MAINTENANCE AND OPERATION

MANUAL

EEC ULTRAFLOW TYPE ‘E-S’ DRILLING

CHOKE AND CONTROL CONSOLE

ENERGY EQUIPMENT CORPORATION

P.O. Box 920939, Houston, Texas 77292-0939, Ph: (713) 957-228
INTRODUCTION

The Energy Equipment Corporation remote operated ‘E-S’ UltraFlow Choke has been field proven to
be a reliable choke for the drilling industry. Like all mechanical and pressure containing equipment
there are certain fundamental rules which operators should observe.

The basic mechanical operation of the EEC ‘E-S’ Ultraflow Choke is very simple. However, the
applications for which this type of equipment is used may be complex enough to require specific
training and experience to complete an operation successfully. The EEC ‘E-S’ Ultraflow Choke
should be operated by, or under the supervision of qualified operators only.

All mechanical equipment is subject to wear caused by either use or abuse. The EEC ‘E-S’ Ultraflow
Choke and control Console should be inspected on a regular basic by qualified personnel. Any repairs
should be made before undertaking any operations involving the EEC ‘E-S’ Ultraflow Choke.

In the event of any problems please contact:

Energy Equipment Corporation

4703 Creekmont
Houston, Texas 77091
PH: 713-957-2288
FX: 713-957-3322
E-Mail: [email protected]
1. GENERAL INFORMATION

A. CHOKE

The Energy Equipment Corporation UltraFlow Type ‘E-S’ Drilling Choke is a hydraulically operated
valve with an adjustable orifice. In the fully open position the maximum orifice size is 1.9 square
inches (12 cm²) to complete closed. The orifice size is controlled by means of rotating the ‘Front’
(upstream) disc from 0° to 180° while the ‘Back’ (downstream) disc remains stationary. The ‘Front’
disc is rotated by a hydraulically-driven rotary actuator. The discs, constructed of Tungsten Carbide,
are precision ground and lapped to a mirror like finish. (See Figure 1)

Figure 1.

The Energy Equipment Corporation UltraFlow Type ‘E-S’ Drilling Choke was designed primarily to
control high pressure gas kicks and various fluid flows during drilling operations but can be used in a
variety of applications.

B. CONTROL PANEL

The control panel is normally used to operate the EEC UltraFlow Type ‘E-S’ Choke from a remote
location. The panel is portable and may be located at any safe location to satisfy specific needs or
requirements that the customer may have. In cases where more than one panel is required to satisfy
needs or requirements, additional panels may be added with only minor adjustments to hose and
fittings, etc.

EEC Energy Equipment Corporation

DIGITAL PUMP STROKE/RATE METER

INTRINSICALLY SAFE, CLASS 1 DIV 1

0000
TOTAL STROKES

0000
STROKES PER. MIN.

60 STROKES
PER MIN.
PUMP PUMP
RESET 1 2
TEST

Figure 2.
The control panel is a completely self-contained unit with the exception of an air supply. The air input
requirements are a minimum of 30 PSI, however 50-125 PSI with an available 10 cubic ft/min. (CFM)
is recommended for maximum performance. There are no electrical requirements for the panel or
choke. The stroke counter assembly has a 6 Volt battery pack located inside the counter box. The
battery pack is a replaceable/expendable item that should last approximately 36 months under normal
conditions.

Should the air operated hydraulic pump fail, the choke may still be operated by using the manual
hydraulic pump located on the control panel base. This method of operation will work only if the
remaining hydraulic systems are intact. If air pressure is lost the position indicator gauge will not
work. Should the hydraulic system have a complete failure, provisions have been made for manual
choke operation by inserting a bar into the indicator head. The indicator head features an indicator
band so adjustment of the orifice size is still possible.

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

EEC Energy Equipment Corporation

DIGITAL PUMP STROKE/RATE METER

INTRINSICALLY SAFE, CLASS 1 DIV 1

0000
TOTAL STROKES

0000
STROKES PER. MIN.

60 STROKES
PER MIN.
PUMP PUMP
RESET 1 2
TEST

Figure 3.
2. INSTALLATION

A. INSTALLING THE CHOKE

The standard inlet and outlet connections supplied on the EEC UltraFlow Type ‘E-S’ Choke are API
Type 2-9/16” 10,000 psi WP with a BX-153 ring groove or a 3-1/16” 10,000 psi WP with a BX-154
ring groove.

All UltraFlow Choke assemblies have a series of solid Tungsten Carbide wear sleeves and a flange
protector. The flange protector when installed extends 1/8” (4mm) from the face of the outlet flange.
This will protect the ring groove and flange from ‘washing out’.

NOTE: MAKE SURE THAT THE MATING FLANGE BEING BOLTED TO THE ULTRAFLOW
OUTLET SPOOL DOES NOT INTERFERE WITH THE FLANGE PROTECTOR. THIS COULD
CRUSH THE CARBIDE PARTS INSIDE THE CHOKE.

Always check all bolting studs and nuts for cracks, damages, and wear to threads before installing.
Any damaged parts should be replaced.

Always use new gaskets when installing the choke. (Refer to API Specification for Wellhead and
Christmas Tree Equipment).

The nuts should be evenly torqued and have full engagement onto the stud. The stud should have 3 to
4 threads showing for best results. After torquing the nuts, the flange raised faces should come
together and be parallel to the companion or adapter flanges.

Whenever possible, two gate or positive sealing valves should be installed upstream of the choke
(between the Blowout Preventer and the choke) and one downstream of the choke to permit isolation
for maintenance while other sections of the manifold are in use.

When using a flare line from the choke it must be securely anchored according to API Specifications.
(Refer to API Bulletin RP 53).

Whenever the choke is reassembled or installed/reinstalled in the manifold the choke should be
retested. Refer to -Section 5- of this manual for test procedure.

B. REPOSITIONING THE ACTUATOR

After installing the UltraFlow Choke assembly in the manifold, it may be necessary to reposition the
hydraulic actuator. The actuator assembly should have the open area facing down or to the side to
facilitate excess water drain-off. Should the actuator assembly not be positioned properly the
following procedure should be followed to rotate it to the proper position.

1) Remove the four mounting bolts which attach the Actuator Assembly to the mounting
bracket.
2) Pull the Actuator Assembly away from the choke body until the square shaft clears the
Indicator Head.

NOTE: DO NOT ROTATE THE SQUARE SHAFT OR INDICATOR HEAD DURING THIS
OPERATION. DOING SO WILL CHANGE THE ALIGNMENT OF THE DISC OR CHANGE THE
POSITION INDICATOR AND THE CHOKE WILL NOT FUNCTION PROPERLY.

3) Rotate the entire actuator assembly 90° or 180° to the desired position.
4) Clean and grease the square shaft and push the actuator assembly into the indicator head.
5) Install the four bolts removed previously and tighten them to 27 ft-lbs.
 C. HYDRAULIC CONTROL LINES

Connect the two 3/16” 3,000 psi hydraulic hoses (with ¼” Male and Female Couplings) to the choke
control panel and the UltraFlow Choke actuator assembly using the quick disconnects. (See Figure 4)
They should be placed in such a manner as to prevent damage by sharp edges and hazards for rig
personnel.

D. CHOKE POSITION INDICATOR

The panel is equipped with ¼” O.D. vinyl poly flow tubing. Connect the ¼” O.D. vinyl tubing from
the fitting on the position indicator regulator (located inside the actuator box assembly) to the position
indicator gauge (located on the control console face).

1) Layout and cut ¼” tubing to the desired length.

2) Connect the tubing to the rear of the panel labeled “Air to Transmitter” and “Air Return
from Transmitter.” Note: Tubing connectors provided on the panel and actuator are a
“Push On” type. Simply push the tubing onto the connector and pull back to insure
connection. To release. Push the ring into the fitting and pull out the hose.
3) The fittings on the position indicator regulator are not labeled. Check the arrow located
on the position indicator regulator to determine the direction of flow.
4) Turn the air supply valve on the control panel to the on position. Operate the choke valve
to the full open position by holding the controls lever in the choke open position until the
pump stalls. The position indicator gauge should show open, if the gauge is not
calibrated correctly, recalibrate per procedures described in -Section 4.8-.

NOTE: THE CONTROL PANEL AND CHOKE VALVE ARE SHIPPED FROM ENERGY
EQUIPMENT CORPORATION FULLY CALIBRATED.

Push the control lever to the right toward the choke close position. The hydraulic pump should start
stroking and the needle of the Position Indicator Gauge should begin moving. Hold the lever in this
position until the choke is fully closed and the hydraulic pump stalls; then release the lever. The
control valve lever should return to the center position.

If there are any problems with any of these operations, refer to -Section 6- of this manual.

E. INSTALLING THE CONTROL PANEL

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

1) AIR SUPPLY

Connect a rig air supply to the rear of the panel. The inlet for the rig air is labeled “Rig
Air Supply.” (See Figure 5) The air supply should be capable of supplying a constant
moisture-free 50-120 psi of air. Trash or moisture in the air supply can cause a
malfunction in the air operated hydraulic pump or in the position indicator assembly. The
air supply should be connected to a source that will not be disconnected from the panel.

Care should be taken when routing the air supply to avoid damage to the hose by
crimping, cutting or from excessive heat. A hose of ½” diameter should be capable of
supplying an adequate amount of air for proper operation up to 50 feet. Should a longer
hose be required, a ¾” diameter hose is recommended. The panel is equipped with a ½”
NPT male connection for installing the air supply line.
2) PUMP STROKE COUNTER

The EEC pump stroke counter is a digital readout type, which is powered by a built in
battery pack located inside the pump stroke counter box. No external electrical power
supply is required. The meter comes complete with a 125’ limit switch assembly
(magnetic proximity switches optional).

The limit switch assemblies mount to the mud pump frame near the exposed portion of
the pump rods so that the pump rod collar or “splash guard” will contact the limit switch
“whisker rod”. Mount the limit switch assemblies to the pump frame using the C-Clamp
bolted to the switch. There should be one full deflection and release of the “whisker rod”
for each pump stroke to assure proper operation of the stroke counter and to avoid double
counting. Route the cable from the switch assembly to the panel so that it will not be cut
or damaged. (NOTE: The panel and switch assemblies are pre-wired and no further
connections are required.)

Operate the pump stroke counter switch assemblies by hand to determine Pump #1, #2 or
#3. There is a pump selector switch located on the bottom of the pump stroke counter
box inside the panel. This switch is used to select the desired pump stroke count and rate
being displayed.

3) GAUGE PROTECTOR

Two gauge protectors have been provided with the panel. Connect the drill pipe pressure
gauge protector (See Figure 5) assembly to the rig standpipe and the casing pressure
gauge assembly to the choke manifold. Whenever possible mount the assembly in the
upright position with the hammer nut down, this will allow the mud and drilling fluids to
drain from the unit when no pressure is in the manifold. Connect the hose from the
gauge protector to the drill pipe pressure or casing pressure gauge on the panel. Use
caution when running the hose so that it does not get cut, crimped, worn, or burned by
other equipment.

The gauge protectors are rated for 10,000 psi WP and may be mounted to a 2” Figure
1502 female hammer union hub on the standpipe and choke manifold. The gauge
protector lines should be filled with hydraulic fluid prior to leaving Energy Equipment. If
the lines are not filled see -Section 4.7.B- of this manual for the hydraulic line filling
procedure.
 F. MULTIPLE CHOKE INSTALLATION

Dual Panel

If two EEC UltraFlow Choke valves are used in the manifold, they both may be operated from a Dual
EEC control panel. The Dual panel is installed in the same manner as the Single panel. On the rear of
the Dual panel there are OPEN and CLOSE connection ports for each choke. There are also “air to”
and “air return” lines for each choke. It is very important not to interchange the lines from Choke
1 with the lines from Choke 2. It is recommended to install one set of lines at a time. The OPEN and
CLOSE lines for Choke 1 are located next to the drill pipe pressure adapter fitting. The OPEN and
CLOSE lines for Choke 2 are located next to the casing pressure adapter fitting. Facing the back of the
EEC Dual Control Console, the air lines for Choke 1 are the right pair and air lines for Choke 2 are on
the left.
The gauge protector assemblies and supply air are installed in the same manner as a Single Control
Console.

3. OPERATION

The choke discs should remain in the full OPEN position when the choke is not in use. Operation of
the EEC UltraFlow Choke should always begin with the choke in the OPEN position. (Closed choke
discs may result in hydraulic shock in the well bore and if the mud pumps are running can result in lost
returns and a downhole blowout.) For example: at the start of a well control procedure, the choke
should not be closed until after the blowout preventer has been closed and drilling fluid is flowing
through the manifold and UltraFlow Choke. This helps to seat the discs and prevents mud particles
from getting between the discs. The choke should be closed slowly to avoid hydraulic shock on the
surface pressure control equipment and the casing seat.

A. NORMAL OPERATING METHOD (FAST)

1) Move master AIR SUPPLY valve to the ON position (See Figure 2).
2) Open the HYDRAULIC REGULATOR all the way.
3) The Control Console displays the following information that is typically used in well
control procedures.

Drill pipe pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 kPa increments).
Casing pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 kPa increments).
Choke position (full OPEN to full CLOSE).
Mud pumps stroke rate and stroke count.

4) Be prepared to shift the CONTROL LEVER in either direction to maintain the desired
casing or drill pipe pressure.

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

5) When the well control operation is complete, open the choke and turn master AIR
SUPPLY valve OFF to remove all pressure on the hydraulic system.
B. ALTERNATE OPERATING METHOD (SLOW)

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

2) Open the HYDRAULIC REGULATOR valve if a faster response is needed.

C. EMERGENCY OPERATION

1) Failure of air supply to air pump.

A. Install PUMP HANDLE on the HAND PUMP which is mounted on the base of the
Control Console skid. (Be sure pump BLEED-OFF valve on the HAND PUMP is
closed).
B. To change choke opening, hold the CONTROL LEVER in the desired position while
stroking the HAND PUMP.

2) Rupture in Hydraulic line or connection.

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

Figure 5.
4. SERVICE AND MAINTENANCE

A. PROCEDURES

1) ROUTINE INSPECTION

The EEC UltraFlow Choke is a key element of the pressure control system used to
prevent rig blowouts. Therefore, it is important that the UltraFlow Choke and Control
Console be maintained in good operating condition at all times (See Figure 6).

EEC Energy Equipment Corporation

DIGITAL PUMP STROKE/RATE METER

INTRINSICALLY SAFE, CLASS 1 DIV 1

0000
TOTAL STROKES

0000
STROKES PER. MIN.

60 STROKES
PER MIN.
PUMP PUMP
RESET 1 2
TEST

2) DAILY VISUAL CHECKS

Check the presence of a hand pump (Item 2 ), a manual choke operating bar, and all panel
labels.

Check fluid level in the hydraulic oil reservoir (Item 1 ). Fill with the correct hydraulic
oil. Keep a supply of oil at the choke panel or close by.

See that all connections fit tight. Make sure the hydraulic hoses, pump switch cable, and
air-lines are properly connected and not cut or pinched.

Check the Pump Stroke/Rate Meter (Item 8). Place the selector switch on “TEST”. The
meter should be counting and should show 128 SPM, Select Pump 1 or Pump 2 and
observe counter and rate display. Reset counter to zero after test.
 See that the pump stroke counter switches (Item 3 ) are properly attached to the mud
pump and counting the correct number of strokes.

3) DAILY OPERATIONAL CHECKS

Turn the master air supply valve (Item 5 ) on. The hydraulic pressure gauge (Item 12 )
should show 1000-1100 psi (6895-7584 kPa).

Close the hydraulic regulator (Item 11 ) and then open 1-1/2 turns. Operate the control
lever (Item 6 ). Complete a full cycle of the choke discs from full OPEN, to full CLOSE,
back to full OPEN. The position indicator (Item 10 ) should track the choke disc
movement according to the choke lever selection.

To operate the hand pump (Item 2 ) to close or open the choke discs, shut the air supply
off. Hold the choke control lever in desired position and operate the hand pump. Make
sure the bleed valve on the hand pump is closed. Leave the pump piston in the DOWN
position to avoid rust or corrosion.

Observe the Drill Pipe and Casing Pressure gauges (Item 7 ). The pressure value should
be approximately the same as the rig gauges. Gauge faces should be clean and visible.

4) REMOVING THE EEC ULTRAFLOW CHOKE FROM THE MANIFOLD

CAUTION:

BEFORE ATTEMPTING TO WORK ON A ULTRAFLOW CHOKE IN A MANIFOLD,

EXTREME CAUTION SHOULD BE EXCERCISED TO ASSURE THAT THERE IS NO
PRESSURE TRAPPED IN THE CHOKE VALVE OR CHOKE MANIFOLD. ALWAYS USE
PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAY BE TRAPPED IN THE CHOKE
VALVE OR MANIFOLD. ONLY PERSONNEL WHO HAVE RECEIVED INSTRUCTION ON
THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT AND PROCEDURES FOR
WORKING IN AREAS WHERE H2S MAY BE PRESENT SHOULD BE PERMITED TO WORK
ON THE ULTRAFLOW CHOKE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN INJURY.

Rotate the choke discs to the full OPEN position. Allow the pressure in the choke valve
to be relieved before continuing with this procedure.

Carefully loosen the outlet flange nuts one turn each until seal or ring gasket is broken
but do not remove the nuts on the outlet flanges of the choke valve. After all the nuts are
loosened, break the seal on the ring gasket by separating the outlet flange from the
manifold flange. Stand on either side of the flange gap, never over it, when breaking the
seal to avoid possible severe personal injury. Once the seal is broken and all pressure
inside the choke is relieved, the nuts and studs may be safely removed. Do not use a pry
bar to remove flange because of possibly damaging the extended wear sleeve.

Provide some manner of support for the valve then carefully loosen the upstream flange
nuts one turn until seal is broken and any trapped pressure is released, then remove the
nuts and studs on the inlet flange.
CAUTION:

THE ULTRAFLOW CHOKE IS RATED FOR H2S SERVICE THEREFORE THE MATERIALS
USED TO MANUFACTURE THE FLANGES, NUTS, AND STUDS ARE RELATIVELY SOFT
AND SUBJECT TO SURFACE DISTORTION AND DENTS FROM POOR WORK PRACTICES.
CARE SHOULD BE EXCERCISED IN THE HANDELING PROCEDURES AND USE OF TOOLS
WHEN WORKING ON THE ULTRAFLOW CHOKE TO AVOID DAMAGING THESE PARTS.
DAMAGED PARTS WILL ADVERSELY AFFECT THE STRUCTURAL INTEGRITY OF THE
ULTRAFLOW CHOKE AND MAY RESULT IN INJURY.

1. Refer to -Section 2.A- of this manual for reinstalling the choke in the
manifold.

5) CHANGING THE DISC ASSEMBLIES

This section describes the procedure for removing the UltraFlow discs from the outlet
end of the valve body for inspection and or replacement and removal of the wear sleeves.
See EEC Drawing 42046-0 for part number information.

CAUTION

BEFORE ATTEMPTING TO WORK ON A ULTRAFLOW CHOKE, EXTREME CAUTION

SHOULD BE EXCERCISED TO ASSURE THAT THERE IS NO PRESSURE TRAPPED IN THE
CHOKE VALVE. ALWAYS USE PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAY
BE TRAPPED IN THE CHOKE VALVE. ONLY PERSONNEL WHO HAVE RECEIVED
INSTRUCITON ON THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT AND
PROCEDURES FOR WORKING IN AREAS WHERE H2S MAY BE PRESENT SHOULD BE
PERMITTED TO WORK ON THE ULTRA FLOW CHOKE. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN INJURY.

Carefully loosen the outlet spool bolts on turn each. After all the bolts are loosened,
break the o-ring seal and unbolt the outlet spool, carefully separating it from the body.
The spool is fastened to the choke body with 7/8” ferry head cap screws. Locating pins
provide alignment between the body and the outlet spool.

1. To remove the choke discs, first rotate the front disc to the full OPEN
position if this has not been previously done. Wash any sand, grit or weight
material from around the exposed portion of the back disc and disc opening.

2. Insert the hook end of the disc puller (EEC Part No. 96-11-083E) in the disc
opening as illustrated in Figure 6a. and gently remove both discs using the
sliding weight on the puller.

CAUTION

TO AVOID INJURY, CAUTION SHOULD BE TAKEN TO AVOID GETTING ANY PART OF

THE HAND CAUGHT BETWEEN THE SLIDING WEIGHT AND THE SOP ON THE END OF
THE PULLER SHAFT.

Maintain the position of the hook on the puller to avoid chipping the corners of the disc orifice. Even if the
discs are worn they may be repairable if not damaged from this procedure. When the discs have been
removed, locate and inspect the stationary disc locking pin. Replace if damaged.
 Figure 6a.

3. Clean both disc assemblies thoroughly and inspect for wear or damage. The
primary criteria for determining whether or not the choke discs are reusable
is that they can provide a positive seal under pressure when installed in the
choke. See -Section 5.2- of this manual for Hydrostatic Disc Test
procedure.

4. Wash out and clean the interior of the choke body and the O-ring sealing
surfaces.

5. Remove the O-rings on the back disc carrier and the choke body flange and
replace these O-rings.

CAUTION

THE O-RINGS USED IN THE ULTRAFLOW CHOKE ARE MADE OF A SPECIAL RESISTANT
MATERIAL. USE ONLY O-RINGS SPECIFIED IN EEC DRAWING 42046-0.

6. Thoroughly clean the disc assemblies and apply a light film of silicone
grease to the O-ring groove on the rear disc carrier. Avoid getting grease on
the polished disc faces because this can cause the choke to leak when tested.

7. Insert the front disc assembly into the body so that the half-moon opening
side is facing the choke inlet flange. Be sure that the turning fork fingers
and the locating pin in one of the fingers align properly with the slots and
locating pin hole in the front disc assembly. The front disc should fit
loosely into the body and into the turning fork fingers.
8. Position the back disc locking pin in the groove on the inside diamter of the
choke body. Align the matching pin groove in the back disc assembly and
insert the back disc. Note: The moon-shaped opening must be facing the
inlet flange of the choke valve. (See Figure 7).

Figure 7.

9. To remove the outlet spool wear sleeves carefully press them out through
the end which bolts to the body. There are three identical large internal
diameter wear sleeves and one with a smaller opening that protects the
outlet flange seal.

10. Inspect the wear sleeves for wear and replace as necessary.

11. Before reinserting the wear sleeves, clean and inspect the bore of the spool.
Be especially careful to remove any dirt, rust or debris from the shoulder
where the extended wear sleeve makes contact. Failure to do so may cause
the wear sleeves to break the choke discs when the spool is bolted to the
valve body.

12. Remove any dirt, rust or debris from the ends of the wear sleeves and the
shoulder on the extended wear sleeve. Apply a light film of silicone grease
on the outside of the wear sleeves and insert them into the spool.

13. Reassemble the outlet spool to the valve body using the alignment pins and
the ferry head cap screws. Check to be sure the O-rings are properly
positioned. Use only the screws and bolts specified in EEC Drawing
42046-0 to assemble. Discard and replace any damaged screws. Tighten
these screws uniformly. The bolts should be torqued to 165 ft/lbs (224
Nm). Over-torquing the bolts will cause them to stretch and reduce their
strength which can result in premature failure.
 14. Clean and inspect the inlet and outlet flange faces and ring grooves. Apply
a light film of general purpose grease or rust inhibitor to the face and ring
groove for corrosion protection.

6) BONNET END DISASSEMBLY

This section describes the procedure for removal of the Actuator Assembly and Bonnet
from the Choke Valve. It also covers the removal and inspection of the turning fork.
These procedures may be done with the UltraFlow Choke either installed in the choke
manifold or removed.

CAUTION

BEFORE ATTEMPTING TO WORK ON A ULTRAFLOW CHOKE IN A MANIFOLD,

EXTREME CAUTION SHOULD BE EXERCISED TO ASSURE THAT THERE IS NO
PRESSURE TRAPPED IN THE CHOKE VALVE OR CHOKE MANIFOLD. ALWAYS USE
PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAY BE TRAPPED IN THE CHOKE
VALVE OR MANIFOLD. ONLY PERSONNEL WHO HAVE RECEIVED INSTRUCTIONS ON
THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT AND PROCEDURES FOR
WOKING IN AREAS WHERE H2S MAY BE PRESENT SHOULD BE PERMITED TO WORK
ON THE ULTRAFLOW CHOKE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN INJURY.

1. The first step in disassembling the Bonnet from the Choke is to remove the
Acutator Assembly. Before doing this, position the choke discs in the full
OPEN position. To remove the Actuator Assembly from the Choke Valve,
remove the four bolts attaching the adapter to the Actuator. This exposes
the four bolts tht attch the adapter to the Choke Valve. Remove these bolts
and proceed to the next step.

2. Remove the cap screw attaching the Indicator Head to the Turning Fork.
Remove the Indicator Head from the Turning Fork shaft.

3. Before removing the Bonnet, mark the Valve Body and Bonnet so they can
be reassembled with the same orientation. Remove the remaining ferry
head cap screw attaching the Bonnet to the body. Inspect these screws for
damage or distortion and replace as necessary. Use only bolts specified in
EEC Drawing 42046-0. Remove the Bonnet from the Valve Body.

CAUTION

MOST COMMON BOLTS, STUDS AND NUTS AVAILABLE DO NOT MEET THE
REQUIREMENTS FOR H2S SERVICE AND WILL FAIL FROM HYDROGENT
EMBRITTLEMENT. REPLACE BOLTS, STUDS AND NUTS WITH AUTHORIZED
REPLACEMENT PARTS.

4. Push the Turning Fork out of the Bonnet being careful not to damage the
shaft surfaces that rotate inside the Bonnet.

5. Clean the Turning Fork and inspect for wear or damage. The Thrust
Bearing and O-ring seal areas should be smooth. The hex should not be
rounded, cracked or deformed. Replace the Turning Fork if any of these
conditions exist. Lubricate the Turning Fork shaft with a light application
of silicone grease before reassembly.
 6. Replace the Thrust Bearing, Shaft Bushing, all O-rings and backup rings on
the Bonnet. Refer to EEC Drawing 42046-0 for the proper location of these
parts. The parts that are used in the UltraFlow Choke are made of special
material for exposure to H2S gas. Use only parts specified in EEC Drawing
42046-0 to replace components in the UltraFlow Choke.

7. Reinsert the Turning Fork in the Bonnet being careful not to damage the O-
rings or bushing. The Bonnet should be clean and have a light application
of silicone grease on the surfaces where there is contact or close proximity
to the Valve Body and Turning Fork.

8. If the Outlet Spool is not to be removed from the body, the front disc
assembly must be properly positioned on the turning fork prior to
installation. Be sure to properly align the locating pin in the Turning Fork
finger with the alignment hole in the front disc assembly. The polished
surfaces on both the front and back disc must be completely clean, dry and
free of grease to assure proper seating.

9. Clean the Indicator Head and apply a light film of grease to the square and
hex sockets. Check that the Indicator Head socket will fit freely on the
Actuator Assembly shaft. This will eliminate problems when assembling
the Actuator Assembly to the valve.

10. When inserting the Bonnet assembly into the valve body, position the half
moon opening on the front disc toward the inlet flange and align the marks
described in Step 3 on the Bonnet and Valve Body.

11. Reinsert and uniformly tighten the bolts securing the Bonnet to the Valve
Body and the Actuator Assembly to the Bonnet. Note: Four of the bolts are
longer than the rest. The longer bolts are used to attach the Actuator
Assembly to the Bonnet. The Actuator Assembly may be positioned in
three possible positions, but never up-side down. Care should be exercised
to assure that both the Actuator Assembly shaft and the choke discs are in
the OPEN position when these two components are reassembled. Evenly
torque these bolts to 165 ft/lbs (224 Nm.) Over-torquing the bolts will
cause them to stretch and reduce their strength which can result in
premature failure.

7) GAUGE PROTECTOR

The purpose of the Gauge Protector is to transmit fluid pressure from the drill pipe or the
casing to the Control Console and isolate the gauges from the drilling mud. See EEC
Drawing 80004-0 for part number information.

A. Gauge Protector Repair

1. If the hydraulic hose is to remain attached to the gauge protector, remove

the plug from the side of the body. This will permit air to enter the body
when the piston is removed.

2. Remove the body from the female hub by removing the wing nut.

3. Remove the stainless steel internal snap ring from the bore of the gauge
protector body.
 4. Insert a ½”-13NC bolt in the tapped hole at the bottom of the piston. Use
the bolt as a handle to extract the piston.

5. Clean the piston and replace the O-rings on the piston. Use only the size
and type O-ring called for in EEC Drawing 80004-0.

CAUTION

THE O-RINGS USED IN THE GUAGE PROTECTOR ARE MADE OF A SPECIAL H2S
RESISTANT MATERIAL. USE ONLY THE O-RINGS SPECIFIED IN EEC DRAWING 80004-0.

6. Clean and inspect the bore of the gauge protector body for corrosion, wear
and pitting. Replace the body if these conditions exist.

7. Before reinstalling the piston apply an ample film of silicone grease on the
piston and O-rings. Manually insert the piston all the way into the body.
The piston should move in the body with only moderate physical effort. If
the piston sticks, replace the piston. Do not file or grind the bore of the
gauge protection body or O.D. of the piston.

8. Reinstall the stainless steel internal snap ring. Refer to -Section 4.7 B- of
this manual for refilling the gauge protector with hydraulic fluid. The body
plug is replaced during the line filling procedure.

B. Filling Gauge Protector Lines

After assembly, the gauge protector, signal line and gauge lines on the Control Console
should be filled with hydraulic oil and purged of air. A few drops of oil will be lost each
time the line is coupled or uncoupled. It is, therefore, advisable to avoid disconnection
these lines once the system has been purged. Loss of hydraulic fluid in the lines may
cause the gauge to read incorrectly. The hydraulic fluid in the system must be free of air
or full pressure cannot be transmitted to the gauge.
1. Place the gauge protector in a vertical position near the Control Console.
The signal line should be connected tightly to the gauge protector and the
Control Console manifold.

2. Remove the check valve cap on the back of the Control Console manifold
and attach the hand pump loosely to the check valve (See Figure 8). Do not
tighten this connection yet.

3. Fill the manual hand pump reservoir with hydraulic fluid. While purging,
keep the hand pump reservoir at least ½ full to avoid pumping air into the
line.

4. Pump slowly, purging air from the pump at the loose connection. When the
pump is purged of air, tighten the connection between the pump and the
check valve.

5. Turn the damper valve on the gauge counterclockwise several turns to

relieve the dampening effect.

6. Remove the pipe plug on top of the gauge to allow air to bleed from the
system.

Figure 8.

7. Pump fluid into the system until no air bubbles appear at the plug on the
gauge. Tighten the plug and push the damper valve in, turning clockwise to
engage the threads.

8. Lay the hydraulic hose out as straight and flat as possible, below the level of
the gauge.

9. Remove the plug from the gauge protector body.

10. Pump hydraulic fluid into the system to purge all air from the signal line
and the gauge protector. Bleed air out at the gauge protector plug opening.
 11. When the signal line and gauge protector appear to be purged or air,
continue pumping slowly and rock the gauge protector slightly to help pass
any remaining air through the vent holes. Rotate the gauge protector plug
end up, to displace any air from the passage.

12. When all the air has been purged from the system, replace the plug on the
gauge protector and tighten.

13. Once the plug in the gauge protector is replaced, continue to pump
hydraulic fluid into the system until the piston contact the internal snap ring
in the bore of the gauge protector.

14. Close the hand pump cover and remove the pump from the check valve.

15. Replace the check valve cap.

8) POSITION INDICATOR SYSTEM

This system utilizes a 3 to 15 psi (21 to 103 kPa) air signal to operate an indicator gauge
on the Control Console. The signal comes from a plunger type regulator. As the choke is
rotated toward the “CLOSE” position, a cam connected to the Control Console shaft
moves the pivot arm assembly. The pivot arm assembly pushes on the regulator plunger
and increases the air signal. At the full OPEN position, the signal is 3 psi (21 kPa), at the
full CLOSED position the signal is 15 psi (103 kPa).
The Position Indicator gauge is labeled OPEN and CLOSE with a mark at the middle
position to indicate ½ or 50% open. The Position Indicator serves as an aid in observing
the direction and speed of changes being made in the choke opening.

Calibration and Adjustment

Connect the supply air from the Control Console to the left tubing fitting, and connect the
signal return air to the right tubing fitting. Turn the air supply on (See figure 9).
 Figure 9.

A. To Zero the “Position the Indicator” Gauge

1. Completely OPEN the choke.

2. Loosen the ¼” nut and set screws on the camshaft so the cam turns on the
shaft.

3. Rotate the cam so the scribe mark on the short side of the cam lines up with
cam follower.

4. Tighten shaft nut and set screws.

5. Loosen the pivot block locking screw on rear of mounting plate and turn the
“zero” adjustment screw until signal output is 3 psi (21 kPa) on a test gauge,
or “OPEN” on the position indicator gauge.

6. Tighten pivot block locking screws.

7. Be sure the output is 3 psi (21 kPa) when the the locking screw is tight.
Movement during tightening may slightly change the setting. This can
result in inaccurate readings of the position indicator. If output is not 3 psi
(21 kPa), adjust pivot block as indicated in Step 5 above to obtain the
required 3 psi (21 kPa).

8. Completely CLOSE the choke. The test gauge should read 15 psi (103
kPa), or “CLOSED” on the position indicator gauge. If not, it will be
necessary to adjust the span of the Indicator Gauge.
 B. To Zero the “Span” of the Indicator Gauge

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

2. If less that 15 psi (103 kPa), loosen both socket head cap screws and move
regulator bracket slightly away from the pivot block; if more than 15 psi
(103 kPa), move regulator bracket slightly toward the pivot block.

3. Tighten both socket head cap screws.

4. Completely OPEN the choke. If output is not 3 psi (21 kPa), re-adjust the
pivot block as in Section 5.1.12 to 3 psi (21 kPa).

5. Completely close the choke and check 15 psi (103 kPa) signals.

6. Repeat Steps 1 through 5 until 3 and 15 psi (21 and 103 kPa) outputs are
obtained.

NOTE:
IF IT IS NOT CONVENIENT TO USE THE CONTROL PANEL TO ROTATE THE CHOKE, USE A
SHORT ADAPTER CONNECTION BETWEEN THE “OPEN” AND “CLOSED” CONNECTORS,
AND ROTATE THE CHOKE BY HAND; HOWEVER, IT IS BEST TO CHECK THE CONTROL
CONSOLE AND CHOKE VALVE TOGETHER.

9) DIGITAL PUMP/STROKE RATE METER

The EEC Digital Stroke / Rate Meter has been designed for simple maintenance. The
meter contains three interconnected modules; a display module, a switch module and a
battery pack. Should any one of these modules fail, they are not repairable and must be
replaced. Refer to the Troubleshooting Guide in -Section 6.5-. Parts information is given
in the attached 96-11-321E Maintenance Manual.

10) ACTUATOR ASSEMBLY

See the Appendix for the manufacturer’s instructions for repair and maintenance of the
Actuator Assembly.

5. PRESSURE TESTING

This section describes how to perform a shell and disc hydrostatic test on the UltraFlow Choke. This
test is not intended to supersede or duplicate the Standard API Specification 6A Shell and Leak Test,
but provide a routine procedure to verify that the seals and discs are not leaking and to verify the
integrity of the pressure containing parts.

A. PROCEDURES

1) SHELL HYDROSTATIC TEST PRESSURE

1. Completely OPEN the choke discs.

 2. Connect test flanges with isolation valves to the inlet and outlet flanges of
the UltraFlow Choke.

3. Place the UltraFlow Choke with the side of the Actuator Assembly
housing and the outlet flange resting on the ground. The inlet flange is
pointing upward.

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

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

6. Open the hydraulic inlet valve and purge any air that may be trapped in the
hydraulic feed line.

7. It may be necessary to purge air from the hydraulic line to the pressure
gauge. Open the bleed fitting for the pressure gauge and close the
isolation valve on the inlet test flange. Pump hydraulic oil through the
gauge line until all air is removed. Close the bleed fitting for the gauge.

8. With the inlet and outlet isolation valves closed and the hydraulic inlet
valve open, slowly raise the pressure on the choke shell to 10,000 psi
(68950 kPa). Check the valve and test flanges for leaks. If leaks occur,
stop the test, take appropriate steps to correct the problem and repeat this
test procedure.

9. If no leaks are evident at this point, close the hydraulic valve on the inlet
test flange and observe the pressure gauge for three (3) minutes. If the
pressure begins to bleed down before three minutes, inspect the choke and
test flanges for leaks. Repair leaks as required and repeat this test
procedure.

10. Open the isolation valve on the outlet test flange and remove the test
flanges.

CAUTION

DO NOT BLOCK THE DISCHARGE OPENING FOR THE ISOLATION VALVES. WHEN THE
VALVES ARE OPENED UNDER PRESSURE A SMALL QUANTITY OF WATER WILL SHOOT
OUT OF THE OPENING.

2) HYDROSTATIC DISC TEST PROCEDURE

1. To prepare the choke for the hydrostatic disc test, fill the valve with water
and remove all of the trapped air as described in -Section 5.A.1- Steps 1-7.

2. With the isolation valves on the inlet and outlet test flanges closed, slowly
raise the pressure in the choke to approximately 2,500 psi (17238 kPa).

3. With the hydraulic valve open and pump on, close the choke discs. Open
the isolation valve on the outlet test flange. This should seat the choke
discs. Slowly raise the pressure in the choke to 10,000 psi (68950 kPa)
leaving the outlet isolation valve open.
 4. Watch the test gauge for three (3) minutes. If the pressure bleeds down,
disassemble the choke to determine the cause for the leakage. Replace the
discs or seals as required and repeat this test procedure.

6. TROUBLESHOOTING

A. DIAGNOSTIC GUIDES

1) CHOKE DISCS WILL NOT OPEN OR CLOSE

CAUTION

BEFORE DISCONNECTING AIR OR HYDRAULIC LINES, TURN THE SYSTEM OFF AND
MAKE ABSOLUTELY SURE THAT ALL PRESSURE IN THE LINES HAS BEEN RELIEVED.
FAILURE TO DO SO MAY RESULT IN INJURY.

To locate the problem when the Control Console will not operate the UltraFlow Choke, turn the master
air supply valve “ON”. The control lever should be in the neutral “HOLD” position. Fully open the
hydraulic regulator by turning the knob counterclockwise several turns. If the hydraulic pump cycles a
few times and stops, proceed to Section -6.A.1-. Step 5.
If the hydraulic pump continues to cycle, proceed with the following steps in the order listed (See
Figure 10).

1. Check the hydraulic fluid level in the reservoir. If less than half full, add
the correct hydraulic fluid, EEC part number 28-67-060E. Do not use
diesel oil because this will cause some valve seals and hydraulic hoses to
deteriorate.

2. Check the low pressure suction hose between the reservoir and the
hydraulic pump for leaks, collapse or crimping. This condition will cause
the pump to lose prime and not pump fluid. Replace this hose as needed.

3. Check the high pressure hose from the output manifold on the hydraulic
pump to the hydraulic regulator and from the hydraulic regulator to the
control valve for leaks. Replace these hoses as needed.

Figure 10.
 4. Disconnect the return line on the hydraulic relief valve. This hose must
temporarily be plugged to prevent hydraulic fluid in the reservoir from
leaking out. Make certain to remove this plug before reinstalling the
hydraulic relief valve return line. If hydraulic oil is leaking from the
discharge of the relief valve when the pump is cycling, slowly tighten the
pressure adjustment screw on the relief valve while observing the pressure
gauge on the output manifold on the hydraulic pump. When the maximum
reading on this pressure gauge reaches 1800 psi (12411 kPa) stop
tightening the adjustment screw on the relief valve and lower the air
pressure on the air regulator feeding the hydraulic pump until the hydraulic
pressure drops to 1500 psi (10342 kPa). At this point, the pump should
stop cycling and the relief valve should stop leaking from the return
connection. If the relief valve continues to leak, replace it.

5. Remove the return line from the control valve. Start the hydraulic pump
and check the return connection for leakage. If hydraulic fluid leaks from
this connection, repair or replace the control valve.

6. Remove the pump suction and discharge check valves. Check for debris or
a frozen valve. Repair or replace as needed.

7. Inspect the open and close hydraulic lines to the choke form crimps,
pinching and damage. Replace as needed.

8. Connect the “Choke Open” hydraulic line to the “Choke Close” hydraulic
line using the quick-connect hose coupling on the Actuator Assembly.

Operate the control lever to both the OPEN and CLOSE positions. If the hydraulic pump begins to
cycle when the control lever is moved to the OPEN and CLOSE positions, check the hydraulic lines
for the leakage and proceed to Step 9. Reconnect the hydraulic lines to the Actuator Assembly.

9. Turn off the air supply to the hydraulic pump and bleed the hydraulic
system to relieve the pressure in the lines between the hydraulic pump and
the rear manifold on the Console.

Remove the high pressure hose between the hydraulic regulator and the control lever. Make sure the
hydraulic regulator is open. Turn on the air supply to the hydraulic pump. If little or no fluid flows
through the hydraulic regulator, then it is plugged and must be repaired or replaced.

10. At this point if the Control Console will still not operate the choke, the
problem has been isolated to either the Actuator Assembly or the Choke
Valve. Remove the Actuator Assembly (See Section 2.B.) and rotate the
Actuator using the Control Console. If the Actuator does not rotate, check
the routing of hydraulic lines inside the Actuator cover and repair or
replace as needed. If the Actuator still does not rotate, replace the
Actuator. (See Appendix D for manufacturer’s instructions.)

If the Actuator rotates when the control lever is operated the problem has been isolated to the Choke Valve.
Remove the Bonnet end of the choke using the procedure beginning the -Section 4.6-. Clear debris from
the valve or repair the choke and reassemble.

2) CHOKE OPENS OR CLOSES TOO SLOWLY

1. Check for partial plugging in the hydraulic regulator needle valve and in
the check valves of the quick disconnect hose couplings.
 2. If faster choke response is desired replace the standard 3/16” ID high
pressure hose with ¼” ID hose or hard piping. DO NOT EXCEED 15 psi
(103 kPa) hydraulic pressure. If the Turning Fork becomes locked,
hydraulic pressure greater than 15 psi (103 kPa) could result in over-
torqing and “twisting off” the end of the Turning Fork. This condition
would make it impossible to control the position of the choke discs.

3) CHOKE VALVE LEAKS

1. Determine the location of the leak. If the leak is at the Bonnet end of the
valve, remove the Bonnet and Turning Fork from the body as described in
-Section 4.6- of this manual. Clean and inspect the sealing surface for
damage and wear. Replace the seals as required and reassemble the valve
as described in -Section 4.6-.

2. If the Choke Valve leaks between the body and outlet spool, remove the
UltraFlow Choke from the manifold and repair the outlet spool end of the
valve as described in -Section 4.5-.

If the inlet or outlet flanges leak, remove the valve and replace the seals as described in -Sections 4.5 and
4.6.

4) CHOKE DISCS LEAK

There are several conditions that will cause the choke discs to leak. The repair procedure
to stop the discs from leaking is to disassemble the choke from the outlet end and
examine the internal parts to determine the cause for the leak. -Section 4.5- describes the
proper disassembly and inspection procedure.

Below is a list of conditions to be checked that will cause the choke discs to leak.

• Dirt, rust or other debris between the discs

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

5) DIGITAL PUMP STROKE/RATE METER

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

A troubleshooting symptom-cure table can be found in the attached EEC PN: 96-11-321E
Manual

6) PRESSURE GAUGES NOT READING CORRECTLY

The pressure gauges located on the EEC UltraFlow Choke Control Console will, in
almost all cases, be the gauges which are used to determine drillpipe pressure and casing
pressure during operations involving the use of the EEC UltraFlow Choke. If these
gauges are not working properly, repairs should be made before operations involving the
UltraFlow Choke are undertaken.

1. Check that the dampening valve on the gauge is not closed.

2. Check the hydraulic hose to the gauge protector for damage or crimping.

3. If the gauge fails to register correctly at higher pressures, check for air in
the hydraulic lines or improperly charged lines to the gauge protectors.
See -Section 4.7.B- of this manual.

4. If the hydraulic lines to the gauge protector are longer than 100 ft. (30
meters), hard piping or special steel braided hose will be required.

7) POSITION INDICATOR NOT WORKING

1. Check the air supply gauge on air regulator attached to the hydraulic pump
for a positive reading of 3-35 psi (27-241 kPa).

2. Check air supply and signal lines for leaks and crimping.

3. Make sure the cam is tight on the cam shaft and the cam shaft connected to
the actuator unit is tight and straight. The cam should turn a full 180°
when the choke position is changed from the OPEN to CLOSED or from
CLOSED to OPEN.

4. Check choke position, 3 psi (21 kPa) applied directly to the gauge should
indicate “OPEN” of the gauge, and 15 psi (103 kPa) should indicate
“CLOSED”, if the gauge is in good condition.

If the position gauge does not agree with the calibration band on the choke, See -Section
4.8.A&B- for the correct installation and adjustment.
MAINTENANCE AND OPERATION
MANUAL

PUMP STROKE RATE METER

TWO DISPLAY P/N: 96-11-321E

EEC Energy Equipment Corporation

DIGITAL PUMP STROKE/RATE METER

INTRINSICALLY SAFE, CLASS 1 DIV 1

0000
TOTAL STROKES

0000
STROKES PER. MIN.

60 STROKES
PER MIN.
PUMP PUMP
RESET 1 2
TEST

ENERGY EQUIPMENT CORPORATION

P.O. Box 920939, Houston, Texas 77292-0939, Ph: (713) 957-2288
 DISCLAIMER

Any recommendation for use, oral or written, shall be considered advisory in

content and as such, Energy Equipment Corporation shall not be held liable
under any warranty, expressed or implied, should this product not perform
under conditions other than its intended use as a accumulative pump stroke
counting device.

Energy Equipment Corporation shall in no way be liable for damages

incurred while using this product.

File copies of this manual are maintained. Revisions and/or additions will be
made as deemed necessary by EEC. The drawings in this book are not drawn
to scale, but the dimensions are accurate.
INTRODUCTION

As with any electronic equipment the EEC 96-11-321E Pump Stroke/Rate

Meter Assembly is subject to wear and eventual failure. Periodic
disassembly and inspection is required and should be left to a qualified
repair technician.

Every precaution has been taken to ensure the highest quality product has
been provided for use. Any question or correspondence should be directed
to:

Energy Equipment Corporation

P. O. Box 920939
Houston, Texas 77292-0939
Telephone number (713) 957-2288
Fax (713) 957-3322
 *** TABLE OF CONTENTS ***

SECTION I GENERAL INFORMATION

WARRANTY INFORMATION

SECTION II TROUBLE SHOOTING AND MAINTENANCE

SECTION III REPLACEMENT PARTS

SECTION I

GENERAL INFORMATION

The EEC 96-11-321E Digital Pump Stroke Rate Meter is a intrinsically safe
Class 1, Div. 1 unit designed for simple maintenance.

Because this unit is intrinsically safe no explosion proof housing or switches

are required.

The meter contains three interconnected modules. They are the display
module or PCB, the switch module and the battery pack.
Should any one of these modules fail they will have to be replaced as they
are not field repairable.

The logic module (PCB) can be repaired if returned to Energy Equipment

Corporation's factory.

Section II provides a trouble shooting guide to assist in the repair of the

counter assembly.

Section III provides a list of replacement parts for the 96-11-321E Pump
Stroke/Rate Meter.

We have made every effort to document all necessary information which

will allow users to install and operate the EEC 96-11-321E Rate Meter.
This information has been carefully reviewed and is believed to be accurate.
However, no responsibility is assumed for inadvertent omissions or errors
that may appear in this document.
WARRANTY INFORMATION

Energy Equipment Corporation’s Pump Stroke/Rate Meter Part No.

96-11-321E is warranted to be free of defects in material and workmanship
under normal usage for a period of one year.

This warranty applies to the original purchaser only. The warranty

period shall be for one year from the date shipped when the product is used
in a manner for which it was manufactured.

Energy Equipment Corporation’s liability for the 96-11-321E Meter

Assembly shall be limited to replacement, free or charge on any parts
found to be defective in materials or workmanship.
This limited warranty does not include service to repair damage to the
product resulting from accident, lightning, high voltage, disaster, misuse,
abuse, modification or service to the product unauthorized by Energy
Equipment Corporation.
SECTION II

TROUBLESHOOTING AND MAINTAINENCE

This section discusses troubleshooting and maintenance for the digital

stroke/rate meter system assembly number 96-11-321E.
The Pump Stroke/Rate Meter system is powered by a built in battery pack.
No outside source or power is required.
The meter assembly contains three modules which were designed for easy
field replacement. Before replacing any of the three modules, check the
counter assembly
as follows:

Place the selector switch in the “Test SPM” position.

The rate meter should read: “60 strokes / min. and count 1, 2, 3, 4....”

Should the counter read as above it is working properly and the

problem may be in the wiring or limit switch assemblies.

If after making any necessary repairs the counter is still not working
properly the switch module should be replaced.
If there are no indications in the Test/Spm position or the readout is
not working properly, replace the Logic Module.

REMEMBER: LIMIT SWITCHES MUST BE WIRED IN

NORMALLY OPEN
FOR MAXIMUM BATTERY PACK LIFE.
Problem/Symptom Cure
Display Flashing Low or bad batteries.

Replace Batteries or check connection to battery pack.

No Display If o.k. then replace logic module.
Display on but is not counting or displaying rate,
including in test mode. Replace the logic module.
Display is on but does not count or indicate
correct rate, but works correctly in test mode. Check wiring and pump switches.
Only one input, (p1 or p2) works, o.k. in test
mode. Check wiring and pump switches.
Count display does not display all digits. Replace Logic Module.
Lines to the pump switches are not properly sheilded or
Erratic Count and stroke rate display. grounded.
SECTION III

REPLACEMENT PARTS

BATTERY PACK: PN: 96-11-328E

LOGIC MODULE: PN: 80-59-397E

SWITCH MODULE: PN: 96-11-325E

LIMIT SWITCH ASSEMBLY: PN: 96-11-049E

 Energy Equipment Corporation
P.O. Box 920939
Houston, Texas 77292-0939
Phone: 713-957-2288
Fax: 713-957-3322
http://www.energy-equipment.com

E-Mail: [email protected]

API 6A-0290
16A-0057
16C-0005

ISO 9001

ENERGY EQUIPMENT CORPORATION

E-S Maintenance Manual Release 1. October 2002, Revision 0
 Energy Equipment Corporation
Choke Type "E-S" H2S Service

Spares:
EEC
Item No. Description 12 24 32 P/N Price(Each)
2 Sleeve, Wear 5/10M PSI Choke 3 6 9 96-11-111E
3 Sleeve, Flange Protector Wear 1 2 3 96-11-216E
6 Pin, 3/8" 2 6 9 94-36-200E
9 Back Disk Assembly 1 3 5 96-11-215E
10 Front Disk Assembly 1 3 5 96-11-214E
12 Fork, Turning 10M H2S w/ Pin 1 2 3 96-11-425E
13 Bearing, Thrust 1 2 3 96-11-428E
18 Pin, 187D 2 2 4 94-36-207E
19 Bushing, Shaft 1 2 3 96-11-427E
25 Pin, Back Disc Super Choke 1/4 1 2 3 58-67-261E
28 Pin, .187D 1 2 3 58-67-256E
30 O-Ring Kit (5,7,8,14,15,16,17,20) 1 3 6 96-11-419E

Actuator, EEC Choke Type 'E-S', H2S Service

2 Regulator Assembly 1 2 3 52-01-029E

3 Ell, 1/4" Poly Flow 2 4 6 54-15-205E
8 Bearing, Cam Follower 1 2 3 04-02-235E
12 Connector, Poly Flow 1/4" Straight 2 4 6 54-15-191E
13 Hose, 3/16" High Pressure, 11" lg. 2 2 3 20-32-543E
14 Hose, 3/16" High Pressure, 13" lg. 2 2 3 20-32-544E
21 Cam 1 1 1 96-11-039E
22 Shaft, Cam 1 1 1 96-11-102E
36 Coupling, Female Quick 1 2 3 20-10-040E
38 Coupling, Male Quick 1 2 3 20-10-041E
40 Nipple 1 2 3 50-05-151E
41 Actuator Seal Kit 1 2 2 39-14-697E
*Recommended Spares: 12, 24 & 32 Months.