A1083290 - MAN - CG+MP16II RevB

MP16II

With CombiGauge I and II

DRAFT - FOR User Manual INFORMATION ONLY ORIGINAL INSTRUCTIONS

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Tel: +31 184 608 700, Fax: +31 184 608 790, www.nov.com NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 1 of 104 Revision B

MP16 User Manual

This document (MAN-10003445) applies to the following parts: A1102422

MEASUREHEAD MP16II BASIC

A1083290

COMBIGAUGE II 0-900 KG/M

L-6501034275

COMBIGAUGE ASSY 2000 KG FT

L-6501034295

COMBIGAUGE ASSY 2000 KG M

L-6501034294

COMBIGAUGE ASSY 2000 LBS FT HI-RES

L-6501034293

COMBIGAUGE ASSY 4400 LBS FT

L-6501037002

COMBIGAUGE ASSY 8800 LBS FT

L-6501038038

COMBIGAUGE ASSY 3200 LBS FT

WARNING DANGEROUS MACHINERY Ignoring the instructions in this manual can result in serious injury or death. All personnel that work with this equipment must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

REVISION HISTORY

Published by: NOV ASEP Elmar Energieweg 26 2964 LE Groot-Ammers The Netherlands © 2012 No part of this document may be reproduced by any means without the written consent of the publisher. Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by NOV ASEP Elmar for loss, damage or injury caused by any errors or omissions in this document.

Revision

Date

Amendments

B

15 November 2012

New revision and part no for referenced part. New layout cover page. New safety section. Added physical descriptions (and new graphics) of: basic configuration, load cells, load pins, encoders, depth drives, spooling assemblies, Combigauge I and II. New figure in Setup section. Updated maintenance table. Updated lubrication procedure. Added pneumatic autospooling check/adjust procedure. New graphics for: access for upper wheel removal, drive splitter, encoder (mounted), Combigauges I and II, load cell. Added list of drawings. New figure appendix 5. Index removed. Minor textual corrections.

A

20 January 2012

2.02

26 May 2011

Minor corrections

2.01

3 June 2010

Minor update tension calibration procedure.

2.00

8 March 2010

New manual part no. and revision no. (NOV ASEP Elmar internal systems). Description chapter now split into functional/physical descriptions. Added autospooling and tension load pin options. New autospooling check/adjust procedure. Replaced tension calibration procedure (new tool).

Restyled; modified tension calibration procedure. Extended minimum temperature down to -20°C.

REVISION HISTORY Page 2 of 104 Revision B Original Instructions

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

MP16 User Manual

TABLE OF CONTENTS 1

2

3

4

5

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 3 of 104 Revision B Original Instructions

Table of Contents

6

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 Scope of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.2 How to use this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3 Documentation Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1.1 Employee responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1.2 Employer responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1.3 Warnings, cautions and requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.1.4 ATEX and zoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 MP16II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2 CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.2.1 CombiGauge I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.2.2 CombiGauge I (model with a secondary correlating depth odometer) . 24 3.2.3 CombiGauge II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.1 MP16II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.2 CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SETUP & TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.1 Measuring head rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.1.1 Release head from transport lock and mount for operations . . . . . . . . 31 5.1.2 Prepare depth measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.1.3 Prepare tension measurement system . . . . . . . . . . . . . . . . . . . . . . . . . 34 5.1.4 Thread wireline through the measuring head . . . . . . . . . . . . . . . . . . . . 35 5.2 Measuring head rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.2.1 Unthread wireline from the measuring head . . . . . . . . . . . . . . . . . . . . . 37 5.2.2 Lock measuring head for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6.1 Periodic maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.2 Special notes on measuring head measurement precision . . . . . . . . . . . . . . . . 41 6.3 Special notes on cleaning and lubrication of the measuring head . . . . . . . . . . . 42 6.4 Safe maintenance shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.5 Remove/install measuring head in winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 6.6 Lubricate measuring head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.7 Service measuring head support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 6.8 Check/adjust autospooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 6.8.1 Electric autospooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 6.8.2 Pneumatic autospooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.9 Remove/install upper wheels and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.10 Remove/install measuring wheel and bearings. . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.11 Remove/install drive splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 6.12 Remove/install depth counter drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.13 Remove/install angle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.14 Remove/install depth encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 6.15 Check/adjust critical tension measurement distances . . . . . . . . . . . . . . . . . . . . 68 6.16 Fill and bleed tension measurement hydraulic system . . . . . . . . . . . . . . . . . . . . 69 6.17 Drain excess tension measurement hydraulic fluid. . . . . . . . . . . . . . . . . . . . . . . 73 6.18 Service tension measurement hydraulic load cell . . . . . . . . . . . . . . . . . . . . . . . 74 6.19 Check/calibrate tension measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . 78

MP16 User Manual

7

6.19.1 Rig-up the measuring head to check tension . . . . . . . . . . . . . . . . . . . . 79 6.19.2 Check tension measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 6.19.3 Calibrate CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 6.19.4 Finalize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 6.20 Rig-up and use of Tension Calibration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 6.20.1 Introduction to Tension calibration Tool. . . . . . . . . . . . . . . . . . . . . . . . . 84 6.20.2 Rig-up/rig-down Tension Calibration Tool . . . . . . . . . . . . . . . . . . . . . . . 87 6.20.3 Using the Tension Calibration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 7.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 7.2 Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Table of Contents

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Appendix 1: MP16II measuring head specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Appendix 2: CombiGauge specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Appendix 3: Referenced documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Appendix 4: Tension measurement hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Appendix 5: MP16II and CombiGauge depth calculation . . . . . . . . . . . . . . . . . . . . . . 99 Appendix 6: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Appendix 7: Notes page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

MP16 User Manual

LIST OF FIGURES MP16II measuring head basic configuration . . . . . . . . . . . . . . . . . . . . . . . . . MP16II tension measurement load cell options . . . . . . . . . . . . . . . . . . . . . . . MP16II load pin options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP16II encoder options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP16II depth drive options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP16II spooling options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - CombiGauge I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - CombiGauge I with a secondary correlating depth odometer . . . Overview - CombiGauge II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring head (basic configuration) working principle . . . . . . . . . . . . . . . . Depth measurement mechanical parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Threading the wireline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended grease gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring head lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring head support bearing and ball cage . . . . . . . . . . . . . . . . . . . . . . . Autospooling assembly with electric sensors . . . . . . . . . . . . . . . . . . . . . . . . . Autospooling assembly with pneumatic sensors . . . . . . . . . . . . . . . . . . . . . . Creating access for upper wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper wheel centre with bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly of measuring wheel & shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . measuring wheel shaft, depth counter side . . . . . . . . . . . . . . . . . . . . . . . . . . Angle drive and drive splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Depth counter drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Depth counter assembly and mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . Angle drive, link key, measuring wheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . Depth encoder mounted on lower subframe . . . . . . . . . . . . . . . . . . . . . . . . . Critical distances at load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CombiGauge bleed point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand pump, bleed key, and connection point . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary bleed point on CombiGauge (classic model only) . . . . . . . . . . . . . . Hand pump and connection point on load cell . . . . . . . . . . . . . . . . . . . . . . . . Dual-bellows load cell and cross-section of a bellows . . . . . . . . . . . . . . . . . . Gaining access to the load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bellows: dismantling & tightening sequence . . . . . . . . . . . . . . . . . . . . . . . . . Removing glass from standard CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . CombiGauge calibration mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tension Calibration Tool assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tension Calibration Tool - exploded diagram. . . . . . . . . . . . . . . . . . . . . . . . . Tension Calibration Tool - load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tension calibration tool rig-up - MPxx series . . . . . . . . . . . . . . . . . . . . . . . . .

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

10 12 14 16 18 20 22 24 26 28 32 36 42 46 47 50 52 55 56 59 59 61 63 65 66 67 68 70 71 72 73 75 76 77 81 82 84 85 86 88

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List of Figures

Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 3.5 Figure 3.6 Figure 3.7 Figure 3.8 Figure 3.9 Figure 4.1 Figure 5.1 Figure 5.2 Figure 6.1 Figure 6.2 Figure 6.3 Figure 6.4 Figure 6.5 Figure 6.6 Figure 6.7 Figure 6.9 Figure 6.8 Figure 6.10 Figure 6.11 Figure 6.12 Figure 6.13 Figure 6.14 Figure 6.15 Figure 6.16 Figure 6.17 Figure 6.18 Figure 6.19 Figure 6.20 Figure 6.21 Figure 6.22 Figure 6.23 Figure 6.24 Figure 6.25 Figure 6.26 Figure 6.27 Figure 6.28

MP16 User Manual

1

INTRODUCTION The MP16II measuring head is one of the many NOV ASEP Elmar products used in the well servicing industry.

1.1

Scope of this manual This manual is intended for operating, maintenance, and supervisory personnel and provides information on installing, operating, and maintaining your MP16II measuring head. The manual is divided into the following sections: • Introduction - (this section) • Safety - Describes all safety aspects required when working with NOV ASEP Elmar equipment • Description - Physical descriptions of major components of the measuring head, plus brief functional descriptions • Setup - How to rig-up the MP16II measuring head for use • Maintenance - Specifically for qualified maintenance personnel to maintain and repair the equipment. Contains sub-sections for periodic maintenance schedules and corrective maintenance procedures

1 Introduction

• Troubleshooting - Tables with potential problems, causes and solutions • Appendices - Contain unit specifications, supplementary information, and NOV ASEP Elmar contact information.

1.2

How to use this manual Before installing, operating or maintaining your measuring head for the first time, always read the Safety section to familiarize yourself with the safety aspects of this manual and your system. To gain a thorough understanding of your system, first thoroughly read the Description section. Read Setup to overview the steps required to setup and use the measuring head. Refer to Troubleshooting to find solutions to setup/operating problems. When performing scheduled maintenance on your measuring head, use the periodic maintenance tables at the front of the Maintenance section to establish when to perform the measuring head maintenance.

1.3

Documentation Package This User Manual is part of a comprehensive Documentation Package that is supplied as an integral part of your measuring head. The Documentation Packet includes: • Certificates and Reports • Drawings Packet with schematics • Parts List • Supplier Documentation

Refer to the Parts List when ordering replacement components during maintenance. Use the supplier documentation as reference for further information on OEM components.

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NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

MP16 User Manual

2

SAFETY TXT-10004141/A

2.1

General Safety High voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be present in ASEP Elmar equipment. Therefore, pay special attention to safety when working with this equipment. • Meet all applicable codes, laws and local field regulations (including environmental and additional owner/user company policy). This manual contains recommendations, but should not be assumed to satisfy all requirements of legal regulations. • Read and understand each item in this manual and follow all procedures, precautions and advice exactly - never take short cuts. Always consider your safety and that of others. • Only use the equipment within its design scope to avoid damage or dangerous situations. This manual (in its most current revision) is a minimum requirement for all persons working with ASEP Elmar equipment. All other current and applicable documents such as certification, drawings, bill of materials, vendor documentation, etc, should be readily available at the worksite.

2.1.1

Employee responsibility • Never leave "operation-ready" equipment unattended. • Keep equipment clean (accumulated dirt can hamper operations and jeopardize safety). • Correctly maintain and use equipment, apparatus, tools, and dangerous substances.

• Never work alone if there is a possibility of an accident. • Keep loose clothing and long hair well away from moving mechanical parts. • Remove rings, wristwatch, etc, before working. • Never disconnect, change or remove safety devices, and use such devices correctly. • Be aware of all emergency equipment and procedures (such as alarms, abandon ship, etc.) and make sure they are in place and valid. • Do not use the equipment after an emergency without verifying that the cause of the emergency has been removed or rectified. • Immediately inform the employer and other workers of any situation that represents a serious danger to safety and health, and of any shortcomings in protection arrangements. • Plan all operations including interdependencies with other equipment operations • If equipment is tied down using rope/line/chains, attach a "flag" to signal their location. • During installation, maintenance and/or equipment inspection:  where possible, make sure electrical/mechanical equipment is switched off completely, and use a decal or similar to prevent unauthorized starting;  always relieve pressure before working on hydraulic and/or pneumatic systems.

2.1.2

Employer responsibility • Define the required competency of personnel working on the equipment (including supervision) and provide the required consultation, information and training.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 7 of 104 Revision B Original Instructions

2 Safety

• Wear personal protection equipment (PPE) where necessary; for example gloves and protective footwear.

MP16 User Manual

• Ensure that only trained, qualified and competent personnel can work on the equipment. • Ensure adequate safety equipment and emergency procedures are available (fire extinguishers, PPE, escape routes, etc.), and that personnel are trained to use them. • Ensure a suitable program for installation, operation, maintenance, periodic inspection and testing of the equipment is defined, adhered to and recorded. • Do not allow work to proceed until a thorough examination and risk assessment of the work site and equipment has been done. The examination should assess (as a minimum) the condition of the work site and all critical components, plus the equipment structure. Only give approval to proceed when controls to manage potential causes are in place and measures are taken to mitigate potential consequences.

2.1.3

Warnings, cautions and requirements Equipment handling may involve residual risks which cannot be reasonably reduced by design alterations. To alert the user to potential hazards and recommend safe working practices, additional information is provided as warnings, cautions and/or requirements: • WARNING shows a relevant icon and the text WARNING with a description of the hazard and the best practise to avoid it. Ignoring a warning can result in equipment damage, plus serious injury and/or death. • CAUTION shows a relevant icon and the text CAUTION with a description of the hazard and the best practise to avoid it. Ignoring a caution can result in damage to equipment.

2 Safety

• REQUIREMENT shows an icon and a description of the required PPE to minimise possible safety risks. Warnings, cautions and/or requirements are listed in the manual as a preceding step to a potentially dangerous action. Never proceed to following step(s) if you do not comply with or fully understand a Warning/Caution/Requirement. See the following examples:

WARNING ELECTRIC SHOCK Connecting or disconnecting an energised electrical cable can cause serious injury and or equipment damage. Always ensure that all cables are not electrically energized before connecting them.

CAUTION EQUIPMENT DAMAGE Components can be damaged during cleaning, causing complete assemblies to need replacement. Take care when cleaning components. Use appropriate cleaning èquipment and materials.

Hearing protection Wear ear protection during this procedure.

NOTE: A warning, caution or requirement icon (occasionally with accompanying text) is often also affixed to the equipment at a prominent location.

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NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

MP16 User Manual

2.1.4

ATEX and zoning TXT-10004142/A

Certain equipment may optionally be certified as Rig safe, Zone 1, Zone 2, and/or ATEX. If the equipment is certified according to ATEX regulations, the following applies: • The power supply, including driven parts, has been manufactured and assessed according to ATEX and tagged with a unique identification number. • Only specially trained personnel may service this equipment otherwise Rig safe, Zone 1, or Zone 2 compliance will be compromised. • Certified explosion safe equipment is suitable for use in gas hazardous classified locations, however limited to Group II Zone 2 (acc. IEC) or Class I Division 2 (acc. NEC). The equipment is designated amongst other as Ex II 3G, IIB T3. • The design and manufacturing is based on European Directive no. 94/9/EC following conformity assessment procedure relating to internal control of production according Annex VIII of the Directive. The construction is documented in a confidential Technical Construction File held at the offices of ASEP Elmar.

2 Safety

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 9 of 104 Revision B Original Instructions

MP16 User Manual

3

PHYSICAL DESCRIPTION

3.1

MP16II

3

drum side

2

well side

1

4 drum side

5 15 3 Physical description

6

7 17

16 8

12 10

13

14 9

11

14

well side See legend next page

Figure 3.1 MP16II measuring head basic configuration Page 10 of 104 Revision B Original Instructions

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

MP16 User Manual

levelwind carriage

This comprises the top assembly that extends into the upper subframe. This section of the measuring head is moved laterally (left and right) by the levelwind drive chain on the levelwind shaft for the purpose of tidy spooling on and off the winch drum. The left and right sides of this top assembly are held together by the mounting plates of the wireline guide rollers.

2

measuring head support bearing

Slider bearing for smooth motion of the measuring head on the levelwind shaft.

3

levelwind chain attachment point

The levelwind chain is attached at this point, usually by a quick-release pin with retaining clip. On certain winches the measuring head must be released from the chain and locked to either the left or right side of the winch frame for transportation.

4

wireline guide rollers

Sealed-bearing rollers that keep the wireline aligned to the top of the guide wheels on the drum and wellhead sides of the measuring head. 2 sets on well side (basic configuration), 2 on drum side (supplied together with any of the spooling assemblies - see Figure 3.6 on page 20).

5

upper subframe

Rigid upper section of the measuring head.

6

guide wheels (2x)

Freewheeling grooved upper wheels, that guide the wireline around the (lower) depth measurement wheel, and together with the lower wheel, serve to compress the load cell when the wireline is under tension.

7

wireline retainer (2x)

Prevents the wire from jumping out of the guide wheel grooves.

8

tension measurement load cell

Converts the compressive force between the upper and lower subframes of a tensioned wireline into hydraulic pressure, which is passed to the analogue tension measurement system (CombiGauge). The load cell can be a single or dual-bellows type. Optionally, a digital pressure transmitter can be connected to supply tension data to an electronic depth and tension monitoring system, such as the ASEP Elmar SmartMonitor.

9

tension measurement hydraulic line

Hose to CombiGauge tension display in winch control panel.

10

load cell hydraulic fill point

Quick connector with ball valve to enable the tension measurement hydraulic system to be filled or drained. NOTE: Never open the valve except when performing maintenance on the hydraulic system.

11

lower subframe retainer/adjuster

Used to keep the measuring head from falling open, and to adjust the critical distance between the upper and lower subframe for tension measurement.

12

lower subframe

Hinged lower section of the measuring head, which carries the depth measurement wheel.

13

depth measurement wheel

Turns with wireline travel, transfers rotation via shaft to depth counter mechanical drive or encoder.

14

lower pressure wheels (2x)

Keep the wireline tight in the depth measurement wheel grooves to ensure maximum contact for precise measurement. Can be lifted from wheel to ease rig-up/ down.

15

wireline oiler tank

Supplies oil to the wireline during operations.

16

wireline oiler drip valve

Manual valve to start/stop the oil flow. Should be closed when not in use to avoid unnecessary spillage.

17

data plate

Contains identification and manufacturing information.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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3 Physical description

1

MP16 User Manual

3 Physical description

3

2

1

See legend next page

Figure 3.2 MP16II tension measurement load cell options Page 12 of 104 Revision B Original Instructions

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MP16 User Manual

1

tension measurement load cell (double)

Converts the compressive force between the upper and lower subframes of a tensioned wireline into hydraulic pressure, which is passed to the analogue tension measurement system (CombiGauge). Optionally, a digital pressure transmitter can be connected to supply tension data to an electronic depth and tension monitoring system, such as the ASEP Elmar SmartMonitor.

2

tension measurement load cell (single)

Converts the compressive force between the upper and lower subframes of a tensioned wireline into hydraulic pressure, which is passed to the analogue tension measurement system (CombiGauge). Optionally, a digital pressure transmitter can be connected to supply tension data to an electronic depth and tension monitoring system, such as the ASEP Elmar SmartMonitor.

3

spacer block

This block is mounted in the open side (well side) of the MP16II to maintain the spacing between the upper and lower subframe. The spacer is attached to one subframe only.

3 Physical description

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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3 Physical description

3

2

1

See legend next page

Figure 3.3 MP16II load pin options Page 14 of 104 Revision B Original Instructions

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MP16 User Manual

1

hinge pin

Holds the upper and lower subframes together in such a manner that they can freely pivot around the pin, allowing the tension measurement load cell to measure the compressive force between the subframes.

2

load pin 2 tonnes

The upper/lower subframe hinge pin is replaced with a load pin that measures the compression at the drum side and supplies an electronic signal to the NOV ASEP Elmar SmartMonitor system in the winch cabin. Option for fully digital depth and tension system (without CombiGauge). Used in combination with depth shaft encoder. Maximum tension load 2 tonnes.

3

load pin 4 tonnes

Option for fully digital depth and tension system (without CombiGauge). Used in combination with depth shaft encoder. Maximum tension load 4 tonnes.

3 Physical description

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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MP16 User Manual

2

1

1

2

See legend next page

Figure 3.4 MP16II encoder options Page 16 of 104 Revision B Original Instructions

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MP16 User Manual

1

standard encoder

Transfers a digital depth signal to an electronic depth and tension monitoring system, such as the ASEP Elmar SmartMonitor. Mounted on the left side of the depth measurement wheel.

2

optional additional encoder

Transfers a digital depth signal to an electronic depth and tension monitoring system, such as the ASEP Elmar SmartMonitor. Mounted on the right side of the depth measurement wheel.

3 Physical description

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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1

3 Physical description

3

2 1

See legend next page

Figure 3.5 MP16II depth drive options Page 18 of 104 Revision B Original Instructions

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MP16 User Manual

1

depth counter angle drive

Turns the mechanical drive through 90 degrees, with a fixed reduction ratio.

2

depth counter drive splitter

(Optional). Splits output from mechanical drive across two separate outputs, with a reduction ratio that matches specific wire thickness. Commonly used on winches with dual drums.

3

depth counter drive cable

Transmits the depth measurement rotary movement to the CombiGauge at the winch control panel. The cable must be connected to an angle drive or drive splitter output that corresponds to the wire size installed in the measuring head.

3 Physical description

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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MP16 User Manual

4 6

5 3

8 1

7

4

Autospooling (electric)

3 Physical description

9 3 11 10 1 2 Autospooling (pneumatic)

1

Manual spooling See legend next page

Figure 3.6 MP16II spooling options Page 20 of 104 Revision B Original Instructions

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MP16 User Manual

1

guide rollers

These rollers are mounted on the lateral deflection cam. When the wireline presses against one of the rollers, the lateral deflection cam is tilted towards the opposite side.

2

connection bracket (manual spooling)

This bracket is used to connect the measuring head (with the manual spooling option) to the levelwind chain.

3

connection bracket (autospooling) This bracket is used to connect the measuring head (with an autospooling option) to the levelwind chain.

4

connection bracket latch pin

Secures the connection bracket (autospooling) in place on the levelwind chain.

5

electric autospooling baseplate

Used to assemble the electric autospooling on the measuring head.

6

electric autospooling sensor

Sends an electric signal representing the wireline levelwind movement.

7

electric autospooling junction box

Keeps the electric connections isolated.

8

lateral deflection cam

Tilts together with the guide rollers and activates the electric sensors.

9

pneumatic autospooling baseplate Used to assemble the pneumatic autospooling on the measuring head.

10

pneumatic autospooling sensor

Sends an electric signal representing the wireline levelwind movement.

11

lateral deflection plate

Tilts together with the guide rollers and activates the pneumatic sensors.

3 Physical description

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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MP16 User Manual

3.2

CombiGauge

3.2.1

CombiGauge I

TXT-10004053/A

15 3

14

7

6 11

12

3 Physical description

16

4

5 8

13

2

1

10

9 See legend next page

Figure 3.7 Overview - CombiGauge I

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MP16 User Manual

1

tension system hose conn. Incoming static hydraulic line from measuring head load cell. NOTE: some models have the hose connection in the back of the gauge body.

2

tension system bleed point For removal of air from highest point in tension hydraulic system. NOTE: Some models have a single bleed point on the top of the gauge body.

3

wireline tension dial

Analogue tension display in pounds (lb) or kilograms. Units specified at time of ordering.

4

wireline tension needle

Indicates wireline tension on dial.

5

wireline tension zero knob Turn to zero tension measurement during rig-up.

6

max. tension setpoint knob Set during rig-up to indicate maximum permitted tension for wireline in use. Based on safe working load and breaking strength of wireline.

max. tension setpoint needle

8

tension system damping valve

Set during operation if necessary to minimize needle oscillation without causing loss of sensitivity. Use depends on the tension variation during spooling. High damping reduces needle shake; low damping reduces response, with the risk that an increasing wire tension may become excessive before you realize it. NOTE: Some models have the damping valve mounted on the top of the gauge body

9

depth counter angle drive

Optional (depends on control panel configuration): used to turn the mechanical drive through 90 degrees. NOTE: Some models have the drive cable coupling in the back of the gauge body.

10

depth counter drive cable

Mechanical drive cable from the depth measurement wheel of the measuring head.

11

depth odometer

Shows well servicing tool depth in the hole, referring to the zero point set during rigup using the zero pull-knob. Units (feet or metres) specified at time of ordering.

12

depth odometer zero pullknob

Pull to zero the odometer.

13

bourdon tube bleed point

DO NOT OPEN OR ADJUST. This bleed point is used during factory calibration of the CombiGauge, and should only be adjusted by qualified personnel in the factory.

14

calibration set screw access hole

If necessary, the glass and front of the gauge can be removed to give access to this hole in order to adjust the calibration of the CombiGauge.

15

depth counter connection point

Used to connect the depth counter angle drive to the measuring head and CombiGauge.

16

tension system hose connection point

Used to connect the tension system hose to CombiGauge.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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MP16 User Manual

3.2.2

CombiGauge I (model with a secondary correlating depth odometer)

TXT-10004054/A

3

2

3 Physical description

1

See legend next page

Figure 3.8 Overview - CombiGauge I with a secondary correlating depth odometer

Page 24 of 104 Revision B Original Instructions

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MP16 User Manual

1

correlating depth odometer Driven by same mechanical drive as main odometer. Used to observe depth changes with reference to a secondary point.

2

correlating depth odometer Pull to zero the correlating odometer. zero pull-knob

3

correlating depth odo set knob

Pull and turn to set the correlating odometer to a specific value.

3 Physical description

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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MP16 User Manual

3.2.3

CombiGauge II

TXT-10004055/A

6 10 5 1 8

3 Physical description

7

4

2 3

9

12

11

See legend next page

Figure 3.9 Overview - CombiGauge II

Page 26 of 104 Revision B Original Instructions

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MP16 User Manual

1

wireline tension dial

Analogue tension display in pounds (lb) or kilograms. Units specified at time of ordering.

2

wireline tension needle

Indicates wireline tension on dial.

3

wireline tension zero knob Turn to zero tension measurement during rig-up.

4

max. tension setpoint knob Set during rig-up to indicate maximum permitted tension for wireline in use. Based on safe working load and breaking strength of wireline.

5

max. tension setpoint needle

6

tension system damping valve

7

tension system bleed point For removal of air from highest point in tension hydraulic system.

8

depth odometer

Shows well servicing tool depth in the hole, referring to the zero point set during rigup using the zero pull-knob. Units (feet or metres) specified at time of ordering.

9

depth odometer zero pullknob

Pull to zero the odometer.

10

calibration set screw access hole

If necessary, the glass and front of the gauge can be removed to give access to this hole in order to adjust the calibration of the CombiGauge.

11

depth counter connection point

Used to connect the depth counter angle drive to the measuring head and CombiGauge.

12

tension system hose connection point

Used to connect the tension system hose to CombiGauge.

Set during operation if necessary to minimize needle oscillation without causing loss of sensitivity. Use depends on the tension variation during spooling. High damping reduces needle shake; low damping reduces response, with the risk that an increasing wire tension may become excessive before you realize it. NOTE: Some models have the damping valve mounted on the top of the gauge body

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MP16 User Manual

4

FUNCTIONAL DESCRIPTION

4.1

MP16II The MP16II is a combined depth and tension measuring head, that supplies analogue and/or digital signals to a display device in a wireline winch cabin. The MP16II is mainly intended for slickline and light braided or monoconductor wireline operations, and can be used with a wide range of wireline sizes with only very minor modification. Furthermore, the design of the MP16II enables the user to thread the head without using any tools, and without needing to remove the rope socket or attached wireline tools. Please refer to the specifications for a comprehensive overview of the features, dimensions and capabilities of the MP16II. Working principle See Figure 4.1. levelwind carriage on levelwind shaft

4 Functional Description

wireline

to wellhead

wireline guide rollers

upper wheels

wire retainer

wireline guide rollers wire retainer

measuring head guide wheel

load cell hinge drum

depth counter drive measuring wheel

wireline pressure wheels

tension signal

depth signal

Figure 4.1 Measuring head (basic configuration) working principle The frame of the MP16II comprises an upper and lower section, hinged together at the drum side. The wireline passes from the drum over a wheel in the upper subframe of the MP16II, down around a wheel in the lower subframe and up and over a second wheel in the upper subframe, from where it exits to the wellhead. The tension in the wireline draws the wheels towards each other in the hinged subframes. This movement compresses a load cell at the well side between the two subframes, causing the

Page 28 of 104 Revision B Original Instructions

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MP16 User Manual

pressure to rise in the sealed, static load cell hydraulic circuit. This pressure is translated into line tension in the analogue gauge. On winch units with digital tension display, an optional pressure transmitter in the pressure circuit transmits a digital signal to the control system and/or display. The optional presure transmitter is mounted either directly on the measuring head or in the winch control panel. Inhole or outhole movement of the wireline causes the three wheels in the MP16II to turn: two in the upper subframe, which are both freewheeling, and one in the lower subframe, which is the measuring wheel. A rotary cable transmission from the measuring wheel shaft causes an odometer to turn in the winch control panel. Between the measuring wheel shaft and the odometer, two angle drives and an optional dual-output (drive splitter) gearbox transforms shaft rotations into odometer cable rotations corresponding to depth units. Optionally, an optical encoder can also be fitted to the opposite end of the measuring wheel shaft to enable digital depth signals to be transferred to an automated control system. See the appendices to this manual for a detailed description on how drive components are combined for specific wireline sizes. Design and structure The frame and subframes are constructed of corrosion-resistant coated plate aluminium for maximum strength with minimum weight. The two upper wheels are of composite material and the (lower) measuring wheel is of stainless steel.

The MP16II is designed to be suspended from a levelwind shaft by a slider bearing in the levelwind carriage, which is the top part of the upper subframe. To keep the MP16II stable during varying tension, a guide wheel near the hinge of the upper subframe runs in a transverse rail attached to the winch or levelwind arms. During transport, the measuring head is anchored to one side of the winch frame by the transport lock. Autospooling Lateral forces can optionally be detected either by electronic or pneumatic deflection sensors mounted on the drum side rollers. When one of the rollers is deflected, the sensors indicate the pressure applied by the wireline as it moves along the axis of the winch drum during spooling. The winch control system reacts to these lateral deflection signals by actuating a sideways movement of the MP16II, thus relieving the lateral force until the wireline moves further. The effect is that the head continuously moves a small amount left or right as the wireline ‘creeps’ along the drum, so that successive windings in each layer of the wireline on the drum fall into the valleys of the previous layer, ensuring constant tension, even layer buildup, and minimum wear and deformation of the wireline. Wireline lubrication An optional wireline oiler can be mounted on the MP16II to keep the wireline lubricated as it passes between the measuring wheel and upper wheels. The drip rate is adjustable.

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Page 29 of 104 Revision B Original Instructions

4 Functional Description

The MP16II is equipped with vertical wireline guide rollers at each side where the wireline enters or leaves the top of the upper wheels. A synthetic wireline retainer keeps the wire in the grooves of the upper wheels, and spring-loaded pressure wheels press the wire tightly into the groove of the measuring wheel on the underside to eliminate slip of the wire against the measuring wheel.

MP16 User Manual

4.2

CombiGauge TXT-10004056/A

The CombiGauge is a hydro-mechanical gauge that displays both wireline depth and tension simultaneously on a single gauge. When used in conjunction with any ASEP Elmar measuring head with an integral hydraulic load cell and a wireline depth measuring wheel with rotary output, this device can display depth and tension with great precision. Depth Depth measurement is recorded on a bidirectional odometer, driven by a rotary drive cable that transmits the rotations of a measuring wheel from the measuring head to the CombiGauge. In the Correlating Depth models, there is an additional depth counter that is synchronized to the main odometer, but can be individually set to record depth changes relative to a set depth. Between the measuring wheel shaft of the measuring head and the drive cable there are additional drive components - an angle drive and optional splitter - that convert the measuring wheel rotations to depth units. The gear ratios in these components are dependent on the measuring wheel diameter and wireline thickness, and convert one depth unit (foot or meter) of wireline travel into the same unit at the CombiGauge.

4 Functional Description

Tension Tension is indicated by the black needle on the large dial of the CombiGauge. Wireline tension at the measuring head compresses a hydraulic load cell in which the pressure rises and falls in direct proportion to the wireline tension. The load cell is connected to hydraulic components in the CombiGauge by a hydraulic hose. This forms a static, fully sealed tension measurement system. As the pressure increases, a C-form Bourdon tube inside the CombiGauge is deformed, which in turn deflects the indicator needle. The CombiGauge is in effect a pressure gauge for the load cell. Once calibrated, provided the hydraulic couplings are never opened and the system has no leaks, it will record tension with great accuracy. Controls There are few controls, as this is solely a display device. The CombiGauge has the following standard controls: • Depth zero knob: pull to reset the counter to zero • Wireline tension zero knob: sets the tension needle to zero when the wireline is slack (compensates for temperature-related pressure changes in the system) • Maximum tension setpoint needle: sets the maximum tension for the wireline in use (usually specified as a percentage of the nominal breaking strain). Note that this is solely for operator guidance; in no way does it prevent exceeding the maximum. • Tension system damping valve: use to reduce needle jitter when the wireline tension is subject to rapid changes, for example when moving outhole or inhole at higher speeds. Should never be closed too far, as this can drastically affect the tension accuracy. The Correlating Depth model of the CombiGauge has two additional controls: • Correlating depth zero knob: pull to reset the counter to zero • Correlating depth set knob: rotate to wind the odometer forward or backward.

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MP16 User Manual

5

SETUP & TRANSPORT

5.1

Measuring head rig-up To rig-up the MP16II measuring head for operations, there are four main procedures: • Release head from transport lock and mount for operations • Prepare depth measurement system • Prepare tension measurement system • Thread wireline through the measuring headThread wireline through the measuring head

5.1.1

Release head from transport lock and mount for operations Refer to your winch manual for instructions.

5.1.2

Prepare depth measurement system Related topics: • 6.9 Remove/install upper wheels and bearings on page 55 • 6.10 Remove/install measuring wheel and bearings on page 58 • 6.11 Remove/install drive splitter on page 60 • 6.12 Remove/install depth counter drive cable on page 63

• Appendix 5: MP16II and CombiGauge depth calculation on page 99 TXT-10004058/A

Proceed as follows to prepare the depth measurement system of the MP 16II measuring head for operations. NOTE: The illustrations in Figure 5.1 show the mechanical parts of the depth measurement system for two different types of MP 16II measuring head. These are examples only, and the corresponding components on your measuring head may be assembled differently.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

1.

Ensure that the MP 16II is properly mounted for operations, and released from any transport locks.

2.

Disable all mechanical movement of the winch, e.g. by operating the unit’s EM WINCH SHUTDOWN or EMERGENCY STOP button.

3.

Note the wireline size to be used for the well servicing job (if necessary, using a micrometer). If there is no drive splitter installed on the angle drive (see Figure 5.1), continue with step 6 below.

4.

If a drive splitter is installed (see Figure 5.1), check that the depth counter drive cable is attached to an output of the drive splitter that matches the wireline size. Normally the two outputs of the drive splitter will correspond to the two wireline sizes installed on either a split drum or dual drum winch. The depth counter drive cable is

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 31 of 104 Revision B Original Instructions

5 Setup & transport

• 6.13 Remove/install angle drive on page 64

MP16 User Manual

6

1

4

5

3

5 Setup & transport

2

1

measuring wheel

Turns the depth counter shaft. On the MP16II (as illustrated) and MP20, this is the lower wheel. On the MP16BS & MP16HD, this is the left side upper wheel. The measuring wheel turns with the drive shaft, to which it is attached.

2

angle drive

Connected to the end of the depth measurement drive shaft, this device provides a drive reduction while turning the rotary movement axis through 90 degrees. The reduction ratio is stamped on the body.

3

drive splitter

Optional feature to make the depth measurement output correspond to one of two possible wire sizes. The corresponding wire size is stamped on the output. As shown, 0.092” or 0.108”.

4

depth counter drive cable

Transmits the depth measurement rotary movement to the CombiGauge at the winch control panel. The cable must be connected to an angle drive or drive splitter output that corresponds to the wire size installed in the measuring head.

5

drive cable ring nut

Threaded nut. Used to secure the drive cable to the angle drive or drive splitter output.

6

protective cap

Must always be in place to protect the unused drive splitter output.

Figure 5.1 Depth measurement mechanical parts attached to a drive splitter with two outputs, mounted on the angle drive. The angle drive and splitter are calibrated to work together. Depending on the result, proceed further: • If the wireline size matches the existing drive splitter output to the depth counter drive cable, then continue with the next procedure to rig up the MP 16II. • If the wireline size matches the other output of the drive splitter, then continue with step 5. • If the wireline size does not match either of the two outputs of the drive splitter, first install a new drive splitter (See related topic), then continue with step 6. NOTE: A detailed description of how to combine drive components for specific wireline sizes is provided in the appendix to this manual. See related topic. 5.

Switch drive splitter outputs as follows.

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MP16 User Manual

a) Undo the drive cable ring nut and withdraw the drive cable from the splitter output. b) Remove the protective cap from the second output. NOTE: The inputs and outputs of the drive splitter and drive cable are a “tongue in groove” type. These are sensitive connections. Use only the method described below! c) Ensure that the input and output tongues and grooves are clean and lightly lubricated with fresh grease. d) Carefully engage the drive cable input to the correct drive splitter output for the wireline size to be used. e) Firmly tighten the drive cable ring nut, without applying excessive force to the drive splitter. f) Fit the protective cap over the unused output. 6.

Have an assistant monitor the CombiGauge while you perform the next step. The depth counter must register a “depth change”.

7.

Check that the depth measuring system is free of friction by spinning the measuring wheel manually. If it turns smoothly and a depth change is registered on the CombiGauge, then the depth measuring system is working properly. Continue with step 8.

a) Detach the depth counter drive cable, and again spin the measuring wheel. If the measuring wheel now turns smoothly and the output tongue of the drive splitter turns, then the problem is in the drive cable or CombiGauge. Isolate the problem further as follows, then continue with step 8. • Detach the drive cable at the CombiGauge. • Insert the blade of a screwdriver in the drive groove at the measuring head end of the drive cable, and spin the screwdriver between your hands. If the cable does not turn smoothly, or there is no movement at the CombiGauge end of the cable, then you must service or replace the drive cable. See related topic. • If the drive cable passes the previous test, attach it again to the CombiGauge, then repeat the “screwdriver” test. If the cable now does not turn smoothly, then the CombiGauge must be replaced or repaired. Contact NOV ASEP Elmar. b) Detach the drive splitter, and again spin the measuring wheel. If the measuring wheel now turns smoothly and the output tongue of the angle drive turns, then the problem is in the drive splitter. Install a new drive splitter, then continue with step 8. See related topic. c) Detach the angle drive, and again spin the measuring wheel. If it now turns smoothly, then the problem is in the angle drive. Install a new angle drive, then continue with step 8. d) If the measuring wheel still does not turn smoothly, then the measuring wheel bearings will need to be serviced or replaced. See related topic. 8.

If necessary, restore the broken connections in the depth counter transmission.

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5 Setup & transport

If the measuring wheel does not turn smoothly, or there is no movement at the CombiGauge, try to isolate the problem as follows.

MP16 User Manual

NOTE: If the MP 16II is equipped with digital depth and tension output, make certain also to select the correct wireline size in your control software.

5.1.3

Prepare tension measurement system Related topics: • 6.15 Check/adjust critical tension measurement distances on page 68 • 6.18 Service tension measurement hydraulic load cell on page 74 TXT-10004059/A

Proceed as follows to prepare the tension measurement system of the MP 16II measuring head for operations.

WARNING

5 Setup & transport

MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

1.

Ensure that the MP 16II is properly mounted for operations, and released from any transport locks.

2.

Disable all mechanical movement of the winch, e.g. by operating the unit’s EM WINCH SHUTDOWN or EMERGENCY STOP button.

3.

Ensure that there is no wireline installed in the MP 16II measuring head.

4.

Pull down on the lower subframe to ensure that the subframe is hanging at the lowest possible position. At this point it will be resting on the lower subframe retainer. The setting of this retainer determines the gap between the upper and lower subframe at the load cell of the tension measurement system.

5.

At the winch control panel: a) Fully open the hydraulic damping valve of the CombiGauge. b) Set the red maximum permitted tension needle on the CombiGauge for the wireline to be used. NOTE:

6.

The maximum permitted tension is a customer-determined percentage, e.g. 60%, of the vendor-specified breaking strain for the wireline product in use. ASEP Elmar does not specify this value.

Inspect the tension measurement system for the three critical distances. If you are not familiar with the correct operating state, perform a comprehensive check. See related topic. • subframe separation = distance between load cell base plate (above) and lower subframe (below). MAXIMUM 40 mm. • piston extension = exposed length of piston (above) when in contact with lower subframe (below). APPROXIMATELY 5-7 mm. • piston/subframe gap = distance between piston (above) and lower subframe (below). MINIMUM 1 mm, MAXIMUM 2 mm.

7.

If necessary, adjust these critical distances. See related topic.

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MP16 User Manual

8.

5.1.4

Inspect the load cell for leakage of hydraulic oil. If there is evidence of leakage from the load cell, then the hydraulic bellows of the load cell must be serviced. See related topic.

Thread wireline through the measuring head Proceed as follows to thread a wireline through the MP16II measuring head.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

WARNING RISK OF INJURY FROM WIRELINE. 1. Wirelines can have sharp points caused by snags and wear. 2. Small pieces of wire can be ejected from a wireline moving at high speed. Always wear suitable gloves and eye protection, when handling or working around wireline.

Ensure that the measuring head is properly mounted for operations, and released from any transport locks.

2.

Set the wireline winch in operations mode, i.e. that the system is energized and the controls are tested and operational.

3.

Using the winch controls, fully lower the levelwind mechanism, and position the measuring head opposite the centre of the winch drum

4.

Referring to Figure 5.2, locate the main parts on the wireline path through the measuring head.

5.

With one person operating the winch controls and one person pulling on the free end, spool about 5 meters of wire off the drum (the rope socket and/or tool may still be attached) and clamp the wire at the drum to prevent it from uncoiling.

6.

Disable all mechanical movement e.g. by operating the unit’s EM WINCH SHUTDOWN or EMERGENCY STOP button.

7.

Position yourself on the open side of the measuring head, so that the vertical subframe members are behind the wheels.

8.

Starting from the drum side of the measuring head, thread the wireline through the measuring head as follows: a) Lift the wire from nearest the drum between the drum side guide rollers (A) and into the groove in the upper wheel (C) furthest from you. b) Loosen the wire retainer (D) on the well side from the upper guide wheel, feed the wire down under the retainer, and tighten the retainer. Pull the wire tight. c) Lifting then releasing each of the wire pressure wheels (F) in turn, feed the wire down on the well side, under the measuring wheel (E) and up again on the drum side. Pull the wire tight. d) Loosen the wire retainer (D) on the drum side from the upper guide wheel, and feed the wire up into the groove in the upper wheel (C) nearest you. Tighten the retainer.

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5 Setup & transport

1.

MP16 User Manual

wireline

to wellhead

A

C

B

D

D

drum

5 Setup & transport

E F

F

A drum side guide rollers (2x) B well side guide rollers (2x) C upper guide wheels (2x) D guide wheel wire retainers (2x) E measuring wheel F measuring wheel wire pressure wheels (2x)

Figure 5.2 Threading the wireline e) Feed the wire further over the upper guide wheel, and out between the well side guide rollers (B) in the direction of the well. Pull the wire tight. 9.

Unclamp the free wire from the drum.

10. Enable winch movement again e.g. by releasing the unit’s EM WINCH SHUTDOWN or EMERGENCY STOP button. 11. With one person operating the winch controls and one person pulling on the free end, spool sufficient wire off the drum through the measuring head to be able to clamp the wire to an object beyond the winch, e.g. at the wellhead. 12. At the winch control panel, once the tool string is rigged up and ready for use, but without tension on the wireline: a) Pull on the CombiGauge depth odometer zero knob, to zero the depth reading. b) Turn the CombiGauge wireline tension zero knob to set the tension needle to zero.

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MP16 User Manual

The measuring head is now correctly threaded with wireline for operations. NOTE: If the measuring head is equipped with analogue depth output, make certain that the depth counter drive cable is connected to the correct drive splitter output. NOTE: If the measuring head is equipped with digital depth and tension output, make certain also to select the correct wireline gauge in your control software.

5.2

Measuring head rig-down To rig-down the MP16II measuring head after operations, there are two procedures: • Unthread wireline from the measuring head • Proceed as follows to unthread a wireline from the MP16II measuring head. Lock measuring head for transport

5.2.1

Unthread wireline from the measuring head Proceed as follows to unthread a wireline from the MP16II measuring head.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

RISK OF INJURY FROM WIRELINE. 1. Wirelines can have sharp points caused by snags and wear. 2. Small pieces of wire can be ejected from a wireline moving at high speed. Always wear suitable gloves and eye protection, when handling or working around wireline.

1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • The tools have been detached, and the wireline is almost fully spooled onto the drum except for the last few metres. • The winch is fully shut down, and there is no hydraulic pressure and no pneumatic pressure showing on the pressure gauges of the winch control panel. • All possible mechanical movement is disabled by pressing either the EM WINCH SHUTDOWN or EMERGENCY STOP button.

2.

Clamp the wireline to the drum to keep it from uncoiling.

3.

Release the free end of the wireline.

4.

Position yourself on the open side of the MP16II, so that the vertical subframe members are behind the wheels.

5.

Starting from the well side of the MP16II, unthread the wireline from the measuring head as follows:

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5 Setup & transport

WARNING

MP16 User Manual

a) Loosen the wire retainer on the drum side from the upper wheel, and withdraw the wire from the nearest upper wheel out of the top side of the measuring head. Retighten the retainer. b) Release each of the lower wire pressure wheels in turn, and withdraw the wire from the measurewheel in the lower section of the measuring head. c) Loosen the wire retainer on the well side from the upper wheel, and withdraw the wire from the furthest upper wheel out of the top section of the measuring head. Retighten the retainer. d) Withdraw the remaining wire from the top side of the measuring head. 6.

With one person maintaining tension on the free end, unclamp the wireline from the drum.

7.

Enable winch movement again e.g. by releasing the unit’s EM WINCH SHUTDOWN or EMERGENCY STOP button.

8.

Carefully spool the remaining free wireline onto the drum, then clamp the wire to the drum.

The MP16II is now ready to be locked for transport or threaded with a different wireline size.

5.2.2

Lock measuring head for transport

5 Setup & transport

Refer to your winch manual for instructions.

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MP16 User Manual

6

MAINTENANCE Introduction to MP16II maintenance TXT-10004062/A

For a general description of the MP16II measuring head, its main components, and the operating principle of this device, please refer to the description section of this manual.

WARNING MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

NOTE: Unless otherwise stated, all maintenance procedures described in this manual must only be carried out with the applicable winch shut down. Never perform maintenance on the MP16II while it is mounted in a winch that is running.

6 Maintenance

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MP16 User Manual

6.1

Periodic maintenance schedule

1800hrs

1500hrs

1200 hrs

900 hrs



General inspection for damage or contamination; spin the guide rollers and check for free movement, wipe down levelwind shaft & support bearing

6 Maintenance

600 hrs

Page daily

Maintenance procedure

300 hrs

Service interval

6.6

Lubricate measuring head

45 

6.7 6.9 6.10

Service measuring head support bearing Remove/install upper wheels and bearings Remove/install measuring wheel and bearings

46 55 58

6.18

Service tension measurement hydraulic load cell

74

6.4 6.5 6.8 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.19 6.20

Safe maintenance shutdown Remove/install measuring head in winch Check/adjust autospooling Remove/install drive splitter Remove/install depth counter drive cable Remove/install angle drive Remove/install depth encoder Check/adjust critical tension measurement distances Fill and bleed tension measurement hydraulic system Drain excess tension measurement hydraulic fluid Check/calibrate tension measurement system Rig-up and use of Tension Calibration Tool

43 44 48 60 63 64 66 68 69 73 78 84

    As required As required As required As required As required As required As required As required As required As required As required As required

Table 6.1 MP16II maintenance schedule

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MP16 User Manual

6.2

Special notes on measuring head measurement precision TXT-10004084/A

The MP16II measures depth and tension. Both of these measurements depend for their precision on smooth mechanical movement and proper adjustment of the entire measuring head. The maintenance procedures in this section are intended to ensure that this precision is sustained throughout every well servicing job. Failure to properly inspect and maintain the measuring head can lead to errors in the measurement, which in turn can render the well servicing job useless, but can also cause damage to the measuring head, the winch and the wireline, and can even cause permanent damage to or loss of the well. Make sure you read and understand the following important information on the depth and tension measurement features of the MP16II measuring head. Depth measurement The length of wireline passing through the measuring head is measured using the measuring wheel in the lower subframe. This measuring wheel is connected to a counter. Each rotation of the measuring wheel will add or subtract a digit from the displayed counter value, depending on the spooling direction: inhole or outhole. (Unlike a car odometer, this system works in reverse as well as forward).

Failure to record depth precisely can be caused by: • Slip between the wireline and the measuring wheel, caused by resistance in the upper wheels, the measuring wheel, the angle drive, the drive splitter, the drive cable or the CombiGauge; this will affect both analogue and digital depth measurement. • Slip between the wireline and the measuring wheel caused by lack of tension in the wireline and an oily contact between the wireline and the measuring wheel; this will affect both analogue and digital depth measurement. • Lost revolutions in the transmission between the measuring wheel and the CombiGauge due to a defect component, e.g. angle drive, drive splitter, drive cable or CombiGauge; this will affect only the analogue measurement. • A loose or faulty connection between the measuring wheel shaft and the depth encoder; this will affect only the digital measurement. • Excessive wear in the measuring wheel, resulting in the diameter falling below the precision tolerance; this will affect both analogue and digital depth measurement. Take account of these potential problems, and follow all rig-up, inspection and maintenance procedures exactly as described in this manual. Tension measurement The tension on the wireline is measured using the load cell at the well side of the MP16II measuring head. The loop of wireline wrapped around the upper and lower wheels attempts to close when tension is applied, compressing the load cell. The load cell is a sealed, static hydraulic system connected to a digital and/or analogue recording device. With analogue recording, there is a hydraulic line between the load cell and the analogue

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Page 41 of 104 Revision B Original Instructions

6 Maintenance

The precision of the depth measurement depends on there being no slip whatsoever between the wireline contact with the measuring wheel and the analogue and/or digital depth recording device. It is possible to have both analogue and digital recording. With analogue recording, there is a mechanical transmission between the measuring wheel shaft and the analogue display, the CombiGauge. With digital recording, an encoder on the measuring wheel shaft supplies a counter signal to a digital control system, e.g. ASEP Elmar SmartMonitor.

MP16 User Manual

display, the CombiGauge. With digital recording, a transducer hydraulically connected to the load cell supplies a digital pressure signal to a digital control system, e.g. ASEP Elmar SmartMonitor. Failure to record tension precisely (causing both analogue and digital recording to register a tension that is too low) can be caused by: • Air trapped in the hydraulic system. • Leakage from any point in the hydraulic system, e.g. the load cell, lines and hoses, or the CombiGauge. • Incorrectly zeroed system, i.e. there is not full separation between the piston of the load cell and the lower subframe when the wireline is not under tension. • Load cell body interference with the lower subframe, i.e. the piston becomes fully compressed into the body of the load cell due to insufficient fluid in the system. • CombiGauge not correctly calibrated. This maintenance section contains specific procedures to prevent and correct all of these problems.

6.3

Special notes on cleaning and lubrication of the measuring head

6 Maintenance

TXT-10004085/A

The MP16II is a highly sensitive instrument which is designed for use in a rough, dirty working environment. However, to ensure reliable depth and tension measurements and a long and trouble free working life, it is important to take special care when cleaning and lubricating the MP16II. • Never use a solvent or a high pressure cleaning tool to clean the complete measuring head assembly. This can cause severe damage to the bearings within the measuring head. • To prevent bearing oxidation, a thin layer of grease must be periodically applied to the sides of all bearings and all exposed steel parts. • Not all measuring head bearings can be lubricated using a regular high pressure grease gun. In some cases, this can cause the seals to be ejected from the bearings, giving access to moisture, dust and grit. All grease nipples of the concave type should be greased using a special type of grease gun. See Figure 6.1.

Figure 6.1 Recommended grease gun

Page 42 of 104 Revision B Original Instructions

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MP16 User Manual

For proper MP16II functioning, the bearings must be lubricated using a high quality grease. During maintenance of the MP16II, the bearings are lubricated with sufficient grease to ensure correct MP16II operation until the next complete overhaul of the measuring head. NOTE: If a bearing is in any way damaged during transport, operations or maintenance, it is recommended to replace the damaged part, and not to attempt repair. For the MP16II to provide precise and dependable measurements, it is essential that all rotating parts can revolve freely, and there must not be the slightest risk of a pulley or wheel jamming, even momentarily.

6.4

Safe maintenance shutdown Related topics: • Wireline winch shutdown (see winch documentation) TXT-10004086/A

WARNING MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

Before carrying out any adjustment, servicing or maintenance to the MP16II, it is essential to ensure that the wireline winch unit is fully shut down, the winch drum brake is applied (and not under tension), and that there is no residual energy in the hydraulic or pneumatic system.

1.

Complete the well servicing operation, and spool all wire onto the drum.

NOTE: If it is necessary to perform maintenance with the wire inhole, then you must apply the brake and clamp the wire to a rigid structure, such that the wire is relieved of all tension, and no incident in the hole or BOP can cause the wire to come under tension. 2.

Perform a regular winch shutdown. See related topic.

3.

Once you have completed the shutdown: a) Inspect all electrical, pneumatic and hydraulic system meters and gauges to ensure that there is no residual energy in the systems (i.e. pressures are zero, and primary electrical power is shut off). b) If applicable, isolate any hydraulic or pneumatic accumulators by closing the ball valve in the line adjacent to each accumulator. c) Release any residual air from the pneumatic system air receivers by opening the air in or out valve at an open coupling.

4.

Ensure that the wireline winch unit cannot be started: as applicable, remove the starter key, lock and/or tag out the starter system or control cabin door; disconnect the starter energy source (air, electricity, etc.).

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6 Maintenance

Proceed as follows to shutdown the winch for safe maintenance.

MP16 User Manual

6.5

Remove/install measuring head in winch Related topic: • 6.4 Safe maintenance shutdown on page 43 TXT-10004063/A

The levelwind carriage is supported on the levelwind shaft, which is mounted in the winch. Certain maintenance procedures require the measuring head to be removed from the winch. Proceed as follows to remove the MP16II measuring head from the winch.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled.

6 Maintenance

• There is no wireline in the MP16II measuring head. 2.

Shutdown the wireline winch for safe maintenance. See related topic.

3.

Completely disconnect/detach the following from the MP16II measuring head, ensuring that there are no tie-wraps or other fastenings left attached: • levelwind chain (loosen tension first) • depth counter drive cable • depth encoder, cable and earth cable • tension section hydraulic connection (you can remove the load cell and - if present pressure transducer and cable, as a complete assembly, to avoid introducing air into the circuit) • if present, lateral deflection sensors and cables of the autospooling system (you can instead remove the entire wireline guide roller assembly from the drum side) • measuring head guide wheel from the measuring head guide rail by removing the securing pins on the left and right ends of the rail. On completion of the above steps, the measuring head should now be connected to the winch only by the levelwind shaft.

4.

Using a suitable crane and slings, support the levelwind shaft at each end.

5.

Loosen and remove the bolts of the levelwind shaft mountings. a) If present, loosen and remove the bolts in the ends of the levelwind shaft. b) Loosen the bolts of the left and right levelwind shaft mountings. The entire weight of the measuring head, including levelwind shaft will now be supported by the hoist.

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MP16 User Manual

6.

Using the crane, hoist the measuring head complete with shaft from the winch, and set it down, supporting it in an upright position (ask two other people to assist you).

7.

Remove the crane and slings.

8.

Slide the levelwind shaft out of the measuring head support bearing.

9.

Support the measuring head to enable it to be serviced.

NOTE: ASEP Elmar recommends supporting the measuring head for servicing on a dummy levelwind shaft (same diameter or less) clamped in a vice such that the lower subframe clears the floor. However, when servicing the support bearing, the measuring head will need to be supported lying down on blocks. 10. Carry out the required maintenance activity. 11. Clean the levelwind shaft, and apply a thin film of grease to the shaft. 12. Carefully insert the levelwind shaft through the bearing. 13. Using a grease gun, pump grease into the bearing through the grease nipple until grease can be seen emerging from both sides. 14. Using a suitable crane and slings, supporting the levelwind shaft at both ends, hoist the complete measuring head and shaft back into place in the winch. 15. Working in reverse through the first steps of this procedure, re-install the levelwind shaft, the measuring head, and all connections that were broken.

17. Restore all adjustments, including tightening levelwind chain. 18. Test that the measuring head performs correctly.

6.6

Lubricate measuring head Related topics: • 6.3 Special notes on cleaning and lubrication of the measuring head on page 42 Proceed as follows to lubricate the MP16II measuring head. 1.

Ensure that the MP16II is properly mounted for operations or servicing, and released from any transport locks.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

If applicable, disable all mechanical movement e.g. by operating the unit’s EM WINCH SHUTDOWN or EMERGENCY STOP button.

3.

Using the appropriate grease gun, apply grease if necessary to the grease nipples of the MP16II as described below, and referring to Figure 6.2. • A: Measuring head support bearing • B: Upper wheel bearings

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Page 45 of 104 Revision B Original Instructions

6 Maintenance

16. Refit the measuring head alignment beam by inserting and securing the pins on the left and right of the beam.

MP16 User Manual

• C: Wireline guide roller bearings (2 on drum side, 2 on well side) 4.

The following parts require no lubrication. Simply check that they can turn freely, and take corrective action if necessary. • wireline pressure wheels in lower subframe (pre-lubricated, factory sealed - replace if worn) • measuring head guide wheel in guide rail (pre-lubricated, factory sealed - replace if worn) • measuring head frame hinge point (apply grease by hand only when dismantled)

A

B

upper wheel bearings

6 Maintenance

measuring head support bearing

C

C

wireline guide rollers (4 in total)

Figure 6.2 Measuring head lubrication points

6.7

Service measuring head support bearing Related procedures: • 6.4 Safe maintenance shutdown on page 43 • 6.5 Remove/install measuring head in winch on page 44 The levelwind carriage is supported on the levelwind shaft, which is mounted in the levelwind support arms of the winch. To enable the measuring head to move smoothly along (and around) the levelwind shaft, there is a support bearing installed in the levelwind carriage. This is mainly a slide bearing designed for smooth lateral movement. It is important that this bearing continues to perform perfectly. Routine daily maintenance is: • Wipe the levelwind shaft clean using a clean cloth;

Page 46 of 104 Revision B Original Instructions

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MP16 User Manual

• Wipe the sides of the support bearing clean; • Lightly grease the shaft; • If necessary, inject a little grease into the bearing via the grease nipple (using only the special grease gun), At regular intervals (see maintenance schedule), the bearing should be completely serviced. This entails removal and cleaning of the bearing. Proceed as follows.

WARNING MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

6 Maintenance

Figure 6.3 Measuring head support bearing and ball cage 1.

:

Ensure that the winch is in the following safe state:

• The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head. 2.

Shut down the wireline winch unit for safe maintenance. See related topic.

3.

Remove the measuring head from the winch. See related topic.

4.

Slide the levelwind shaft out of the measuring head support bearing.

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Page 47 of 104 Revision B Original Instructions

MP16 User Manual

NOTE: The support bearing comprises the bearing body and two ball cages that run between the levelwind shaft and the bearing body. The ball cages are a very tight fit, and cannot be removed without damaging the synthetic cage and possibly ejecting the tiny balls. .

NOTE: It is not necessary to remove the support bearing from the levelwind carriage of the measuring head. It is shown removed in the above figure simply for clarity. 5.

To clean the bearing: a) Protect the measuring head below the levelwind carriage by wrapping it in rags. b) Using a brush and a suitable solvent, wash the bearing thoroughly. c) Dry the bearing thoroughly using an air pistol. d) Inject a little grease into the bearing through the grease nipple. e) Continue with step 7.

6.

To replace the bearing: a) Remove the circlip from both sides of the bearing. b) Using a suitable drift, work through the opposite ball cage to tap the cage out of the nearest opening. c) Repeat on the opposite side.

6 Maintenance

d) Clean the interior of the bearing body using a clean rag, and inspect the inside face. e) Lightly grease the inside face of the bearing housing. f) Using a suitable drift (almost the same diameter as the inside of the bearing body), gently tab the new ball cage into one side of the bearing until it is just past the circlip groove. g) Repeat on the opposite side. h) Fit the circlips to both sides of the bearing. i) Inject a little grease into the bearing through the grease nipple. 7.

Clean the levelwind shaft, and apply thin film of grease to the shaft.

8.

Carefully insert the levelwind shaft through the bearing.

9.

Using a grease gun, pump grease into the bearing through the grease nipple until grease can be seen emerging from both sides.

10. Install the measuring head in the winch. See related topic. 11. Restore all adjustments. 12. Test that the measuring head performs correctly.

6.8

Check/adjust autospooling Related topics: • 6.4 Safe maintenance shutdown on page 43 TXT-10004090/A

Introduction Autospooling is an automatic repositioning of the measuring head during outhole or inhole spooling, ensuring the straightest possible path from the drum to the hay pulley for greatest

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MP16 User Manual

measurement precision, and smooth buildup of wireline wraps on the drum during outhole spooling. It also leaves the operator’s hands free for drum control and other activities when spooling over large distances in safe depth zones. Correct autospooling depends on the adjustment of the lateral deflection sensors on the drum side of the measuring head. The deflection sensors are tripped by pressure of the moving wireline against the left or right side rear guide rollers. The sensitivity on each side is independently adjusted. Note that the sensitivity of autospooling is influenced by several factors: • Wireline tension: wire under high tension will trip a sensor more quickly than wire under low tension. • Levelwind chain tension: ensure that this is correctly adjusted. When the chain is too slack, the response when changing direction (at the sides of the drum) will be slower. • Wire gauge: a thicker wire is less flexible, and will trip the sensor more quickly than a thinner wire. • Wire path from drum to upper guide wheel: when the drum is fully loaded, the wire will enter the rollers high up. When the drum is almost unloaded, the wire will enter the rollers low down. The lever effect means the sensors are tripped more quickly when the wire is high up (drum full) than when the wire is low down (drum empty).

There are two types of autospooling assembly in use on MP16II measuring head: pneumatic and electric. Autospooling is an option that is not present on every measuring head. Before continuing with this procedure, verify whether autospooling is present, and if so, what type. Inspect the rear (drum side) guide rollers of your MP16II measuring head. • If the guide rollers have a movable mounting with sensors (electric or pneumatic), then your measuring head has autospooling. If not, then you should skip this procedure, there is nothing to adjust. • If the assembly is identical to that in Figure 6.4 on page 50, then you can continue with the check/adjust procedure instructions in 6.8.1. • If the assembly is identical to that in Figure 6.5 on page 52, then you can continue with the check/adjust procedure instructions in 6.8.2. • If you have an autospooling assembly of a different type, then please contact NOV ASEP Elmar for advice.

6.8.1

Electric autospooling NOTE: On this autospooling assembly, the levelwind movement is triggered by the lateral deflection sensor on the opposite side, i.e. for levelwind movement left, you must adjust the sensor on the right, and vice versa. Proceed as follows to check the settings, and adjust if necessary. Refer to Figure 6.4. Check autospooling 1.

Make the winch operational.

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6 Maintenance

• Levelwind assembly type: This depends on the winch model. On winches with the ability to raise and lower the measuring head, the wireline path can sometimes be adjusted to maintain a constant point of contact with the rear guide rollers. This has the advantage that the operator can compensate for the changing wire path as the wire is spooled further on or off.

MP16 User Manual

1 6 7

3 5

8

6 Maintenance

2

4

9 1

autospooling assembly baseplate

2

lateral deflection cam

3

sensor body

4

sensor plunger

5

centreline

6

4th scale line

7

inner screw

8

outer screw

9

guide roller

Figure 6.4 Autospooling assembly with electric sensors 2.

Ensure that the MP16II is in operational state and positioned roughly opposite the centre of the drum.

3.

If there is no wireline in the measuring head, thread the measuring head with wireline.

4.

Clamp the wireline firmly to a rigid structure in front of the winch.

5.

Apply approximately 200 kg (440 lb) of tension to the wireline.

6.

Select autospooling mode at the winch control panel.

7.

Apply the winch brake.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

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MP16 User Manual

8.

Take steps to ensure that the winch cannot be operated, e.g. have all personnel leave the cabin, and lock the cabin door.

9.

Take up a safe position beside the MP16II. Do not stand between the drum and the measuring head!

10. At the drum side of the measuring head, push the wireline to one side of the wireline path (left or right). This should cause the autospooling system to activate the levelwind motor, so that the complete MP16II moves one wireline thickness to the left or right, depending on the side that was pressed. Repeat the test in the opposite direction. 11. If the autospooling behaves normally, then the lateral deflection sensor adjustment is in order. Leave the winch bay, and restore the winch unit to normal operating state. 12. If the autospooling movement is excessive or insufficient on either side, adjust the sensitivity as described below. Adjust electric autospooling

Adjust one side as follows. The instructions apply to both the left and right side. 13. Ensure that: • the winch is running; • the drum brake is applied; • autospooling is OFF; • the winch drum cannot be operated inadvertently. 14. Inspect the sensor position. The inner side of the sensor should lie approximately on the 4th line on the scale (from the centreline). 15. If the sensor is in the wrong position, loosen the two sensor mounting screws just enough to move the sensor in the slot until it is aligned to the 4th line. 16. Tighten the inner screw a little to prevent the sensor from moving sideways in the slot. 17. Rotate the sensor around the inner screw to set the plunger of the sensor against the cam. Some limited up/down movement is possible at the outside ends of the slot. 18. Manually deflect the guide rollers and watch the sensor plunger closely. It must not “bottom out” in the switch body. In time, this will destroy the switch. 19. Tighten the outer screw a little so that it holds its position. 20. At the winch control panel, select autospooling. 21. Repeat the autospooling check for the side you have adjusted.

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6 Maintenance

NOTE: Referring to the list of factors that can influence the sensitivity of autospooling (see Introduction above), take account of your expected use, and try to adjust the autospooling for the situation when you will make the most use of autospooling.

MP16 User Manual

22. If you need to readjust, repeat from step 13. 23. When the adjustment seems about right, firmly tighten both sensor mounting screws. 24. Repeat from step 1 for the sensor on the other side (if necessary). 25. When both sensors have been set, repeat the autospooling check on both sides. 26. Restore the winch to normal operating state.

6.8.2

Pneumatic autospooling Proceed as follows to check the settings, and adjust if necessary. Refer to Figure 6.5.

1

6 Maintenance

3

2

4

7 6

5

5

1

autospooling assembly baseplate

2

lateral deflection plate

3

sensor body

4

sensor plunger

5

guide roller

6

adjustment screw

7

locknut

Figure 6.5 Autospooling assembly with pneumatic sensors Check pneumatic autospooling 1.

Make the winch operational.

2.

Ensure that the MP16II is in operational state and positioned roughly opposite the centre of the drum.

3.

If there is no wireline in the measuring head, thread the measuring head with wireline.

4.

Clamp the wireline firmly to a rigid structure in front of the winch.

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MP16 User Manual

5.

Apply approximately 200 kg (440 lb) of tension to the wireline.

6.

Select autospooling mode at the winch control panel.

7.

Apply the winch brake.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

8.

Take steps to ensure that the winch cannot be operated, e.g. have all personnel leave the cabin, and lock the cabin door.

9.

Take up a safe position beside the MP16II. Do not stand between the drum and the measuring head!

10. At the drum side of the measuring head, push the wireline to one side of the wireline path (left or right). This should cause the autospooling system to activate the levelwind motor, so that the complete MP16II moves one wireline thickness to the left or right, depending on the side that was pressed. Repeat the test in the opposite direction.

Leave the winch bay, and restore the winch unit to normal operating state. 12. If the autospooling movement is excessive or insufficient on either side, adjust the sensitivity as described below. Adjust pneumatic autospooling NOTE: Referring to the list of factors that can influence the sensitivity of autospooling (see Introduction above), take account of your expected use, and try to adjust the autospooling for the situation when you will make the most use of autospooling. Adjust one side as follows. The instructions apply to both the left and right side. 13. Ensure that: • the winch is running; • the drum brake is applied; • autospooling is OFF; • the winch drum cannot be operated inadvertently. 14. Inspect the adjustment screw position. 15. Loosen the locknut. 16. Adjust the adjustment screw. 17. At the winch control panel, select autospooling. 18. Repeat the autospooling check for the side you have adjusted. 19. If you need to readjust, repeat from step 13.

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6 Maintenance

11. If the autospooling behaves normally, then the lateral deflection sensor adjustment is in order.

MP16 User Manual

20. When the adjustment seems about right, firmly tighten the locknut. NOTE: Use two spanners to tighten the locknut and hold the adjustment screw. Take care not to misadjust the adjustment screw. 21. Repeat from step 1 for the sensor on the other side (if necessary). 22. When both sensors have been set, repeat the autospooling check on both sides.

6 Maintenance

23. Restore the winch to normal operating state.

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MP16 User Manual

6.9

Remove/install upper wheels and bearings Related topics: • 6.4 Safe maintenance shutdown on page 43 • 6.5 Remove/install measuring head in winch on page 44 The upper wheels turn on individual sealed bearings that require very little servicing. Regular lubrication is not required, but grease can be added via a grease nipple if the bearing has been subjected to extreme circumstances (e.g. cleaning with a high pressure tool, heavy contamination, loss of a dust cap, etc.). The wheels should be removed for servicing according to the maintenance schedule, or in the event of damage. This procedure requires the measuring head to be removed from the winch. Proceed as follows to remove and install the MP16II measuring head upper wheels and bearings.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Ensure that the unit cannot be operated during maintenance or rig-up activity.

B

A D

C

Figure 6.6 Creating access for upper wheel removal NOTE: Figure 6.6 shows MP16II with manual spooling. MP16II with either of the autospooling options has the autospooling assembly baseplate mounted on the levelwind carriage side plate C instead of the wireline guide roller mounting plate A on the drum side. 1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the wireline winch unit for safe maintenance. See related topic.

3.

If present, loosen the mounting bolts and remove the wireline oiler tank and drip valve from the measuring head.

4.

Fully loosen the upper wireline retainer rollers, and remove the rollers.

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6 Maintenance

A

MP16 User Manual

5.

Remove the measuring head from the winch. See related topic.

6.

Lay the measuring head on a suitable clean workbench, with the open side on top, and with a block of wood under each of the upper and lower subframes, so that there is a clearance for the shaft to be pressed downwards and out of the frame. Place a cushioning layer between the measuring head and the workbench and wooden blocks.

7.

Create access for removal of the upper wheels (see Figure 6.6): a) Remove the wireline guide roller mounting plates A (4 bolts each) from the wellhead and drum sides, and remove each complete roller assembly from the measuring head.

NOTE: If present, remove the autospooling assembly baseplate the same way as the wireline guide roller mounting plate A. b) Unscrew the support bearing retainer grub screw B in the top of the upper subframe (on the closed side of the measuring head). c) Carefully lift the levelwind carriage side plate C and support bearing D out of the upper subframe. 8.

Remove the upper wheels:

6 Maintenance

a) On the open side of the measuring head, using an Allen key, unscrew the retaining bolt, and remove the bolt and rings from the upper wheel shaft. b) Using a drift and soft hammer, gently tap the shaft through the frame and wheels, and out of the opposite side of the upper subframe. c) Carefully withdraw the wheels from the upper subframe. 9.

Separate the wheels, and place the wheels and shaft on a clean workbench.

10. Clean all old grease and residue from the upper subframe. Make use of the access with the wheels removed to inspect and clean the rest of the measuring head frame. 11. Clean the shaft and wheels thoroughly, and inspect each wheel on both sides. See Figure 6.7):.

Figure 6.7 Upper wheel centre with bearing 12. Test that the bearing turns freely, and there is no damage to the wheel itself. 13. If a bearing needs replacement: a) Remove the circlip from each side of the bearing. Page 56 of 104 Revision B Original Instructions

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MP16 User Manual

b) Support the flat side of the wheel around the bearing. c) Using a drift and soft hammer, carefully tap the bearing out of the centre of the wheel. d) Press a new bearing into the wheel, and secure it using the circlips 14. Apply a small amount of grease to the area around the bearing on each side. 15. Turn the measuring head over, so that the closed side is upwards. 16. Place the wheels together at the flat side, and insert then into position in the upper subframe. 17. Insert the shaft through the subframe and the wheels, with the flanged end on the closed side of the upper subframe. If you need to use a little force to press the shaft home, first remove the grease nipple. Use a soft hammer. 18. Using a suitable grease gun, inject plenty of grease into the grease nipple on the upper wheel shaft until the grease is seen to emerge around the bearings. Wipe off any excess grease around the shaft area. 19. Turn the measuring head over and fit the retaining ring to the open side, tightening the shaft with the Allen bolt. 20. Fit the levelwind carriage side plate and support bearing back into the upper subframe. Do not yet tighten the grub screw.

22. Tighten the support bearing retaining grub screw in the top of the upper subframe (on the closed side of the measuring head). 23. Spin the upper wheels and check that they turn freely. 24. Install the measuring head in the winch. See related topic. 25. Mount the wireline retainer rollers. 26. Fit the wireline oiler tank and drip valve. 27. Restore all adjustments. 28. Test that the measuring head performs correctly.

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6 Maintenance

21. Mount the wireline guide rollers back on each side of the levelwind carriage.

MP16 User Manual

6.10

Remove/install measuring wheel and bearings Related topics: • 6.4 Safe maintenance shutdown on page 43 • 6.13 Remove/install angle drive on page 64 • 6.14 Remove/install depth encoder on page 66 The measuring wheel turns on a shaft running in sealed bearings that require very little servicing. Regular lubrication is not required, but grease can be added via a grease nipple if the bearings have been subjected to extreme circumstances (e.g. cleaning with a high pressure tool, heavy contamination, loss of a dust cap, etc.). The wheel should be removed for servicing according to the maintenance schedule, or in the event of damage. Proceed as follows to remove and install the MP16II measuring head measuring wheel and bearings.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Ensure that the unit cannot be operated during maintenance or rig-up activity.

6 Maintenance

1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the wireline winch unit for safe maintenance. See related topic.

3.

If a digital encoder is fitted, remove the encoder. See related topic. If no encoder is present, loosen the bolts of the encoder mounting plate, and remove the plate.

4.

Remove the complete depth counter assembly from the opposite end of teh measuring wheel shaft. See related topic.

5.

Remove the two wireline pressure wheels from the lower subframe.

6.

Remove the circlip from the measuring wheel shaft on the depth counter side. See Figure 6.8.

7.

While supporting the wheel, slide the measuring wheel shaft out of the bearings in the lower frame. You may need to use a drift and a soft hammer to tap the shaft out of the bearings. The bearing on the opposite side may also come out. The key will stay in the keyway in the measuring wheel.

8.

Carefully withdraw the measuring wheel from the lower frame. NOTE: Take care not to lose the key, and the two synthetic rings between the measuring wheel and the bearings on each side.

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MP16 User Manual

2

4

3

1 1

measuring wheel

2

bearing

3

depth counter coupling

4

circlip

Figure 6.8 measuring wheel shaft, depth counter side Using a bearing puller or a drift and soft hammer, remove the bearings from the lower subframe.

10. Clean all old grease and residue from the lower subframe. Make use of the access with the wheel removed to inspect and clean the rest of the measuring head frame. 11. Carefully clean all the removed parts and inspect them for damage or wear. Replace any worn parts, in particular the bearings.

A

B

(This is intended simply to show the intention with the shaft and synthetic ring. This is not an assembly step.)

Figure 6.9 Reassembly of measuring wheel & shaft 12. Reassemble the measuring wheel section as follows. See Figure 6.9.

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6 Maintenance

9.

MP16 User Manual

a) Fit the (new) bearings into each side of the lower subframe. b) Insert the key into the measuring wheel, and tap it carefully in until it is precisely centred (A). c) Check that the shaft can fit into the measuring wheel centre. d) Insert the shaft from the encoder side through the bearing until it just extends inside the subframe. e) Fit one synthetic ring over the shaft. f) Support the measuring wheel in the lower subframe, and press the shaft further through the bearing and the nylon ring until just before it emerges through the measuring wheel. This will require more force, as the key in the measuring wheel will now engage in the keyway of the shaft. g) Carefully insert the second synthetic ring between the measuring wheel and the lower subframe, and press the shaft all the way through the lower subframe until it is tight against the bearing on the encoder side. h) Ensure that the bearing on the depth counter side is properly seated, and fit the circlip onto the shaft. 13. Inject grease into the bearing on each side of the measuring wheel, and check that sufficient grease has penetrated the bearing (the grease will emerge from the bearing). 6 Maintenance

14. Wipe off the excess grease. 15. Mount the two wireline pressure wheels on each side of the lower subframe. 16. Mount the complete depth counter assembly on the lower subframe, by proceeding through the removal in reverse. See related topic. Make certain to insert the link key in the coupling between the shaft and the angle drive, taking care to align the two sides first by turning the measuring wheel. 17. If applicable, install the depth encoder removed in step 3, otherwise fit the encoder mounting plate, and tighten the bolts. 18. Check that the measuring wheel turns freely, and that the depth measurement is correctly registered at the CombiGauge and (if applicable) digital control system.

6.11

Remove/install drive splitter Related topics: • Appendix 5: MP16II and CombiGauge depth calculation on page 99 TXT-10004087/A

The optional drive splitter on the measuring head is just one part of the complete depth counter drive train between the measuring wheel and the CombiGauge. These components must be carefully matched for accurate depth measurement, and the combination is different for every wireline size. A drive splitter can only work with two wireline sizes, and only in combination with certain specific drive ratios in the angle drives of the measuring wheel and the CombiGauge. NOTE: For a detailed description of how to combine drive components for specific wireline sizes see the related topic. Proceed as follows to remove and install a drive splitter on the MP16II measuring head.

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MP16 User Manual

NOTE: The illustrations in this procedure are examples only, and may not appear exactly the same as the corresponding components on your measuring head.

WARNING MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

6

5

7 3

4

6 Maintenance

1 2

1

angle drive

Connected to the end of the depth measurement drive shaft, this device provides a drive reduction while turning the rotary movement axis through 90 degrees. The reduction ratio is stamped on the body.

2

angle drive output

Threaded output coupling to depth counter drive cable or drive splitter.

3

drive splitter

Optional feature to make the depth measurement output correspond to one of two possible wire sizes. The corresponding wire size is stamped on the output.

4

drive splitter ring nut and retaining The retaining wire ensures that the ring nut cannot become loosened during operation. The ring nut must not be overtightened, otherwise the assembly can be wire damaged.

5

depth counter drive cable

Transmits the depth measurement rotary movement to the CombiGauge at the winch control panel. The cable must be connected to an angle drive or drive splitter output that corresponds to the wire size installed in the measuring head.

6

drive cable ring nut

Threaded nut. Used to secure the drive cable to the angle drive or drive splitter output.

7

protective cap

Must always be in place to protect the unused drive splitter output.

Figure 6.10 Angle drive and drive splitter 1.

Ensure that the MP16II is properly mounted for operations or servicing, and released from any transport locks.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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2.

If applicable, disable all mechanical movement e.g. by operating the unit’s EM WINCH SHUTDOWN or emergency stop button.

NOTE: The depth counter drive cable is attached to a drive splitter mounted on the angle drive, that has two outputs. The angle drive and splitter are calibrated to work together. 3.

Remove the existing drive splitter as follows. a) Undo the drive cable ring nut and withdraw the drive cable from the splitter output. b) Using needlenose pliers, pull the retaining wire carefully from the drive splitter ring nut. c) The drive splitter ring nut should be finger tight. Support the drive splitter with one hand, remove the ring nut and withdraw the drive splitter from the angle drive output.

4.

Install the correct drive splitter as follows. NOTE: The inputs and outputs of the angle drive, drive splitter and drive cable are a “tongue in groove” type. These are sensitive connections, requiring different methods to avoid causing mechanical fatigue to the internal mechanism of the angle drive and drive splitter. Above all, the connection of the drive splitter to the angle drive must not be over-tightened. Use only the method described below! a) Ensure that the input and output tongues and grooves are clean and lightly lubricated with fresh grease.

6 Maintenance

b) Carefully engage the drive splitter input to the angle drive output. c) Ensure that the lug on the input side of the drive splitter is properly seated in the hole in the drive splitter mounting bracket. d) Gently hand-tighten the drive splitter ring nut, to the point where the retaining wire is aligned with the hole in the ring nut. If necessary to align the wire to the hole, loosen the nut one turn or less. e) Using the needlenose pliers, fit the retaining wire into the ring nut hole. 5.

Carefully engage the drive cable input to the correct drive splitter output for the wireline size to be used.

6.

Firmly tighten the drive cable ring nut, without applying excessive force to the drive splitter.

7.

Ensure that the unused drive splitter output is fitted with a protective cap.

NOTE: If the MP16II is equipped with digital depth and tension output, make certain also to select the correct wireline size in your control software.

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MP16 User Manual

6.12

Remove/install depth counter drive cable Related topics: • 5.1.3 Prepare tension measurement system on page 34 • 6.4 Safe maintenance shutdown on page 43 TXT-10004088/A

The depth counter drive cable should not normally require any servicing. In the event of a defect in the cable (due to damage or wear and tear):

WARNING MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

6 Maintenance

Figure 6.11 Depth counter drive cable 1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the wireline winch unit for safe maintenance. See related topic.

3.

Route the new cable alongside the old cable.

4.

Cut any tie-wraps fastening the old cable to the winch, fastening the new cable with new tiewraps at the same point.

5.

At each end of the cable: a) Loosen the drive cable ring nut. b) Withdraw the drive cable from the angle drive or drive splitter. c) Clean the tongue of the angle drive or drive splitter and lightly grease it. d) Carefully engage the drive cable to the angle drive or drive splitter.

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MP16 User Manual

Turn the measuring wheel or the CombiGauge input tongue to help align the two sides of the coupling. e) Tighten the ring nut firmly.

6.13

6.

Dispose of the old cable.

7.

Prepare the depth measurement section to ensure that the depth measurement is now working correctly. See related topic.

Remove/install angle drive Related topics: • 5.1.3 Prepare tension measurement system on page 34 • 6.4 Safe maintenance shutdown on page 43 • 6.11 Remove/install drive splitter on page 60 Installation of a new angle drive may be required when changing wire sizes, or due to damage or wear of an existing angle drive. There may be two angle drives in the depth measurement system: • at the CombiGauge input • at the measuring wheel shaft of the measuring head The angle drive is always screwed into the mounting, and secured with a locknut.

6 Maintenance

NOTE: The angle drive mounting thread is left handed, i.e. turn clockwise to loosen, counterclockwise to tighten! Proceed as follows.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Ensure that the unit cannot be operated during maintenance or rig-up activity.

1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the wireline winch unit for safe maintenance. See related topic.

3.

As applicable, remove the drive cable, plus drive splitter or gearbox attached to the angle drive. See related topic.

4.

To remove the angle drive at the CombiGauge: a) Loosen the locknut of the angle drive (turn clockwise). b) Unscrew the angle drive (turn clockwise).

:

5.

To remove the angle drive at the measuring wheel shaft of the measuring head, you must first remove the complete depth counter assembly (see Figure 6.12):

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MP16 User Manual

1

2

4 3

1

measuring wheel

2

depth counter assembly mounting plate

3

angle drive

4

drive splitter (optional)

Figure 6.12 Depth counter assembly and mounting plate

b) Loosen the bolts of the depth counter assembly mounting plate. c) Withdraw the complete depth counter assembly, and place the assembly and mounting bolts, washers, etc in a safe place. NOTE: Take care not to lose the link key from the coupling between the measuring wheel shaft and the angle drive. d) Loosen the locknut on the measuring wheel side of the mounting plate (turn clockwise). e) Unscrew the angle drive (turn clockwise). 6.

To install the (new) angle drive at the CombiGauge, proceed through step 4 above in reverse. Make sure to turn the angle drive and locknut counterclockwise to tighten them.

7.

To install the (new) angle drive at the measuring wheel shaft of the measuring head, proceed through step 5 above in reverse. NOTE: Make certain to insert the link key in the coupling between the shaft and the angle drive, taking care to align the two sides first by turning the measuring wheel.

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6 Maintenance

a) Note the mounting position of all parts.

MP16 User Manual

Figure 6.13 Angle drive, link key, measuring wheel shaft

6.14

8.

If you have installed a new angle drive to match a different wire size for your winch, make sure all other depth counter drive components between the measuring head and CombiGauge are properly matched. See related topic.

9.

As applicable, attach the drive cable, drive splitter or gearbox attached to the angle drive. See related topic.

Remove/install depth encoder Related topics:

6 Maintenance

• 6.4 Safe maintenance shutdown on page 43 Proceed as follows to remove and install a depth encoder on the measuring wheel shaft of the MP16II measuring head.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Ensure that the unit cannot be operated during maintenance or rig-up activity.

1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the wireline winch unit for safe maintenance. See related topic.

3.

Remove the depth encoder: a) Note the position of the existing encoder, and how the cables are routed. b) Disconnect the depth encoder signal cable at the connector for the automatic control system. c) Disconnect the depth encoder earth cable from the grounding point. d) Cut or remove all tie-wraps from the depth encoder cables, so that the cables are completely free.

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3

1 2

1

measuring wheel

2

depth encoder

3

depth encoder mounting plate

Figure 6.14 Depth encoder mounted on lower subframe

f) Carefully withdraw the encoder with mounting plate from the lower subframe. g) Unscrew the four Allen screws holding the encoder to the encoder mounting plate, and separate the encoder from the mounting plate. 4.

Prepare the encoder (new or existing) for installation: NOTE: If any parts, especially the synthetic rings, are damaged or worn, obtain new parts. a) Thoroughly clean the encoder body without the use of any solvents. b) Thoroughly clean the encoder shaft and the coupling parts, ensuring that no oil or grease is present on any of the parts.

5.

Install the depth encoder: a) Attach the encoder to the encoder mounting plate using the four Allen screws; tighten the screws firmly. b) Align the encoder coupling to the slot in the measuring wheel shaft and offer the encoder up to the lower subframe. c) Turn the encoder to the same position as previously mounted, and align the bolt holes. d) Firmly tighten the four mounting bolts. e) Ensure the earth cable is attached to the encoder body. f) Route the cables to their connectors and make the connections. g) Using tie-wraps, fasten the cables in position.

6.

Using the automatic control system, check that the depth encoder is working correctly by spinning the measuring wheel without any wireline in the measuring head.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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6 Maintenance

e) Completely loosen the four encoder mounting bolts from the lower subframe of the MP16II.

MP16 User Manual

7.

6.15

First zero both systems, then check that the analogue (CombiGauge) and automatic control system both register the same depth difference after a certain number of turns of the measuring wheel.

Check/adjust critical tension measurement distances Related topics: • 6.4 Safe maintenance shutdown on page 43 TXT-10004089/A

Proceed as follows to check the critical distances in the tension measurement section of the MP16II measuring head.

WARNING

6 Maintenance

MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

A

WRPP =

B

WRPP 

C

WRPP 

Figure 6.15 Critical distances at load cell 1.

Ensure that the MP16II is properly mounted for operations or servicing, and released from any transport locks.

2.

Shut down the unit for safe maintenance. See related topic.

3.

Using an internal calliper and a feeler gauge, check the following three critical distances at the load cell of the non-loaded MP16II tension measurement system. See Figure 6.15.

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MP16 User Manual

A: subframe separation = distance between load cell base plate (above) and lower subframe (below). MAXIMUM 40 mm. B: piston extension = exposed length of piston (above) when in contact with lower subframe (below). APPROXIMATELY 5-7 mm. C: piston/subframe gap = distance between piston (above) and lower subframe (below). MINIMUM 1 mm, MAXIMUM 2 mm. Measure approximately using a 1 to 2 mm feeler gauge or a piece of card of about 1.5 mm thickness. Explanation: • There must always be a minimum gap (C) between the extended piston and the lower subframe of 1 to 2 mm to make certain that the tension system always reads zero when there is no tension on the wireline. In that situation, the weight of the lower subframe will cause it to drop down against the retainer. • The piston extension (B) is necessary to ensure that the load cell body can never interfere with the tension measurement.by contacting the lower subframe. It is however important that there is no air in the load cell hydraulic circuit, otherwise the piston extension will not be sufficient to prevent interference. • The subframe separation (A) is a way to help set the normal, unloaded position of the subframe at the subframe retainer. 4.

If the distances are not correct, adjust the distances as follows.

5.

First adjust distance B: a) To decrease the piston extension, drain excess fluid from the hydraulic tension measurement system. See related topic. b) To increase the piston travel, add fluid to the tension measurement system as described in the procedure for fill and bleed of the hydraulic tension measurement system. See related topic.

6.

Second, adjust distance A and C: a) If you have adjusted distance B, first check whether A still needs adjustment. b) Place a piece of card or a feeler gauge (1 - 2 mm) between the piston and the subframe. c) Loosen the locknut in the lower subframe retainer bolt, and turn the bolt clockwise (to reduce the distance) or counter-clockwise (to increase the distance) until the piston touches the card or feeler gauge. d) Loosen the bolt slightly and remove the card or feeler gauge. e) Tighten the locknut, and check the distances again.

6.16

Fill and bleed tension measurement hydraulic system Related topics/procedures: • 6.4 Safe maintenance shutdown on page 43

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6 Maintenance

NOTE: The measured distances can be significantly affected when the ambient temperature varies greatly. In particular, expansion of the hydraulic fluid can affect the piston extension. When temperatures vary greatly, routinely check that the settings are still in order.

MP16 User Manual

• 6.15 Check/adjust critical tension measurement distances on page 68 • 6.19 Check/calibrate tension measurement system on page 78 • Appendix 4: Tension measurement hydraulic fluid on page 98 TXT-10004091/A

It is essential for correct tension measurement that the static hydraulic system is completely filled with hydraulic fluid and free of any trapped air, from the load cell in the MP16II up to and including the CombiGauge in the winch control panel. Proceed as follows to fill and bleed the hydraulic tension measurement system of the MP16II measuring head.

WARNING

6 Maintenance

MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

CombiGauge II

standard CombiGauge

Figure 6.16 CombiGauge bleed point 1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the unit for safe maintenance. See related topic.

3.

Using the method described in the procedure for checking the critical distances, set the separation between the lower subframe and the base plate of the load cell to 38 mm. See related topic. NOTE: The lower subframe must be suspended on the lower subframe retainer.

4.

Place a piece of card or a feeler gauge between the lower subframe and the piston (1 - 2 mm).

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MP16 User Manual

5.

At the winch control panel, obtain access to the CombiGauge hydraulic connections. Every winch control panel has a different layout. You may need to withdraw the CombiGauge from the winch control panel in order to gain access to the hydraulic connector.

6.

Ensure that the hydraulic hose connections at the load cell bellows and the CombiGauge are tight, and there is no sign of leakage at any point in the system.

7.

If a pressure transducer is present on the MP16II, ensure that the bleed point is closed using the supplied key.

CAUTION EQUIPMENT DAMAGE Hydraulic systems and components are extremely sensitive to contaminants such as grit and metal fragments, which can be accidentally introduced during servicing activity. Apply maximum standards of cleanliness when servicing hydraulic components. Before reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.

8.

Prepare the hand pump: a) Fill the hand pump with a suitable hydraulic fluid for use with in the tension measurement system. See related topic. b) Allow the fluid to settle for a few minutes in the hand pump so that air bubbles can escape.

d) Operate the pump until clear fluid with no air bubbles enters the transparent hose. The hand pump will now deliver only air-free oil to the tension measurement hydraulic circuit. Do not allow the tank on the hand pump to become empty. Regularly check the level and carefully top up, allowing the fluid to settle each time. 9.

At the winch control panel, locate the bleed point on the hydraulic connector of the CombiGauge. See Figure 6.16.

10. Wrap a clean rag around the fittings below the bleed point to catch fluid released from the bleed point. 11. Locate the hand pump connection on the load cell of the MP16II.

Figure 6.17 Hand pump, bleed key, and connection point NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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6 Maintenance

c) Connect a transparent, open-ended hose to the quick connector on the handpump.

MP16 User Manual

12. Wipe the hand pump nozzle and the connection point with a clean rag to remove any dust or grit. 13. Connect the hand pump to the connection point (quick connector). 14. Fully open the valve at the hand pump connection point. 15. Have an assistant take position at the CombiGauge. Instruct the assistant to: a) Open the bleed point using the supplied key; b) Monitor the bleed point until hydraulic fluid emerges; c) Catch spilled fluid with a rag. 16. Slowly pump fluid into the system until fluid emerges from the bleed point. If maintenance has been carried out on the system, there may still be air in the hose. Continue pumping until you are sure there is no more air in the hose. NOTE: The bellows of the load cell have to be filled. Pumping oil into the circuit will cause the piston(s) to extend down to the lower subframe and feeler gauge or card placed in step 4. 17. Close the bleed point firmly using the supplied key, and wipe up any spilled fluid.

6 Maintenance

18. If no other maintenance is required at the CombiGauge, re-fit any panels removed for access. 19. If a pressure transducer is present on the MP16II, repeat steps 15 through 17 at the bleed point on the transducer. 20. Close the valve on the hand pump connection. 21. Disconnect the hand pump. 22. Check and if necessary adjust the critical distances in the tension measurement system. See related topic. 23. Calibrate the tension measurement system. See related topic. NOTE: There is an additional (auxiliary) bleed point at the bottom of the standard CombiGauge (Figure 6.18). This point is used to bleed air during manufacturing of the CombiGauge. If required, it can be used after maintenance on the bourdon tube of the CombiGauge. However, it should not be used during routine servicing.

Figure 6.18 Auxiliary bleed point on CombiGauge (classic model only)

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MP16 User Manual

6.17

Drain excess tension measurement hydraulic fluid Related topics: • 6.4 Safe maintenance shutdown on page 43 • 6.15 Check/adjust critical tension measurement distances on page 68 • 6.19 Check/calibrate tension measurement system on page 78 • Appendix 4: Tension measurement hydraulic fluid on page 98 TXT-10004092/A

If the piston extends too far from the load cell, then there is excess hydraulic fluid fluid in the system, which must be drained off. Proceed as follows to drain excess fluid from the hydraulic tension measurement system of the MP16II measuring head.

WARNING MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

6 Maintenance

Figure 6.19 Hand pump and connection point on load cell 1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the wireline winch unit for safe maintenance. See related topic.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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MP16 User Manual

CAUTION EQUIPMENT DAMAGE Hydraulic systems and components are extremely sensitive to contaminants such as grit and metal fragments, which can be accidentally introduced during servicing activity. Apply maximum standards of cleanliness when servicing hydraulic components. Before reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.

3.

Make sure there is room in the hand pump to collect excess fluid.

4.

Locate the hand pump connection point on the load cell of the MP16II.

5.

Wipe the hand pump nozzle and the connection point with a clean rag to remove any dust or grit.

6.

Connect the hand pump to the connection point (quick connector).

7.

Fully open the valve at the hand pump connection point.

8.

Loosen the locknut on the lower subframe retainer bolt.

9.

Place a piece of card or a feeler gauge (1 - 2 mm) between the piston and the lower subframe.

10. Using the retainer bolt, carefully raise the lower subframe against the piston until the piston extension is at the correct length of approximately 7 mm. 6 Maintenance

The excess fluid will drain into the hand pump. 11. Close the valve on the hand pump connection. 12. Disconnect the hand pump. 13. Wipe up any spilt fluid. 14. Check and if necessary adjust the critical distances in the tension measurement system. See related topic. 15. Tighten the locknut on the lower subframe retainer.

6.18

Service tension measurement hydraulic load cell Related topics: • 6.4 Safe maintenance shutdown on page 43 • 6.15 Check/adjust critical tension measurement distances on page 68 • 6.16 Fill and bleed tension measurement hydraulic system on page 69 TXT-10004093/A

If there is leakage from or damage to the hydraulic load cell, you will need to dismantle the load cell, and possibly replace the piston membrane and O-rings. This can be done without removing the MP16II from the winch. Figure 6.20 gives an overview of the construction of a load cell.

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MP16 User Manual

NOTE: The following instructions apply to a load cell with either a single or a dual hydraulic bellows. NOTE: Always assemble the bellows using new O-rings and membrane. Proceed as follows to service the hydraulic load cell of the MP16II measuring head tension measurement section.

WARNING MOVING PARTS Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death. Ensure that the unit cannot be operated during maintenance or rig-up activity.

1.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled. • There is no wireline in the MP16II measuring head.

2.

Shut down the wireline winch unit for safe maintenance. See related topic.

3.

Fully loosen the locknut and the bolt of the lower subframe retainer(s), and swing the lower subframe away from the upper subframe, so that you have clear access to the load cell.

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6 Maintenance

Figure 6.20 Dual-bellows load cell and cross-section of a bellows

MP16 User Manual

4 3

5

2

1 1

lower subframe

2

lower subframe retainer

3

load cell(s)

4

load cell base plate

5

hydraulic connector

6 Maintenance

Figure 6.21 Gaining access to the load cell 4.

Remove the load cell as follows.

CAUTION EQUIPMENT DAMAGE Hydraulic systems and components are extremely sensitive to contaminants such as grit and metal fragments, which can be accidentally introduced during servicing activity. Apply maximum standards of cleanliness when servicing hydraulic components. Before reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.

a) Place a container below the measuring head to catch any hydraulic fluid leaking from the system. b) Using a wrench, loosen the hydraulic connector from the load cell.

CAUTION ENVIRONMENTAL HAZARD Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site regulations and obey local environmental by-laws.

c) With the hose loosened, attach an end-cap to the hose and elevate the hose opening to avoid further leakage. If a pressure transducer is present, remove the transducer connection. d) Working from below, unscrew each of the Allen key bolts that fasten the load cell base plate to the upper subframe. Support the load cell with one hand as you remove the last bolts. e) Move the load cell to a clean work bench Page 76 of 104 Revision B Original Instructions

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MP16 User Manual

NOTE: For a dual-bellows load cell, repeat the following instructions for dismantling, cleaning and reassembling the load cell bellows.

A

B

C

D

E

F 6 Maintenance

Figure 6.22 Bellows: dismantling & tightening sequence 5.

Dismantle the bellows as follows, referring to Figure 6.22. a) Loosen the 14 screws of the bellows top ring (A). b) Remove the top ring and set it aside with the screws. c) Remove the piston with membrane from the bellows body (B). d) Remove the large O-ring from the bellows body and discard it (C). e) Loosen the 4 screws of the piston assembly (D). These screws are secured with Loctite 222, so apply force with great care, avoiding damage to the piston assembly. f) Dismantle the piston assembly, and discard the O-ring (E) and membrane.

6.

Clean and inspect the metal parts. a) Thoroughly clean the metal parts using a non-aggressive solvent. b) While cleaning each part, check that it is in good condition. In particular, check the inside faces of the piston and the bellows body (which holds the membrane) for surface damage. If a surface is damaged, replace the part.

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MP16 User Manual

c) Use a fine wire brush to remove the Loctite from the screws removed from the piston. 7.

Re-assemble bellows. a) Remove any oil or grease from all parts. The membrane may only come in contact with hydraulic fluid. Other oils and greases can cause the membrane to corrode. b) Fit new O-rings into the bellows housing and inner piston section. c) Place the new membrane on the inner section of the piston, aligning with the screw holes. d) Place the outer section of the piston over the membrane, aligning the screw holes. e) Working quickly, apply a dab of Loctite 222 to the threads of the screws and firmly clamp the membrane between the piston sections by tightening the four screws, working diagonally. f) Place the piston assembly on the bellows body, aligning with the screw holes. g) Place the bellows top ring over the membrane, aligning with the screw holes. h) Insert all 14 screws and lightly hand tighten the screws. i) Following the sequence shown in Figure 6.22 picture (F), tighten the screws to approximately 80% of the final tightness.

6 Maintenance

This is essential to ensuring that the membrane and O-ring are evenly sandwiched between the top ring and the body. Failure to do so can cause leakage from the membrane joint. j) Following the same sequence, tighten the screws to the final tightness. k) Check that the piston is approximately centred and can move freely in the body of the bellows. 8.

Mount the load cell on the upper subframe, firmly tightening the Allen key bolts.

9.

Attach the transducer connection (if applicable).

10. Remove the dust cap from the hydraulic hose, and attach the hydraulic hose. 11. Raise the lower subframe and re-mount the lower subframe retainer, until the distance between the lower subframe and the base plate of the load cell is approximately 38mm. 12. Fill and bleed the hydraulic system. See related topic. 13. Adjust the critical tension measurement distances. See related topic.

6.19

Check/calibrate tension measurement system Related topics: • 3.2 CombiGauge on page 22 • 5.1.3 Prepare tension measurement system on page 34 • 6.15 Check/adjust critical tension measurement distances on page 68 • 6.16 Fill and bleed tension measurement hydraulic system on page 69 • 6.20 Rig-up and use of Tension Calibration Tool on page 84

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MP16 User Manual

TXT-10004094/A

‘

Proceed as follows to calibrate the tension measurement system for correct operation together with the MP16II measuring head. NOTE: The CombiGauge is preset at the factory to provide a full scale deflection at 25, 30, 40, 45 or 60 bar (scale dependent). This corresponds to the 360 degrees of travel of the CombiGauge scale. Recalibration of this setting is not a recommended field maintenance activity, and should only be undertaken by personnel trained and familiar with fine mechanical instrumentation. Incorrect handling of the CombiGauge will result in instrument damage necessitating factory repair and recalibration. NOTE: This procedure requires the use of an auxiliary reliable and precise tension measurement device with sufficient range to match that of the MP16II and the installed CombiGauge. Use either a second wireline winch with accurate tension measurement, or a special purpose tool such as the NOV ASEP Elmar Tension Calibration Tool. NOTE: This procedure requires at least two people. One person must control the tension on the auxiliary tension measurement device, while the other adjusts the CombiGauge.

6.19.1 Rig-up the measuring head to check tension 1.

Before commencing, and during this procedure: • Ensure that the operating area is adequately marked and cordoned off.

• Do not use wireline of inferior or substandard condition. • Agree with the assistant monitoring the line tension as to how to signal when a target tension is reached. 2.

Ensure that the winch is in the following safe state: • The levelwind support arms are in the operating position with the MP16II positioned roughly opposite the centre of the drum. • The winch is in manual mode, if applicable, i.e. the automatic control program (e.g. SmartMonitor) has been disabled.

3.

Prepare the tension measurement system as described in the setup and transport chapter. See related topic.

4.

Rig the measuring head for tension measurement calibration by either of the following methods: • Second winch NOTE: Use only wireline of a breaking strength higher than the maximum range of the CombiGauge. a) Position your winch opposite a second, reliably calibrated winch, with identical wireline to the current rigging of your MP16II. b) Thread the free end of the wireline through your MP16II, and fasten it in a suitable manner to your winch drum. c) Spool several wraps to ensure good attachment, then apply the winch brake. d) Shut down the winch for safe maintenance. See related topic.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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6 Maintenance

• Do not allow anyone to cross, approach, or stand in the path of any wireline under tension.

MP16 User Manual

e) Continue with section 6.19.2, using the controls of the second winch to tension the wireline when instructed. • NOV ASEP Elmar Tension Calibration Tool a) Shut down the winch for safe maintenance. See related topic. b) Rig-up the Tension Calibration Tool. See related topic. c) Continue with section 6.19.2, using the adjustment features of the tool to tension the wireline when instructed.

6.19.2 Check tension measurement 1.

Reduce the wireline tension to zero (the wireline is slack).

2.

Zero the CombiGauge needle for the slack wireline, using the tension zero-set knob.

3.

On a notepad, create a two-column table for the test values for the wireline tension. • The left column is the test tension (indicated on the second winch or calibration tool). • The right column is the value indicated on the CombiGauge. • You will be testing in specific increments up to 90 % of the maximum breaking strength of the wire used during this test. Recommended increments: 0, 25 %, 50 %, 75 %, 90 %.

6 Maintenance

NOTE: Never exceed the maximum tension range on the scale of the CombiGauge! 4.

Obtain a test value at the first increment (25%): a) Carefully increase the test tension to the percentage of maximum tension for your CombiGauge. Example: If the maximum range is 1000 kg, apply an approximately 250 kg tension. b) Record the test tension in the left column, and the CombiGauge tension value in the right column. NOTE: Provided the tension measurement hydraulic system is completely free of trapped air, the difference between the CombiGauge value and the test tension must be linear.

5.

Repeat for the remaining increments of the maximum CombiGauge range. NOTE: For a proper CombiGauge calibration the CombiGauge must be tested to a minimum of 90 % of the full-scale deflection. For example: if the CombiGauge has a range of 0 to 2000 kg (8800 lb), the maximum test value should be approximately 1800 kg (7920 lb). Further adjustment of the calibration screw setting will be proportional to the measurement discrepancy.

6.

Evaluate the test results: • If the CombiGauge is showing the correct tension through the full range of test values, then it is correctly calibrated. No further action is required, and the test set-up can be rigged down. The procedure is complete. • If the CombiGauge shows a deviation from the test values (reading too low or too high), then continue with section 6.19.3. NOTE:

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If the difference between the CombiGauge and test values is non-linear, the most likely cause is air in the MP16II tension measurement hydraulic system, from the load cell to the CombiGauge. In this case you must bleed the air from the system and re-adjust the critical distances. See related topics. NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

MP16 User Manual

6.19.3 Calibrate CombiGauge 1.

Establish the model of CombiGauge installed in your winch, referring to the physical description pages of this manual. See related topic. NOTE: The adjustment mechanism is in a different position on the standard CombiGauge and CombiGauge II.

2.

Remove the glass from the CombiGauge as follows. See Figure 6.23. NOTE: Every winch control panel has a different layout. You may need to withdraw the CombiGauge from the winch control panel in order to remove the glass. a) Remove each of the knobs from the face plate and centre of the dial. NOTE: Some of the knobs are held by a nut below the cap on the knob. Use a knife or screwdriver to lift the cap for access to the nut. Take care to keep all parts together! b) Loosen the four (4) screws in the face plate and lift the face plate and glass off the gauge.

Figure 6.23 Removing glass from standard CombiGauge 3.

Re-fit the tension zero-set knob.

4.

Referring to Figure 6.24, create access to the adjustment mechanism. Rotate the line tension needle using the zero-set knob. As the needle turns, the calibration set screw will appear in the access hole in the CombiGauge dial.This calibration set screw clamps the variable linkage to the Bourdon tube, which is actuated by the pressure in the load cell of the MP16II. NOTE: The calibration set screw itself does not make the actual adjustment; it simply fastens the adjustment. The actual adjustment is made by shifting the position of the screw in the slot in the linkage.

5.

Adjust the CombiGauge as follows. NOTE: If the calibration set screw is loosened too much in the following step, the link will fall away, and the CombiGauge will have to be disassembled to reassemble the linkage mechanism. a) Slightly loosen the calibration set screw just enough (approximately half a turn) to reduce the grip of the screw in the slot in the linkage. b) Using a very small screwdriver inserted into one side of the slot in the linkage, move the screw a nominal amount (1 mm or 2 mm) in the direction of the required adjustment

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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6 Maintenance

NOTE: Your CombiGauge may appear different to the above photos

MP16 User Manual

-..........+

6 Maintenance

CombiGauge I

+..........-

CombiGauge II

Figure 6.24 CombiGauge calibration mechanism (towards or away from tension needle shaft), then retighten the calibration set screw. See the table below: to adjust tension value

...move set screw

lower (-)

towards tension needle

higher (+)

away from tension needle

Table 6.2 Adjusting set screw position 6.

Repeat the tension measurement check of section 6.19.2, and if necessary adjust the calibration again in the above steps until the tension measurement at the CombiGauge corresponds to the test values on the second winch or tension calibration tool.

6.19.4 Finalize 1.

Ensure that the calibration set screw is firmly tightened.

Page 82 of 104 Revision B Original Instructions

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MP16 User Manual

2.

Reduce the wireline tension to zero (the wireline is slack) and shutdown the winch.

3.

Rig-down the test setup.

4.

Remove the tension zero-set knob, re-install the glass in the CombiGauge, re-fit the removed knobs, and (if necessary) re-mount the CombiGauge in the winch control panel.

6 Maintenance

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 83 of 104 Revision B Original Instructions

MP16 User Manual

6.20

Rig-up and use of Tension Calibration Tool Related topics: • 6.4 Safe maintenance shutdown on page 43 • 6.19 Check/calibrate tension measurement system on page 78 TXT-10004095/A

6.20.1 Introduction to Tension calibration Tool The Tension Calibration Tool is a separate product available from NOV ASEP Elmar for precise calibration of the tension measurement system of a wireline winch, and is especially suitable for calibration of the MP16II measuring head in combination with the CombiGauge analogue tension display or the SmartMonitor digital depth and tension measurement system. The Tension Calibration Tool is completely self-contained, and can be used to test and calibrate a tension measurement system without the need to dismantle or otherwise modify the wireline winch in which it is used. NOTE: Maximum permitted tension on the load cell is 5,000 kg (11,000 lb). The fully-assembled tool is shown in Figure 6.25 as used with two different types of wrap-around measuring head, such as the NOV ASEP Elmar MPxx series. MP20 setup

6 Maintenance

MP16 setup

Figure 6.25 Tension Calibration Tool assembled The tool comprises the following main components, which are shown in the exploded diagram of Figure 6.26: • a rigid frame, that fits around the measuring head; • a test cable which is installed in the measuring head in the same way as a regular wireline (various typical wire gauges are available); • a precision load cell that directly measures the tension in the test cable (see Figure 6.27); • a hydraulic piston that applies tension to the cable; • a manual hydraulic pump and hose to supply pressure to the piston.

Page 84 of 104 Revision B Original Instructions

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MP16 User Manual

8 4 5 6

1 2 7 2 6 Maintenance

3

1

main frame

Absorbs compression forces between winch-side and well-side of test cable. Anchored to levelwind shaft by the hooks in the mid-section, and secured by the vertical pins with retaining clips. Can be used as shown or inverted, depending on the measuring head and winch configuration.

2

levelwind shaft hooks 2x

These hooks support the main frame during testing. The main frame can be repositioned up or down on the hooks to enable a straight-through test cable path.

3

piston subframe

Detachable frame end, enables easy frame installation. Secured by retaining clips.

4

load cell (dynamometer)

Measures tension in test cable up to max. 5000 kg (11000 lb). Anchored to frame by vertical pin with retaining clip. See also Figure 6.27 on page 86. NOTE: Transmits signal wireless to handheld unit. Mounting direction is important!

5

load cell cable connector

Attaches cable to load cell. Cable end screws into connector. Anchored to load cell by vertical pin with retaining clip.

6

test cable

Specially manufactured cable for each measuring head type and wireline gauge. Screws into load cell cable connector at one end, attached to piston by nut and washer. (SmartHead test cable shown). NOTE: The cable is longer for wrap-around type heads than for straight-through heads (as shown).

7

piston

Applies tension to test cable. Test cable end passes through hollow piston, and is anchored by nut and washer.

8

manual pump and hose

Supplies pressure to extend piston and tension the test cable. Connects to piston by hydraulic quick coupling.

Figure 6.26 Tension Calibration Tool - exploded diagram NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 85 of 104 Revision B Original Instructions

MP16 User Manual

3

1

6 Maintenance

3

5 4 2

radio signal

1

load cell

Digital load cell. Started, stopped and read out using the wireless handheld unit.

2

handheld unit

Wireless remote control/display for load cell. The units of measurement are shown on the label (this example shows “tonne”, see item 3).

3

display

Shows measured force and status of the handheld and load cell (indicated by small bar above labels below display). The units of measurement cannot be changed.

4

power button

To start/stop load cell: press and hold until BUSY displayed.

5

tare button

Press to set tare load (zero the display) or gross mode. The display will indicate the mode (G or N).

NOTE: Configuration and use of the load cell is briefly described in 6.20.3 Using the Tension Calibration Tool on page 89. For detailed operation and maintenance information, please refer to the supplier’s documentation, provided in your documentation package.

Figure 6.27 Tension Calibration Tool - load cell Page 86 of 104 Revision B Original Instructions

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MP16 User Manual

6.20.2 Rig-up/rig-down Tension Calibration Tool 1.

Position the levelwind support arms in the operating position with the measuring head positioned roughly opposite the centre of the drum.

2.

Shut down the winch for safe maintenance

3.

Unthread the wireline from the measuring head, and fasten it to the drum.

4.

Prepare the tension measurement system as described in the setup and transport chapter for the wireline winch.

5.

Dismantle the tension calibration tool, and set the components ready for installation, approximately as shown in the exploded diagram in Figure 6.26 on page 85.

6.

Check that all parts are present, and that the load cell and handheld unit batteries have sufficient charge. See 6.20.3 Using the Tension Calibration Tool.

7.

If necessary, reposition the side members of the tool on the levelwind shaft hooks, in order to achieve the straightest possible wireline path from the load cell into the measuring head, and from the measuring head to the piston. To do this, simply unscrew the mounting bolts of the hooks, position the bolt-holes against a different slot, and re-tighten the bolts.

8.

Install the tension measurement tool on the measuring head as shown in Figure 6.28. The following steps correspond to the illustrations in the figure.

b) Lay the frame horizontal, and insert the anchor pins, securing them with the retaining clips. c) Thread the test cable through the measuring head in the usual way. See related topic. Ensure that the long threaded end of the cable is on the well side of the measuring head. d) Mount the piston subframe onto the ends of the main frame, and fasten it with the retaining clips. e) Mount the load cell in the main frame at the winch drum end, using the anchor pin and retaining clip. Insert the load cell cable connector into the frame, screw it onto the end of the test cable until the cable threaded end just emerges from the inner side of the connector, and link the cable connector to the load cell using the anchor pin and retaining clip. NOTE: The wireless communication between the load cell and handheld unit is strongest in the direction of the “bottom” of the load cell. If you intend to read the measured load in the winch cabin, then position the bottom end of the load cell towards the cabin. f) Mount the piston onto the piston subframe, and anchor the free end of the test cable through the piston with the nut and washer. Tighten the nut hand tight only. 9.

Connect the manual pump to the piston.

10. Test the setup by applying pressure sufficient to cause the measuring head to react, then release the pressure using the control knob on the pump. 11. Hand-tighten the test cable nut once more (if necessary) to take up the slack. 12. Inspect the complete setup to check that all parts are properly settled and ready for the test procedure. NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 87 of 104 Revision B Original Instructions

6 Maintenance

a) Bring the main frame down over the measuring head from the winch drum side, with the hooks on the top side.

MP16 User Manual

b

c

d

e

f

6 Maintenance

a

Figure 6.28 Tension calibration tool rig-up - MPxx series

Page 88 of 104 Revision B Original Instructions

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MP16 User Manual

This concludes the rig-up. To rig-down the tool, first release all pressure from the manual pump, then proceed through the same steps as above in reverse.

6.20.3 Using the Tension Calibration Tool Related topics: • Supplier documentation for Straighpoint load cell • Supplier documentation for Enerpac manual hydraulic pump Once the tension calibration tool is rigged up, operation is very straightforward, and you need only operate the pump and observe the reading on the load cell display. NOTE: The units of measurement of your load cell are determined at the time of ordering of the Tension Calibration Tool and cannot be changed. The load will be displayed in either lb, kg or tonne. Proceed as follows to apply a specific tension to the measuring head. Prepare the load cell to take readings See Figure 6.27 on page 86. If the unit has been stored for a longer period or the batteries are suspected to be old, open the battery compartment and insert new batteries.

2.

Switch the handheld and load cell ON by pressing and holding the power button until BUSY displayed.

3.

The display will initialize, then show the current measurement value “0.0”. You should start with a slack test cable, and zero load.

Take a tension reading 1.

Determine the target tension you want to test at, e.g. 250 kg or 600 lb (depending the of your load cell). You will normally be taking a series of readings over a range to calibrate the tension measurement system of a wireline winch.

2.

Close the release valve on the manual pump.

3.

Start the handheld unit and load cell (if applicable).

4.

Manually pump pressure into the calibration tool piston to tension the wireline.

5.

While observing the display of the load cell, continue pumping until the approximate target value is reached.

6.

Allow the test setup to stabilize for several minutes, or if necessary longer.

7.

The test cable will stretch when first placed under tension. It will stretch further as higher tensions are applied.

8.

If necessary, pump again until you have a stable tension force close to your target value. If you overshoot the target value, carefully release a little pressure using the release valve. It is not essential to arrive at exactly the target value. The main objective is to compare the calibration tension with the tension measured at the measuring head and displayed on the tension display of the winch.

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 89 of 104 Revision B Original Instructions

6 Maintenance

1.

MP16 User Manual

9.

Once the value in the load cell display is stable, record this value and the value given by the winch tension measurement system.

Finalize Open the release valve to relieve the tension on the load cell.

2.

Check that the display shows zero force.

3.

Switch the handheld and load cell off by pressing and holding the power button until BUSY displayed.

6 Maintenance

1.

Page 90 of 104 Revision B Original Instructions

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MP16 User Manual

7

TROUBLESHOOTING

7.1

Troubleshooting principles TXT-10004239/A

This section offers information for troubleshooting various problems encountered while operating the equipment. If you encounter a problem that is not covered here or cannot be corrected by the suggested remedy, please contact NOV ASEP Elmar for technical guidance. Support contact information is provided in the appendices to this manual. We are always grateful for customer feedback. The troubleshooting guide is divided into sections according to the components or group that need troubleshooting. Within each section, problem symptoms and their possible causes are described, plus a suggested remedy that should enable you to get that component operational again. More detail on the remedies is found in the maintenance section of this manual.

7.2

Troubleshooting table TXT-10004240/A

POSSIBLE CAUSE

SUGGESTED REMEDY

No depth measurement on CombiGauge (but measuring wheel rotates)

Broken/defective drive element

Check that the link key between measuring wheel shaft and angle drive is present and turning For each drive element, check that a turning input gives a turning output

Depth measurement consistently incorrect (but all rotating components turn smoothly)

Wire/ cable changed without changing output drive ratio

Check that every angle drive, gearbox and splitter is correct for the wire/ cable size

Incorrect drive elements (angle drive, drive splitter) between measuring head and CombiGauge

Check that every angle drive, gearbox and splitter is correct for the wire/ cable size and CombiGauge scale (metric or imperial depth) Check that the angle drives for the CombiGauge and measuring head are not swapped around

CombiGauge counter ratio is incorrect

Check that the CombiGauge counter is: • 1:5 for imperial depth units • 1:1 for metric depth units

Worn measuring wheel

Use precision instruments to check the diameter of the measuring wheel ; Replace if worn

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 91 of 104 Revision B Original Instructions

7 Troubleshooting

MP16 PROBLEM

MP16 User Manual

MP16 PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Depth measurement is inaccurate

Wire slipping on measuring wheel

Ensure pressure wheels are correctly aligned to wireline and can turn freely (clean and lubricate); replace defective pressure wheels Ensure pressure wheels apply sufficient pressure to the wire in the groove; week spring action indicates a defect; replace defective pressure wheels Ensure that the measuring wheel: • can turn freely (clean and lubricate) • does not contact subframe

Wire slipping or jamming in the depth counter transmission

Where installed: Ensure depth encoder is properly mounted Ensure depth counter transmission rotates freely from measuring wheel to CombiGauge (angle drives, splitters, cable)

7 Troubleshooting

Ensure link key between measuring wheel shaft and angle drive is correctly engaged Slip or jam in upper wheels

Ensure CombiGauge can turn freely (turn input shaft by hand) Ensure wire retainers/ wheel guards are not pressing against wheels Ensure upper wheels can turn freely (clean, lubricate) and do not contact frame

Page 92 of 104 Revision B Original Instructions

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MP16 User Manual

POSSIBLE CAUSE

SUGGESTED REMEDY

No tension measurement at CombiGauge when load cell under load

CombiGauge tension damping valve closed

Open damping valve

Lower subframe contacting load cell body

Check/adjust critical distances in tension measurement system

Insufficient fluid in tension measurement hydraulic system

Fill and bleed system

Bleed point open

Make sure all bleed points on the measuring head and CombiGauge are closed

Hand pump connection open

Fill and bleed system, close hand pump connection

Leaking hydraulic component

Inspect, identify, and repair

Defective bellows in load cell

Service the load cell

Air in tension measurement hydraulic system

Fill and bleed system

Tension system out of calibration

Recalibrate tension system

Defective CombiGauge

Check and repair/replace as necessary

Air in tension measurement hydraulic system

Fill and bleed system

No piston/subframe gap when not loaded (no tension)

Check/adjust critical distances in tension measurement system (refer to Measuring Head User Manual for gap specifications)

Lower subframe contacting load cell body, piston fully compressed into load cell body

Check/adjust critical distances in tension measurement system according to maintenance section instructions; charge and bleed tension circuit according to Measuring Head User Manual

Inaccurate tension measurement

Displayed tension does not increase above a certain point

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 93 of 104 Revision B Original Instructions

7 Troubleshooting

MP16 PROBLEM

MP16 User Manual

APPENDICES Appendix 1: MP16II measuring head specifications Appendix 2: CombiGauge specifications Appendix 3: Referenced documents Appendix 4: Tension measurement hydraulic fluid Appendix 5: MP16II and CombiGauge depth calculation Appendix 6: Contact us

APPENDICES

Appendix 7: Notes page

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MP16 User Manual

Appendix 1: MP16II measuring head specifications Classification Specification

Marking

Apparatus group

II (surface industries)

Category apparatus

2 (Zone 1)

Explosive atmosphere

G (Gas)

Protection method(s)

c (Constructional safety)

Gas Group

IIB (ethylene)

Temperature classification

T4 (Max. surface temperature 135°C)

Design temperature

Ta -20°C to +40°C

 

II 2G c T4

Specifications Specification

Marking

Dimensions (L x W x H)

553 x 269 x 1006 mm

Weight

Approximately 54 kg

Construction

• Three-wheel wrap-around type with 2 independent upper wheels and 1 lower measuring wheel • Analogue and (optional) digital depth and tension measurement • Integrated level wind slide bearing • Wireline installation with rope socket intact, no tools required

Wheel material and structure

• High grade composite upper (guide) wheels • Stainless steel lower wheel (measuring wheel) • Hollow wheel grooves

Tension measurement principal

• Measurement of pressure in load cell compressed between upper and lower sections by wire line tension, pressure output to ASEP Elmar K-Winch Combi Gauge • Optional transducer on load cell circuit for use with automated monitoring

Autospooling

Optionally available lateral deflection sensors: - Electrical limit switches, IP66 protection - ATEX certified; pneumatic autospooling control

Wireline gauges

3/16" - 7/32" (braided line and monoconductor line) and 0.092"- 0.135" (slicklline)

Wireline gauge adjustment

• No measurewheel changes required • Selectable output from optional drive splitter on measuring wheel shaft (2 wireline sizes possible) • Additional drive splitter combinations available for all wire sizes

Load cell configuration

• Single hydraulic and optional dual bellows

Maximum line tension

2,000 kg (4.410 lb).

Transportation

Locking features enable safe transportation while mounted on winch. Optional carrying case available separately.

Power supply

24V

Maximum pneumatic pressure

10bar

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 95 of 104 Revision B Original Instructions

Appendix 1: MP16II measuring head specifications

Marking

MP16 User Manual

Appendix 2: CombiGauge specifications

Appendix 2: CombiGauge specifications

NOV ASEP Elmar CombiGauge - specifications Design

• Analogue hydro-mechanical wireline depth and tension display • Single gauge enabling both wireline depth and tension to be viewed simultaneously • For use with any ASEP Elmar measuring head design with an integral hydraulic load cell • Metric, imperial or mixed scale (kg-m, kg-ft, lb-m, lb-ft) Specified at time of ordering

Material & structure

• Glass gauge face recessed for protection • Main body parts manufactured from corrosion resistant aluminium

Depth measurement

• Odometer-type depth display • Depth scale of 0 to 99,999 ft with resolution of 1 ft (metric optional) • Angle drive with rotary drive cable connector for use with ASEP Elmar K-Winch MP series measuring heads • Zero depth reset pull-knob

Tension measurement

• Large dial (360°) display with black needle and clear tension increments • Bourdon type pressure measurement (C-form) • Tension scale 0 to 900, 1500, 2000, 4400 or 7000 kg (0 to 2000, 3200, 4400, 8800 or 15400 lb) Specified at time of ordering • Red maximum tension setpoint needle • Hydraulic hose connector for use with ASEP Elmar K-Winch MP series measuring heads • Zero tension reset knob • Hydraulic damping valve to reduce needle jitter

Options

• Correlating depth display (secondary depth odometer)

Standard operating temperature range

-20°C to +40°C (-4°F to +104°F)

ATEX compliance (optional)

Standard non-zoned configuration

Tension measurement hydraulic fluid

ESSO/EXXON ATF D-3. For alternatives, see separate fluid specification in appendices.

Page 96 of 104 Revision B Original Instructions

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MP16 User Manual

Appendix 3: Referenced documents NOTE: This list does not contain drawings of the depth drive assemblies and the encoder set. Contact NOV ASEP Elmar for more information on these parts. ITEM

DOCUMENT/DRAWING NUMBER

FILE TYPE

1

AXLE WIRE GUIDE

DDA1028252

TIF

2

MEASURE HEAD SUPPORT DOUBLE DRUM

DDA1028305

TIF

3

MP16-II BASIC

DDA1102422

DWF

4

ANTI CABLE RUN-OFF

DDA1096135

TIF

5

TOP FRAME ASSY

DDA1102414

TIF

6

GUIDE ROLLER ASSY F/ MEASURE HEADS

DDA1028254

DWF

7

WIRE GUIDE ASM

DDA1081198

TIF

8

BOTTOM FRAME ASSY

DDA1102373

TIF

9

MEASURE WHEEL ASSY

DDA1102375

TIF

10

MEASURE WHEEL

DDA1028220

TIF

11

MEASURE WHEEL

DDA1028207

TIF

12

TENSIONER WITH RUNNER WHEEL

DDA1028303

TIF

13

RUNNER WHEEL ASSY

DDA1030846

TIF

14

WIRE SPRAY TANK 3L

DDA1028270

TIF

15

LOADCELL 100mm

DDA1008970

DWF

16

FEEDING DEVICE PRESSURE BOX

DDA1009169

TIF

17

PRESSURE BOX ASSEMBLY

DDA1028271

DWF

18

LOADCELL 100mm

DDA1008970

DWF

19

FEEDING DEVICE PRESSURE BOX

DDA1009169

TIF

20

MEASUREHEAD MP16II

DDA1119468

DWF

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 97 of 104 Revision B Original Instructions

Appendix 3: Referenced documents

DOCUMENT/DRAWING TITLE

MP16 User Manual

Appendix 4: Tension measurement hydraulic fluid TXT-10004139/A

Hydraulic oil for tension measurement system For reliable, accurate measurement and minimum service problems, it is important that the tension measurement system is filled with the correct fluid type. The fluid used is an automatic transmission fluid type. The table below shows the NOV ASEP Elmar recommended fluid type and approved alternatives. MANUFACTURER

OIL TYPE CODE

NOV ASEP Elmar recommended: ESSO/EXXON

ATF D-3

Appendix 4: Tension measurement hydraulic fluid

Alternative: AGIP

DEXRON III

ARAL

ATF 55

BP

AUTRAN DXIII

CASTROL

TQ DEXTRON III

ELF

ELFMATIC G3

FINA

FINAMATIC HP

KPC / Q8

AUTO 15

MOBIL

ATF

SHELL

DONAX TX

TEXACO

TEXAMATIC 7045

TOTALFINAELF

FLUIDE AT42

NOV ASEP Elmar recommended oil types for the ASEP Elmar MPxx measuring head family

Page 98 of 104 Revision B Original Instructions

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MP16 User Manual

Appendix 5: MP16II and CombiGauge depth calculation TXT-10004105/A

The length of wireline passing through the measuring head is calculated as follows: With each rotation of the measuring wheel, a point on the edge of the wheel travels a distance equal to the wheel diameter multiplied by . The centre of the wireline travels at a diameter equal to the wheel diameter plus the wire diameter (on each side of the wheel, half the wire diameter). EXAMPLE: With: wire thickness = 0.108” = 2.743 mm measuring wheel diameter = 411.84 mm wire centre diameter = 411.84 + 2.743 = 414.583 mm

Appendix 5: MP16II and CombiGauge depth

Diameter calculation

Wireline distance travelled with one turn of the wheel = 414.583 *  = 1302.45 mm The counter inside the CombiGauge is connected to the measuring wheel. When connected directly, one rotation of the measuring wheel is indicated with one unit on the counter. We have calculated that one rotation of the measuring wheel equates to 1.30245 metres. If our CombiGauge is to record depth in metres, then we need to accelerate the depth odometer to register the same depth from a single turn of the measuring wheel. This is accomplished by the combinations of gears in the angle drives (at the measuring head and CombiGauge) and (optional) drive splitter on the measuring head. ASEP Elmar has a variety of angle drives and drive splitters to accomplish the required conversion for various wireline sizes. Returning to the example above: measuring head angle drive ratio = 0.658 :1 (step-up) CombiGauge angle drive ratio = 1 : 0.857 (step-down) NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

Page 99 of 104 Revision B Original Instructions

MP16 User Manual

Resulting overall ratio = 1/0.6758 * 0.857/1 = 1.30243 One turn of the measuring wheel therefore registers 1.30243 metres at the CombiGauge. You may notice that there is a difference of 0.00002 metres between these figures. Over 10,000 metres of depth, this equates to 0.00002/1.30245 * 10,000 = 0.15 metres (15 cm). This is negligible for normal purposes. Combining different wireline sizes Most slickline winch units have either a dual drum or split drum, allowing the use of two or more different wireline sizes. Referring to the calculation above, this means that the drive ratio must be adjusted for the different wireline thicknesses (diameters). The measuring wheel diameter of course remains the same. This adjustment is achieved using a drive splitter with two internal drive ratios. The splitter has one input and two outputs. When switching the winch to a different wireline size, you must also connect the depth counter drive cable to the correct splitter outlet.

Appendix 5: MP16II and CombiGauge depth

With: wire size=

0.125” (3.175 mm)

measuring wheel=411.84 mm diameter Wireline distance travelled with one turn of the wheel = (411.84+3.175) *  = 1303.808 mm If the 0.108” output is a 1:1 (straight-through) drive in the splitter, then the 0.125” output must have a different ratio, calculated as follows: second output ratio = 1303.808 / 1302.450 = 1.001 You do not need to remember the ratio. The output is labelled for the correct wireline size. Combining drive components No more than 2 gearboxes (angle drive, splitter) may be connected directly to each other, and no more than 3 gears may be used in the external counter system. (The internal ratio of the odometer inside the CombiGauge is ignored). Imperial units Taking the example above, one turn of the measuring wheel equates to 1.30245 m = 4.273 ft. So one rotation of the measuring wheel needs to indicate 4.273 feet. To avoid needing to accelerate the depth counter drive cable to more than 4 times the normal (metric) speed, which could create service and performance problems, CombiGauges with imperial units have an internal step-up ratio of 1 : 5, i.e. the counter is accelerated by 5 turns for every incoming turn. This needs to be reduced to 4.273 by the external drive components. The required overall deceleration is therefore 4.273 / 5 = 1 : 0.855. This is achieved by using drive components with the internal ratios 1.002 :1 and 1 : 1.166 (= 0.857 : 1) as follows: (1/1.002) x (1/1.166)= 0.855 For an overview of the typical drive ratios available for various wireline sizes, see the table below.

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MP16 User Manual

Measuring head & CombiGauge drive ratios

Appendix 5: MP16II and CombiGauge depth

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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Appendix 6: Contact us

Appendix 6: Contact us

TXT-10004145/A

Organization

Facilities

Address

Telephone, Fax and E-mail

NOV ASEP Elmar

Corporate Headquarters

7909 Parkwood Circle Dr., Houston, TX 77036, United States of America

Tel.: +1 713 375 3700 1-888 262 8645 Fax: +1 713 346 7687 www.nov.com

NOV ASEP Elmar UK Ltd.

Sales Manufacturing Service

Enterprise Drive, Westhill Ind. Estate, Westhill, Aberdeen AB32 6TQ, Scotland, United Kingdom

Tel.: +44 1224 740261 Fax: +44 1224 743138 [email protected]

NOV ASEP Elmar BV Netherlands

Sales Manufacturing Service

Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

Tel.: +31 184 608 700 Fax: +31 184 608 790 [email protected]

NOV ASEP Elmar North America, Inc.

Sales Manufacturing Service

11993 FM 539, Houston, TX77041, United States of America

Tel.: +1 713 983 9281 Fax: +1 713 983 9282 [email protected]

NOV ASEP Elmar Middle East

Manufacturing

Dubai, United Arab Emirates

Tel.: +971 4 8835 910 [email protected]

NOV ASEP Elmar Singapore

Manufacturing

Singapore

Tel.: +65 6546 0928 [email protected]

Regional Sales, Rental & Service

Location

Telephone & E-mail

Australia

Perth, Western Australia, Australia

Tel.: +61 8 9456 0999 [email protected]

Mexico

Veracruz, Mexico

Tel.: +52 229 937 2890 [email protected]

Brazil

Macaé, Brazil

Tel.: +55 22 2773 3328 [email protected]

Representative Offices

Location

Telephone

USA

Louisiana, USA

Tel.: +1 337 839 0024 ext. 201

Canada

Edmonton, Canada

Tel.: +1 780 986 6063

China

Beijing, China

Tel.: +86 10 8485 1973

Colombia

Bogota, Colombia

Tel.: +57 1602 0414

Malaysia

Kuala Lumpur, Malaysia

Tel.: +60 13931 8869

Former Soviet Union

Moscow, Russia

Tel.: +7 495 258 1473

Belarus

Minsk, Belarus

Tel.: +375 17 298 24 11

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MP16 User Manual

Appendix 7: Notes page

Appendix 7: Notes page

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012

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MP16 User Manual

Published by: NOV ASEP Elmar Energieweg 26 2964 LE Groot-Ammers The Netherlands © 2012 No part of this document may be reproduced by any means without the written consent of the publisher. Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by NOV ASEP Elmar for loss, damage or injury caused by any errors or omissions in this document.

Page 104 of 104 Revision B Original Instructions

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 15 November 2012