Drilling Choke

Control System
Model "CW" Control Panel
Dual or Single Choke Operation

Operation and Maintenance Manual

TC1569

Cameron, P.O. Box 1212, Houston, Tx 77251-1212, 713-939-2211, http://www.coopercameron.com

 All the information in this manual is the exclusive property of Cooper
Cameron Corporation, Cameron Division. Any reproduction or use of
the calculations, drawings, photographs, procedures, or instructions, ei-
ther expressed or implied, is forbidden without the expressed written
permission of Cameron or its authorized agent.

Initial Release 01
May 2004

Copyright © 2004 all rights reserved

by
Cooper Cameron Corporation, Cameron Division

TC1569 ii
PREFACE
The procedures included in this book are to be performed in conjunction
with the requirements and recommendations outlined in API Specifica-
tions. Any repairs to the equipment covered by this book should be done
by an authorized Cameron service representative. Cameron will not be
responsible for loss or expense resulting from any failure of equipment or
any damage to any property or death or injury to any person resulting in
whole or in part from repairs performed by other than authorized
Cameron personnel. Such unauthorized repairs shall also serve to termi-
nate any contractual or other warranty, if any, on the equipment and
may also result in equipment no longer meeting applicable require-
ments.

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

This book covers Cameron products, which are products of Cooper

Cameron Corporation.

Cooper Cameron Corporation

Cameron Division
P.O. Box 1212
Houston, Texas 77251-1212
713-939-2211
http://www.coopercameron.com

TC1569 iii
TC1569 iv
Table Of Contents

Section 1 - Description

Section 2 - Installation

Section 3 - Operation

Section 4 - Maintenance

Section 5 - Troubleshooting

Appendix - HDI 200B & 200P Series Pressure Gauges

TC1569 v
TC1569 vi
Section 1

Description

I. Total System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

II. Choke Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Design File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

DF-055050-02

TC1569 1-1
TC1569 1-2
I. Total System

Figure 1.1 Typical Manifold Arrangement

The Cameron Drilling Choke Control System assists in maintaining near con-
stant bottom hole pressure while circulating contaminated mud out of the
hole.

A “kick” is a flow of formation fluid into the well bore. Since there are many
methods of “kick” control, and each rig operator has his own preferred ap-
proach, no attempt is made to detail a “kick” control procedure.

The drilling choke system consists of one or more chokes with manual or hy-
draulic actuators and choke position indicators. A control panel on the rig
floor enables the Driller to open or close the hydraulic chokes by remote con-
trol, using self-contained hydraulic pressure as the power source. Mud pres-
sure gauges are located on the rig floor to facilitate choke control. There are
high pressure lines within the panel; hydraulic pressure is set between 1450
and 1550 psi. The standpipe and choke manifold gauges receive direct hy-
draulic pressure from their respective manifolds. Maximum pneumatic pres-
sure is the 80 to 125 psi rig air supply. The gauge protectors, which isolate (or
protect) the gauges on the control panel from the drilling mud, are located
on the standpipe and choke manifolds. These protectors transmit pressure
through the hoses to the gauges on the control panel where the pressure
readings are registered.

TC1569 1-3
II. Choke Control Panel
Note: Refer to Figure 1.2

STANDPIPE MANIFOLD PRESSURE CHOKE MANIFOLD PRESSURE

HYDRAULIC PRESSURE RIG AIR PRESSURE

POSITION INDICATOR
HOLD

FAST SLOW CLOSE OPEN

SPEED CONTROL
CHOKE

SD 035063
SINGLE PANEL

CAMERON

SD 035064
DUAL PANEL

Figure 1.2 Panel Controls

TC1569 1-4
 Standpipe Pressure Gauge (Item A)
Displays the actual standpipe pressure.

Hydraulic Pressure Gauge (Item B)

Displays the hydraulic pressure available to operate the choke.

Actual Choke Position Gauge(s) (Item C)

Shows the position of the choke gate relative to full open such as 1/8” , 1/2”,
or 3/4” open. The indicated position is not a measure of orifice size, flow
rate, or pressure.

Rig Air Pressure Gauge (Item D)

Displays the rig air supply entering the console.

Choke Manifold Pressure Gauge (Item E)

Displays the actual choke manifold pressure.

Hydraulic Pressure Adjust Regulator

Controls the hydraulic pressure output
from the pump unit.

Manual Choke Control Lever(s) (Item F)

Manually controls the choke gate positing
CHOKE CLOSE-CHOKE OPEN.

Speed Control Valve(s) (Item G)

Controls the opening and closing speed of
the hydraulically actuated choke.

Pump Stroke Counter (Item H)

Displays total mud pump strokes and pump
speed in strokes per minute.

TC1569 1-5
TC1569 1-6
 DF-055050-02

DESIGN FILE

MODEL “CW” DRILLING CHOKE

CONTROL PANEL
(Single or Dual Choke operation)
API 16C

TC1569 1-7
 1. Design Plan – Single and Dual Choke operation Choke Control Panels are individual units of a
product family of similar units. The product family consists of all Model “CW” units with a nominal
working pressure of 1500 psi. Thus all the design calculations are common to the product family and
no specific design file for each unit will be maintained.

2. Design Input – These Choke Control Panels are designed to comply with API 16C.

2.1 The unit is sized in accordance with API 16C to operate a Cameron Willis “rotary gate” type
choke(s).The choke actuator has a operating volume of approximately 36 cubic inches = .15 gallons.
The pump in this unit is sized to provide as a minimum, .15 gallons @ 1500 PSI in 30 seconds ( API
16C choke closure time requirement), plus a reasonable design safety margin.

2.2 The arrangement of the system schematic is determined by input received from the purchaser at
the time of placement of the order. Further clarifications after receipt of the order may occur. Confor-
mance to the design inputs is to be monitored during design reviews. Sales dept is to fill out sheet
three (3) of this document. QA will file sheet three (3) in the WORK ORDER package.

2.3 Design operating pressure is 1500 PSI. Relief valves are set @ 1750 PSI. Relief valve setting is
based on 1500 PSI maximum system pressure and as a thermal relief for the system hoses when in di-
rect sunlight.

2.4 Reservoir size is six (6) gallon working volume. This is sufficient for the approximate .15 gallon
output volume plus reserve.

2.5 Gauges

2.5.1 Standpipe and Manifold Pressure Gauges - These gauges are normally direct reading hydraulic
but may be arranged for use with Cameron J2 pressure transmitters. J2 or direct reading must be spec-
ified by the customer and/or matched to the pressure monitoring equipment on the choke manifold.

2.5.1.1 Standpipe and Manifold Pressure Gauges (for use with J2 pressure transmitters) – These
gauges will be 0-30 PSI actual pressure movement with ‘false reading’ dials reading pressure as speci-
fied by the customer.

2.5.1.2 Standpipe and Manifold Pressure Gauges 10,000 PSI or less (for use with 1:1 gauge isolators)
– These gauges are direct reading hydraulic gauges reading actual pressures as specified by the cus-
tomer.

2.5.1.3 Standpipe and Manifold Pressure Gauges greater than 10,000 PSI (for use with 4:! Gauge iso -
lators) – These gauges are ‘False Reading’ hydraulic gauges where the actual pressure movement is
25% of the indicated full scale.

2.6 Stroke Counter – Stroke counters are purchased certified and explosion proof in accordance with
API 16C.

3. Design Verification - Evidence of design verification for this product family exists in the historical
performance similar units. Choke Control Panels built to these same design standards have operated
satisfactorily for many years. Product family is design reviewed, however at the receipt of each order
an individual design review is not required because each order does not constitute a change in form, fit
or function (IAW Cameron procedure PMP 403).

4. Design Validation - Design validation is accomplished by the execution of the FAT which is speci-
fied on the unit BOM.

TC1569 1-8
 Cameron Choke Control Consoles
Models
____ Basic I - aluminum enclosed style cabinet, for control of one Cameron style choke, 350
PSI control system pressure.
____ Basic II - aluminum enclosed style cabinet, for control of two Cameron style chokes,
350 PSI control system pressure.
____ CC - open, painted style frame, available for control of one or two Cameron style
chokes, 350 PSI control system pressure.
____ CW - open, painted style frame, available for control of one or two Willis style chokes,
1500 PSI control system pressure.
Options that must be specified at time of purchase:
1. For control of one or two chokes per console? ____________________________________

2. For use with 1:1 or 4:1 gauge isolators (gauge protectors) or Cameron J2 type pneumatic
transmitters?

__________________________________________________________________________
3. Nomenclature & pressure range of gauges on panel.
2.1 nomenclature _________________ pressure _____________
2.2 nomenclature _________________ pressure _____________
2.3 nomenclature _________________ pressure _____________
2.4 nomenclature _________________ pressure _____________
4. Pressure units of gauges if other than standard (standard units are PSI/BAR). ___________
5. Pump stroke counter features if other than standard. (standard unit is for two pumps, dis-
play of rate and total strokes, certified explosion proof for hazardous duty location).
4.1 number of pumps _______________________________________

4.2 other special requirement _________________________________

_________________________________________________________
_________________________________________________________
_________________________________________________________
6. Paint if other than standard (standard paint is enamel suitable for onshore service only)

_______________________________________________________________________
7. Other special requirements ___________________________________________________
_________________________________________________________________________

TC1569 1-9
TC1569 1-10
Section 2

Installation

I. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

II. Hydraulic and Pneumatic Line Connections. . . . . . . . . . . . . . . 2-3

A. Quick-Connect Fittings . . . . . . . . . . . . . . . . . . . . . . . 2-3

B. Air Supply Connection . . . . . . . . . . . . . . . . . . . . . . . 2-3
C. Choke Connections for Single Choke Panels . . . . . . . . . . . . 2-3
D. Choke Connections for Dual Choke Panels . . . . . . . . . . . . 2-4

III. Gauge Protector and Hydraulic Hose Installation . . . . . . . . . . . 2-4

A. Standpipe Connections . . . . . . . . . . . . . . . . . . . . . . . 2-4

B. Choke Manifold Connections . . . . . . . . . . . . . . . . . . . . 2-4

IV. Purging the Hydraulic Choke Lines . . . . . . . . . . . . . . . . . . . 2-5

A. Chokes without Quick-Connect Purge Outlets . . . . . . . . . . 2-5

B. Chokes with Quick-Connect Purge Outlets. . . . . . . . . . . . . 2-6

V. Pump Stroke Counter . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

A. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

VI. Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

A. Set the Pneumatic Pressure . . . . . . . . . . . . . . . . . . . . . 2-9

B. Set the Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . 2-10
C. Set Open-Close Time . . . . . . . . . . . . . . . . . . . . . . . . 2-10
D. Calibrate the Choke Position Gauge . . . . . . . . . . . . . . . . 2-11

TC1569 2-1
TC1569 2-2
I. CONTROL PANEL
Install the control panel in any convenient location on the rig floor as close to
the choke manifold as practical.

II. HYDRAULIC and PNEUMATIC LINE CONNECTIONS

A. Quick-Connect Fittings

1. Ensure that all quick-connect fittings are clean and clear of debris.

2. Ensure that the O-rings on the quick-connect fittings are lightly lubri-
cated with oil or silicone grease.

3. Ensure that the quick-connect fittings are secure and fully engaged,
and that the lock ring has snapped into place to prevent pneumatic or
hydraulic leaks.

B. Air Supply Connection

Connect a ½” pneumatic line between the male quick-disconnect and any

oil-free source of 80 to 125 psi rig air.

C. Choke Connections for Single Choke Panels

1. Connect a ½” hydraulic line between the female quick-disconnect

CHOKE OPEN and the OPEN port on the choke actuator.

2. Connect a ½” hydraulic line between the female quick-disconnect

CHOKE CLOSE and CLOSE port on the choke actuator.

SD 035061

TC1569 2-3
 D. Choke Connections for Dual Choke Panels

1. Connect a ½” hydraulic line between the female quick-disconnect

choke 1 OPEN and the OPEN port on the choke 1 actuator.

2. Connect a ½” hydraulic line between the female quick-disconnect

choke 1 CLOSE and the CLOSE port on the choke 1 actuator.

SD 035062

Repeat steps 1-2 for Choke 2 OPEN CLOSE.

III. GAUGE PROTECTOR and HYDRAULIC HOSE INSTALLATION

A. Standpipe Connections

Connect the Standpipe Pressure Gauge protector assembly to the rig

standpipe. The assembly should be mounted in an upright position to al-
low mud to drain when there is no pressure in the standpipe. The hydrau-
lic hose is connected to the Standpipe Pressure Gauge connection located
on the Control Panel Bulkhead. Make sure the hose is run in a manner
which will not interfere with pedestrian or vehicle traffic or be cut,
crimped, worn by rig structures or burned by other equipment.

B. Choke Manifold Connections

Connect the Choke Manifold Pressure Gauge protector assembly to a suit-

able place on the choke manifold. This assembly should be mounted up-
right and have a valve below it that can be closed off to allow repair of
the gauge protector. The hydraulic hose is connected to the Choke Mani-
fold Pressure Gauge connection located on the Control Panel Bulkhead.
Make sure the hose is routed in the same manner as described above.

TC1569 2-4
IV. PURGING the HYDRAULIC CHOKE LINES
A. Chokes without Quick-Connect Purge Outlets

Purge all hydraulic lines of air as follows:

1) Fully open the choke, using the manual choke control lever on
the panel.

2) Move the manual choke control lever to the center position.

3) Disconnect the hydraulic line at the CLOSE port on the choke 1

actuator.

4) Install a female quick-connect fitting into the end of the discon-

nect CLOSE hydraulic line.

5) Place the end of the hydraulic line either into a clean bucket or
into the pump tank fill-up throat.

6) Move the manual choke control lever to the CLOSE position.

7) Observe the hydraulic fluid pumping from the hydraulic line un-
til it is free of air.

Caution: DO NOT allow the fluid level in the reservoir to drop below the sight
glass level, or more air will be pumped into the hydraulic lines.

8) Remove the female

quick-connect fitting from
the hydraulic line while
pumping.

9) Move the manual choke con-

trol lever to the center posi-
tion.

10) Connect the hydraulic line to

the 1 choke CLOSE port.

11) Fully close the choke, using

the manual choke control le-
ver on the panel.

12) Move the manual choke con-

Figure 2.14 Monitor Fluid Level at the Sight Glass
trol lever to the center posi-
tion.

TC1569 2-5
 13) Disconnect the hydraulic line at the OPEN port on the choke 1
actuator.

14) Install a female quick-connect fitting into the end of the discon-
nected OPEN hydraulic line.

15) Place the end of the hydraulic line either into a clean bucket or
into the pump tank fill-up throat.

16) Move the manual choke control lever to the OPEN position.

17) Observe the hydraulic fluid pumping from the hydraulic line un-
til it is free of air.

Caution: DO NOT allow the fluid level in the reservoir to drop below the sight
glass level or more air will be pumped into the hydraulic lines.

18) Remove the female quick-connect fitting from the hydraulic line
while pumping.

19) Move the manual choke control lever to the center position.

20) Connect the hydraulic line to the 1 choke OPEN port.

B. Chokes with Quick-Connect Purge Outlets

1) Ensure that both open and close hydraulic lines are connected to
the choke and the panel.

2) Fully open and fully close the choke three times.

3) Fully open the choke, using the manual choke control lever on
the panel.

4) Disconnect the hydraulic line at the OPEN port on the choke 1

actuator.

5) Connect a flex hose assembly to the CLOSE female quick-connect

purge outlet on the choke.

6) Connect an open-ended female quick-connect to the other end

of the flex hose assembly.

7) Place the end of the flex hose into a clean bucket or the hydrau-
lic pump reservoir fill-up throat.

8) Close the choke.

TC1569 2-6
 9) Observe the hydraulic fluid pumping from the flex hose until it
is free of air.

Caution: DO NOT allow the fluid level in the reservoir to drop below the sight
glass level or more air will be pumped into the hydraulic lines.

10) Remove the female quick-connect fitting from the flex hose
while pumping.

11) Connect the hydraulic line to the OPEN port on the choke 1 ac-
tuator.

12) Disconnect the flex hose assembly from the CLOSE purge outlet
on the choke.

13) Connect the flex hose assembly to the OPEN female quick-con-
nect purge outlet on the choke.

14) Disconnect the hydraulic line at the CLOSE port on the choke 1
actuator.

15) Connect an open-ended female quick-connect to the other end

of the flex hose assembly.

16) Place the end of the flex hose into a clean bucket or the hydrau-
lic pump reservoir fill-up throat.

17) Open the choke.

18) Observe the hydraulic fluid pumping from the flex hose until it
is free of air.

Caution: DO NOT allow the fluid level in the reservoir to drop below the sight
glass level or more air will be pumped into the hydraulic lines. Refer to
Figure 2.14.

19) Remove the female quick-connect fitting from the flex hose
while pumping.

20) Connect the hydraulic line to the CLOSE port on the choke actu-
ator.

21) Disconnect the flex hose assembly from the OPEN purge outlet
on the choke.

22) Fully open and fully close the choke several times using the man-
ual choke control lever.

TC1569 2-7
 23) Repeat the purging procedure if choke operation seems slug-
gish.

24) Repeat the purging procedure, steps A1 through B23, for

choke 2.

25) Connect a ¼” pneumatic line between the male quick-discon-

nect outlet and the supply port of the position indicator on the
choke actuator.

26) Connect a ¼” pneumatic line between the male quick-discon-

nect INLET and the return port of the position indicator on the
choke 1 actuators.

For Dual Choke Controls Panels. Repeat above steps for second position indi-
cator for choke 2.

V. PUMP STROKE COUNTER

A. Connections

1. Connect the mud pump input cable to the appropriate socket on the
pump stroke counter. Refer to Figure 2.16.

Figure 2.16 Pump Stroke Counter

TC1569 2-8
 2. Connect a mud pump input cable to each mud pump. Route the ca-
bles away from high voltage lines and avoid heavy traffic areas.

3. It is recommended that the input switch at the mud pump is installed

so that switch operating rod is
pointing down. Refer to Figure
2.17.

4. Ensure that the slush ring on the

mud pump operates the input
switch operating rod smoothly.

5. Ensure that the slush ring on the

mud pump does not deflect the
actuating wire on the switch
more than 45°.

Figure 2.17 Regulator

VI. CALIBRATION
A. Set the Pneumatic Pressure

1. Observe the pressure indicated on the regulated air supply pressure

gauge.

2. If the gauge does not read 50 psi, adjust the

gauge as follows:

3. Before applying inlet pressure to regulator,

turn adjustment knob counterclockwise to re-
move all force on regulating spring.

4. Apply inlet pressure, then turn adjustment

knob clockwise to increase and counterclock-
wise to decrease pressure setting.

5. Always approach the desired pressure from a

lower pressure. When reducing from a higher
to a lower setting, first reduce to some pres-
sure less than that desired, then bring up to Figure 2.18 Air Pressure Gauge
the desired pressure.

6. KNOB ADJUSTMENT. Push knob down to lock pressure setting. Pull

knob up to release.

TC1569 2-9
 B. Set the Hydraulic Pressure

1. Apply air supply to the panel.

2. Fully open the choke by moving the manual choke control lever to the
right to CHOKE OPEN.

3. Observe the pressure indi-

cated on the HYDRAULIC
PRESSURE gauge mounted
on instrument panel to en-
sure that between 1450 and
1550 psi is present. Refer to
Figure 2.19. STANDPIPE MANIFOLD PRESSURE CHOKE MANIFOLD PRESSURE

4. If the pressure reading is HYDRAULIC PRESSURE RIG AIR PRESSURE

POSITION INDICATOR

not between 1450 and 1550 HOLD

psi, adjust the pressure as FAST SLOW

SPEED CONTROL
CLOSE OPEN

CHOKE

follows:
SD 035063

a. Adjust the hydraulic SINGLE PANEL

pump pressuring regula-

tor as follows: Figure 2.19 Set The Hydraulic Pressure

1) Loosen the lock nut on the pressure regulator.

2) Turn the regulator T-Handle clockwise to increase the pressure.

3) Turn the regulator T-Handle counterclockwise to decrease the

pressure.

b. Fully open, then close the choke, using the manual choke control
lever.

c. Observe the pressure indicated on the HYDRAULIC PRESSURE

gauge for a corrected reading while the choke is fully closed.

d. Continue this process until the proper adjustment is made.

e. Tighten the lock nut to hold the pressure regulator in this position.

C. Set OPEN – CLOSE Time

1. Fully open the choke, using the manual choke control lever.

2. Move the manual choke control lever to the CLOSE position and en-
sure that the time required for full closure is 25 to 30 seconds.

TC1569 2-10
 3. Move the manual choke
control lever to the OPEN
position and ensure that
the time required for full
opening is 25 to 30 sec-
onds. STANDPIPE MANIFOLD PRESSURE CHOKE MANIFOLD PRESSURE

4. If the opening and clos-

ing time is not within HYDRAULIC PRESSURE
POSITION INDICATOR
RIG AIR PRESSURE

these limits, follow the HOLD

FAST SLOW CLOSE OPEN

adjustment procedure SPEED CONTROL

CHOKE

below. Refer to Figure SD 035063

2.20. SINGLE PANEL

a. If the travel time is

more than 30 seconds: Figure 2.20 Model "CW" Choke Control Panel

1) Slightly open the SPEED CONTROL valve by turning the knob

counterclockwise.

2) Repeat steps 1 through 4.

b. If the travel time is less than 25 seconds:

1) Slightly close the SPEED CONTROL valve by turning the knob

clockwise.

2) Repeat Step 1 through 4.

D. Calibrate the CHOKE POSITION Gauge

1. Fully close the choke, using the man-

ual choke control lever.

2. Observe the ACTUAL CHOKE

POSITION gauge. Refer to Figure
2.21. If the gauge does not register
full CLOSE:

a. Loosen the lock nut on the indica-

tor regulator. Refer to Figure 2.23

b. Loosen the locking clamp holding

the threaded sleeve.

c. Turn the threaded sleeve into the

regulator body io increase the Figure 2.21 Actual Choke Position Gauge at
CLOSE setting. Full Close.

TC1569 2-11
 d. Turn the threaded sleeve out of the
regulator body to decrease the
CLOSE setting.

Note: The tail rod of the choke should be just con-

tacting the actuator rod on the indicator.

e. Tighten the lock nut

f. Tighten the locking clamp holding

the threaded sleeve.

3. Fully open the choke, using the manual

Figure 2.23 Choke Position Indicator Box
choke control lever.

4. Observe the ACTUAL CHOKE POSITION

gauge. Refer to Figure 2.24. If the
gauge does not register full OPEN:

a. Remove the indicator regulator from

the housing on the choke. Refer to
Figure 2.23.

b. Unscrew the threaded sleeve from

the position indicator regulator body
Refer to Figure 2.25.
Figure 2.24 Choke Position Gauge at
c. Remove the compression spring and
Full Open
actuator rod.

d. If the reading on the gauge is past

full OPEN turn the spring off the actu-
ator rod approximately one quarter
turn.

e. If the reading on the gauge is below

full OPEN, turn the spring onto the
actuator rod approximately one quar-
ter turn.

f. Reassemble the position indicator

regulator.

g. Install the position indicator regulator

in the housing on the choke. Figure 2.25 Position Indicator Regulator

5. Repeat steps 1 through 4 until full CLOSE

and full OPEN readings are correct.

TC1569 2-12
Section 3

Operation

I. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Standpipe Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Choke Manifold Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 3-3

Hydraulic Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Choke Position Gauge(s) . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Rig Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Manual Choke Control Lever(s) . . . . . . . . . . . . . . . . . . . . . 3-3

Hydraulic Pressure Adjust Regulator . . . . . . . . . . . . . . . . . . . 3-4

Speed Control Valve(s) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Pump Stroke Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

TC1569 3-1
TC1569 3-2
I. OPERATION

STANDPIPE PRESSURE GAUGE (Item A)

The pointer indicates the actual standpipe pressure.

HYDRAULIC
PRESSURE GAUGE
(Item B)

The pointer indi-

cates the hydraulic
pressure available
to operate the STANDPIPE MANIFOLD PRESSURE CHOKE MANIFOLD PRESSURE

choke. Hydraulic
pressure should be
set between 1450 HYDRAULIC PRESSURE RIG AIR PRESSURE
POSITION INDICATOR
and 1550 psi. HOLD

FAST SLOW CLOSE OPEN

ACTUAL CHOKE SPEED CONTROL

CHOKE

POSITION
SD 035063
GAUGE(S) (Item C)
SINGLE PANEL
The pointer indi-
cates the position Figure 3.1 Panel Controls
of the gate relative to full open. The indicated
position is not a measure of orifice size, flow rate,
or pressure.

RIG AIR PRESSURE GAUGE (Item D)

The pointer indicates the air pressure supplied to the console. Recom-
mended supply pressure is 80 to 125 psi.

CHOKE MANIFOLD PRESSURE GAUGE (Item E)

The pointer indicates the actual pressure at the choke manifold.

MANUAL CHOKE CONTROL LEVER(s) (Item(s) F)

Open the choke by moving the lever to the right to CHOKE OPEN.

Close the choke by moving the lever to the left to CHOKE CLOSE

Note: In the spring-centered position the choke is hydraulically locked and will not
move.

TC1569 3-3
 HYDRAULIC PRESSURE ADJUST REGULATOR

The regulator controls the hydraulic output pressure of the pump unit.
Refer to the calibration instructions in Section2.

SPEED CONTROL VALVE(s) (Item G)

The valve regulates the opening and closing speed of the hydraulically op-
erated choke. Refer to the calibration instructions in Section 2.

PUMP STROKE COUNTER (Item H)

The ECS 101118 Pump Stroke Counter is a dual input counter designed to
independently monitor the rate and total strokes of two mud pumps. The
counter uses four LCD displays, two for the indication of rate as expressed
in counts per minute and two for total count.

The rate displays have a range of 7.5 to 1024 strokes per minute. Accurate
indication of rate will be displayed on the second contact closure and will
be automatically updated once per second thereafter. Counts below 7.5
strokes per minute will cause the rate indicator to reset to zero.

The total stroke accumulation range of the instrument is from 0 to 9999.

Reset to zero is controlled by front panel switches. The rate and range of
the instrument is controlled by the frequency of external contact closures.

There are three pushbutton switches located on the front panel. The two
outside switches control reset of the total stroke displays. The center
switch controls power on and off.

The instrument is supplied in a sealed and rugged stainless enclosure to

withstand the harsh environment of the oilfield. The unit requires little or
no maintenance, has a life expectancy of approximately 50,000 hours of
continuous use, and requires no calibration.

TC1569 3-4
 Operation
The ECS 10118 Pump Stroke Counter has been designed for simple opera-
tion requiring the use of only three switches to control all functions.

• Depress the center switch to power the meter on or off. The counter
should respond with all four displays indicating an initial count and
rate. With no active input, the rate displays should zero within a
few seconds.

• Depress Reset 1 and Reset 2 to clear the total count displays. The
Reset switches should be depressed at any time the user wishes to
zero the counter.

TC1569 3-5
TC1569 3-6
Section 4

Maintenance

Routine Maintenance

I. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

A. Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

B. Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
C. Pump Stroke Counter . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Equipment

Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

TC1569 4-1
TC1569 4-2
I. CONTROL PANEL

A. Air Filter

Disassembly

1. Filter can be disassembled without re-

moval from air line.

2. Shut off inlet pressure. Reduce pres-

sure in inlet and outlet lines to zero.

3. Remove bowl – push into body and

turn counterclockwise.

4. Disassemble in general accordance

with Installation and Maintenance In-
structions at the end of this section.
Figure 4.1 Air Filters
Do not remove the drains or the ser-
vice indicators unless replacement is necessary.
Remove and replace only if they malfunction.

SERVICING

1. Open manual drain to expel accumulated liquids.

2. Clean or replace filter element when dirty.

3. Inspect the filter and drain containers to ensure that there are no air
leaks.

B. Hydraulic Pump

Maintain the oil level in the reservoir at approximately ¾ full on the sight
glass. Use transformer oil, P/N 003141-10. The tank capacity is 5 U.S. gal-
lons.

C. Pump Stroke Counter

1. Examine all cables for breakage or abuse. Replace if necessary.

2. Ensure that all connections are secure and free of water and debris.

3. Inspect the input signal switches on each mud pump. Ensure that they
operate smoothly and are free of mud and debris.

TC1569 4-3
TC1569 4-4
TC1569 4-5
TC1569 4-6
TC1569 4-7
TC1569 4-8
Parts List: Spare Parts Kit, Model "CW" Drilling Choke Control Panel
P/N 2185524-22-99

Item Part Number Qty Description

1 2762723-01 1 Valve, 4-Way, Manual, 1/4" port, 3000 psi
2 706102 1 Repair Kit, 1/2" Valves
3 2711209-02 1 Filter, Air, 1/2"
4 2711209-02-01 1 Filter Element
5 2711209-02-98 1 Service Kit, Seal & Gasket, Filter Series F74G
6 2750347-02 1 Lubricator, Oil Fog
7 2750347-02-01 1 Drain, Replacement, Manual
8 2750347-02-98 1 Service Kit, L74C Series Lubricator
9 2185640-34 1 Valve, Relief, Inline Direct
10 2762533-01 1 Regulator, Pressure, 3/8"
11 2762533-01-98 1 Service Kit, 3/8" Regulator
12 713277 1 Regulator, Pressure, 1/2"
13 713277-99 1 Service Kit, 1/2" Regulator
14 667172-02-30-98 1 Seal Kit, Pump, Hydraulic - Hand Operated
15 626842-01-98 1 Repair Kit, Pump

TC1569 4-9
TC1569 4-10
Section 5

Troubleshooting

Pneumatic Circuits

I. Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

II. Position Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

TC1569 5-1
TC1569 5-2
I. Air Supply

AIR SUPPLY TROUBLESHOOTING

Problem Cause Solution

1. Pneumatic supply line is Connect the pneumatic
not connected supply line.

2. Pneumatic supply line Connect the pneumatic

quick-connect is not fully supply line quick-connect.
engaged at the male
quick-disconnect.

3. Pneumatic supply line is Replace the pneumatic

Air not supplied to 50 psi broken or crimped. supply line .
regulator
4. Pneumatic supply line Turn on the pneumatic
valve is turned off at the supply line valve at the
compressor. compressor.

5. Filter retainer rings and Tighten the filter retainer

drains are not tightly rings and drains.
secured and are leaking air.

Problem Cause Solution

1. 80 to 125 psi pressure is Ensure that 80 to 125 psi

not supplied to the pressure is supplied to the
regulator. regulator.
50 psi air pressure gauge
does not register. 2. Regulator is bad. Replace the regulator.
3. Gauge is bad. Replace the gauge.

1. 80 to 125 psi pressure is Ensure that 80 to 125 psi is

not supplied to the supplied to the regulator.
regulator.
Male quick-connect delivers 2. Test equipment a. Ensure that the
no air when test equipment quick-connect is not fully quick-connect is fully
is connected. engaged. engaged.
b. Replace the male
quick-connect.

TC1569 5-3
II. POSITION INDICATOR

POSITION INDICATOR TROUBLESHOOTING

Problem Cause Solution

1. Pneumatic lines are not Connect the pneumatic

connected. line.
2. Pneumatic lines are Replace the pneumatic
broken or crimped. lines.
3. Quick-connect fittings Ensure that the fittings are
are not securely engaged. securely engaged.

4. Quick-connect fittings Replace the quick-connect

are defective. fittings.
ACTUAL CHOKE POSITION 5. Indicator is not Calibrate the indicator.
gauge does not register calibrated. Refer to Paragraph A
below.
6. Position indicator Replace the regulator.
regulator on the choke is
bad.

Ensure that 50 psi pressure

7. 50 psi pressure is not is supplied to the position
supplied to the position indicator regulator.
indicator regulator.

Replace the gauge.

8. Gauge is bad.

Recalibrate the Choke Position Indicator

1. Observe the ACTUAL CHOKE POSITION gauge. If the gauge does not
register full CLOSE:

a. Loosen the lock nut on the indicator regulator. Refer to Figure 5.2.

b. Loosen the locking clamp, holding the threaded sleeve.

c. Turn the threaded sleeve into the regulator body to increase the
CLOSE setting.

d. Turn the threaded sleeve out of the regulator body to decrease the
CLOSE setting.

Important: The tail rod of the choke should just contact the regulator push rod.

TC1569 5-4
Figure 5.2 Choke Position Indicator Box

e. Tighten the lock nut.

f. Tighten the locking clamp, holding the threaded sleeve.

2. Fully open the choke, using the manual choke control lever.

3. Observe the Actual Choke POSITION

gauge. Refer to Figure 5.3. If the
gauge does not register full OPEN:

a. Remove the indicator regulator from

the housing on the choke. Refer to
Figure 5.4.

b. Unscrew the threaded sleeve from

the position indicator regulator
body.
Figure 5.3 Choke Position Gauge at
Full Open

Figure 5.4 Position Indicator Regulator

TC1569 5-5
 c. Remove the compression spring and actuator rod.

d. If the reading on the gauge is past full OPEN, turn the spring off
the actuator rod approximately one quarter turn.

e. If the reading on the gauge is below full OPEN, turn the spring
onto the actuator rod approximately one quarter turn.

f. Reassemble the position indicator regulator.

g. Install the position indicator regulator in the housing on the choke.

4. Repeat steps 1 through 3 until full CLOSE and full OPEN readings are
correct.

TC1569 5-6
Appendix

HDI 200B & 200P Series Pressure Gauges

Operation & Maintenance

TC1569
TC1569
TC1569 6-3
TC1569 6-4
TC1569 6-5
TC1569 6-6
TC1569 6-7
TC1569 6-8
TC1569 6-9
TC1569 6-10
TC1569 6-11
TC1569 6-12
TC1569 6-13
TC1569 6-14
TC1569 6-15
TC1569 6-16
TC1569 6-17
TC1569 6-18
TC1569 6-19
TC1569 6-20
TC1569 6-21
TC1569 6-22
TC1569 6-23
 P.O. Box 1212
Houston, TX 77251-1212
Ph: 713-939-2211
Fax: 713-939-2620
http://www.coopercameron.com

TC1569 6-24