2S well conditions. Others, used exclusively as a line
wiper above a pack-off are rated 3,000 psi WP standard service.

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Grease Injection Control Heads

Line Wipers

Manual Line Wiper

This type is now obsolete, although is still used for slickline low-pressure
service (less than 5,000 psi) in liquids and with no H2S and where the
"packing nut" is easily accessible, from the rig floor. The manually oper-
ated line wiper is equipped with a threaded device, which is used to com-
press the packing element. This threaded device is commonly known as
the "packing nut" or "packing cap", and a seal around the wireline is
achieved by turning the nut in a clockwise direction thus squeezing the
packing element around the wireline.

Hydraulic Line Wiper

With this type, the packing element (line rubber) is compressed to the
desired tightness, by means of a hydraulic pump. This allows the operator
to control the line wiper from a distance; which is important where high
pressure and toxic gases are present. Depending upon the model,
hydraulic operating pressure varies from 200 to 3,000 psi. Hydraulic pres-
sure is provided by a hand pump and a suitable length of hose. Hydraulic
pressure can also be supplied by more modern control panels like the air
operated hydraulic and grease control panel designed by Elmar as part of
the complete WHE control skid.

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Grease Injection Control Heads

ENVIRO™ Grease Injection Head

ENVIRO™ Grease Injection Head

The Elmar Enviro™ grease injection

control head is an evolution of the con-
ventional control head. It is designed to
serve the same functions, with a much
improved grease containing action.

In the conventional design the line

wiper and the pack-off (stuffing box) are
in separate bodies, and separate return
hoses are needed to drain the excess
grease and/or well fluids.

In the Enviro™ combination stuffing box

and line wiper both the pack-off and the
line wiper functions are contained in
one single high-pressure body (rated
10,000 psi WP; H2S Service), con-
nected on top of the grease injection
head flotubes. The line wiper is posi-
tioned below the stuffing box, immedi-
ately on top of the flotubes. This new
design improves the wiping action as
the wiped-off grease has sufficient
residual pressure to flow easily through
the grease return hose. There is no
need to have separate return hoses for
the line wiper and the flotubes. Grease
spillage is also reduced significantly, as
there is no bleed hole or pop-off valve,
as in the conventional design. The
combination is rated the full 10,000 psi WP, H2S service. It has only one
high pressure grease return hose.

The Enviro™ stuffing box and line wiper can be dressed for use with
braided wire from 0.188" to 0.520" diameter and can be supplied for use
with concentric or solid type flotubes.

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Liquid Seal Slickline Control Head

Liquid Seal Slickline Control Head

LIQUID SEAL SLICKLINE CONTROL HEAD

When operating in high-pres-

sure dry gas, with larger diam-
eter stainless steel slick lines,
the liquid seal slickline control
head provides a more reliable
means of controlling the well
fluids than the conventional
slickline stuffing box. The
liquid seal slickline control
head consists of two sub-
assemblies, the hydraulic stuff-
ing box and the flotube assem-
bly.

The hydraulic stuffing box is

equipped with a 16" sheave. It
is used to seal-off only on sta-
tionary lines. Seal on the mov-
ing line is achieved in the
flotube assembly, which
includes a stack of short flo-
tubes into which viscous
grease is injected. A velocity check valve is included in the control head,
to automatically shut-off in case of line pull-off.

Liquid seal control heads are available in 10,000 psi and 15,000 psi WP
ratings, H2S service.

They are connected onto the lubricator stack with a male quick union.

Hydraulic pressure and grease injection can be provided by separate

pumps. A compact air-operated grease and hydraulic control panel is also
available from Elmar.

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Large Casing and Openhole/Pack-offs

Large Casing and Openhole/Pack-offs

LARGE CASING AND OPENHOLE/PACK-

OFFS

Large casing and openhole line wipers and

pack-offs generally have large inside diame-
ter bodies, which allow the passage of large
openhole tools and perforating guns thus
eliminating the need to remove the line wiper
and/or lubricator between operations when
there is no wellhead
pressure.

They are most fre-

quently used as a
line wiper while the
wireline is moving,
and they can pack-
Typical Large
ID Packoff off moderate liquid
pressures. When the
wireline is stopped, they can be closed tightly
around the wireline thus providing a low well
pressure seal (less than 5,000 psi WPI).

Some models, also called annular wireline valves

require the cable and rope socket to be initially
threaded through before assembling the logging
head. In subsequent runs the logging head
engages an overshot, lifting the seal assembly,
which remains around the cable while logging
tools are laid down. Annular wireline valves are
rated 3,000 psi WP, STD Service. Elmar Annular
Wireline Valve
(BOP-V)

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Large Casing and Openhole/Pack-offs

Large Diameter Dual Line Wiper / Pack-offs

Large Diameter Dual Line Wiper / Pack-offs

A large inside diameter low working pressure line wiper / pack-off system
is used on wells that contain little (less than 3,000 psi WP) or no initial
wellhead pressure and when no surface pressure is expected throughout
the wireline operation. It was developed mainly for use when openhole
services are run and for perforating low-pressure zones with large diame-
ter guns.

This system eliminates the necessity of "rigging up" large ID lubricators

and large ID wireline valves to cover the downhole equipment, while
maintaining well control.

It consists of two major assemblies, the upper and lower pack-off. Both
utilize hydraulic activated packing elements (line rubbers), upper and
lower line guide bushings, a top line protector funnel with air inlet line
cleaners, and quick union lower connections. Additionally, the lower pack-
off has a side outlet port to accommodate a plug valve and any necessary
high-pressure fluid hoses. A cablehead overshot in the lower assembly
holds and guides the downhole equipment when rigging up and removing
the equipment from the well. The lower internal pack-off assembly can be
released by unscrewing lock-down latches to allow downhole equipment
as large as 6.50" OD to be lifted through it. This helps expedite downhole
equipment changeover and "rig-down" procedures.

During operations, the packing element (line rubber), is compressed by

hydraulic pressure and can be utilized as a stuffing box (line wiper). When
the wireline is stopped, it can be used as a low pressure pack-off to com-
pletely seal the well. In the event downhole equipment encounters unex-
pected wellhead pressure, the lower pack-off is closed, the wireline
secured (clamped). The wireline is cut and fed through the lubricator sec-
tion(s) and the upper pack-off. Then the wireline is tied to the end of the
hoist wireline and the equipment is pulled out of the well and into the lubri-
cator pressure control equipment.

Dual line wiper / pack-off systems have a maximum working pressure rat-
ing up to 3,000 psi and are rated for standard service well conditions only.
They can accommodate wireline sizes of 0.312" to 0.52".

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Large Casing and Openhole/Pack-offs

Large Diameter Dual Pack-Off

Large Diameter Dual Pack-Off

Upper Pack-Off Assembly

Lower Pack-Off Assembly

Assembled Dual Pack-Off

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Wellhead Adapters
Flange Adapters

WELLHEAD ADAPTERS

The wellhead adapter connects to the wellbore on one side and to the
WHE on the other side. On the WHE side it is equipped with a quick
union. In most circumstances on the wellbore side the WHE is connected
on top of the client's christmas tree or wellhead. However pressure equip-
ment may be required in a wide variety of situations, and may be con-
nected to the rig BOP stack, to a testing flow-head, to drill pipes, or even
directly to a tubing string.

Two methods are generally used to connect wireline pressure control

equipment to a wellhead: a flange adapter or a threaded adapter. The
threaded adapter that is screwed into the top threaded connection of the
wellhead can be used on wells with pressures up to 5,000 psi and where
no H2S is present.

Wellhead adapters must conform to API 6A specifications and to the

same identification and qualification procedures as other pressure control
equipment.

Flange Adapters

A flanged adapter is the safest method of connecting a WHE string to a

wellhead, as it distributes evenly the weight of the entire lubricator string,
and any bending stresses transmitted through it. Moreover the quality of
the seal in a flanged connection specifically designed for this purpose is
better than with threaded connections which are easily damaged.

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Wellhead Adapters
Flange Adapters

Typical Flange Adapter

Wellhead Adapter

There are two acceptable types of flange construction:

• A one piece type construction that is integral or factory welded or

• A two piece type that consists of a flange and a top quick union
adapter that utilizes ACME threads and an O-ring seal to connect into
the flange.

Flange adapters are available in sizes ranging from 2.06" to 21.25" (nom-
inal) and working pressures up to 20,000 psi. They are rated for standard
and/or H2S well condition service.

The flange utilizes an API standard ring gasket to provide the pressure
seal. The cross section of the ring gasket is related to the working pres-
sure rating.

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Wellhead Adapters
Flange Adapters

API Ring Gasket Cross-Section Illustrations

Type R Type RX Type BX

API type 6B flanges with an "R" or "RX" ring gasket are generally used on
wellheads with working pressures from 2,000 psi to 5,000 psi.

API type 6BX flanges with a "BX" ring gasket are used on wellheads with
working pressures from 5,000 psi to 20,000 psi.

Ring gaskets are constructed of either alloy steel for standard well service
conditions or stainless steel for use in H2S conditions.

Flange connection procedure

1. Clean and inspect ring grooves.

2. Lightly grease ring groove. Do not fill the groove with grease.

3. Inspect seal ring for nicks. Only ring gaskets in top condition
should be used, never install a damaged one.

4. Install and connect flanges together with an appropriate ring in

the grooves.

5. Make sure the gap between flanges is uniform all around as you
tighten bolts. Alternatively, tighten bolts on opposite sides of the
flange to bring the flanges together uniformly.

6. Use all bolts, making sure they are tightened to the correct torque
specifications.

See the “API Flange Data Tables” Section for details of API Flanges.

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Wellhead Adapters
Flange Adapters

Threaded API Wellhead Adapters ("Swedges")

An alternative and faster method of connecting pressure control equip-

ment is to use an API threaded adapter that has a quick union box at the
top and an API threaded connection at the bottom. It is screwed directly
into the top connection of the wellhead. Because of the features of an API
threaded connection, swedges are only acceptable for working pressures
up to 5,000 psi, non H2S (STD) service, and for short lubricator strings
(24-30 ft maximum).

Refer to the table below for specific API threads pressure ratings.

Typical API Adapter

This type of adapter relies on torque to provide a seal rather than using a
replaceable ring gasket. Therefore, the threads must be tightened to the
recommended API torque-rating amount.

Typical API Tubing Threaded Adapter Torque

Nominal Size Grade Thread Type Torque Rating
2.375” J-55 8RD 1200 ft/lb
2.375” N-80 8RD 1500 ft/lb
2.875” J-55 8RD 1500 ft/lb
2.875“ N-80 8RD 1800 ft/lb

Unusual operations may require special adapters, made up with more

than one crossover, but stacked crossovers must be kept to a minimum.

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Wellhead Adapters
Flange Adapters

WHE Adapter Connection to Xmas Tree

Drilling Rig BOP Wellhead Adapters

Wireline service operations on a drilling rig generally include running

openhole downhole equipment or low well pressure perforating. This
involves using pressure control equipment with large inside diameters
with low working pressure ratings (maximum 3,000 or 5,000 psi).

The wireline valve should be easily accessible, i.e. at waist height on the
rig floor when connected to the drilling stack. Since the rig floor is usually
much higher than the stack, a riser is needed. The riser is attached to the
stack at its lower end and extends through the rotary table. If the riser is
too long and the wireline valve is too high above the rig floor then a work
platform has to be constructed to allow easy and safe access to the BOP.

Several types of riser adapters can be used to connect pressure control

equipment to the drilling rig's wellhead. Usually the uppermost section is
an annular type BOP, commonly referred to as a "Hydril".

There are two main types of adapters used for connecting the pressure
control equipment to a drilling BOP stack:
• Use a "shooting nipple" i.e. a length of pipe partially lowered
through the drilling BOP stack
• Flange-up on top of the annular BOP

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Wellhead Adapters
Flange Adapters

51
 [Link] Page 52 Tuesday, April 13, 2004 11:03 AM

Shooting Nipple
Shooting Nipple

SHOOTING NIPPLE

In the most simple and most unsafe configuration this can be a piece of
API casing (usually 7") held in the drilling stack by closing the annular
BOP or pipe rams around it. It is connected to the wireline valve with a
suitably strong API casing thread. Lugs are welded on the OD of the cas-
ing and hold-down chains are used to secure it to the rig floor.

Warning: This is an UNSAFE practice and is NOT

recommended.

Because of the large cross-section of the casing joint, there is a very large
upward thrust with this configuration: with 1,000 psi, the shooting nipple
will be subject to a 38,500 lbs upward thrust. Chains under such high ten-
sion are a risk, especially if the legs are not taking the load equally.

A more secure way to hold the shooting nipple is to equip it with a lower
retainer ring that shoulders on the lower surface of the annular BOP or
pipe rams seals. Use of specially designed Hydril adapters is recom-
mended. Usually they are available with an ID of 4.89", 7.62" and 8.53".
The lower end has a specially designed retainer ring screwed onto the
riser body, with a certified thread, that doubles as a wireline re-entry
guide. Slimline quick union connections are used to split the length in
manageable section (6, 8 or 10 ft).

In operations, the retainer ring must be located directly under the annular
BOP packing element, in contact with the packing metal fingers, to avoid
any movement when pressure increases.

Some major service companies prefer to have the Hydril adapter held in
the pipe rams of the drilling BOP instead of the annular BOP. This
requires a longer riser length, and also may require changing the drilling
BOP rams to suit the size of the Hydril adapter.

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Shooting Nipple
Flanged Hydril Adapter

Hydril Retainer Adapter

Advantages Disadvantages
• Quick to rig up • The Hydril is disabled and cannot
be used in an emergency.
• If assigned to a specific
rig, can be dimensioned • Unsafe when locally made equip-
to the correct length. ment is used.

• There is no visual control of the

mud level in the well.

Flanged Hydril Adapter

With this solution the wireline pressure control equipment is connected to

the top of the Hydril with a flanged connection. This system is the safest.
There are a few variations.

Hydril Flange / API Threaded Adapter

This type of adapter has an API threaded connection connected to the

flange box using the correct amount of torque. The riser is then connected
to the pressure control equipment. This type of connection is not recom-
mended, and should only be allowed for use at working pressures below
3,000 psi and low concentrations of H2S (less than 5 ppm).

Hydril Flange / ACME O-ring Union Box Adapter

This type of adapter connects to the Hydril through a flange with an

ACME threaded box connection with an O-ring seal. This type of connec-
tion can be used for operations below 5,000 psi working pressure.

Hydril Flange / Quick Union Box Adapter

This is a large ID one-piece flange adapter that is connected directly to

the top of the Hydril. A riser string with the same quick union connection is
connected to the top of the quick union connection of the flange and the

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Shooting Nipple
Permanent Flange Hydril Adapter

bottom of the pressure control equipment at the rig floor. This is the most
secure way to "rig-up" but is long to install, as it requires removal of the
bell nipple, and flanging-up.

Permanent Flange Hydril Adapter

In this version the flange is permanently bolted on top of the annular pre-
venter (Hydril). The top of the flange is the box part of a high-pressure
quick union.

In "drilling mode": the rig bell nipple adapter (riser for mud return) is
directly connected to the flange via the high-pressure quick union.

In "wireline mode": the riser is connected to a riser adapter that fits the
high-pressure quick union from the flange.

Permanent Flange Adapter

Advantages Disadvantages
• Hydril remains operational. • Longer rig-up time.

• Secure connection to drilling stack,

not depending on space-out.

Lock Down Shooting Nipple

This is more a modern system, recently introduced by Elmar. With this

system a special permanent flange adapter is used. The shooting nipple
is connected to the flange using locking pins that engage on a special
mandrel on the shooting nipple body. The Hydril seal elements are ener-
gized only if well pressure is present. This system separates the hold-
down and sealing functions and allows monitoring of the fluid level during
operations.

Pins are manually or hydraulically operated. The bell nipple remains per-
manently connected on the flange.

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Shooting Nipple
Lock Down Shooting Nipple

Lock Down Shooting Nipple

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Accessory Equipment
Tool Traps (Retainers)

ACCESSORY EQUIPMENT

Tool Traps (Retainers)

A tool trap (or tool retainer) is a safety device normally installed immedi-
ately above the wireline valve. Its purpose is to retain any wireline down-
hole equipment that may be accidentally "pulled off" inside the lubricator
and prevent it from falling down into the well. This can occur whenever
depth control is lost and the wireline equipment is pulled too high into the
lubricator string. The tool trap has an internal retainer plate, called "flap-
per". The flappers have a slot larger than the wireline, but smaller than the
tool string. They are spring-loaded and will be lifted when a tool is pulled
through but will fall back as soon as the tool is above the trap. The tool
trap flapper remains closed during normal operation. It is only opened at
the commencement of a job to allow the downhole tool to descend from
the lubricators into the well. It is closed again once the tool is in the well.

Tool Traps are available in both manually and hydraulically operated mod-
els.

Manually Operated Tool Traps

The manually operated tool trap has the flapper connected to a shaft with
an external operating handle. The shaft is pressure balanced. By lifting
the handle, the flapper is raised, allowing the tool to go down. When the
handle is lowered, the flapper returns to the closed position, with the wire-
line running through its slot. When the tool string is pulled back, it hits the
plate deflecting it upwards. The handle will move with the plate, giving an
external indication. The flapper will drop back into the trap position under
the force of a spring once the tool string bottom has cleared it.

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Accessory Equipment
Tool Traps (Retainers)

Top View of a Flapper Assembly for a Manual Tool Trap

Manual tool traps are available with ID's ranging from 2.50" to 6.76" and
are rated for maximum working pressures up to 5,000 psi. They are nor-
mally used only for standard service, because they require the operator to
be in physical contact with the trap to operate it.

Typical Manually Operated Tool Traps

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Accessory Equipment
Tool Traps (Retainers)

Hydraulically Operated Tool Traps

In a hydraulically operated Tool Trap hydraulic pressure is used to move a

piston to open and close the retainer plate(s). Two separate hydraulic
pressure lines are needed to operate the trap. Most hydraulic Tool Trap
models have no external indicators.

Hydraulic Tool Traps are available with ID's ranging from 2.50" to 6.76"
and rated for maximum working pressures up to 15,000 psi and in stan-
dard and H2S service.

Typical Hydraulically Operated Tool Traps

Elmar has developed a hydraulic tool trap with external indicator. It oper-
ates on the same principle as a manual trap but has an external hydraulic
actuator to operate the handle, allowing opening and closing from a
remote station.

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Accessory Equipment
Cablehead Catchers

Typical Elmar Hydraulically Operated Tool Traps

Cablehead Catchers

The hydraulic cablehead catcher is a safety device that is installed at the

top of the lubricator string to automatically engage the fish neck on a wire-
line cablehead or socket (slickline). It prevents wireline downhole equip-
ment from falling down into the well should it be accidentally pulled
against the top of the lubricator string, breaking the wireline or "pulling-
out" of the wireline rope socket. Additionally, it can be utilized to "hold"
wireline equipment inside the lubricator string during the "rig-up" and "rig-
down" of the pressure control equipment.

It is highly recommended to have at least one 'catching' system, either

tool trap or tool catcher in the WHE string.

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Accessory Equipment
Cablehead Catchers

The cablehead catcher utilizes a spring-loaded "collet" to catch the fish

neck along with a unique "activate-to-release" design. With this system
and the absence of any hydraulic pressure, the cablehead catcher is
always in the "catch" position. To release equipment hydraulic pressure is
applied against a piston that compresses the "collet spring", opening the
"collet". The spring returns the "collet" to the "catch" position when
hydraulic pressure is released.

The cablehead catcher is available in two styles. One is equipped with a

quick union upper connection by a lower quick union connection. This
allows it to be inserted into a pressure control equipment string without
modification. This device is readily adaptable for slickline operations
where a grease control head is not always used.

The second type is equipped with a lower quick union connection while
the top connection fits the lower grease control head flotube connection
along with an integral safety ball check valve assembly. The safety ball
valve provides a means to close and seal the well pressure from escaping
in the event of a parted cable.

Both models can be rated for maximum working pressures up to 15,000

psi and for use in standard and H2S well conditions.

The catch mechanism is normally available for fish necks sizes 1" to
1-3/4" OD. Additional sizes are available on special request. Older mod-
els are limited to one size only.

Latest models of Elmar tool catchers are adapted to catch different sizes
of fishing heads. These range from 1''- 2 5/16''. In most head catcher
models, the wireline must be passed though the head catcher body
before making it up to the head.

Quick interchange tool catchers are available from Elmar, allowing switch-
ing from a slickline head to an electrical line monohead without having to
re-head either line. This is made possible by the unique features of a 1.5"
through-bore and a split tool stop that can be inserted after the head is
passed through the tool catcher body.

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Accessory Equipment
Pump-In Subs

Typical Cablehead Catchers

Union Type with Safety Ball Valve Union-to-Union Type

Pump-In Subs

A pump-in sub is a short section of pres-

sure control equipment with a side outlet
port to connect a control plug valve. They
are normally installed immediately below
the wireline valve, but can be positioned
most anywhere in a pressure control
string. They provide a means to inject flu-
ids or pressure into the well and/or into
the pressure control string or to release
fluids or pressure when necessary.

Typical Pump-In Sub with Plug Valve

Pump-in subs can be used during hydro-
static testing of the pressure control string on the well or to inject glycol or
other fluids into the well for hydrate (internal ice) control. During openhole
operations, they are used to provide an access port to bleed-off any well
pressure "kicks" should they occur and then pump liquids into the well to
control the well pressure.

There are several variations of the side outlet port on pump-in subs that
provide a means to accommodate plug valves, pressure gauges, a pres-
sure recorder/transducer, and high-pressure fluid hoses.

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Accessory Equipment
Chemical Injection Subs

Available in ID's ranging from 2.5" to 6.76" and rated for working pres-
sures up to 15,000 psi and for use on any well service condition.

For 5,000 psi and higher-rated equipment, the side port line should be
connected with a bolt-on flange arrangement or O-ring type seals. 2" LP
ports are not recommended.

Chemical Injection Subs

The chemical injection sub is designed to allow

injection of chemicals directly onto the wireline
during wireline operations. De-icing agents (meth-
anol, glycol) or sulfide corrosion inhibitors are
injected into a chamber through which the wire-
line passes.

The chemical injection sub incorporates replace-

able felt packing, which acts to wipe the wireline
and help prevent the chemicals from dispersing
downhole.

The chemical injection sub is supplied complete

with quick unions top and bottom and is posi-
tioned in the lubricator string between the upper
lubricator section or the tool catcher, and the
stuffing box or grease control head.

Chemical injection subs are available with various sizes of quick unions
and in working pressures up to 10,000 psi and are also available for stan-
dard service and H2S service.

Quick Test Union

The quick test union, also called quick test sub (QTS), is designed to
reduce changeover time during operations where multiple runs of slickline
or electrical wireline are required, such as with fishing, bailing or perforat-

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Accessory Equipment
Quick Test Union

ing operations. Prior to opening the well to the wireline pressure control
string, the string must be pressure tested to ensure its pressure retaining
capacity.

This can be a time consuming process as the lubricator string must be

filled completely and all air removed before pressure build-up. In subse-
quent runs, only the integrity of one O-ring is in question (the one in the
quick union which is disconnected to change guns or downhole equip-
ment).

The quick test union simply provides a method to perform a quick pres-
sure test against the only O-ring disturbed during the changeover pro-
cess.

The quick test union is positioned in the pressure control string at such a
position that it is the main make/break quick union connection used dur-
ing downhole equipment or gun changeover. The union pin has two O-
rings, one that seals well pressure and one that is used to perform a
"quick test" against. The annular chamber between the two O-rings (of
very small volume) is connected to a high-pressure test hand pump
through a needle valve.

The union is connected in the normal fashion, and the hand pump is used
to apply the desired pressure to test between the two O-rings. If a good
seal is obtained, the hand pump is "bled" down and removed. The needle
valve is then closed and the wireline pressure control string is ready to be
equalized with respect to well pressure, before running the tools in the
hole.

A quick test sub can also be used to eliminate the risk present while pres-
sure testing a lubricator string with an armed perforating gun inside.

By using a quick test union the whole lubricator string can be tested with-
out the gun, which is introduced from the QTS union after a successful
test has been performed on the lubricator string.

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Accessory Equipment
Hydraulic Ball Valve

Quick Test Union

Hydraulic Ball Valve

The hydraulic ball valve is a full opening, hydraulically controlled, ball

valve, normally installed below the wireline valve and above the wellhead
valves. Its primary function is to isolate the wellhead from pressure from
above when testing the lubricator string, and to act as a back-up of well-
head valves on work-over operations. The hydraulic ball valves operate
with up to 3,000 psi hydraulic pressure supplied by a dual-output hand
pump or by a hydraulic accumulator module.

Hydraulic ball valves are available up to 15,000 psi WP, H2S service, with
IDs from 2-1/2" to 4". Some models have wireline cutting capabilities.
Hydraulic ball valves are delivered with top and bottom quick unions, to fit
the WHE string.

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Accessory Equipment
Union Connections

Union Connections

Sections of pressure control equipment are normally joined with quick

unions, sealed by elastomer joints. All quick union connections have a
box end threaded on its outer diameter, and a pin end on which a
threaded collar is shouldered. The pin end seals on the box end of an
adjacent piece of equipment, and the two are held together by the collar
screwed on the box threads.

Hammer (Knock-Up) Unions

Hammer unions use a threaded collar with 3 or 4 projections on the outer

diameter that are struck with a hammer in order to tighten it. As the con-
nection wears, it requires an increasing amount of impact to make it pres-
sure tight. This excessive force often causes the collar to crack and
become unsafe. Hammer unions for use with wireline pressure control
equipment are not recommended and are being replaced with quick
unions.

Quick Union Connections

Quick unions are self-aligning due to the profile of the box and pin sec-
tion. The seal is made by an internal O-ring on the pin end sealing in the
box end of the union. The two ends are kept together by a knurled collar
resting on the shoulder of the pin end, and screwing onto the external
thread on the box end. ACME threads are used. With this configuration
the threaded connection does not need to be made-up tight to energize
the O-ring. The collars can be made-up and undone by hand easily and
quickly if the mating pieces are well aligned. Only a small pin spanner
wrench may be used to secure the connection.

Various profiles and sizes of quick unions are available for use depending
on the well conditions.

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Accessory Equipment
Union Connections

Most common patterns are the Bowen-type and Otis-type patterns

Bowen Type Quick Union Connection

Otis Type Quick Union Connection

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Accessory Equipment
Union Connections

The following charts include most of the frequently used unions.

These charts will help identify union connections on pressure equipment

for selection of the correct union to use with a particular type of well condi-
tion, for additional equipment, and for determining O-ring size.

A quick union is defined by:

• Type: Bowen, Otis, Slimline, etc.
• ACME thread diameter in inches
• Thread pitch in threads per inch (TPI). Some connections use
double start threads (“DL”, sometimes also identified as “DBL” or
"x2")
• Seal diameter in inches, to the thousandths

Example: BOWEN 8-1/4"- 4DL - (6.000") connection is a Bowen connec-

tion with a 8-1/4" ACME thread, 4 Threads Per Inch, double start, with a
seal diameter of 6.000 inches. Can also be designated as BOWEN 8.25 -
4x2 - (6.000). It can be used for 4" ID equipment rated 10K psi, H2S ser-
vice.

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Accessory Equipment
Union Connections

Quick Union Connection Legend

A Denote ACME Thread
B Outside Diameter of the Threads (inches)
C Number of Threads per Inch (inches)
D Seal Diameter (inches)
E Nominal Inside Diameter of the Equipment (inches)
F Maximum OD (inches)

Typical Bowen Type Union Pin and Collar

Typical Bowen Type Union Box

68
 Bowen Type Quick Union Identification Chart
Union “A” “B” “C” “D” “E” “F” Working Srv O-ring O-ring Bu-ring Bu-ring Elmar
Designation Thread Thread TPI Seal Nom Max Pressure [Link] Elmar Elmar Retainer Designation
Type Size Dia. ID OD L Part No Part No Elmar
Part No
4-1/16" - 4 ACME 4.062 4 3.000 2.00 4.94 5K H2 S 334 L-870430 NO NO B14
4-1/2" - 4 ACME 4.500 4 3.000 2.00 -- 10K H2S 334 L-870430 L-873630 NO B16
4-3/4" - 4 ACME 4.750 4 3.750 3.00 5.36 5K H2S 340 L-870470 NO NO B01
4-3/4" - 4 ACME 4.750 4 3.750 3.00 6.08 10K STD 340 L-870470 L-873660 NO B12
5-1/2" - 4x2 ACME DL 5.500 4x2 4.375 3.00 6.39 5K H2 S 345 L-870520 NO NO B04
5-1/2" - 4x2 ACME DL 5.500 4x2 4.375 3.00 6.86 10K STD 345 L-870520 L-873700 NO B13
6" - 4x2 ACME DL 6.000 4x2 4.875 4.00 6.75 5K STD 349 L-870550 NO NO --
[Link] Page 69 Tuesday, April 13, 2004 11:03 AM

6-5/16" - 4 ACME 6.312 4 4.375 3.00 7.33 10K H2 S 345 L-870520 L-873700 NO B02
6” - 4x2 ACME DL 6.000 4x2 4.875 3.38 6.75 5K H2 S 348 L-870540 NO NO B20
6-5/16" - 4 ACME 6.312 4 3.750 2.50 7.33 15K H2S 340 L-870470 L-974535 873170 B03
7" - 5 STUB ACME 7.000 5 4.375 3.00 7.81 15K H2S 345 L-870520 L-974603 873260 B06
7" - 5 STUB ACME 7.000 5 5.250 4.00 8.08 5K H2S 427 L-875560 NO NO B08
8-1/4" - 4x2 ACME DL 8.250 4x2 6.750 5.50 9.63 5K H2S 438 L-870850 NO NO B09
8-1/4" - 4x2 ACME DL 8.250 4x2 6.000 4.00 9.45 10K H2S 433 L-870690 L-875340 NO B07
8-1/4" - 4x2 ACME DL 8.250 4x2 6.000 3.00 9.38 15K STD 433 L-870690 YES YES --
8-7/8" - 4x2 ACME 8.875 4x2 7.250 6.00 10.00 5K H2 S 440 L-870484 NO NO --
8-7/8" - 4x2 ACME 8.875 4x2 6.500 5.00 10.49 10K STD 437 L-873280 L-875540 NO B17
8-7/8" - 4x2 ACME 8.875 4x2 6.500 4.50 10.38 10K H2 S 437 L-873280 NO NO --
8-7/8" - 4x2 ACME 8.875 4x2 5.500 4.00 9.94 15K H2 S 429 L-873270 L-875530 L-871029 B19
9-5/32" - 4x2 ACME DL 9.156 4x2 6.750 5.50 10.99 10K H2 S 438 L-870850 L-876160 NO B10
9-7/8" - 4x2 ACME DL 9.875 4x2 8.000 6.38 10.99 5K H2S 443 L-873120 NO NO B11
10-5/8” - 4 ACME 10.625 4 7.500 5.63 12.11 10K H2S 441 L-870720 L-870021 NO B15
10-5/8” - 4x2 ACME DL 10.625 4x2 8.000 6.00 12.25 10K H2S 443 L-873120 NO NO --
13" - 4 ACME 13.000 4 9.500 7.06 15.11 10K H2S 447 L-874008 L-874009 NO B18

69
Union Connections
Accessory Equipment
 [Link] Page 70 Tuesday, April 13, 2004 11:03 AM

Accessory Equipment
Union Connections

Quick Union Connection Legend

A Denote ACME Thread
B Outside Diameter of the Threads (inches)
C Number of Threads per Inch (inches)
D Seal Diameter (inches)
E Nominal Inside Diameter of the Equipment (inches)
F Maximum OD (inches)

Typical OTIS Type Union Pin and Collar

Typical OTIS Type Union Box

70
 OTIS Type Quick Union Identification Chart
Union “A” “B” “C” “D” “E” “F” Working Srv O-ring O-ring Bu-ring Bu-ring Elmar
Designation Thread Thread TPI Seal Nom Max Pressure [Link] Elmar Elmar Retainer Designation
Type Size Dia. ID OD L Part No Part No Elmar
Part No
5" -4 ACME 5.000 4 3.500 2.50 5.75 10K STD 338 L-870640 NO NO --
5" -4 ACME 5.000 4 3.500 3.00 5.86 5K STD 236 L-870310 NO NO O01
5" - 4 ACME 5.000 4 3.500 3.00 5.86 5K H2S 236 L-870310 NO NO O16
5" -4 ACME 5.000 4 3.500 3.00 5.86 10K STD 236 L-870310 L-873570 NO O21
5" -4 ACME 5.000 4 3.500 2.50 5.86 15K H2S 338 L-870460 L-976083 L-875640 O20
5 3/4" - 4 ACME 5.750 4 4.000 3.00 6.62 10K H2S 342 L-870490 L-873680 NO O02
6 1/4" - 4 ACME 6.250 4 4.000 2.50 7.63 15K H2S 342 L-870490 L-974353 L-873260 O03
[Link] Page 71 Tuesday, April 13, 2004 11:03 AM

6” - 4 ACME 6.000 4 4.875 4.00 6.84 5K H2S 349 L-870550 NO NO 023

6-1/2" - 4 ACME 6.500 4 5.188 4.00 7.61 5K STD 249 L-873140 NO NO O05
6-1/2" - 4 ACME 6.500 4 4.750 4.00 7.58 10K STD 348 L-870540 L-873720 NO O04
6-1/2" - 4 ACME 6.500 4 4.750 4.00 7.58 5K H2S 348 L-870540 NO NO O17
6-1/2" - 4 ACME 6.500 4 4.750 3.00 7.58 10K H2S 348 L-870540 L-873720 NO O19
7-1/2" - 4 ACME 7.500 4 5.500 4.50 8.62 10K H 2S 354 L-870580 L-873760 NO O18
7-1/2" - 4 ACME 7.500 4 5.500 3.00 8.87 15K H 2S 354 L-870580 L-974602 L-876260 O06
8-1/4" - 4 ACME 8.250 4 6.188 5.00 9.61 5K H2S 434 L-870710 NO NO O07
8-1/4" -4 ACME 8.250 4 6.188 5.12 9.61 10K H2S 434 L-870710 L-875001 NO O22
8-3/8" - 4 ACME 8.375 4 5.250 4.00 9.64 10K H 2S 427 L-875560 L-875570 NO O08
8-3/4" - 4 ACME 8.750 4 7.500 6.38 9.88 5K STD 441 L-870720 NO NO O09
9" - 4 ACME 9.000 4 6.750 5.00 10.12 10K H2S 438 L-870850 L-876160 NO O10
9-1/2" - 4 ACME 9.500 4 8.000 6.38 10.58 5K H 2S 443 L-873120 NO NO O12
9-1/2" - 4 ACME 9.500 4 6.250 4.00 10.88 15K H2S 435 L-872560 L-977411 L-871005 O11
11-1/2" - 4 ACME 11.500 4 8.250 6.38 13.08 10K H 2S 444 L-876060 L-876070 NO O13
12" - 4 ACME 12.000 4 10.312 9.00 13.36 5K H2S 448 L-872440 NO NO O14
12 1/4” - 4 ACME 12.250 4 7.000 5.00 13.58 15K H2S 439 L-875810 L-982000 L-873150 015

71
Union Connections
Accessory Equipment
72
Elmar Type Quick Union Identification Chart
Elmar Profile Type “B” “C” “D” “E” “F” Working Srv O-ring O-ring Bu-ring
Designation Thread TPI Seal Nom Max OD Pressure [Link] Elmar Elmar
Size Dia. ID L Part No Part No
Union Connections

E06 (LIGHTWEIGHT) Bowen 4.750 4 3.750 3.00 5.33 10K H2S 340 L-870470 L-873660
Accessory Equipment

E09 (LIGHTWEIGHT) Bowen 4.750 4x2 3.750 3.00 5.33 10K H2S 340 L-870470 L-873660
E12 (LIGHTWEIGHT) Bowen 6.125 4X2 4.750 4.06 6.83 10K H2S 348 L-870540 L-873720
E22 Slimlite 6.875 4 5.625 4.892 7.58 5K H2S 355 L-870590 NO
E08 Otis 8.750 4 6.500 5.00 9.88 10K STD 437 L-873280 L-875540
E21 Slmlite 9.375 4 7.750 6.67 10.08 5K H2S 442 L-870006 NO
E04 Slimline 6.750 4 5.375 4.892 7.59 5K STD 356 L-870610 NO
E16 Slimline 6.750 4 5.375 4.892 7.59 5K H2S 356 L-870610 NO
E07 Slimline 8.500 4 7.250 6.765 9.44 3K STD 366 L-870840 NO
E05 Slimline 9.000 4 7.500 6.765 9.99 5K STD 367 L-870660 NO
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[Link] Page 73 Tuesday, April 13, 2004 11:03 AM

Accessory Equipment
Union Connections

Quick Union Connection Legend

A Denote ACME Thread
B Outside Diameter of the Threads (inches)
C Number of Threads per Inch (inches)
D Seal Diameter (inches)
E Nominal Inside Diameter of the Equipment (inches)
F Maximum OD (inches)

Slimline/Slimlite Type

Slimline unions are made up on pipes that have the same dimensional
characteristic as API casing. Pin and box end are screwed onto the pipe.
With this arrangement it is possible to have a seal diameter equal to the
OD of the pipe. Slimline unions are available in 3K and 5K working pres-
sure rating, both STD and H2S Service. They are not rated per API 6A
and test pressure is only 1.5 times working pressure. Slimlite unions built
by Elmar have full API rating, with TP = 2 x WP.

Typical Slimline Type Union Pin & Collar

Typical Slimline Type Union Box

Typical Slimlite Type Union Pin & Collar

Slimlite Type Union Box

73
74
Casing (Slimline/Slimlite) Quick Union Identification Chart
Equipment Union “B” “C” “D” “E” “F” Working Srv O-ring O-ring Elmar
Nominal OD Designation Thread TPI Seal Nom Max OD Pressure [Link] Elmar Designation
Size Dia. ID L Part No
Union Connections

Slimline 5-1/2" 6-3/4" - 4 6.750 4 5.375 4.892 7.59 5K STD 356 L_870610 E04
Accessory Equipment

Slimline 5-1/2" 6-3/4" - 4 6.750 4 5.375 4.892 7.59 5K H2S 356 L-870610 E16
Slimline 5-1/2" 7-1/4" - 4 7.250 4 5.375 4.670 5K H2S 356 L-870610
Slimline 7-5/8" 8-1/2" - 4 8.500 4 7.250 6.765 9.44 3K STD 366 L-870840 E07
Slimline 7-5/8" 9" - ‘4 9.000 4 7.500 6.765 9.99 5K STD 367 L-870660 E05
Slimline 7-5/8" 9-1/2" - 4 9.500 4 7.500 6.620 5K H2S 367 L-870660
Slimline 7-5/8" 9" - 4 9.000 4 7.500 6.62 9.99 5K H2S 367 L-870660
Slimline 9-5/8" 11-1/4" - 4 11.250 4 9.446 8.530 5K STD 375 L-870065
Slimlite 5-1/2" 6-7/8” - 4 6.875 4 5.625 4.892 7.58 5K H2S 355 L-870590 E22
Slimlite 7-5/8" 9-3/8” - 4 9.375 4 7.750 6.67 10.08 5K H2S 442 L-870006 E21
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[Link] Page 75 Tuesday, April 13, 2004 11:03 AM

Accessory Equipment
Pressurized Sheave Wheel

Pressurized Sheave Wheel

The Pressurized Sheave Wheel (PSW), also known as the Turn Around
Sheave (TAS) has been specially designed to reduce the overall height of
the pressure equipment string. With the conventional pressure equip-
ment system, the top sheave is positioned above the tool catcher, grease
injection control head and line wiper. By installing the sheave inside a
pressure retaining chamber and connecting one end to the tool catcher,
the grease injection control head and line wiper can be connected verti-
cally downward, thus reducing the overall height of the system.

Pressurized Sheave Wheel & Rig-up

Pressurized sheave wheels are available for 5,000 and 10,000 psi WP,
STD and H2S Service, with 12" and 14" OD sheaves.

It is essential that the sheave be fully supported in the rig-up and not
transmitting any weight on the lubricator string.

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Accessory Equipment
Safety Flow Diverter

Elmar have developed a full rig-up system specifically for PSWs, includ-
ing spreader beam, and bottom sheave clamp.

Safety Flow Diverter

The safety flow diverter is a safety device to be used whenever lubricators

have to be removed on a well under pressure, with the wireline valve
closed around the braided line, for example during stranded cable repair.

The diverter provides an additional seal allowing any leakage from the
wireline valve to be safely diverted through an attached high pressure
hose. A cable clamp is integral to the design, allowing rig-down of the
equipment above the wireline valve without resting the wireline weight on
the ram seals. All components of the safety diverter are split.

Safety flow diverters are available with 5K and 10K psi ratings, for instal-
lation on wireline valves with ID ranging from 2-1/2" to 6-3/8" ID.

Hydraulic Hand Pumps

Many of the pressure control equipment assemblies are hydraulically

operated for convenience and safety.

Lightweight portable hand operated hydraulic oil pumps equipped with

necessary hoses and quick connections are available for use with each
specific type hydraulically actuated assembly.

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Accessory Equipment
Hydraulic Hand Pumps

The pumps can be single output, or dual output through a switching man-
ually operated valve. Dual output pumps are needed for equipment hav-
ing separate OPEN and CLOSE ports, such as hydraulic tool traps or
wireline valves. For wireline valves the pumps are equipped with a special
"Bridle" or "Y" hose assembly used to move in and out opposite rams
equally.

The hand pumps are rated for a maximum pressure of 3,000 psi except
for some special equipment, which requires pumps rated to 10,000 psi.

The hydraulic hoses have an ID of 0.25" and are supplied in standard

lengths of 50', 75', 100', 120' and 150'. The working pressure rating for the
hose is usually a minimum of 1.5 times the pump output pressure.

Elmar supplies stainless steel body hand pumps for maximum durability.

Hand Pumps

Single Outlet Hydraulic Hand Pump Dual Outlet Hydraulic Hand Pump

Hoses & Quick Couplings

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Grease & Hydraulic Pressure Supply Systems

Grease Pressure Pumps

GREASE & HYDRAULIC PRESSURE

SUPPLY SYSTEMS

A grease pressure supply system suitable for use with a wireline pressure
control system consists of three major sub-systems:
• Pressure Pumps
• Hoses
• Grease Tanks and Packaging

Grease Pressure Pumps

There are many different brands, styles and types of pumps available for
use in supplying high-pressure grease for wireline pressure control opera-
tions. These pumps can be divided into two basic types:
• Air-driven (pneumatic)
• Hydraulically driven (Intensifiers)

Air-Driven Pumps

Air powered grease pressure pumps use an air motor driven by a supply
of compressed air to provide high-pressure grease to the grease control
head or the wireline valve.

These pumps are designated by their "ratio" (pump output pressure / air
input pressure).

A pump's maximum output pressure is found by multiplying the air input

pressure by the ratio. For example, the Lincoln Power Master 4 specified
ratio is 75:1. Therefore, with an air input pressure of 100 psi, the pump
can supply grease pressure at 7,500 psi.

It is important to notice that the full output pressure is available only at

minimum flow rates, and at the pump outlet.

The higher the grease flow rate needed, the lower the pressure output will
be at the end of the grease hose.

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Grease & Hydraulic Pressure Supply Systems

Grease Pressure Pumps

Popular Grease Pressure Pumps Used

Pump Brand/Type Ratio Input Air Pres- Applications
sure
ARO 4:1 150 psi maximum. Grease Transfer
WIWA 4:1 100 psi maximum. Grease Transfer
Lincoln Power Master 4 75:1 100 psi maximum. 5,000 psi operations
Lincoln Power Master 6 140:1 100 psi maximum. 10,000 psi operations
ARO 100:1 150 psi maximum. 10,000 psi operations
WIWA 85:1 100 psi maximum. 5,000 psi operations
WIWA 175:1 100 psi maximum. 10,000 psi operations
WIWA 235:1 100 psi maximum. 15,000 psi operations

Air driven pumps are lighter, cheaper and less maintenance -intensive
than the hydraulically driven pumps. They require a separate air compres-
sor if an air supply is not available on the well site.

For trouble-free operations it is important to have a suitable moisture trap

and "mist lubricators" on the air supply before the pumps input.

The air driven pumps can be spotted anywhere convenient on a well site
and are not limited by zoning requirements. They are self regulating: they
will stall when the maximum grease injection pressure is reached, and
resume pumping at high rate when the grease pressure drops suddenly
(loss of seal).

A pump's output pressure is controlled by changing the air input pressure.

This is accomplished by means of an air regulator valve, which can be
attached to the motor section via a quick ("snap-on") coupling.

Note: The higher ratios pumps require a large volume

of air input (up to 75-125 [Link]/min) for correct opera-
tion.

The air supply piping must be large enough to supply sufficient air volume
without excessive drop of pressure. Insufficient or poorly scrubbed air
supply is one of the main reasons of poor pump performance. Air driers
must always be used on the supply line. If independent compressors are
used, it is important to have a sufficiently large storage tank to cope with
the high demand surge if seal is lost.

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Grease & Hydraulic Pressure Supply Systems

Grease Pressure Pumps

As air-driven pumps cost less than hydraulically driven pumps, two redun-
dant air-driven pumps in combination, with a central pressure manifold
are utilized for efficiency and economy.

Hydraulically-Driven Pumps

Hydraulically powered pumps utilize hydraulic pressure to drive a high-

volume high-pressure pump in order to generate high-pressure grease for
wireline pressure control. Hydraulic pumps generate higher horsepower
(energy) than air-driven pumps thus providing a greater volume of grease
output. Regulating the inlet hydraulic pressure controls the grease output
pressure.

Most hydraulically driven grease pressure pump designs utilize an

opposed twin piston arrangement with a switching slide valve. This
assures a constant high pressure and high volume output. These pumps
have the capability of an output of up to 30,000 psi pressure.

A radial piston pump usually supplies the hydraulic oil pressure required
to power the grease pump with pressure output up to 5,000 psi. Most
radial piston pumps require up to 25 horsepower to operate efficiently. A
suitable diesel or gasoline engine is used to power the pump and in some
areas electric motors are used. The systems require hazardous areas
protection when spotted close to well-heads.

Hydraulically driven pumps most frequently found in use today for grease
injection purposes are the “intensifier" type pumps. The Hydrolex design
manufactured by Elmar has an output ratio of 7:1. Pumps manufactured
by Petrodyne, McFarland, Lee Specialties companies have an output
ratio of 12:1 to 14:1. Grease flow-rate varies from 1 to 1.5 gallons per
minute (3.8 to 5.7 liters per minute) at 20,000 psi.

Main applications for hydraulically driven pumps are:

• 15,000 psi, operations when a reliable air supply of sufficient
capacity is not available
• 20,000 psi operations

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Grease & Hydraulic Pressure Supply Systems

Grease Hoses
I

Intensifier Skid

Intensifier Pump

Grease Hoses

The high-pressure grease is normally conveyed from the pump outlet to

the applicable injection points in the pressure control equipment by
means of flexible hoses, called "grease hoses". In the past, steel tubing
lines have also been used for higher pressures.

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Grease & Hydraulic Pressure Supply Systems

Grease Hoses

When choosing grease hoses it is important to take into account that:

• The grease maximum pressure must be higher than the well
pressure for proper control.
• There is a large pressure drop in the hoses, linked to hose length,
ID, temperature and viscosity.

It is therefore important in the selection of grease hoses to check:

• Maximum working pressure rating and burst pressure
• Length
• Inside diameter

To prevent a decrease in the output capacity (GPM) of a grease injection

hose, it is critically important to use a full pressure rated hose with the
greatest ID and shortest length.

The grease return hoses should always be the same pressure rating and
ID as the injection hose.

High pressure grease hoses are made of a rubber or synthetic body, rein-
forced by steel braiding. End fittings are swaged on both ends and union
connections screwed onto them. The swaged hose ends are designed to
be stronger than the hoses, i.e. the hose will burst before the ends blow
off. The rating of assembled hoses is limited by the rating of the union
connectors. Autoclave unions must be used for working pressures above
10,000 psi. Titanium hose ends are recommended when CO2 or H2S are
present.

Most hoses with maximum working pressures up to 10,000 psi are a

steel/rubber "waterblast" type of construction with a liner and/or steel wire
reinforced.

For higher pressures or gas operations Polyflex hoses with Nylon/Kevlar

lining and stainless steel braiding are recommended. These hoses, rated
up to 26,000 psi WP are impervious to gas, corrosion resistant and are
not affected by H2S or CO2.

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Grease & Hydraulic Pressure Supply Systems

Grease Hoses

For maximum operation safety, the grease injection hose and the return
grease hose should have a test pressure of at least 2 times the rated
working pressure and a burst pressure of at least 4 times the rated work-
ing pressure.

Hoses are available with standard lengths of 50', 60', 75', 100', 120', and
150'.

Available IDs are 0.25", 0.31", 0.44", and 0.50".

To avoid excessive pressures losses in the hoses, ID should be 1/2" for all
10,000 psi and above applications.

All grease hoses should be clearly identified, either in the body or with
tags showing at least working pressure rating and year of manufacturing.

Hose Unions

Connectors for the grease hose vary with the type and maximum pres-
sure rating of the pressure control equipment and the grease hose ID that
is used. Grease hoses rated for working pressures up to 10,000 psi and
0.50" ID usually employ a hex union assembly connector with ½" NPT
threaded connections to the hose ends (Huber Union).

Huber Union

Huber unions must be made up tightly to ensure a good seal.

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Grease & Hydraulic Pressure Supply Systems

Grease Hoses

Elmar have developed a replacement hose union that can be made-up

manually.

Elmar Hose Union

Grease hoses rated for working pressures up to 20,000 psi with a 0.50" ID
use a 1" - 12-swivel nut type connector while hoses with 0.33" ID use a
0.75" - 16-swivel nut connector. Many grease hose adaptors are available
to couple the hose connector to the pressure equipment including high-
pressure 0.56" and 0.75" Autoclave Engineer threads.

Hoses and end connections should continually be inspected for damage

of the outer cover and the steel braiding. Cuts in the outer cover allow
accelerated corrosion of the steel wires.

They must be hydrostatically tested at regular intervals, to 50% above the

rated working pressure, to insure their pressure integrity. End connections
should be replaced as required.

In operations excessive side pulls on the crimped ends must be avoided:

e.g., do not pull on grease or hydraulic hoses to align a lubricator string in
the derrick.

For transportation and storage, hoses can be rolled into coils or spooled
on reels. The loop diameter should be larger than the minimum diameter
of curvature specified by the manufacturers.

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Grease & Hydraulic Pressure Supply Systems

Packaging

Packaging

A grease pressure supply system is normally specified for 5,000 psi,

10,000 psi or 15,000 psi working pressure to match the pressure rating of
the pressure control equipment used.

It can vary from a very basic unit, for instance, a pump, a drum of grease
and loose hoses up to a fully self-contained skid-mounted module for use
on land and offshore operations.

A basic 5,000 psi working pressure system can be supplied as:

• Air-driven 75:1 or 85:1 grease pump, drum mounted flange, air
pressure filter/regulator/lubricator, and hoses (all separate items)
• Air-driven 75:1 or 85:1 or 100:1 redundant grease pumps, inte-
gral steel grease reservoir tank, stainless steel control panel,
gauges, tubing fittings and valves, hose reels with hoses;
mounted on a galvanized or painted steel skid

Compared to the conventional methods of packaging, the use of self-con-

tained modules brings many advantages. The modular grease pressure
systems mounted on skids are compact requiring a minimum of space,
and allow the use of redundant pumps. Job preparation and logistics are
simplified. Safety is improved because one operator can easily control all
the equipment with one set of controls from a single location at a safe dis-
tance from the wellhead.

Control systems for 10,000 and 15,000 psi are generally always skid
mounted.

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Grease & Hydraulic Pressure Supply Systems

Grease and Hydraulic Control Skids

Grease and Hydraulic Control Skids

The grease injection system modules can be integrated with similar

hydraulic control modules, and configured in a skid, equipped to transport
the wireline pressure control equipment and spares.

It can be fitted with steel cages for the wireline valves and storage racks
for all other equipment. This provides excellent protection for the equip-
ment, improving reliability and reducing damage during transport.

The grease control modules provide a grease supply to the grease injec-
tion head and the wireline valve. Grease hoses are permanently con-
nected to the control valves on the control panel via wet center reels.

Common grease module configurations are:

• For 5,000 psi working pressure equipment -- two redundant 75:1
or 85:1 air pumps
• For 10,000 psi working pressure equipment -- two redundant
140:1 or 175:1 air pumps
• For 15,000 psi working pressure equipment-- two redundant 235:
1 air pumps or one hydraulic grease intensifier
• Special intensifier-based modules are available for 20,000 psi
working pressure equipment

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Grease & Hydraulic Pressure Supply Systems

Grease and Hydraulic Control Skids

Elmar Mini Series Grease Module for 10,000 psi operations

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Grease & Hydraulic Pressure Supply Systems

Grease and Hydraulic Control Skids

In the hydraulic control modules the hand pumps are kept only as back-
up, and replaced by air-operated hydraulic pumps. The simplest control
modules available are designed for a single wireline valve. The more
complete fully integrated modules for 10,000 and 15,000 psi equipment
provide control for a triple Wireline Valve stuffing box, line wiper, tool
catcher and tool trap.
Elmar Portable Wireline Valve Control Unit

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Grease & Hydraulic Pressure Supply Systems

Grease and Hydraulic Control Skids

Elmar Mini Series Hydraulic Module for 10,000 psi operations

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Grease & Hydraulic Pressure Supply Systems

Grease and Hydraulic Control Skids

Intensifier Module

Elmar has designed the original integrated control skid for pressure con-
trol equipment in 1981, including a mimic stainless steel engraved control
panel.

Complete integrated wellhead pressure control equipment skids for

10,000 and 15,000 psi operations are available with many features includ-
ing:
• Twin air driven grease pumps (17,500 or 22,500 psi WP)
• Integral hydraulic control for WHE
• Stainless steel engraved control panels with gauges, steel tubing,
HP fittings and valves
• Wet Centre storage reels
• Integral grease and hydraulic fluid tanks
• Back-up stainless steel hydraulic hand pumps
• Complete transportation frame for pressure control equipment
and accessories with certified lifting slings.
• Galvanized steel cages for wireline valves with certified lifting
slings
• PVC / Canvas cover

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Grease & Hydraulic Pressure Supply Systems

Grease and Hydraulic Control Skids

Other options available include:

• Modular add-on or built-in pressure test unit
• Glycol or chemical inhibitor injection pump
• Hydraulic accumulators to operate the wireline valves
• Add-on controls for master valves and downhole Safety valves

Elmar 3-BOPs Grease and Hydraulic Control Module for 10,000 psi operations

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Grease & Hydraulic Pressure Supply Systems

Grease and Hydraulic Control Skids

Elmar 3-BOP WHE Skid System for 10,000 psi operations

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Grease & Hydraulic Pressure Supply Systems

Grease

Grease

Wireline grease (also called "honey oil") is used in the wireline grease
injection head, to create a barrier to well fluids while allowing to move the
wireline in and out of the well. The grease shuts off the flow passages
between the stranded line and the flotubes, and also permeates the voids
between strands in a braided line or in an armored electric wireline. Sec-
ondary but important functions are to lubricate the wireline, avoiding
excessive wear, and to protect it from corrosive attacks by the well fluids.

Wireline grease is also injected in-between the two rams of a dual wireline
valve closed around a stranded line, to block fluid migration through the
voids in-between the cable strands.

There are many types of grease on the market for use in wireline grease
injection systems. The ideal characteristics of the wireline grease are:
• The grease should be able to ensure a good seal at the range of
operating temperatures and pressures normally encountered
throughout the day and the seasons.
• Viscosity should be in the range of 4,000 to 20,000 centiPoise
in the desired temperature range.
• It should be stringy and tacky at the temperatures to be used, to
form a continuous film and to reduce spatter.
• It should be of low toxicity, non flammable and chemically inert.
• It should have low solubility in well fluids and glycol.
• It should have H2S and CO2 inhibiting properties or mix with H2S
and CO2 inhibitors if needed.
• It should have a clear color, be harmless to the environment and
easy to clean up from the rig site. It should be, as much as is pos-
sible, biodegradable.
• It should be easily available and cost effective.

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Grease & Hydraulic Pressure Supply Systems

Grease

To choose the correct viscosity grease for a particular job, determine the
minimum and maximum grease operating temperature expected, taking
into account that sun radiation in hot areas can add several degrees
above ambient air temperature. If the grease has too low a viscosity at
maximum operating temperature, consumption will increase and it may
be impossible to maintain a seal over a moving cable. If viscosity is too
high at minimum operating temperature the pressure drop in the hoses
may become excessive and the pumps may be unable to supply sufficient
flow to maintain the seal. In case of extreme ambient temperature differ-
ences it may be necessary to have a dual tank system and switch grease
viscosities in the course of a job.

Refer to the following chart giving the temperature range for some VIS
grades of grease.

Grease Viscosity vs. Temperature

Grease
Operating Temperature Range (ºF)
VIS
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
12
16
20
24
28
-17.8 -12.2 -6.7 -1.1 4.4 10.0 15.6 21.1 26.7 32.2 37.8 43.3 48.9 54.4 60.0 65.6
Operating Temperature Range (ºC)

A number of products more or less meet the above ideal characteristics.

The most common are polybutenes, also called "honey grease" or "honey
oil".

Polybutene is a generic name for a series of products resulting from the

polymerization of butene and isobutene and are produced by several
chemical companies. Some "gear oils" or “steam cylinder oils” can also be
used.

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Grease & Hydraulic Pressure Supply Systems

Viscosity

Some products are specifically created for wireline seal applications; they
contain inhibitors and are formulated to have high viscosity, with a smaller
viscosity variation over a wider range of temperatures. Some have a
degree of biodegradability.

Amongst other suppliers, Champion Technologies has developed a "Poly-

butene Multigrade" grease, containing H2S inhibitors.

Oil Center Research Inc. (OCR), a US specialist supplier has developed a

patented range of greases with viscosities ranging from VIS 10 to 30, also
available in an enhanced biodegradable form. Care must be taken not to
intermix the biodegradable with petroleum-based oils or oils from other
manufacturers as the mixture can gel and plug the supply and return
lines.

Polybutene Multigrade and OCR greases can be obtained from Elmar.

Viscosity

The viscosity of a fluid is a measure of its resistance to flow, or the resis-

tance opposed to the movement of a solid inside the fluid. The higher the
value of the viscosity then the greater is the resistance. The viscosity of
grease/oil decreases rapidly with increasing temperature.

There are several ways of expressing viscosity of a fluid.

Most common measurement is "Absolute" Viscosity, expressed in centi-

Poise (cP). Water at 20ºC has a viscosity of 1.0 cP, bee’s honey has
10,000 cP.

"Kinematic" viscosity of a substance is a measure of its dynamic viscosity

per unity density of that substance. Kinematic viscosity is measured in
centiStokes (cSt).

Kinematic Viscosity (cSt) = Absolute Viscosity (cP /Specific Gravity).

95
 [Link] Page 96 Tuesday, April 13, 2004 11:03 AM

Grease & Hydraulic Pressure Supply Systems

Viscosity

There are a number of experimental ways to measure kinematic viscosity.

Most are based on the time taken by a quantity of fluid to flow through a
standard orifice at given conditions. These experimental measurements
are expressed in "seconds". One of the most often used is the Saybolt
Universal Second (SUS or SSU). An approximate practical conversion in
the range of viscosities interesting for wireline greases is: CentiStokes =
0.22 x SSU.

Another way to indicate viscosity is the viscosity "number": VIS 10, 12,; 30
related to increasing viscosity at 25°C (77 °F).

Viscosity is the most important characteristic of wireline grease. If it is too

low it is impossible to create a seal, if it’s too high, it cannot be pumped at
a sufficient flow rate to obtain a seal.

Pressure drop along a 1/2" 100ft long grease hose at different viscosities
5
ps

cps

ps

s
cp
3,000 c

0c

00
5,000

,00

4.5
,0

s
15

cp
10

0
4 , 00
20

3.5 s
cp
0
00
FLOW RATE LT/MIN

,
25
3 s
0 cp
,0 0
30 s
2.5 cp
,0 00
35
2

1.5

0.5

0
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000

PRESSURE - PSI

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Pressure Test Units

Pressure Test Units

PRESSURE TEST UNITS

Pressure test units (PTUs) are designed for pressure testing wellhead
equipment and well test equipment and piping, and can in most configura-
tions be used for injection of chemical products (Inhibitors, hydrates treat-
ment, etc.) in oil wells production strings.

Typical models have air-operated high-volume low pressure pumps for

fast filling of the equipment to be tested, and high pressure low-volume
pumps rated 10,000 psi, 15,000 psi or 22,500 psi, as required by API 6A
specifications.

Typical Pressure Test Unit specifications (100 psi Air input)

Volume Pump Volume Pump High Pressure Pump
Rated Max
Max Pressure Output @ 0 psi output @ max press.
Pressure (psi)
(psi) (US gal/min) (cu in/min)
10,000 1,000 4.1 45
15,000 1,000 4.1 16
22,500 1,000 4.1 18

Typical Pressure Test Unit

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Pressure Test Units

Pressure Test Units

Typical Pressure Test Unit Performance

Compact transportable systems are mounted in a steel frame that

includes pumps, a tank for test fluid or injection fluids, a pressure gauge,
and a pressure chart recorder. More complete systems have air and pres-
sure test hoses permanently connected, mounted on wet center reels,
and stroke counters for pump cycles.

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Pressure Test Units

Pressure Test Units

Typical Chemical Injection Unit specifications (100 psi Air input)

Volume Pump Volume Pump High Pressure Pump
Rated Max
Max Pressure Output @ 0 psi output @ max press.
Pressure (psi)
(psi) (US gal/min) (cu in/min)
6,000 1,200 19.8 201
10,000 1,200 19.8 176
15,000 1,200 19.8 207

Typical Chemical Injection Unit

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Pressure Test Units

Pressure Test Units

Wall mounted PTUs are available for installation on the external walls of
permanent pressure test bays. Complete systems include safety inter-
locks with the bay's doors (pressure is dumped whenever the door is
opened) and Closed Circuit TV to observe the equipment under pressure
without exposing personnel.

Typical Wall Mounted Pressure Test Unit

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Pressure Test Units

Pressure Test Units

Typical Wall Mounted Pressure Test Unit Installation in a Pressure Test Bay

101
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Quick Connect Couplings

Quick Connect Couplings

QUICK CONNECT COUPLINGS

There are two main types of quick connect coupling, "dry break" and "wet
break". Dry break couplers avoid air inclusion and fluid loss and prevent
spillage and contamination to the system. Spillage or air inclusion will
occur when using wet break couplers.

For use in dirty or dusty site conditions, flat faced couplings (wet or dry
break) can be used to avoid particles of dirt entering the connectors; the
flat face can be wiped clean before use. For non flat faced couplers dust
caps and plugs can be supplied.

Dry Break Coupling

Wet Break Coupling

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Quick Connect Couplings

Snaptite Connectors

Snaptite Connectors

Primarily used to connect

hydraulic control units to grease
injection points on wellhead
equipment. For use on systems
of up to 10,000 psi (690bar)
working pressure depending on
size and material selected. Both
the 7000 and H series are dry or
wet break. Both series can be
supplied as flat faced. push to
connect.

Holmbury Connectors

Primarily used to connect

hydraulic control units to
grease injection points on
wellhead equipment. For use
on systems of up to 10,000
psi (690bar) working pres-
sure. Supplied as dry break
and flat faced. Push to con-
nect.

Walther Connections

Primarily used on pressure test

units and for glycol injection.

For use on pressure systems of

10,000 psi (690bar) to 30,000
psi (2070bar) working pressure.
Supplied as dry break. Push to
connect.

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Quick Connect Couplings

Pioneer Connections

Pioneer Connections

Primarily used on pressure test

units. For use on pressure systems
of up to 10,000 psi (690bar) work-
ing pressure. Supplied as dry or
wet break. Screw to connect.

Chicago Connections

Commonly called a “Crow’s Foot” con-

necton. Primarily used on air supply
and other pneumatic systems. For use
on systems of up to 175 psi (12.5bar)
working pressure. Supplied as wet
break. Twist to connect.

104
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Quick Connect Couplings

Huber Connections

Huber Connections

Primarily used on grease injection systems on wellhead equipment.

For use on pressure systems of up to 10,000 psi (690bar) working pres-

sure. Supplied as wet break. Screw to connect.

Elmar Connections

Primarily used on grease injection sys-

tems on wellhead equipment.

For use on pressure systems of up to

10,000 psi (690bar) working pressure.
Supplied as wet break. Screw to con-
nect.

Unlike Huber, connections do not need tightening to energize their seals.

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Seals: Elastomers and Thermoplastics

Seals: Elastomers and Thermoplastics

SEALS: ELASTOMERS AND

THERMOPLASTICS

Many different sizes and types of seals are used throughout wireline pres-
sure control equipment to ensure a leak free system. The majority of
these are made from moulded elastomer such as ram elements, packing
elements (line rubbers) and O-ring seals. An elastomer is a material that
can be stretched repeatedly and upon release of stress will return with
force to its original length.

Thermoplastics such as Teflon, Ryton or PEEK, are polymers that are

stronger and have better chemical resistance than elastomers but do not
have the resilience (elasticity) properties of elastomers. Thermoplastics
are mainly used for more hard wearing applications and where elasticity
is not required such as stuffing box packing. Plastics are normally used in
conjunction with elastomers for anti-extrusion back-up.

Metal to metal (flange gaskets) seals are often used on the flange con-
nection to the well-head because of their greater resistance to attack by
produced or injected fluids.

There are two main applications in which seals are used:

• Static seals - where there is no movement between the parts con-
taining the seals (union connections).
• Dynamic seals - where a seal is maintained between moving
parts (shafts, pistons).

Compatibility of any elastomeric seal with the intended service environ-

ment should be determined when selecting seals for a particular job. This
includes consideration of the temperatures at which seals are required to
perform, and the effect of any fluid that elastomer seals may be exposed
to. These fluids include the completion fluids, anticipated well production
fluids and any other fluid and/or any chemical additives introduced to the
well or used for pressure testing.

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Seals: Elastomers and Thermoplastics

Seals: Elastomers and Thermoplastics

The user should also be aware that for a given generic type of elastomer
(e.g. nitrile), manufacturers may have different formulations or com-
pounds each with different chemical resistance and temperature ratings.
Commercially available seals may also have different purity material and
poorer finish than industrial grade seals.

The following table shows the elastomer materials most commonly used
in conjunction with wireline intervention equipment. The process of elas-
tomer selection is a complex one involving many variables and a vast
array of material candidates. The table presents a guideline only and
should not be assumed to guarantee elastomer performance.

For extremely hostile environments, the manufacturers' recommendations

must be sought.

107
 Typical Applications for Oilfield Elastomers
108

Typical Applications for Oilfield Elastomers

Seals: Elastomers and Thermoplastics

[Link] Page 108 Tuesday, April 13, 2004 11:03 AM

Common ASTM Hardness H2 S Temp. Trade Comments
Name Name Rating Resist Rating Names
(Shore A) °C (°F)
Acrylonitrile, Butadiene, Nitrile NBR 40-90 Fair -50 to 120 Buna N Most common oilfield elastomer, good oil
Hycar resistance. Not recommended above 93°C. Used
commonly for packer, ram elements. Low
(- 58 to 248) temperature rating varies depending on levels of
acrylonitrile.
Excellent with Glycol and Methanol, do not use
with Toluene

Hydrogenated Nitrile HNBR 40-90 Fair -25 to 130 HSN Better H2S and amine resistance than Nitrile.
Excellent with Glycol and Methanol, do not use
with Toluene
(- 13 to 266)
Fluorocarbon FKM 60-95 Fair -30 to 205 Viton Common oilfield elastomer often replaces NBR
for higher temperatures, very good oil resistant,
however, can harden in amine inhibitors.
(- 22 to 400) Fluorel Generally used to replace NBR where greater
temperature or chemical resistance required.
Excellent with Glycol and [Link] not use with
Hifluor
Methanols.

As standard Elmar supplies all wireline pressure control equipment with seals made of Acrylonitrile butadiene (NBR) with the exception of ram
elements which are supplied in Fluorocarbon (FKM). Other elastomers are available upon request but provided a regular replacement programme
is in place these seals have acceptable performance in the majority of cases.
 [Link] Page 109 Tuesday, April 13, 2004 11:03 AM
Typical Applications for Oilfield Elastomers

Common ASTM Hardness H2 S Temp. Trade Comments

Name Name Rating Resist Rating Names
(Shore A) °
C (°F)
Tetrafluoroethylene-propylene FEPM 60-95 Good 0 to 230 Aflas Excellent general thermo-chemical resistance,
poor mechanical properties below 0°C, moderate
swelling in hydrocarbons, better in amine
(32 to 446) inhibitors than FKM. Mainly downhole
applications.

Ethylenepropilene EPDM 65-90 Good -50 to150 Nordel Good high temperature resistance, excellent
water resistance. Poor oil resistance, large
swelling. Used mainly for Geothermal
Diene (- 58 to 302) applications.
Unsuitable for Oilfield Use.

Perfluoroelastomer FFKM 65-95 Good 0 to 250 Kalrez Excellent general thermo-chemical resistance,

Typical Applications for Oilfield Elastomers

poor mechanical properties below 0ºC, superior

Seals: Elastomers and Thermoplastics

amine and hydrocarbon resistance. Mainly used
(32 to 482) Chemraz downhole for O-ring or chevron ring packing.
Chemraz has slightly improved low temperature
Parofluor properties. Kalrez has higher temperature rating.
Excellent with Glycol, Methanol, and Toluene
Considerably more expensive than FKM or NBR
Zalak
As standard Elmar supplies all wireline pressure control equipment with seals made of Acrylonitrile butadiene (NBR) with the exception of ram
elements which are supplied in Fluorocarbon (FKM). Other elastomers are available upon request but provided a regular replacement programme
is in place these seals have acceptable performance in the majority of cases.
109
 Typical Applications for Oilfield Elastomers
110

Typical Applications for Oilfield Elastomers

Seals: Elastomers and Thermoplastics

[Link] Page 110 Tuesday, April 13, 2004 11:03 AM

Common ASTM Hardness H2 S Temp. Trade Comments
Name Name Rating Resist Rating Names
(Shore A) °
C (°F)
Polyurethane AU, EU poor -42 to 82 Primarily used for its high resistance to abrasion
in packing and line wiper elements. Poor chemical
resistance , although is resistant to mineral oils.
(-44 to 180) Low temperature resistance and high absorption
preclude steam and water.

As standard Elmar supplies all wireline pressure control equipment with seals made of Acrylonitrile butadiene (NBR) with the exception of ram
elements which are supplied in Fluorocarbon (FKM). Other elastomers are available upon request but provided a regular replacement programme
is in place these seals have acceptable performance in the majority of cases.
[Link] Page 111 Tuesday, April 13, 2004 11:03 AM

Seals: Elastomers and Thermoplastics

O-ring Seals

O-ring Seals

O-ring seals are widely used in pressure control equipment. The O-ring is
a torus shaped ring of elastomer material, used within a cavity or groove
to make a pressure tight seal against a surface. The O-ring in the groove
must be compressed, generally 15% or more, to form an effective seal.
Under pressure, the elastomer conforms to the micro fine grooves
between the surface and the sealing piece, forming a leak free seal. The
higher the pressure the better the seal, at least up to the point at which
failure would occur and at which point the elastomer will extrude and
shear.

In wireline pressure control equipment O-rings are generally subjected to

high wear and the worst environmental conditions and should be replaced
frequently. It is imperative that the exact size and type replacement be
used.

O-rings are measured by cross-section width (w) and inside diameter

(ID). The following charts detail the O-ring sizes most commonly used
within the industry. They are taken from BS 1806 and are given in inches
and mm.

111
 O-ring Size Reference Table
112

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 112 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W

-001 1/32 3/32 1/32 .029 .040 .0003 0.74 1.02

-002 3/64 9/64 3/64 .042 .050 .0006 1.07 1.27
-003 1/16 3/16 1/16 .056 .060 .0010 1.42 1.52
-004 5/64 13/64 1/16 .070 .070 .0017 1.78 1.78
-005 3/32 7/32 1/16 .101 .070 .0021 2.57 1.78
-006 1/8 1/4 1/16 .114 .070 .0022 2.90 1.78
-007 5/32 9/32 1/16 .145 .070 .0026 3.68 1.78
-008 3/16 5/16 1/16 .176 .070 .0030 4.47 1.78
-009 7/32 11/32 1/16 .208 .070 .0034 5.28 1.78
-010 1/4 3/8 1/16 .239 .070 .0037 6.07 1.78
-011 5/16 7/16 1/16 .301 .070 .0045 7.65 1.78
-012 3/8 1/2 1/16 .364 .070 .0052 9.25 1.78
-013 7/16 9/16 1/16 .426 .070 .0060 10.82 1.78
-014 1/2 5/8 1/16 .489 .070 .0068 12.42 1.78
-015 9/16 11/16 1/16 .551 .070 .0075 14.00 1.78
-016 5/8 3/4 1/16 .614 .070 .0083 15.60 1.78
-017 11/16 13/16 1/16 .676 .070 .0090 17.17 1.78
 [Link] Page 113 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-018 3/4 7/8 1/16 .739 .070 .0098 18.77 1.78
-019 13/16 15/16 1/16 .801 .070 .0105 20.35 1.78
-020 7/8 1 1/16 .864 .070 .0113 21.95 1.78
-021 15/16 1-1/16 1/16 .926 .070 .0120 23.52 1.78
-022 1 1-1/8 1/16 .989 .070 .0128 25.12 1.78
-023 1-1/16 1-3/16 1/16 1.051 .070 .0136 26.70 1.78
-024 1-1/8 1-1/4 1/16 1.114 .070 .0143 28.30 1.78
-025 1-3/16 1-5/16 1/16 1.176 .070 .0151 29.87 1.78
-026 1-1/4 1-3/8 1/16 1.239 .070 .0158 31.47 1.78
-027 1-5/16 1-7/16 1/16 1.301 .070 .0166 33.05 1.78

Seals: Elastomers and Thermoplastics

-028 1-3/8 1-1/2 1/16 1.364 .070 .0173 34.65 1.78
-029 1-1/2 1-5/8 1/16 1.489 .070 .0188 37.82 1.78
-030 1-5/8 1-3/4 1/16 1.614 .070 .0204 41.00 1.78
-031 1-3/4 1-7/8 1/16 1.739 .070 .0219 44.17 1.78
-032 1-7/8 2 1/16 1.864 .070 .0234 47.35 1.78

O-ring Seals
-033 2 2-1/8 1/16 1.989 .070 .0249 50.52 1.78
-034 2-1/8 2-1/4 1/16 2.114 .070 .0264 53.70 1.78
113
 O-ring Size Reference Table
114

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 114 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-035 2-1/4 2-3/8 1/16 2.239 .070 .0279 56.87 1.78
-036 2-3/8 2-1/2 1/16 2.364 .070 .0294 60.05 1.78
-037 2-1/2 2-5/8 1/16 2.489 .070 .0309 63.22 1.78
-038 2-5/8 2-3/4 1/16 2.614 .070 .0324 66.40 1.78
-039 2-3/4 2-7/8 1/16 2.739 .070 .0340 69.57 1.78
-040 2-7/8 3 1/16 2.864 .070 .0355 72.75 1.78
-041 3 3-1/8 1/16 2.989 .070 .0370 75.92 1.78
-042 3-1/4 3-3/8 1/16 3.239 .070 .0400 82.27 1.78
-043 3-1/2 3-5/8 1/16 3.489 .070 .0430 88.62 1.78
-044 3-3/4 3-7/8 1/16 3.739 .070 .0460 94.97 1.78
-045 4 4-1/8 1/16 3.989 .070 .0491 101.32 1.78
-046 4-1/4 4-3/8 1/16 4.239 .070 .0521 107.67 1.78
-047 4-1/2 4-5/8 1/16 4.489 .070 .0551 114.02 1.78
-048 4-3/4 4-7/8 1/16 4.739 .070 .0581 120.37 1.78
-049 5 5-1/8 1/16 4.989 .070 .0612 126.72 1.78
-050 5-1/4 5-3/8 1/16 5.239 .070 .0642 133.07 1.78
-102 1/16 1/4 3/32 .049 .103 .0040 1.24 2.62
 [Link] Page 115 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-103 3/32 9/32 3/32 .081 .103 .0048 2.06 2.62
-104 1/8 5/16 3/32 .112 .103 .0056 2.84 2.62
-105 5/32 11/32 3/32 .143 .103 .0064 3.63 2.62
-106 3/16 3/8 3/32 .174 .103 .0072 4.42 2.62
-107 7/32 13/32 3/32 .206 .103 .0081 5.23 2.62
-108 1/4 7/16 3/32 .237 .103 .0089 6.02 2.62
-109 5/16 1/2 3/32 .299 .103 .0105 7.59 2.62
-110 3/8 9/16 3/32 .362 .103 .0122 9.19 2.62
-111 7/16 5/8 3/32 .424 .103 .0138 10.77 2.62
-112 1/2 11/16 3/32 .487 .103 .0154 12.37 2.62

Seals: Elastomers and Thermoplastics

-113 9/16 3/4 3/32 .549 .103 .0171 13.94 2.62
-114 5/8 13/16 3/32 .612 .103 .0187 15.54 2.62
-115 11/16 7/8 3/32 .674 .103 .0203 17.12 2.62
-116 3/4 15/16 3/32 .737 .103 .0220 18.72 2.62
-117 13/16 1 3/32 .799 .103 .0236 20.30 2.62

O-ring Seals
-118 7/8 1 1/6 3/32 .862 .103 .0253 21.89 2.62
-119 15/16 1 1/8 3/32 .924 .103 .0269 23.47 2.62
115
 O-ring Size Reference Table
116

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 116 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-120 1 1-3/16 3/32 .987 .103 .0285 25.07 2.62
-121 1-1/16 1-1/4 3/32 1.049 .103 .0302 26.64 2.62
-122 1-1/8 1-5/16 3/32 1.112 .103 .0318 28.24 2.62
-123 1-3/16 1-3/8 3/32 1.174 .103 .0334 29.82 2.62
-124 1-1/4 1-7/16 3/32 1.237 .103 .0351 31.42 2.62
-125 1-5/16 1-1/2 3/32 1.299 .103 .0367 32.99 2.62
-126 1-3/8 1-9/16 3/32 1.362 .103 .0383 34.59 2.62
-127 1-7/16 1-5/8 3/32 1.424 .103 .0400 36.17 2.62
-128 1-1/2 1-11/16 3/32 1.487 .103 .0416 37.77 2.62
-129 1-9/16 1-3/4 3/32 1.549 .103 .0432 39.34 2.62
-130 1-5/8 1-13/16 3/32 1.612 .103 .0449 40.94 2.62
-131 1-11/16 1-7/8 3/32 1.674 .103 .0465 42.52 2.62
-132 1-3/4 1-15/16 3/32 1.737 .103 .0482 44.12 2.62
-133 1-13/16 2 3/32 1.799 .103 .0498 45.69 2.62
-134 1-7/8 2-1/16 3/32 1.862 .103 .0514 47.29 2.62
-135 1-15/16 2-1/8 3/32 1.925 .103 .0531 48.90 2.62
-136 2 2-3/16 3/32 1.987 .103 .0547 50.47 2.62
 [Link] Page 117 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-137 2-1/16 2-1/4 3/32 2.050 .103 .0564 52.07 2.62
-138 2-1/8 2-5/16 3/32 2.112 .103 .0580 53.64 2.62
-139 2-3/16 2-3/8 3/32 2.175 .103 .0596 55.25 2.62
-140 2-1/4 2-7/16 3/32 2.237 .103 .0612 56.82 2.62
-141 2-5/16 2-1/2 3/32 2.300 .103 .0629 58.42 2.62
-142 2-3/8 2-9/16 3/32 2.362 .103 .0645 59.99 2.62
-143 2-7/16 2-5/8 3/32 2.425 .103 .0662 61.60 2.62
-144 2-1/2 2-11/16 3/32 2.487 .103 .0678 63.17 2.62
-145 2-9/16 2-3/4 3/32 2.550 .103 .0694 64.77 2.62
-146 2-5/8 2-13/16 3/32 2.612 .103 .0711 66.34 2.62

Seals: Elastomers and Thermoplastics

-147 2-11/16 2-7/8 3/32 2.675 .103 .0727 67.95 2.62
-148 2-3/4 2-15/16 3/32 2.737 .103 .0743 69.52 2.62
-149 2-13/16 3 3/32 2.800 .103 .0760 71.12 2.62
-150 2-7/8 3-1/16 3/32 2.862 .103 .0776 72.69 2.62
-151 3 3-3/16 3/32 2.987 .103 .0809 75.87 2.62

O-ring Seals
-152 3-1/4 3-7/16 3/32 3.237 .103 .0874 82.22 2.62
-153 3-1/2 3-11/16 3/32 3.487 .103 .0940 88.57 2.62
117
 O-ring Size Reference Table
118

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 118 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-154 3-3/4 3-15/16 3/32 3.737 .103 .1005 94.92 2.62
-155 4 4-3/16 3/32 3.987 .103 .1071 101.27 2.62
-156 4-1/4 4-7/16 3/32 4.237 .103 .1136 107.62 2.62
-157 4-1/2 4-11/16 3/32 4.487 .103 .1202 113.97 2.62
-158 4-3/4 4-15/16 3/32 4.737 .103 .1267 120.32 2.62
-159 5 5-3/16 3/32 4.987 .103 .1332 126.67 2.62
-160 5-1/4 5-7/16 3/32 5.237 .103 .1398 133.02 2.62
-161 5-1/2 5-11/16 3/32 5.487 .103 .1463 139.37 2.62
-162 5-3/4 5-15/16 3/32 5.737 .103 .1529 145.72 2.62
-163 6 6-3/16 3/32 5.987 .103 .1594 152.07 2.62
-164 6-1/4 6-7/16 3/32 6.237 .103 .1660 158.42 2.62
-165 6-1/2 6-11/16 3/32 6.487 .103 .1725 164.77 2.62
-166 6-3/4 6-15/16 3/32 6.737 .103 .1790 171.12 2.62
-167 7 7-3/16 3/32 6.987 .103 .1856 177.47 2.62
-168 7-1/4 7-7/16 3/32 7.237 .103 .1921 183.82 2.62
-169 7-1/2 7-11/16 3/32 7.487 .103 .1987 190.17 2.62
-170 7-3/4 7-15/16 3/32 7.737 .103 .2052 196.52 2.62
 [Link] Page 119 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-171 8 8-3/16 3/32 7.987 .103 .2118 202.87 2.62
-172 8-1/4 8-7/16 3/32 8.237 .103 .2183 209.22 2.62
-173 8-1/2 8-11/16 3/32 8.487 .103 .2249 215.57 2.62
-174 8-3/4 8-15/16 3/32 8.737 .103 .2314 221.92 2.62
-175 9 9-3/16 3/32 8.987 .103 .2379 228.27 2.62
-176 9-1/4 9-7/16 3/32 9.237 .103 .2445 234.62 2.62
-177 9-1/2 9-11/16 3/32 9.487 .103 .2510 240.97 2.62
-178 9-3/4 9-15/16 3/32 9.737 .103 .2576 247.32 2.62
-201 3/16 7/16 1/8 .171 .139 .0148 4.34 3.53
-202 1/4 1/2 1/8 .234 .139 .0178 5.94 3.53

Seals: Elastomers and Thermoplastics

-203 5/16 9/16 1/8 .296 .139 .0207 7.52 3.53
-204 3/8 5/8 1/8 .359 .139 .0237 9.12 3.53
-205 7/16 11/16 1/8 .421 .139 .0267 10.69 3.53
-206 1/2 3/4 1/8 .484 .139 .0297 12.29 3.53
-207 9/16 13/16 1/8 .546 .139 .0327 13.87 3.53

O-ring Seals
-208 5/8 7/8 1/8 .609 .139 .0357 15.47 3.53
-209 11/16 15/16 1/8 .671 .139 .0386 17.04 3.53
119
 O-ring Size Reference Table
120

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 120 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-210 3/4 1 1/8 .734 .139 .0416 18.64 3.53
-211 13/16 1-1/16 1/8 .796 .139 .0446 20.22 3.53
-212 7/8 1-1/8 1/8 .859 .139 .0476 21.82 3.53
-213 15/16 1-3/16 1/8 .921 .139 .0505 23.39 3.53
-214 1 1-1/4 1/8 .984 .139 .0535 24.99 3.53
-215 1-1/16 1-5/16 1/8 1.046 .139 .0565 26.57 3.53
-216 1-1/8 1-3/8 1/8 1.109 .139 .0595 28.17 3.53
-217 1-3/16 1-7/16 1/8 1.171 .139 .0624 29.74 3.53
-218 1-1/4 1-1/2 1/8 1.234 .139 .0654 31.34 3.53
-219 1-5/16 1-9/16 1/8 1.296 .139 .0684 32.92 3.53
-220 1-3/8 1-5/8 1/8 1.359 .139 .0714 34.52 3.53
-221 1-7/16 1-11/16 1/8 1.421 .139 .0744 36.09 3.53
-222 1-1/2 1-3/4 1/8 1.484 .139 .0774 37.69 3.53
-223 1-5/8 1-7/8 1/8 1.609 .139 .0833 40.87 3.53
-224 1-3/4 2 1/8 1.734 .139 .0893 44.04 3.53
-225 1-7/8 2-1/8 1/8 1.859 .139 .0952 47.22 3.53
-226 2 2-1/4 1/8 1.984 .139 .1012 50.39 3.53
 [Link] Page 121 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-227 2-1/8 2-3/8 1/8 2.109 .139 .1072 53.57 3.53
-228 2-1/4 2-1/2 1/8 2.234 .139 .1131 56.74 3.53
-229 2-3/8 2-5/8 1/8 2.359 .139 .1191 59.92 3.53
-230 2-1/2 2-3/4 1/8 2.484 .139 .1250 63.09 3.53
-231 2-5/8 2-7/8 1/8 2.609 .139 .1310 66.27 3.53
-232 2-3/4 3 1/8 2.734 .139 .1370 69.44 3.53
-233 2-7/8 3-1/8 1/8 2.859 .139 .1429 72.62 3.53
-234 3 3-1/4 1/8 2.984 .139 .1489 75.79 3.53
-235 3-1/8 3-3/8 1/8 3.109 .139 .1548 78.97 3.53
-236 3-1/4 3-1/2 1/8 3.234 .139 .1608 82.14 3.53

Seals: Elastomers and Thermoplastics

-237 3-3/8 3-5/8 1/8 3.359 .139 .1668 85.32 3.53
-238 3-1/2 3-3/4 1/8 3.484 .139 .1727 88.49 3.53
-239 3-5/8 3- 7/8 1/8 3.609 .139 .1787 91.67 3.53
-240 3-3/4 4 1/8 3.734 .139 .1846 94.84 3.53
-241 3-7/8 4-1/8 1/8 3.859 .139 .1906 98.02 3.53

O-ring Seals
-242 4 4-1/4 1/8 3.984 .139 .1966 101.19 3.53
-243 4-1/8 4- 3/8 1/8 4.109 .139 .2025 104.37 3.53
121
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122

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 122 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-244 4-1/4 4-1/2 1/8 4.234 .139 .2085 107.54 3.53
-245 4-3/8 4-5/8 1/8 4.359 .139 .2144 110.72 3.53
-246 4-1/2 4-3/4 1/8 4.484 .139 .2204 113.89 3.53
-247 4-5/8 4-7/8 1/8 4.609 .139 .2264 117.07 3.53
-248 4-3/4 5 1/8 4.734 .139 .2323 120.24 3.53
-249 4-7/8 5-1/8 1/8 4.859 .139 .2383 123.42 3.53
-250 5 5-1/4 1/8 4.984 .139 .2442 126.59 3.53
-251 5-1/8 5-3/8 1/8 5.109 .139 .2502 129.77 3.53
-252 5-1/4 5-1/2 1/8 5.234 .139 .2561 132.94 3.53
-253 5-3/8 5-5/8 1/8 5.359 .139 .2621 136.12 3.53
-254 5-1/2 5-3/4 1/8 5.484 .139 .2681 139.29 3.53
-255 5-5/8 5-7/8 1/8 5.609 .139 .2740 142.47 3.53
-256 5-3/4 6 1/8 5.734 .139 .2800 145.64 3.53
-257 5-7/8 6-1/8 1/8 5.859 .139 .2859 148.82 3.53
-258 6 6-1/4 1/8 5.984 .139 .2919 151.99 3.53
-259 6-1/4 6-1/2 1/8 6.234 .139 .3038 158.34 3.53
-260 6-1/2 6-3/4 1/8 6.484 .139 .3157 164.69 3.53
 [Link] Page 123 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-261 6-3/4 7 1/8 6.734 .139 .3277 171.04 3.53
-262 7 7-1/4 1/8 6.984 .139 .3396 177.39 3.53
-263 7-1/4 7-1/2 1/8 7.234 .139 .3515 183.74 3.53
-264 7-1/2 7-3/4 1/8 7.484 .139 .3634 190.09 3.53
-265 7-3/4 8 1/8 7.734 .139 .3753 196.44 3.53
-266 8 8-1/4 1/8 7.984 .139 .3872 202.79 3.53
-267 8-1/4 8-1/2 1/8 8.234 .139 .3992 209.14 3.53
-268 8-1/2 8-3/4 1/8 8.484 .139 .4111 215.49 3.53
-269 8-3/4 9 1/8 8.734 .139 .4230 221.84 3.53
-270 9 9-1/4 1/8 8.984 .139 .4349 228.19 3.53

Seals: Elastomers and Thermoplastics

-271 9-1/4 9-1/2 1/8 9.234 .139 .4468 234.54 3.53
-272 9-1/2 9-3/4 1/8 9.484 .139 .4588 240.89 3.53
-273 9-3/4 10 1/8 9.734 .139 .4707 247.24 3.53
-274 10 10-1/4 1/8 9.984 .139 .4826 253.59 3.53
-275 10-1/2 10-3/4 1/8 10.484 .139 .5064 266.29 3.53

O-ring Seals
-276 11 11-1/4 1/8 10.984 .139 .5303 278.99 3.53
-277 11-1/2 11-3/4 1/8 11.484 .139 .5541 291.69 3.53
123
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124

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 124 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-278 12 12-1/4 1/8 11.984 .139 .5779 304.39 3.53
-279 13 13-1/4 1/8 12.984 .139 .6256 329.79 3.53
-280 14 14-1/4 1/8 13.984 .139 .6733 355.19 3.53
-281 15 15-1/4 1/8 14.984 .139 .7210 380.59 3.53
-282 16 16-1/4 1/8 15.955 .139 .7672 405.26 3.53
-283 17 17-1/4 1/8 16.955 .139 .8149 430.66 3.53
-284 18 18-1/4 1/8 17.955 .139 .8626 456.06 3.53
-309 7/16 13/16 3/16 .412 .210 .0677 10.46 5.33
-310 1/2 7/8 3/16 .475 .210 .0745 12.07 5.33
-311 9/16 15/16 3/16 .537 .210 .0813 13.64 5.33
-312 5/8 1 3/16 .600 .210 .0881 15.24 5.53
-313 11/16 1-1/16 3/16 .662 .210 .0949 16.81 5.33
-314 3/4 1-1/8 3/16 .725 .210 .1017 18.42 5.33
-315 13/16 1-3/16 3/16 .787 .210 .1085 19.99 5.33
-316 7/8 1-1/4 3/16 .850 .210 .1153 21.59 5.33
-317 15/16 1-5/16 3/16 .912 .210 .1221 23.16 5.33
-318 1 1-3/8 3/16 .975 .210 .1289 24.77 5.53
 [Link] Page 125 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-319 1-1/16 1-7/16 3/16 1.037 .210 .1357 26.34 5.33
-320 1-1/8 1-1/2 3/16 1.100 .210 .1425 27.94 5.33
-321 1-3/16 1-9/16 3/16 1.162 .210 .1493 29.51 5.33
-322 1-1/4 1-5/8 3/16 1.225 .210 .1561 31.12 5.33
-323 1-5/16 1-11/16 3/16 1.287 .210 .1629 32.69 5.53
-324 1-3/8 1-3/4 3/16 1.350 .210 .1697 34.29 5.33
-325 1-1/2 1-7/8 3/16 1.475 .210 .1833 37.47 5.33
-326 1-5/8 2 3/16 1.600 .210 .1970 40.64 5.33
-327 1-3/4 2-1/8 3/16 1.725 .210 .2106 43.82 5.33
-328 1-7/8 2-1/4 3/16 1.850 .210 .2242 46.99 5.53

Seals: Elastomers and Thermoplastics

-329 2 2-3/8 3/16 1.975 .210 .2378 50.17 5.33
-330 2-1/8 2-1/2 3/16 2.100 .210 .2514 53.34 5.33
-331 2-1/4 2-5/8 3/16 2.225 .210 .2650 56.52 5.33
-332 2-3/8 2-3/4 3/16 2.350 .210 .2786 59.69 5.33
-333 2-1/2 2-7/8 3/16 2.475 .210 .2922 62.87 5.53

O-ring Seals
-334 2-5/8 3 3/16 2.600 .210 .3058 66.04 5.33
-335 2-3/4 3-1/8 3/16 2.725 .210 .3194 69.22 5.33
125
 O-ring Size Reference Table
126

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 126 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-336 2-7/8 3-1/4 3/16 2.850 .210 .3330 72.39 5.33
-337 3 3-3/8 3/16 2.975 .210 .3466 75.57 5.33
-338 3-1/8 3-1/2 3/16 3.100 .210 .3602 78.74 5.53
-339 3-1/4 3-5/8 3/16 3.225 .210 .3738 81.92 5.33
-340 3-3/8 3-3/4 3/16 3.350 .210 .3874 85.09 5.33
-341 3-1/2 3-7/8 3/16 3.475 .210 .4010 88.27 5.33
-342 3-5/8 4 3/16 3.600 .210 .4146 91.44 5.33
-343 3-3/4 4-1/8 3/16 3.725 .210 .4282 94.62 5.53
-344 3-7/8 4-1/4 3/16 3.850 .210 .4418 97.79 5.33
-345 4 4-3/8 3/16 3.975 .210 .4554 100.97 5.33
-346 4-1/8 4-1/2 3/16 4.100 .210 .4690 104.14 5.33
-347 4-1/4 4-5/8 3/16 4.225 .210 .4826 107.32 5.33
-348 4-3/8 4-3/4 3/16 4.350 .210 .4962 110.49 5.53
-349 4-1/2 4-7/8 3/16 4.475 .210 .5098 113.67 5.33
-350 4-5/8 5 3/16 4.600 .210 .5234 116.84 5.33
-351 4-3/4 5-1/8 3/16 4.725 .210 .5370 120.02 5.33
-352 4-7/8 5-1/4 3/16 4.850 .210 .5506 123.19 5.33
 [Link] Page 127 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-353 5 5-3/8 3/16 4.975 .210 .5642 126.37 5.33
-354 5-1/8 5-1/2 3/16 5.100 .210 .5778 129.54 5.53
-355 5-1/4 5-5/8 3/16 5.225 .210 .5914 132.72 5.33
-356 5-3/8 5-3/4 3/16 5.350 .210 .6050 135.89 5.33
-357 5-1/2 5-7/8 3/16 5.475 .210 .6186 139.07 5.33
-358 5-5/8 6 3/16 5.600 .210 .6322 142.24 5.33
-359 5-3/4 6-1/8 3/16 5.725 .210 .6458 145.42 5.53
-360 5-7/8 6-1/4 3/16 5.850 .210 .6594 148.59 5.33
-361 6 6-3/8 3/16 5.975 .210 .6730 151.77 5.33
-362 6-1/4 6-5/8 3/16 6.225 .210 .7002 158.12 5.33

Seals: Elastomers and Thermoplastics

-363 6-1/2 6-7/8 3/16 6.475 .210 .7274 164.47 5.33
-364 6-3/4 7-1/8 3/16 6.725 .210 .7546 170.82 5.53
-365 7 7-3/8 3/16 6.975 .210 .7818 177.17 5.33
-366 7-1/4 7-5/8 3/16 7.225 .210 .8090 183.52 5.33
-367 7-1/2 7-7/8 3/16 7.475 .210 .8362 189.87 5.33

O-ring Seals
-368 7-3/4 8-1/8 3/16 7.725 .210 .8634 196.22 5.33
-369 8 8-3/8 3/16 7.975 .210 .8906 202.57 5.53
127
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128

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 128 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-370 8-1/4 8-5/8 3/16 8.225 .210 .9178 208.92 5.33
-371 8-1/2 8-7/8 3/16 8.475 .210 .9450 215.27 5.33
-372 8-3/4 9-1/8 3/16 8.725 .210 .9722 221.62 5.33
-373 9 9-3/8 3/16 8.975 .210 .9994 227.97 5.33
-374 9-1/4 9-5/8 3/16 9.225 .210 1.0266 234.32 5.53
-375 9-1/2 9-7/8 3/16 9.475 .210 1.0538 240.67 5.33
-376 9-3/4 10-1/8 3/16 9.725 .210 1.0810 247.02 5.33
-377 10 10-3/8 3/16 9.975 .210 1.1083 253.37 5.33
-378 10-1/2 10-7/8 3/16 10.475 .210 1.1627 266.07 5.33
-379 11 11-3/8 3/16 10.975 .210 1.2171 278.77 5.53
-380 11-1/2 11-7/8 3/16 11.475 .210 1.2715 291.47 5.33
-381 12 12-3/8 3/16 11.975 .210 1.3259 304.17 5.33
-382 13 13-3/8 3/16 12.975 .210 1.4347 239.57 5.33
-383 14 14-3/8 3/16 13.975 .210 1.5435 354.97 5.33
-384 15 15-3/8 3/16 14.975 .210 1.6523 380.37 5.53
-385 16 16-3/8 3/16 15.955 .210 1.7590 405.26 5.33
-386 17 17-3/8 3/16 16.955 .210 1.8678 430.66 5.33
 [Link] Page 129 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-387 18 18-3/8 3/16 17.955 .210 1.9766 456.06 5.33
-388 19 19-3/8 3/16 18.955 .210 2.0854 481.41 5.33
-389 20 20-3/8 3/16 19.955 .210 2.1942 506.81 5.53
-390 21 21-3/8 3/16 20.955 .210 2.3030 532.21 5.33
-391 22 22-3/8 3/16 21.955 .210 2.4118 557.61 5.33
-392 23 23-3/8 3/16 22.940 .210 2.5190 582.68 5.33
-393 24 24-3/8 3/16 23.940 .210 2.6278 608.08 5.33
-394 25 25-3/8 3/16 24.940 .210 2.7366 633.48 5.33
-395 26 26-3/8 3/16 25.940 .210 2.8454 658.88 5.33
-425 4-1/2 5 1/4 4.475 .275 .8863 113.67 6.99

Seals: Elastomers and Thermoplastics

-426 4-5/8 5-1/8 1/4 4.600 .275 .9097 116.84 6.99
-427 4-3/4 5-1/4 1/4 4.725 .275 .9330 120.02 6.99
-428 4-7/8 5-3/8 1/4 4.850 .275 .9563 123.19 6.99
-429 5 5-1/2 1/4 4.975 .275 .9796 126.37 6.99
-430 5-1/8 5-5/8 1/4 5.100 .275 1.0030 129.54 6.99

O-ring Seals
-431 5-1/4 5-3/4 1/4 5.225 .275 1.0263 132.72 6.99
-432 5-3/8 5-7/8 1/4 5.350 .275 1.0496 135.89 6.99
129
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130

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 130 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-433 5-1/2 6 1/4 5.475 .275 1.0729 139.07 6.99
-434 5-5/8 6-1/8 1/4 5.600 .275 1.0963 142.24 6.99
-435 5-3/4 6-1/4 1/4 5.725 .275 1.1196 145.42 6.99
-436 5-7/8 6-3/8 1/4 5.850 .275 1.1429 148.59 6.99
-437 6 6-1/2 1/4 5.975 .275 1.1662 151.77 6.99
-438 6-1/4 6-3/4 1/4 6.225 .275 1.2129 158.12 6.99
-439 6-1/2 7 1/4 6.475 .275 1.2595 164.47 6.99
-440 6-3/4 7-1/4 1/4 6.725 .275 1.3062 170.82 6.99
-441 7 7-1/2 1/4 6.975 .275 1.3528 177.17 6.99
-442 7-1/4 7-3/4 1/4 7.225 .275 1.3995 183.52 6.99
-443 7-1/2 8 1/4 7.475 .275 1.4461 189.87 6.99
-444 7-3/4 8-1/4 1/4 7.725 .275 1.4928 196.22 6.99
-445 8 8-1/2 1/4 7.975 .275 1.5394 202.57 6.99
-446 8-1/2 9 1/4 8.475 .275 1.6327 215.27 6.99
-447 9 9-1/2 1/4 8.975 .275 1.7260 227.97 6.99
-448 9-1/2 10 1/4 9.475 .275 1.8193 240.67 6.99
-449 10 10-1/2 1/4 9.975 .275 1.9126 253.37 6.99
 [Link] Page 131 Tuesday, April 13, 2004 11:03 AM
O-ring Size Reference Table

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-450 10-1/2 11 1/4 10.475 .275 2.0059 266.07 6.99
-451 11 11-1/2 1/4 10.975 .275 2.0992 278.77 6.99
-452 11-1/2 12 1/4 11.475 .275 2.1925 291.47 6.99
-453 12 12-1/2 1/4 11.975 .275 2.2858 304.17 6.99
-454 12-1/2 13 1/4 12.475 .275 2.3791 316.87 6.99
-455 13 13-1/2 1/4 12.975 .275 2.4724 329.57 6.99
-456 13-1/2 14 1/4 13.475 .275 2.5657 342.27 6.99
-457 14 14-1/2 1/4 13.975 .275 2.6590 354.97 6.99
-458 14-1/2 15 1/4 14.475 .275 2.7523 367.67 6.99
-459 15 15-1/2 1/4 14.975 .275 2.8456 380.37 6.99

Seals: Elastomers and Thermoplastics

-460 15-1/2 16 1/4 15.475 .275 2.9389 393.07 6.99
-461 16 16-1/2 1/4 15.955 .275 3.0285 405.26 6.99
-462 16-1/2 17 1/4 16.455 .275 3.1218 417.96 6.99
-463 17 17-1/2 1/4 16.955 .275 3.2151 430.66 6.99
-464 17-1/2 18 1/4 17.455 .275 3.3084 443.36 6.99

O-ring Seals
-465 18 18-1/2 1/4 17.955 .275 3.4017 456.06 6.99
-466 18-1/2 19 1/4 18.455 .275 3.4950 468.76 6.99
131
 O-ring Size Reference Table
132

O-ring Seals
Seals: Elastomers and Thermoplastics

[Link] Page 132 Tuesday, April 13, 2004 11:03 AM

Size Only Nominal Size (in) Standard O-ring Size (in) Basic Metric O-ring Size (mm)
AS 568A (Reference Only) Actual (b) per AS 568A Volume Actual (b) per AS 568A
Uniform
Dash No. ID OD W ID W Cu In ID W
-467 19 19-1/2 1/4 18.955 .275 3.5883 481.46 6.99
-468 19-1/2 20 1/4 19.455 .275 3.6816 494.16 6.99
-469 20 20-1/2 1/4 19.955 .275 3.7749 506.86 6.99
-470 21 21-1/2 1/4 20.955 .275 3.9615 532.26 6.99
-471 22 22-1/2 1/4 21.955 .275 4.1481 557.66 6.99
-472 23 23-1/2 1/4 22.940 .275 4.3319 582.68 6.99
-473 24 24-1/2 1/4 23.940 .275 4.5185 608.08 6.99
-474 25 25-1/2 1/4 24.940 .275 4.7051 633.48 6.99
-475 26 26-1/2 1/4 25.940 .275 4.8917 658.88 6.99
[Link] Page 133 Tuesday, April 13, 2004 11:03 AM

Seals: Elastomers and Thermoplastics

O-ring Seals

O-ring Extrusion

One of the main problems with O-rings is extrusion, which is the exces-
sive distortion under pressure of a portion of a seal into the clearance gap
between mating parts. This is usually the result of subjecting seal to
extreme high-pressure. Extrusion of O-rings may be prevented by the use
of anti-extrusion (backup) rings. These are thin rings of much harder
material that are fitted into the O-ring gland to provide zero clearance.
They are available in many elastomer materials. For extremely high-pres-
sure, a metal or hard plastic non-extrusion ring may be employed.

If only one back of ring is used, it should be placed so that the O-ring is
between it and the pressure.

O-ring Failure

There are many different ways in which an O-ring seal can fail during ser-
vice and the recognition of these can quite often help to resolve the prob-
lem.
• Compression Set
One of the mechanical properties measured in elastomer com-
pounds is its resistance to compression set. This is the ability of a
compound to recover after extended periods of compression.
Obviously the lower a compound's compression set the better.
Compression set leads to a loss of initial seal energizing and

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Seals: Elastomers and Thermoplastics

O-ring Seals

hence sealing ability and is probably the most common failure of

an O-ring seal. Compression set can be caused by several fac-
tors but is in the majority of cases, attributable to the use of poor
quality elastomers. Poor quality elastomers will undoubtedly have
higher compression set than those supplied by a reputable sup-
plier.
Other conditions that lead to compression set include:
• excessive temperature causing the O-ring to harden and
lose its elastic properties
• high temperatures external or internal, caused by fluid con-
tact or mechanical friction
• swelling due to fluid incompatibility
• excessive O-ring squeeze due to incorrect section size
used or the over tightening of adjustable gland nuts
Compression set is normally characterized by a loss of regular
cross-section shape i.e. the O-ring has flats in the direction of
compression and has no longer an “O” cross-section.
• Extrusion
O-ring failure through extrusion is usually caused by excessive
pressure, temperature and is often present in dynamic applica-
tions. Extrusion is normally characterized by a peeling or nibbling
of the O-ring furthest away from the pressure side.
• Spiral Failure
Spiral failure of an O-ring is normally found on long slow stroking
dynamic applications. This type of failure occurs when the O-ring
twists within its housing at one point on its diameter. As the seal
reciprocates this causes spiral markings and in severe cases
deep cuts on the O-ring's surface.

Conditions that lead to spiral failure include:

• Eccentric components.
• Compound too soft.
• Poor surface finish or corrosion pitting.
• Poor O-ring lubrication.
• Low stroke speed.
• O-ring rolled or pinched on assembly.
Spiral failure is characterized by the spiral marks or cuts on the
O-ring surface.

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Seals: Elastomers and Thermoplastics

Ram Seal Elements

• Explosive Decompression
When the fluid contained is a gas and the system pressure is high
a proportion of the gas migrates into the structure of the O-ring.
When the pressure is released this trapped gas expands within
the structure causing ruptures and blisters. There is little that can
be done to prevent this from occurring with the exception of
selecting a material that has a good resistance to explosive
decompression.
In wireline pressure control equipment ram elements are particu-
larly at risk from this type of failure. Ram elements spend the
greater part of their life in a relaxed state i.e. not energized, which
means that unlike an O-ring that has an initial compression and
therefore contains an increased internal pressure they are more
susceptible to gas migration.
Explosive decompression is characterized by bubbles and blis-
ters on the surface of the seal.
• Abrasion
Only found in dynamic applications and usually as a result of one
of the following:
• Poor surface finish through damage or corrosion.
• Lack of proper lubrication.
• Surface finish too high leading to abrasion due to the sur-
face's inability to retain lubricant.
• Excessive temperatures.
• Highly abrasive particles present in the system fluid.
Abrasion is characterized as flattening or cuts on one side of the
O-ring.

Ram Seal Elements

The wireline valve rams utilize two elastomer seals, the outer seal and the
inner seal (often termed ram elements).

The outer seal is a moulded one-piece horseshoe shape that seals the
clearance gap of the upper half of the ram body when pressure is applied
from below. The inner seal is a rectangular shape moulded seal between
two backup plates that is grooved to fit a particular wireline size. It is com-

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Seals: Elastomers and Thermoplastics

Packing Elements

pressed around the outside diameter of the wireline when the rams are
closed and links with the outer seal to form a complete seal around the
ram body.

The inner seals are generally and often replaced after closing the rams on
a braided wireline. It is imperative to replace them with inner seals that
have the correct size wireline groove to fit the wireline or the wireline
could be damaged and cut. (Notice that multiline seals adapt to several
wireline sizes, and seals for small slickline have no grooves on the rubber
seal).

The inner seals are available for most wireline sizes and in a variety of
elastomer compounds. Elmar's standard material for ram elements is flu-
orocarbon.

Packing Elements

Packing elements, which include line rubbers, stuffing box packing and
blow-out plugs, can be made from elastomer materials or thermoplastics
depending on conditions present. For most applications basic elastomer
materials perform adequately. For high wear applications elastomers with
filler materials or thermoplastics are commonly used. For high-pressure
and high temperature applications glass or carbon filled thermoplastics
may be used.

They are wireline size dependent in order to provide the most effective
pressure sealing. When changing the wireline size used all packing ele-
ments must be changed to reflect the different line size.

By the very nature of their use packing elements are replaced often due to
the high wear encountered as the wireline passes through them.

They are available to fit most wireline sizes.

How to Recognize O-ring Materials

A quick way to differentiate amongst oil field elastomers is based on den-

sity:

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Seals: Elastomers and Thermoplastics

How to Recognize O-ring Materials

• Nitrile has a density of 1.30 to 1.40

• Viton has a density of 1.85 to 1.90
• Kalrez has a density of 2.02 to 2.05

It is therefore possible to immerse the O-rings in liquids of different densi-

ties and determine which material is used. Different density fluids are
often available in the mud logger’s office on a rig.

The method is valid for unused O-rings. O-rings exposed to well fluids
may contain trapped gas and their apparent density may be lower.

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Maintenance
Pressure Testing

MAINTENANCE

Pressure control equipment maintenance can be divided into two basic

categories: "spot" maintenance and preventive maintenance.

Spot maintenance is performed each time the equipment has been used
on a job. It consists of a visual inspection for any damage and cleaning
the dirt and grease off the external surfaces of the equipment and
removal of well fluids that have collected or become trapped in the equip-
ment during the job. All external O-ring seals should be checked and
replaced, if needed.

Preventative maintenance is performed periodically every 12 months. (In

high-activity areas the interval between maintenance sessions should be
reduced to 6 months or shorter). It consists of disassembly, thorough
cleaning, inspection, and replacement of worn or damaged parts, seals
and O-rings. Then all major components of the equipment are reassem-
bled, painted or coated as required, pressure tested, and function tested
under pressure.

Spot maintenance keeps the equipment in a constant state of readiness

while preventative maintenance, as the name implies, prevents small
problems from becoming big ones, and preserves the integrity of the
pressure control system. The equipment will function only as well as it is
maintained.

Pressure Testing

Pressure control equipment is subjected to two different types of pressure

test: a well site operational pressure test and an "in-shop" controlled envi-
ronment pressure test.

In-shop Tests

The pressure rating of any pressure control equipment is expressed in

pounds per square inch (psi) and it is shown as two numbers; a working
pressure rating (WP) and a test pressure rating (TP).

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Maintenance
Pressure Testing

The "in-shop" pressure test is preferably carried out in a purpose built

pressure test bay, allowing proper protection for personnel and surround-
ing equipment. It is carried out to WP, and once a year to TP, to verify that
a safety margin exists for wellsite operations. The wireline valves are
tested to WP with closed rams, using a test rod instead of the wireline.

Caution: Never test closed rams to test pressure, only

the valve body.

Well-Site Tests

It is good practice, (and it is a requirement for several major oil compa-

nies) to pressure test the equipment when rigged-up, before running into
the well.

The wellsite pressure test is normally carried out against a closed christ-
mas tree valve, to a value 15-20% above the maximum expected well-
head pressure during operation. Make sure that this maximum pressure
applied for testing does not exceed the equipment WP rating, nor the
wellhead valve rating.

Some christmas tree valves do not allow applying pressure from above.
In this case a ball valve or additional gate valve must be used between
the wellhead equipment string and the christmas tree.

Major oil companies require that all connections broken during subse-
quent runs are pressure tested before opening-up the well.

Elmar's quick test sub allows testing only the single connection broken to
introduce a new tool/perforating gun in the lubricator string, without the
need of a full riser string pressure test. A significant rig time saving is pos-
sible using a quick test sub.

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Maintenance
Pressure Testing

Wellsite pressure tests should be carried out with water or inhibited water
(for instance, a 75% water- 25% glycol mixture) to avoid hydrates prob-
lems.

The volume of fluid needed can be estimated from the following table:

Approximate Volume of WHE Strings,

per foot of lengths
String ID Volume (Liters) Volume (Gallons)
2-1/2 in 0.97 0.26
3 in 1.39 0.37
4-1/16 in 2.55 0.67
5-1/8 in 4.06 1.07

Allow 30-50% excess for hose connections and spillage during repetitive
tests.

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Certifications & Major Surveys

Safety Factor

CERTIFICATIONS & MAJOR SURVEYS

The following section is provided as an aid to understanding the certifica-

tion requirements and terminology.

Safety Factor

Pressure-containing equipment is designed to perform with a sufficient

margin of safety to allow for several variables and uncertainties, such as
materials yield strength variations, approximations in design calculations,
stress concentrations, machining tolerances, shock loading, additional
stresses caused by the way the equipment is used, abuse and misuse in
the field. Such margin of safety is embodied in a "factor of safety" (FS),
defined as:

Minimum Yield Strength

FS=
Design Working Stress

For example, a factor of safety 2 means that the design working stress is
only half of the minimum yield strength of the materials used. A minimum
value of FS is imposed by industry codes and/or government agencies.

Working Pressure

The choices of FS and of the materials yield strength define the pressure
rating of the equipment, usually expressed in psi (pounds per square
inch) working pressure, WP. This is the maximum allowable pressure
never to be exceeded during field operations of the equipment. Standard
ratings are 3,000 psi, 5,000 psi, 10,000 psi, 15,000 psi or 20,000 psi WP
rating.

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Certifications & Major Surveys

Test Pressure

Test Pressure

To ensure integrity and safety at WP, pressure equipment is tested by the

manufacturer at a maximum pressure greater than or equal to WP,
defined as test pressure TP. The value of TP is stipulated by industry
standards. For WHE equipment normally TP = 2 x WP for working pres-
sure ratings up to 5,000 psi, and TP = 1.5 x WP for ratings 10,000 psi and
higher.

Industry Standards

Industry standards normally applying to wellhead pressure control equip-

ment are API 6A, (American Petroleum Institute Specification 6A: Specifi-
cation for wellhead and christmas tree equipment) and for H2S
equipment, NACE MR-01-75 (National Association of Corrosion Engi-
neers Material Requirements: Sulfide Stress Cracking Resistant Metallic
Material for Oilfield Equipment).

API 6A defines the design and test criteria for all pressure containing
equipment used on a wellhead, while NACE MR-01-75 defines the type of
metallic materials that are allowed in conditions where H2S is present.

Equipment conforming to NACE Standards is normally built with steel

alloys having reduced hardness and reduced yield strength. Therefore
most H2S pressure equipment has thicker walls and is heavier than stan-
dard equipment. Elmar lightweight equipment is an exception as it uses
special high yield alloys.

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Certifications & Major Surveys

Temperature Rating

Temperature Rating

API 6A specifies classes of material suitable for use in defined tempera-

ture brackets.

Temperature Ratings
Material Class °F °C
K -75 to 180 -70 to 82
L -50 to 180 -46 to 82
P -20 to 180 -29 to 82
R 40 to 120 4 to 49
S 0 to 150 -18 to 65
T 0 to 180 -18 to 82
U 0 to 250 -18 to 121
X 0 to 350 -18 to180
Y 0 to 650 -18 to 345

High Temperature

Most metals used in WHE are suitable for operations at temperatures well
above the temperatures normally encountered on WHE operations. Elas-
tomer seals set the high temperatures operating limits. In special cases
(HPHT wells, geothermal operations) WHE might be subject to tempera-
tures above 250°F, as high as 500°F. In these cases, besides using spe-
cial seal systems, the material strength used to determine the maximum
working pressure is derated (material Classes X and Y) - refer to API 6A
for the derating factors.

Low Temperature

In very cold conditions, the steel tends to become brittle and can shatter
under an impact. To define the resistance of materials in very cold envi-
ronments a toughness test is made (toughness = ability to resist shock
loads). The most common impact test is the Charpy Test. API 6A Specifi-
cation dictates that Charpy values for pressure control equipment steel
should be a minimum of 15 ft-lbs for equipment to be certified for use
below 0°F (-20°C).

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Certifications & Major Surveys

Equipment Certification

Equipment Certification

"Certification" for pressure bearing equipment is dictated by government

regulations, or requested by customers. Often third party certification is
requested.

A certification document can be issued by the manufacturer (sometimes

called manufacturer survey), or by a third party. Certifications state that
the components, equipment, or assemblies meet the requirements speci-
fied by the industry standards (e.g. API 6A) or by local government regu-
lations, such as SI 289 for mobile rigs in the UK sector of the North Sea,
the Norwegian Petroleum Directorate Regulations in the Norwegian Sec-
tor of the UK, Alberta Recommended Practices (ARP) in Canada, etc.

Third party certification documents are issued by recognized certifying

agencies such as Bureau Veritas (BV), American Bureau of Shipping
(ABS), Lloyds, Det Norske Veritas (DNV), etc. There are two kinds of cer-
tificates:
• Design Approval Certificates: Type Approval (TA), Independent
Review Certificate (IRC), Design Verification Report (DVR).
These are assessments by a competent body verifying that the
specifications for manufacture of an assembly meet the require-
ments of the authorities' regulations and the industry standards.
• Certificates of Conformity (COC): These certify that a specific
asset or assembly, identified by its serial number conforms to the
approved design (TA, IRC and DVR) and manufacturing file and/
or the industry regulations. They often include test and inspection
reports that certify to the performance of tests (pressure, load, lift-
ing capacity, etc.), according to standards and to the validity of
test results.

For wellhead pressure control equipment a certification package normally

consists of an IRC and a COC issued by a third party agency. The IRC is
valid for all pieces of equipment manufactured under the same part num-
ber, and the same engineering file. The certificate of conformity is valid for
one specific piece of equipment, identified by a serial number. A certifi-
cate of conformity is valid for a limited period of time, normally five years
and must be renewed.

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Certifications & Major Surveys

Equipment Certification

Renewal of Certification

Renewal of certification requires a major survey, that is a detailed inspec-

tion and performance verification carried out or controlled by a certifica-
tion agency. This survey is normally required every five years. It entails as
a minimum:
• Visual inspection
• Random thickness tests on all pressure containing parts using
direct measurements, X-rays, or Ultrasonics
• Dye-penetrant or MPI examination on all threads and any dam-
aged area determined at visual inspection
• Hydrostatic body test at Test Pressure (TP)
• Operational test at Working Pressure (WP)
• Review of quality files

Traceability

Traceability is often part of certifications' requirements. By "traceability"

we mean the ability for parts to be identified as to their origin, manufactur-
ing process and materials used. For a piece of equipment to be traceable,
the specific material batch used for each part must be identifiable, and a
material spec certificate available. Traceability requirements for certified
items cover also replacement parts used in maintenance and repairs, e.g.
O-rings.

Quality File

A quality file is a compilation of documents showing, for one individual

asset or assembly the following information:
• Manufacturer's bulletins or manuals
• Certification documents, usually an IRC and a COC, with all rele-
vant renewals
• Traceability of critical components and materials when required
• Maintenance, test and inspection records
• Operating history notes

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Certifications & Major Surveys

Good Practice for Certifiable Operations

Good Practice for Certifiable Operations

The following good practice rules apply to all operations with WHE equip-
ment:
• All equipment used for pressure control operations must be pres-
sure rated, to a defined working pressure (WP) and a test pres-
sure (TP). For high or low temperature applications a
temperature rating must also be defined.
• WHE shall never be used above its working pressure (WP) rating,
nor outside its temperature rating.
• In a string of WHE equipment, the WP of the weakest component
gives the string overall pressure rating.
• All WHE components holding pressure must have valid certifica-
tion.
• All WHE components holding pressure must have a quality file.
• All WHE equipment used on the well-site is qualified for its use by
passing annually a hydrostatic body test and an operational
check at WP.
• A well-site pressure test must be carried out after set-up on each
job. The maximum allowable working pressure during the job
equals the wellsite test pressure.
• All crews operating WHE equipment must be qualified to carry
out pressure operations. This normally entails having followed a
specific training course on WHE operations, and having per-
formed at least two jobs under supervision of a certified operator.
• In the presence of H2S, only H2S certified equipment must be
used. Crew member must be qualified to work in H2S environ-
ment.

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Certifications & Major Surveys

Good Practice for Certifiable Operations

Selection of WHE Working Pressure Rating

When operating on a well under existing or potential pressure, it is good

practice to allow for the overpressure necessary to "bullhead" and kill the
well if well control problems arise. Therefore the WP rating of the equip-
ment must be chosen to exceed the maximum potential wellhead pres-
sure by 20 to 25%.

WP ≥ 1.2×Maximum Potential Well Head Pressure

If no information is available on the maximum potential wellhead pres-

sure, the bottom-hole reservoir pressure less a gas gradient to surface
can be chosen.

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Cold Weather Operations Hints

O-ring Seals

COLD WEATHER OPERATIONS HINTS

Operations of WHE in arctic/extreme cold conditions require special pre-

cautions and equipment particularly adapted to below-freezing tempera-
tures.

O-ring Seals

• Normal Viton or Neoprene 90-Duro O-rings lose their "memory" in

extreme cold.

• They become very stiff, are easily nicked, and cannot be installed. If
already installed, they may not seal after flexing.

• Arctic Grade 80-Duro (down to -10 °C) or 70-Duro O-ring must be

used.

• Keep the O-ring warm for ease of installation.

• Make sure there is no moisture trapped in the O-ring grooves.

Remove all normal grease, clean and dry the O-ring area thoroughly,
and coat the O-ring with a light coat of arctic grease or arctic hydraulic
oil.

Hydraulic Systems

• Hydraulic pumps and systems require the use of an arctic or aviation

hydraulic oil.

• In extreme conditions (-40 °C or less) dilute the hydraulic oil with

automotive antifreeze or neat glycol.

Hydraulic Hoses

• Use rubber hoses, as Polyflex or equivalent will easily crack.

• Hoses become extremely stiff in cold weather. Unwind them with care
to avoid splits and kinks. Large ID hoses should be used for spring

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Cold Weather Operations Hints

Air Operated Pumps

return components i.e. stuffing boxes, due to the increased oil viscos-
ity in extreme cold.

Air Operated Pumps

Any moisture carried by the air will create condensation and freeze
impeding proper operations. It is important to minimize the amount of
moisture carried by the air before it reaches the pump system.

Use an air dryer and air lubricator with “Kilfrost” right at the output of the
compressor. Using a large volume tank to store and cool the air before the
grease and hydraulic control system is very beneficial. Small amounts of
antifreeze will keep the tanks from freezing.

The air lubricator at the input of the control skid should be filled with “Kil-
frost”.

Grease and Grease Injection System

In cold weather operations there may be up to 30° difference between

midnight and midday if there is sunlight.

It is therefore necessary to have different viscosity greases to adapt to

temperature. The grease injection system should have a split tank or two
different tanks and two separate pumps, which can be operated indepen-
dently or simultaneously through a manifold to obtain a mixture of lower
and higher viscosity greases.

Largest ID hoses available should be used.

For -40 to -20°C a 30 weight mineral oil can be used, replaced by 10VIS
wireline grease for higher temperatures.

Upon arrival at job site, it is very important to circulate grease through the
injection and return hoses, open-ended into the right viscosity tank, finish-
ing off with the lighter weight grease. This makes it easier to get the tools
moving in the lubricator. Switch to a higher viscosity once line weight has
increased to maintain well control at higher line speeds. Measuring the

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Cold Weather Operations Hints

WHE Strings

pressure necessary to pump open-ended will give an indication of the

extra pressure losses due to the increased viscosity of the cold grease. In
case the grease type initially in the hoses is unknown it is recommended
to flush the hoses with diesel into a waste tank. Make sure to avoid spills
and site contamination.

WHE Strings

Any water or moisture remaining in the string will freeze and make it
impossible to connect or operate the equipment. After servicing the equip-
ment let it dry thoroughly, and spray it with WD-40 to displace any remain-
ing moisture.

When pressure testing equipment in the base use only a 50-50 mixture of
water and glycol or hydraulic oil. On the well site use only neat glycol
below -30°C and a 50-50 mixture of water and glycol above. If glycol is
not available a 50-50 mixture of water and methanol can be used with
added precautions. Methanol is toxic and can explode if air is left in the
lubricator.

Use of Steam and Heat Tracing

Use of steam directly on the equipment connections is not recommended.

The connection will remain wet and freeze, requiring more steam at every
operation.

On extremely cold days, a steam hose can be run alongside the grease
injection hose and wrapped around the lubricator and GIH, and tied
securely. A tarpaulin or an insulating "sock" can be wrapped around
grease hoses and lubricator string to conserve heat.

If the rig site is equipped with portable hot air generators/space heaters,
the whole string can be surrounded by a light fabric "heat sock" through
which the hot air stream is channelled.

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Cold Weather Operations Hints

Hydrates

Hydrates

Under certain conditions of temperature and pressure, some constituents

of natural gas will combine with the water vapor to form hydrocarbon
hydrates. These hydrates have the appearance of snow or ice and form in
the valves, flow lines or even several hundred feet below surface in the
tubing. They will form also in oil wells if gas segregates at the top.
Hydrates formation is a function of gas composition. Generally the prob-
lem appears at temperatures below 21°C and is accelerated by low tem-
peratures.

Glycol can be used to prevent formation of ice or hydrates and injected

continuously during the job through the wireline valve or through purpose
designed chemical injection subs, or glycol injection valves at the top of
the lubricator string.

Methanol mixed with the wet gas reduces the maximum temperature at
which hydrates can form. Methanol injected on top of ice or hydrates will
cause them to melt.

Caution: Methanol is poisonous and should be used

with care; it also attacks 'O'-rings if left a long time;
should only be injected with a dedicated methanol
pump. Therefore, use glycol to prevent hydrates for-
mation, use methanol to dissolve hydrates if they form.

151