Control panel for choke manifold

(English)

Operation Manual

YANCHENG SANYI BRANCH COMPANY

YANCHENG HUADA CONTROL EQUIPEMNT CO., LTD.
The control console for choke manifold implements the following
standards:

e API Spec 16C 2nd Edition

«specification for choke and kill systems»
e Q/ SYJJ.02.01--2004
«control console for choke manifold --enterprise standard»

Test Report:
Report ID: BGW 2005--317
Testing department : Petroleum industry center for quality
surveillance and inspection of well-control equipment
Petroleum industry center for quality surveillance and determination
and review of well-control
Production: control console
Model: ]Y2-105BX

YANCHENG SANYI BRANCH COMPANY

YANCHENG HUADA CONTROL EQUIPEMNT CO., LTD.
 Safety Instruction

1 . Control console operator and maintainer shal1 be well qualified and

certificated. Take measure against pressure container' s breaking.
2. Read this operational manual thoroughly before you operate or repair the
control console, and correctly install, use and repair it according to the
manual. The user should know rules to the safety in the operation of the well
control equipment related to this control console.
3. The accumulator bank is the major source of pressure for the normal operation
of the control console. The user should make regular checks on the nitrogen
pressure pre-charged in the accumulators to eliminate the malfunctions as
damaged bladder or lack of nitrogen pressure.
4. The accumulator bottle should be pre-charged with nitrogen only. It is not
allowed to pre-charge the bottle with oxygen, compressed air or other
flammable gases, in order to avoid equipment damage and personnel injury.

5. The oil tank ~hould be full filled with hydraulic oil according to regulations
in case the accumulator is not filled with oil. The hydraulic oil shall be
kept clean to avoid damage the components. As for damaged, replace it in good
time. No oil supplementation to the oil tank is allowed after the accumulator
is filled with oil and is pressurized. No fuel oil 1s allowed to fill into
the tank.

6. The control console should be safely inspected and regularly maintained timely
after used. The relevant components such as air, hydraulic valves, and gauges
and so on, shall be adjusted and calibrated.
In case the safety may not be guaranteed after long term use, great accident
· occurring, and maintenance for many times, overhaul or discard and renewal
should be taken into account.
7. The service life of control console should not exceed ten years on the condition
of normal usage and maintenance. In case the safety may not be guaranteed
after long term use, great accident occurring, and maintenance for many times,
overhaul or discard and renewal should be taken into account. Parts
manufactured by Huada or recommended by Huada shall be first used for
replacing when repair.

8. The product composition of the control console is subject to the design

improvement and range of customers order. You are kindly advised to refer
to the list of the files with shipment.

YANCHENG SANYI BRANCH COMPANY

YANCHENG HUADA CONTROL EQUIPEMNT CO., LTD.
 Contents

1. Introduction ········· ········· ····················· ························!

2. Model Illustration ......................... ................................. 1
3. Main technical parameters ............... .. .......... 1
4. Features and structure ......... ............... ···2
4. 1 Control console for choke manifold······ ........................ 2
4. 2 Pump stroke counter·········· ...................................... 3
4. 3 Air pipeline .. ············· ................................. 4
4. 4 Oil pipeline ...................................................... 4
4. 5 shock r~sistant pneumatic pressure transmitter ......... 5
4. 6 Air-operated valve position transmi tter ........................ 5
4. 7 Angle valve driver .............................. 5
5. Working principles and operation instruction ...... 6
5. 1 Air-operated hydraulic pressure pump control .. ·7
5. 2 Hand-operated pump control ............... 7
5. 3 Hydraulic control principle ...... 8
6. Installation and Test-run ...... g
6. 1 Installation ........................................................................ g
6. 2 Test Run··········································································~···13
7. Usage and Maintenance······························································· ···18
7. 1 Usage·····················~························································18
7. 2 Maintenance········································································18
8. Trouble shooting········································································19
9. Instruct ion of order ................................................................ 20

Appendix A: Exchange between English Unit and Metric Uni t ..................... 21

Appendix B: Recommended hydraulic oil ...................................................... 21

Appendix C: Technical Parameters of the Control console ........................ 22

1. General
The control console is control device of choke manifold, and can close and
open hydraulic valve in remote. It can display standpipe pressure, casing
pressure, and choke valve position, also show three mud pumps stroke and
frequency in simultaneity respectively. Therefore, the console can be used to
hold well pressure, and it is key indispensability equipment in well control
serVIce.
The long time service productions which are discarded with useless or
remanufactured are not included in scope of the book, by this is not meant that
control console service life isn' t limited. The user or operator should make
proper judgment, if required.

2. Model Illustration
The symbols of the models of the control console are shown as below:

cp_ T:CS backing enamel cover

X:SS cover

J:Used for angle choke valve

B:Completed with pump stroke counter

Choke manifold pressure class

1:Control 1 No. choke valve 2: Control 2 Nos choke valve

Control console series No.

3. Main technical parameters

Nominal Working pressure :3 MPa 435 psi (angle valve control panel: 6 MPa
870 psi)
System max imum working pressure: 4 MPa 480 psi (angle valve control panel:
8 MPa 1160 psi)
Accumulator nitrogen charging pressure: 1 +0. 1MPa 145 + 14. 5psi (angle valve
control panel for accumulators nitrogen charging pressure: 2+0. 1MPa 290
+29psi)

Air supply pressure: 0.65--0.8MPa 93--115psi

Ambient Temp. : -2o·c--+6o ·c

Note: Special order is needed when beyond the above technical parameters.

--1--
4. Features and Structure
The JY serial control console basically consists of the following
components:
1. Control box 2.Pump stroke counter
3.Air pipeline 4.0il pipeline
3. Air-operated shock resistant pressure transmitter
4. Air-operated valve position transmitter or angle valve driver
Layout and connection of the control console are as shown In
Figure 1.

,---------------i Air cable t--------11 Pressure transmitter I

I
t----- ----ji
Con tro I console pump stroke cable l~----------1rum p stroke transm itte i

~'---------------jl'----0-il_c_a -b 1-e _ ·_ _ ___jlf--------rr a lv e position tra s m itte rl

Figure 1-Layout and connection of the control console

CAUTION: Composition of the control console is subject to the range of

customers order.
4. 1 Control box
The control box consists of box cover, oil tank, pneumatic hydraulic pump,
hand-operated pump, accumulators, gauges, and various valves fittings, etc. The
control box is mainly used to control generating of high-pressure fluid by the
pump and the storage of the high-pressure oil in the accumulator. When there
is a need to open or close hydraulic valve of the choke manifold, high-pressure
fluid will go from the accumulator via the manual position changing valve of
the choke panel to open /close hydraulic valve in remote.
Control box is featured in:
1. It is equipped with tow different pump systems: air-operated hydraulic
pump and hand-operated pump. Therefore, in case of power failure, you may keep
the system in normal operation.
2. The accumulator has high-pressure liquid reserved enough to meat the
control requirement of closing/opening all hydraulic valves of the choke
manifold.
3. The air-operated pump are both equipped with the pressure switch to start
and /or stop the pumps automatically. Even when the automatic control device
goes wrong in normal operation, the overflow valve may quickly open to avoid
overload.
4. The control panel can display standpipe pressure, casing pressure, the
choke valve position opening of choke manifold, and mud pump' s strokes and
frequency.

--2--
The schematic drawing for control console are shown as figure 2 and
figure 3.

0
0
N
1'""'"'"1

850X550
0

0 ~ ~~~ a:;:o!!J. 0 _:1:-:; •::E o:J.;

0 0 0 0

Figure 2-.JY1 serial control console schematic drawing figure 3 -JY2 serial control console schematic drawing

4.2 Pump stroke counter

The pump stroke counter consists of 6" LCD screen, main cable, branch cable, and
pump stroke sensor and so on. The main function: store and display three pumps stroke
counter and frequency respectively, and also show three pumps total stroke number
simultaneous.
Pump stroke counter features:
1. There are function buttons like power supply, selection, clear.
2. It can show the three pumps frequency respectively by using "selection" button.
3. The counter is completed with self-feeding power (6V low voltage DC buttery), with 2-3
years service life.
4. After complete installing and debugging, and power is off, as the counter is of save function,
the counter could open for relevant datum about mud pump at any time.

--3--
Pump stroke counter panel 1s shown as figure 4

m ·8 ·
BC-200A* ttP it~~
MODEL BC-ZOOA PUMP STROKE COUNTER

** 1 /PUMP1:
2/PUMP2:
*~it
3/PUMP3:
/TOTAL:
._._._._.
fCICICJCI

5999l
~ 2B
PUMP 1/jjji: 1 ~::E .:s
~ *~
~ ON-OFF ® PUMP 2/ jjji:2
~'
((_))
ti=J ~

PUMP 3/ jjji:3 ~ CLEAR

1 ...
195
Figure 4- Model BC-200 pump stroke counter schematic drawing
4.3 Air Hose
The air hose is connection between console and air-operated shock proof
pressure transmitter, and air-operated valve position transmitter. The line is
nominal 6" rubber hose with steel wire inter layer, 15 m long in normal.
Feature: the pipe is of pressure and break resistance, connection end is
nominal 6" self-seal SS quick coupler, for easy installing and disassembly.
4.4 Oil Hose
The oil hose is connection between console and hydraulic choke valve on
choke manifold. The line is nominal 8" rubber hose with steel wire interlayer,
15 m long in normal.
Feature: the hose is of pressure and break resistance, connection end is
nominal 8" self sealing SS quick coupler, for easy installing and disassembly.

CAUTION: The specification and length of air/oil hose

are subject to the customers' order.

--4--
4.5 Air-operated anit-shock pressure transmitter.
The pressure transmitter could change high pressure flow of choke manifold, drilling
pipes or other into lower ·pressure, which is transmitted remotely to control console for
pressure display

Feature: corrosion proof, anit-shock, and be of good impact performance. See figure 5

4.6 Air-operated valve position transmitter

The air-operated valve position transmitter could indicate hydraulic choke valve open
and close position.

Feature: corrosion proof, anit-shock. See figure 6

Figure 5-pressure transmitter structural drawing Figure 6-valve position transmitter structural drawing

4. 7 Angle valve driver

Angle valve driver is for controlling control consol angle valve to open and close,
which could be showed on panel.
Feature: corrosion resistance, anit-shock, and good impact performance. See
figure 7.

C>
C>

(~~
L ==o==~©L
~~~
· @
_o ______~
M

Figure 7- Angle valve driver structural drawing

' - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - '

--5--
4.8 Bladder Accumulator
1. Purpose: The bladder accumulator in the hydraulic system is used for
cumulating energy, stabilizing pressure and reducing the power dissipation,
compensating leak, and absorbing pressure impulse and relaxing the impact force
and so on.
2. Futures: construction type----- large diameter, maintain from the top of .
accumulator.
Fixed type: dead ring
Installation type: vertical
Work medium : nitrogen - Petro base hydraulic oil
Work temperature : - lOoC -- + 70oC
Work pressure : 3Mpa- 6Mpa(435psi-870psi)
3. Specification : nominal volume- lOL. Nominal pressure- 10Mpa(1450psi)
4. Dimension: <P219X670
5. Charge pressure: Use the charging tools to charge, discharge, measure and
correct the charging pressure and so on. The accumulator can' t be charged with
oxygen, compressed air or other inflammable gas. The charging pressure of the
accumulator is thirty percent of working pressure of the control console for
the choke manifold.
6. Inspect and Repair: When control console has ceased to be used for a long
time, the stop valve for the accumulator should be closed to keep the oil pressure
in the accumulator over the charging pressure. In case of the accumulator
doesn' t work, please check if the air valve is leakage and charge when necessary.
If there is no nitrogen in the bladder and bleed from the air valve, please check
if the bladder is damaged. If the bladder is leakage, please tighten the
connection part. If the leakage is going on, all the relative parts should be
replaced.

Nameplate
··------------
~
7-
Jk ------------=--
Model NXQ accumulator structural Figure.

.. ·---...._-...........__ Charging valve

........... '\
Bladder

Body Mushroom holder

/
Rubber holder

0-ring ,retainer ring

Plug(used for releasing)

--- --- ·- - ---

Oil port The oil port area should be bigger than
the max. flow area .current capacity the area

--6--
5. Working principles and operation instruction
The control console could convert outer air supply pressure into high
pressure liquid reserved in accumulators, which is controlled to open& close
choke manifold hydraulic choke valve, according to sensed pressure of standpipe
&case and requirements of dri 11 ing. Therefore, the control console could
stabilize well pressure for choke and kill.
The parts connection of control console is shown as Figure 8 and Figure 9.

15

L______/1'---- - - -$-- -...,._ Air supply

~--~------~

Figure 8-Model JY1 Parts connection drawing

]U_
I _8 r F6

J:J~J[~ -------$-----~ Air supply

Figure 9-Model JY2 parts connection drawing

·------- -- - -

--7--
 Part Details Sheet---Table 1
No. Parts Qty Specification Remark
1 Manual diversion valve 1 JY-01. 4. 2 JY2 series completed
with 2 PCs
2 Hand-operated pump 1 JYKQ-4
3 Accumulators 1 NSQA-10/ 10-L-A
4 Combination valve 1 JYKL-10
5 Regulator valve 2 JYK-TF-15
6 Air-operated hydraulic pump 1 JYKQ-63 (80)
7 Pilot valve 1 JYKX-5
8 Air controlled diversion valve 1 JYK-QK25
9 Air-operated F. R. L combination 1 JYKQ3-1
10 Standpipe pressure indicator 1 JYK150-35 (70, 105)
11 Oil pressure gauge 1 JYK60-10
12 Valve position indicator 1 JYKl00-35.47(1-9/16) JY2 series completed
with 2 PCs
13 Air supply gauge 1 JYK60-1 .6
14 Casing pressure indicator 1 JYK150-35 (70, 105)
15 Air line quick coupler 20 JYK-C]-6 JY2 series completed
with 25 PCs
16 Oil line quick coupler 5 ]YK-C]-8 JY2 series completed
with 10 PCs
17 Air line hose 7 JYK-TQ-6 ]Y2 series completed
with 9 PCs
18 Oil line hose 2 JYK-TQ-8 ]Y2 series completed
with 4 PCs
19 Air-operated valve QFW-35.47
JY2 series completed
position transmitter 1 CJF6)
with 2 PCs
(angle valve driver)
20 Standpipe pressure transmitter 1 YPQ-40A C70A, 105A)
21 Casing pressure transmitter 1 YPQ-40A (70A, 105A)
22 Pump stroke counter 1 CBC-200) as per customers'
requirement
5. 1 The control of Air-operated hydraulic pump
Connect with air supply, open Air-operated hydraulic pump regulator.
Hydraulic pump is driven by compressed air through regulator, and discharge
pressurized oil into control system. When the system pressure is less than
nominal pressure 3MPa(435 psi), the Air-operated hydraulic pump could start to
work under the compressed air.
CAUTION: when using the air-operated hydraulic pump ,normal operation of
overflow valve of hydraulic system should be confirmed. Prior test should be done
if required to ensure it fully open and overflow at the max. working pressure of
4Mpa(480psi).
5.2 Hand-operated pump
The hand-operated pump is spare pump for choke manifold control console
backup pump. It is used to hold system pressure up to 3MPa ( 435psi) for control
console working in normal station.

--8--
5.3 Control principles of hydraulic system
The hydraulic system working principle is that reserved pressurized oil
go by accumulator stop valve into hydraulic system, · operate manual diversion
valve to effect choke manifold hydraulic choke valve' opening and closing.
Manual directional control valve is spring self-returning, 3-posi ton 4-way
valve. Operating handle effects choke manifold' s open and close.

The control principles of console control are shown as Figure 10 and Figure
11.

Figure 10-Model JY1 working principles

1 ~ Manual directional 8 ~ Air-operated directional 15~Air course quick coupler

control valve control valve
2~ Hand-operated pump 9 Air-operatedF.L.R 16 ~ Oil course quick coupler
combination
3 ~ Accumulator 10 ~ Standpipe pressure indicator 17 ~ Air course hose
4~ Combination valve 11 ~ Oil pressure gauge 18 ~ Oil course hose
5 ~ Regulator valve 12 ~ Valve position transmitter 19 ~ Air-operated valve
position transmitter
6 ~ Air-operated hydraulic 13 ~ Air supply pressure gauge 20 ~ Standpipe pressure
pump transmitter
7 ~ Pilot valve 14 ~ Casing pressure indicator 21 Casing pressure
transmitter

--9--
 Figure 11 Mode I JY2 working principle

6. Installing and debugging

6. 1 Installation
1.0pen mainframe and spare parts case, fit mainframe on corresponding place of rig
floor. Take out two Air-operated shock proof pressure transmitters from the spare case,
one installed on standpipe of rig floor, the other installed on choke manifold. Then install
Air-operated valve position transmitter on hydraulic choke valve of choke manifold.
Connect well air and oil line according to connection figure 12, 13.

Caution: Pipeline must be connected accurately, or else cause equipments

damage and system failure.
Model ]Yl choke manifold control console
Right side air line connection plate:
Air-supply signal for the valve position transmitter----connect with Air-operated valve
position transmitter: input
Air-supply signal for the casing pressure----connected with the air-operated anti-shock
pressure transmitter for choke manifold: input
Air-supply signal for the standpipe pressure --connected with standpipe pressure
transmitter on the drilling floor: input
Return signal for the valve position transmitter--connect with air--'operated valve
position transmitter of hydraulic choke valve: Output
Return signal for the casing pressure ----connect with the air-operated anti -shock pressure
transmitter for the choke manifold : output.
Return signal for the standpipe pressure--connect with the air-operated anti-shock
pressure transmitter for the drilling floor: output
Air -supply ----connect with the external air-supply of the drilling floor : 0. SNPa
Left of oil line connection plate:
Valve Opening----connect with hydraulic choke valve of the choke manifold: valve opening
port.
Valve closing----connect with hydraulic choke valve of the choke manifold: valve closing
port.
--10--
Model ]Y2 control console for choke manifold
Right of air circuit connection plate:
Air supply for Valve position transmitter No.1 --connect with air-operated valve
position transmitter of hydraulic choke valve No. 1 for choke manifold: input .
Air supply for Valve position transmitter No. 2 - - connect with air-operated valve
position transmitter of hydraulic choke valve No. 2 for choke manifold: input
Air supply for casing pressure - - connect with air-operate anti -shock pressure
transmitter for the choke manifold : input.
Air supply for standpipe pressure-- connect with air-operate anti -shock pressure
transmitter of the standpipe on the drilling floor: input.
Return signal for the valve position transmitter No.1 --connect with air-operated valve
position transmitter of hydraulic choke valve No. 1 for choke manifold: output
Return signal for the v.al ve position transmitter No. 2--connect with air-operated valve
position transmitter of hydraulic choke valve No. 2 for choke manifold: output
Return signal for casing pressure --connect with air-operate anti-shock pressure
transmitter for the choke manifold : output.
Return signal for standpipe pressure--connect with air-operate anti-shock pressure
· transmitter of the standpipe on the drilling floor: output:
Air supply--connect with external air supply on the drilling floor: 0.8NPa
Left of oil circuit connection plate:
Hydraulic choke valve No.1 opening----connect with the hydraulic choke valve No.1: valve
opening port .
Hydraulic choke valve No.1 closing--Connect with the hydraulic choke valve No.1: valve
closing port
Hydraulic choke valve No.2 opening--Connect with the hydraulic choke valve No.2: valve
opening port .
Hydraulic choke valve No.2 closing --Connect with the hydraulic choke valve No.2: valve
opening port .
Quick coupler connected with hose shall not be blocked, or else the system will
be unreliable.
After complete oil and air pipeline connecting, keep them in sequence as
per well equipments installation requirements.
If choke manifold complete with pump stroke counter, install the pump stroke
sensor on the corresponding place of mud pump according to the "pump stroke
counter" instruction. Separate main cable and branch cable in right direction,
and signal plug on main cable shall connect with the port of pump stroke counter
on the left of control console.
If completed with angle valve driver, the driver shall be installed on choke
manifold angle valve according to its instruction.
After control console completely installing, if any fault is found in oil
or air line connection, and adjustment is needed. Fist of all, close the external
air supply and unload the system oil pressure to zero, and then move the
open/close button of the manual change valve on the control panel for two times
or three times. Adjust the oil /air hose connection after unloading the oil
pressure in the oil hose.

--11--
 = (l]!D

External a i r supplyO. BMPa

Standp ipe pressure

Output Input

Pump stroke Casing pr essu r e

transmitter

Figure 12-Model JY1 control

console installation for choke manifole

--1 2- -
 =OJIII
=OJIII

External air supplyO. 8MPa

Choke va I ve No . 1

Standpipe pressure

Output Input

Pump stroke Casing pressure

transmitter

Figure 13-Model JY2 control

console installation for choke manifole

--1 3-- .
6. 2 Debugging
The following procedures shall be performed before choke manifold control
console to be operated.
1, Check to know accumulators' nitrogen pressure, and the pressure is 1
+O. 1MPa C145+ 14. 5psi ), nitrogen must be charged when in .shortage.
2, Oil reservoir oil charge: oil charge amount should be controlled at 4/5
non ius.
When ambience temperature is above OOC, use L-
' HM32 normal hydraulic
oil or substitute.
When ambience temperature is below OOC, use L-HM32 hydraulic oil
for low temp. or substitute.

3, Open accumulators' stop valve and discharging valve.

4, Adjust pressure of F. R. L combination regulator to 0. 35MPa, and then lock
down the handle.
5, Adjust hydraulic pump regulator pressure to 0. 1MPa. Then run the pump
2-3 minutes without load.
Debugging procedure
1. Air-operated hydraulic pump start and stop running test
Close hydraulic system unloading valve, adjust regulator to run Air-operated hydraulic
pump, stop adjustment of the unloading valve when the system pressure is up to 3MPa C435ps i) .
.When the pump reaches the balance between gas and liquid, it shall stop working. Turn on
hydraulic system unloading valve gradually, when system pressure drop to around 2. 5MPa (362
psi), hydraulic pump automatically run.
In the above process of checking, adjust regulator on air operated pump to assure that
the regulator pressure could make air operated hydraulic pump work properly. While the
hydraulic system pressure goes up, check and see if there is any leak, and take measure
timely if necessary.
Refer to the figure13 air-operated hydraulic pump to debug.

Air-operated change valve

Figure 13.Air-operated hydraulic pump

--14--
2. Manual pump debugging
Turn off accumulator stop valve and unload valve, pump pressure manually,
check whether the system pressure (oil pressure gauge) rise up, or else pump
pressure again until the system pressure rise up to 4MPa.
Refer to figure 14 manual pump and combination valve to debug.

Manual pump
//

Figure 14-manual pump and combined valve

3.0verflow valve debugging

Reference to figure 14 manual pump and combination valve to debug.
Open accumulator stop valve, close unloading valve, adjust air-operated hydraulic pump
regulator, observe the system pressure (oil pressure gauge)
Choke valve control console' s overflow valve: when the system pressure rise up to around
5MPa, turn on overflow valve. Then open unloading valve slowly, the system pressure drop
to 4. 5MPa, overflow valve shall in closing position.
Angle valve control console' s overflow valve: when the system pressure rise up to around
9MPa, turn on overflow valve. Then open unloading valve slowly, the system pressure drop
to 8. 5MPa, overflow valve shall in closing position.
The overflow pressure of the overflow valve should be adjusted when necessary.
4.Air-operated F.R.L combination debugging
Connected with external air supply, adjust regulator on the F. R. L combination to the
pressure of 0. 35Mpa, press the handle to lock t(The pressure is furnished to air-operated
anti-shock pressure transmitter exterior of the control console and the air supply input
signal of air-operated valve position transmitter)
Refer to the figure 15 to debug the ~.R.L combination

Divide filter '-,,_D rain valve

Figure 15- F.R.L combination

--15--
5.Air-operated valve position transmitter debugging
Open upper cover, loosen set screw 1 and 2, remove air operated valve
position transmitter machine core, check and see whether the needle of valve
position indicator on control console panel rise up to "close" scale. Then
tighten the two set screws (1, 2), adjust micro-switch to assure the needle reach
the intermediate "close" scale. Handle manual directional control valve on
the panel, if the stem travel of hydraulic choke valve on choke manifold equals
47mm, the needle indicate valve position opening at inner track 47mm of "open"
position, and while the stem travel of hydraulic choke valve on choke manifold
equals 35, the needle indicate valve position opening at outer track 35mm of
"open" position
Please refer to figure 16 air-operated valve position transrni tter to debug

L)

Screw No.1 to
Clamp screw tighten the machin core

Screw No.2 to
'trghte n t he machine core

Figure 16- Air-operated valve position transmitter adjustement

6.Complete control console debugging

Open unloading valve on combination valve, accumulator globe valve and regulator
on the Air-operated hydraulic pump, then close the unload ing valve after control
console' s running 1-2mini tues without load, check to know whether the oil
pressure indicated on the panel rise up, or else perform the above operation
again to make sure the oil pressure rise up. Secondly, adjust regulator of
Air-operated hydraulic pump to pump pressure up to specified pressure
value( pressure set value for choke manifold control console is 3MPa, and 6MPa
for angle valve control console). Then lock down handle of regulator, adj ust
regulator of Air-operated F. R. L combination to reach output pressure of 0. 35MPa,
lock down the handle. Operate directional control valve on the panel, valve
position indicator shall take less than 60 seconds to indicating position form
open to close, or from close to open. The pressure difference between practical
pressure of casing &standpipe and indicator pressure shall not exceed 2. 5% of
full-scale. Otherwise, check whether all inside and outside pipeline is
connected well. and have defective parts rectified, repaired or replaced.
Reference to practical figure 16, 18 choke manifold control console chart to debug

--16--
 Q) Q)

0 0 0 0 -
.-a. 0 0
.. :c--200!!li!i>~ltJI!it
IIIIa m:• I!IIR aa:la IIIZIDI •
004-
0 0 e
c
?1[1/PUMPl, 1'!1'!1'!1'!1
?1[2/PUMP2, illii 0 c
00 0 I ;R3/PUMP3, 1999'!1
lJBt/TOTAL, 59991
() co
;)[/ PUMP :1•;-;:., li!B E
0
-0
0 0 0
.. .
e ~@ ""' ®::: ~:: 0 '~-I
IJI'-af _ ,. , Q.EAR

...
e

0
!......~
+.J
Q)

0
c....c
0 ()
()

Air contro I .,..... !......

0
>-4-
"""")

Q)
!a... I :
r--
Ppressure
--···u...... 11 IH
Combination va I ve
...__, Q)
""'C
:::::S
b.O l
..--<

0
:2::4-
1
,.......
.,..... co
()
Q)
!..... +.J
I ~a
1
G f /
.. -~- · --,...- ·
ating gas fi Iter
\VIQIII VQIYV
. . :::::S ()
L X WX H Figure 13 Air-ope rated hydrau I i c pump
Air operated F. R. L combination
•_
b.O CO
!......

u.. a.
 0 0 0 0 <1) <1)

0~0
0 0
-~

of
0 0
-
c
0
-
0 0
(f)4-
c
o ro
II®'"' ®::::::o,.•l E
0
0 0
•

~ .CJII-iR' _ , ,., a.f.M

.
~
•

0
0 0
0 <1)
!.....~
Overflow +' 0
c..c
0 ()
()
Air control !.....
change valve C'\1 0 I
cc
>-
"""")
4-
Combination valve <1)
!.....
<1) ~
""'0 b.O
0
::E 4-

.,..... ro
()
<1)
!..... +'
Figure 13 Air-operated hydraulic pump Air operated F.R.L combination ~ ()
b.O ro
!.....
L1.. a.
7. Usage and maintenance
Choke manifold control console is critical for well control. Thus, the operating
personnel must be specially qualified to well know configure&·principle, and how to install,
operate and maintain the control console.
The operator shall grasp the following standards and relative documentations.
SY/ T5225-2005 oil and gas drilling, exploitin~ storage and transports safety
regulation
SY/ T5742-1995 oil and gas drilling, well control technic assessing& management code
SY/ T5964-2003 combined well control equipments installation, debugging and
maintenance.
SY/ T6203-1996 wrecking method for oil and gas well blowout and fires
SY/ T6283-1997 Health, safety and environment management system guideline for oil and
gas drilling
SY/ T6426-2005 Well drilling& control technic regulation.
7. 1 Operating notice
1. In general, the handle of manual directional control valve shall locate in central
section. And the hydraulic choke valve is in fully closed position.
2. The control console outside connection pipeline must not be passed vehicles in event
of being pressed broken.
3. choke manifold control console must be checked every tour in drilling. Tested item
include:
6. If oil reservoir liquid level is correct
6. If accumulator pressure is correct
6. If air-operated, hydraulic components work safely and reliably
6. If there is any leak in oil& gas circuits
6. If automatic start and stop of hydraulic pump work properly.
6. If indicating valve of pressure gauges are in demand.
6. According to relation safety regulation, perform hydraulic valve opening and
closing test.
4. User should make a record for usage, failure, testing and repairmen. All documents
and record must be run in random.
7.2 Maintenance
1. Keep all filter and screens of reservoir oil inlet clean. Take the screens out and
have them washed carefully in order . to protect them from dirt stuff .
2. To the water-trap in the air treatment unit: open the water discharge valve at its
lower end and drain dirty water out of the cup daily, remove and wash the filter cup and
the water cup once every two weeks, wash them with gasoline or other mineral oils, dry them
with compressed air. Do not use acetone or toluene to wash them avoiding damage.
3. Check the pressure of the pre-charged nitrogen in the accumulator periodically.
During the beginning period, check nitrogen pressure weekly, and thereafter, during normal
operation, check it monthly, (charge nitrogen pressure of choke valve control console is
l±O.lMPa 145±14. 5psi and chare pressure of angle vale control console is 2±0.1MPa
290±29psio ), recharge nitrogen when the pressure is low. Check nitrogen pressure only
after the accumulators releases pressure thoroughly.
4. Check air-operated hydraulic pump and manual pump seals, and replace damaged one
timely.
5. Clean console panel, be careful of broking any identification plate.
6. After one well drilling completed, check all pressure gauge.

--19-
 8. Failure and elimination
1. Air-operated hydraulic pump doesn' t work.
Reason: Air-operated directional control valve with excessive displacement.
Measure: Demount muffler and clean it up, then restart after installing
Reason: Pilot valve with excessive displacement.
Measure: Demount muffler and clean it up, then restart after installing
Reason: There is leakage of air line
Measure: Examine air line connector whether exist break, replace the broken
connector timely if required.
Reason: Check whether directional control, pilot valve, and regulator is damaged
or failure.
Measure: Do replacement and adjustment.
5. Aair operated hydraulic pump start system pressure doesn' t rise or rise
up slowly
Reason: The oil reservoir oil level is too low, and pump sucks air
Measure: Refill oil
Reason: The valve for the oil suction orifice is closed or the oil filter 1s
blocked.
Measure: Open unload valve, run it without load, discharge air in the pipeline;
wash oil filter
Reason: Hydraulic system unloading valve is not closed
. Measure: o Close the unload valve
Reason: There is no pressure in accumulators
Measure: Check the accumulators' capsule, replace it timely if required
6. Air operated hydraulic pump could not stop automatically after start
Reason: Oil sucking one way valve couldn' t be seal completely ( oil may be
dirty, or to much feculence)
Measure: Replacing oil
Reason: There is leak in hydraulic components, connector or oil circuit.
Measure: Check hydraulic components, connector and oil circuit
Reason: Overflow valve open pressure is lower
Measure: Adjust overflow valve open pressure
7. The hydraulic choke valve can' t be opened /closed from the choke
manifold or the relative action is out phase.
Reason: The connection of hydraulic pipeline is not accuracy or pipeline is broken
or quick coupler is blocked.
Measure: Replace the broken pipeline and blocked quick coupler after checked.
If the opening/closing is out of phase, exchange the hydraulic pipeline.
8. Valve position opening index is not accurate
Reason: The air supply pressure of regulator valve for air operated F.R.L
combination is not accurate.
Measure: Adjust originator pressure to 0. 35MPa
Reason: Valve position transmitter become loose
Measure: Rerun-test the valve position transmitter according to above debugging
procedures.

--20--
9. how to order
Console standard configuration
1. Controlled object: 1 PC hydraulic choke valve
2. Console panel: standpipe pressure, casing pressure, hydraulic choke
valve position.
3. Hydraulic system completed with double pump: Air-operated hydraulic pump
and manual pump
4. Oil reservoir capacity: 40L
5. Accumulator capacity: 10L
6. Air line control line: nominal size 6mm, length 15m, rubber hose
7. Oil line control line: nominal size 8mm, length 15m, rubber hose
8. Air-operated shock resistance pressure transmitter: 2 ea
9. Air-operated valve position transmitter: 1 ea.

Information required in order:

control console for choke manifold is rather complicated and a large variety
of structure and models available, in order to help customers make right choice
and a proper order, and make its configuration comply with national standard
and API specification, customers are kindly requested to provide technical data
and operation requirements as detailed as possible. These date and requirements
include:
1. Choke manifold model or pressure scale
2. The quantity of hydraulic valve in control console.
3. Choke manifold hydraulic valve type: (plug choke valve ,orifice plate
choke valve, or other types)
4. · If completed with " pump stroke counter"
5. Shell material choice: CS painting cover and SS polished cover.

If there are any special requirements, please express clearly in order.

Without special expression, the console shall be manufactured according to
standard configuration.

The choke manifold control console manufactured by our company is in

accordance with national standard and ministerial standard, and could satisfy
general service. The special requirements proposed by buyer are according to
the technical agreement.

--21--
Appendix A. general metric and inch units conversion

1. Mass
1 kg=2. 2 lbs
1 lbs =0. 45 kg

2. Capacity
1 L=2.64 US gal=61 cn.1n
1 US gal=3. 785 L=231cn. in

3.Pressure
1 MPa= 145 psi
1 psi =0. 069MPa

4.Length
1 m=3. 28 ft=39. 37 in
1 ft=O. 305 m

5. Temperature
1 ·c =5/9 cc - 32)
1 ·c = 1. 8 x ·c + 32

Appendix B: hydraulic system recommended oil

G B: L-HM32 (ambience temp. above 0 ·c)
L-HL32 (ambience temp. below 0 ·c)

ISO: HM32 Clower zincs or non-zincs hydraulic oil for plunger pump.)

Mobil: D. T. E24 Clower zincs or non-zincs hydraulic oil for plunger pump.)

Shell: Tellus32 Clower zincs or non-zincs hydraulic oil for plunger pump.)

2
Note: hydraulic oil viscosity is 17-33mm/s in motion when
temperature is 50 °C.

--22--
 Appendix C: Control console configuration parameters table.
Manifo Contro Pump Valve Pressure Angle W. P.
Shell
Model ld lled stroke position transmit valve
material
scale object counter transmitter ter driven
JY1-35T 35 1 CI S Painting none 1 ea 2 ea 40 none 3MPa
JY1-35BT 35 1 CI S Painting lea 1 ea 2 ea 40 none 3MPa
JY1-35JT 35 1 CI S Painting none none 2 ea 40 1 ea 6MPa
JY1-35BJT 35 1 CI S Painting 1 ea none 2 ea 40 1 ea 6MPa
JY2-35T 35 2 CI S Painting none 2 ea 2 ea 40 none 3MPa
JY2-35BT 35 2 CI S Painting 1 ea 2 ea 2 ea 40 none 3MPa
JY2-35JT 35 2 CI S Painting none none 2 ea 40 2 ea 6MPa
JY2-35BJT 35 2 CI S Painting 1 ea none 2 ea 40 2 ea 6MPa
JY1-70T 70 1 CI S Painting none 1 ea 2 ea 70 none 3MPa
JY1-70BT 70 1 CI S Painting 1 ea 1 ea .2 ea 70 none 3MPa
JY1-70JT 70 1 CI S Painting none none 2 ea 70 1 ea 6MPa
JY1-70BJT 70 1 CI S Painting 1 ea none 2 ea 70 1 ea 6MPa
JY2-70T 70 2 CI S Painting none 2 ea 2 ea 70 none 3MPa
JY2-70BT 70 2 CI S Painting 1 ea 2 _ea 2 ea 70 none 3MPa
JY2-70JT 70 2 CI S Painting none none 2 ea 70 2 ea 6MPa
JY2-70BJT 70 2 CI S Painting 1 ea none 2 ea 70 2 ea 6MPa
JY1-105T 105 1 CI S Painting none 1 ea 2 ea 105 none 3MPa
JY1-105BT 105 1 CI S Painting 1 ea 1 ea 2 ea 105 none 3MPa
JY1-105JT 105 1 CI S Painting none none 2 ea 105 1 ea 6MPa
JY1-105BJT 105 1 CI S Painting 1 ea none 2 ea 105 1 ea 6MPa
JY2-105T 105 2 CI S Painting none 2 ea 2 ea 105 none 3MPa
JY2-105BT 105 2 CI S Painting 1 ea 2 ea 2 ea 105 none 3MPa
JY2-105JT 105 2 CI S Painting none none 2 ea 105 2 ea 6MPa
JY2-105BJT 105 2 CI S Painting 1 ea none 2 ea 105 2 ea 6MPa
JY1-35BJX 35 1 SI S 1 ea none 2 ea 1 ea 6MPa
JY2-35BJX 35 2 SI S 1 ea none 2 ea 2 ea 6MPa
JY1-70BJX 70 1 SI S 1 ea none 2 ea 1 ea . 6MPa
JY2-70BJX 70 2 SI S 1 ea none 2 ea 2 ea 6MPa
JY1-105BJX 105 1 SI S 1 ea none 2 ea 1 ea 6MPa
JY2-105BJX 105 2 SI S 1 ea none 2 ea 2 ea 6MPa

--23--