a1119468 - Man - Mp16ii Rev A

MP16IIStandard CombiGauge

CombiGauge IIDRAFT - FOR INFORM N ONLYUserManual

NOV ASEP Elmar - NL, Energieweg 26, 2964 LE GTel: +31 184 608 700, Fax: +31 184 608 790, www.NOV ASEP Elmar K-Winch MP16II, MAN-10003445

ORATIOroot-Ammers, The Netherlandsnov.com Page 1 of 100, 20 January 2012 Revision A

IGINAL INSTRUCTIONS

MP16 User Manual

Page 2 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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

A1119468 MEASUREHEAD MP16II

A1114113 MEASUREHEAD MP16II WITH LOADPIN 2T

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



MP16II is a trademark of NOV ASEP Elmar, Groot-Ammers, The Netherlands.

All rights reserved.

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

Revision Date Amendments

A 20-Jan-2012 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).

2.02 26 May 2011 Minor corrections

2.01 3 June 2010 Minor update tension calibration procedure.

2.00 8 March 2010 Restyled; modified tension calibration procedure.Extended minimum temperature down to -20C.

REVISION HISTORY

Published by:NOV ASEP ElmarEnergieweg 262964 LE Groot-AmmersThe 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.

MP16 User Manual

Table of ContentsTABLE OF CONTENTS

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.1 Scope of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 How to use this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.3 Documentation Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 General safety responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1.1 Wireline operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.1.2 Working with open doors and hatches: . . . . . . . . . . . . . . . . . . . . . . . . . . 92.1.3 Transport/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.2.1 Warning and caution icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.2.2 Restriction icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.1 MP16II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.2 CombiGauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.2.1 CombiGauge standard (classic model) . . . . . . . . . . . . . . . . . . . . . . . . . 183.2.2 CombiGauge II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.1 MP16II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.2 CombiGauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5 SETUP & TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.1 Measuring head rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.1.1 Release head from transport lock and mount for operations . . . . . . . . 265.1.2 Prepare depth measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . 265.1.3 Prepare tension measurement system . . . . . . . . . . . . . . . . . . . . . . . . . 295.1.4 Thread wireline through the measuring head . . . . . . . . . . . . . . . . . . . . 30

5.2 Measuring head rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.2.1 Unthread wireline from the measuring head . . . . . . . . . . . . . . . . . . . . . 325.2.2 Lock measuring head for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.1 Periodic maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.2 Special notes on measuring head measurement precision . . . . . . . . . . . . . . . . 366.3 Special notes on cleaning and lubrication of the measuring head . . . . . . . . . . . 376.4 Safe maintenance shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386.5 Remove/install measuring head in winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.6 Lubricate measuring head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.7 Service measuring head support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446.8 Check/adjust autospooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466.9 Remove/install upper wheels and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506.10 Remove/install measuring wheel and bearings. . . . . . . . . . . . . . . . . . . . . . . . . . 536.11 Remove/install drive splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556.12 Remove/install depth counter drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586.13 Remove/install angle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596.14 Remove/install depth encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616.15 Check/adjust critical tension measurement distances . . . . . . . . . . . . . . . . . . . . 636.16 Fill and bleed tension measurement hydraulic system . . . . . . . . . . . . . . . . . . . . 656.17 Drain excess tension measurement hydraulic fluid. . . . . . . . . . . . . . . . . . . . . . . 686.18 Service tension measurement hydraulic load cell . . . . . . . . . . . . . . . . . . . . . . . 706.19 Check/calibrate tension measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.19.1 Rig-up the measuring head to check tension . . . . . . . . . . . . . . . . . . . . 74NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 3 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A

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6.19.2 Check tension measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756.19.3 Calibrate CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766.19.4 Finalize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.20 Rig-up and use of Tension Calibration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796.20.1 Introduction to Tension calibration Tool. . . . . . . . . . . . . . . . . . . . . . . . . 796.20.2 Rig-up/rig-down Tension Calibration Tool . . . . . . . . . . . . . . . . . . . . . . . 826.20.3 Using the Tension Calibration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Appendix 1: MP16II measuring head specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 89Appendix 2: CombiGauge specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Appendix 3: Tension measurement hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Appendix 4: MP16II and CombiGauge depth calculation . . . . . . . . . . . . . . . . . . . . . . 92Appendix 5: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

CUSTOMER NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Page 4 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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MP16 User Manual

List of Figures

LIST OF FIGURES

Figure 3.1 MP16II measuring head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Figure 3.2 MP16II additional options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Figure 3.3 Overview - standard CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Figure 3.4 Overview - CombiGauge II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Figure 4.1 Measuring head working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Figure 5.1 Depth measurement mechanical parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Figure 5.2 Threading the wireline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Figure 6.1 Recommended grease gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Figure 6.2 Levelwind shaft mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Figure 6.3 Measuring head lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Figure 6.4 Measuring head support bearing and ball cage . . . . . . . . . . . . . . . . . . . . . . . 44Figure 6.5 Autospooling assembly with electric sensors . . . . . . . . . . . . . . . . . . . . . . . . . 47Figure 6.6 Creating access for upper wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Figure 6.7 Upper wheel centre with bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Figure 6.9 Reassembly of measuring wheel & shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Figure 6.8 measuring wheel shaft, depth counter side . . . . . . . . . . . . . . . . . . . . . . . . . . 54Figure 6.10 Angle drive and drive splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Figure 6.11 Depth counter drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Figure 6.12 Depth counter assembly and mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . 60Figure 6.13 Angle drive, link key, measuring wheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . 61Figure 6.14 Depth encoder mounted on lower subframe . . . . . . . . . . . . . . . . . . . . . . . . . 62Figure 6.15 Critical distances at load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Figure 6.16 CombiGauge bleed point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Figure 6.17 Pressure transducer & bleed point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Figure 6.18 Hand pump, bleed key, and connection point . . . . . . . . . . . . . . . . . . . . . . . . 67Figure 6.19 Auxiliary bleed point on CombiGauge (classic model only) . . . . . . . . . . . . . . 68Figure 6.20 Hand pump and connection point on load cell . . . . . . . . . . . . . . . . . . . . . . . . 69Figure 6.21 Dual-bellows load cell and cross-section of a bellows . . . . . . . . . . . . . . . . . . 70Figure 6.22 Gaining access to the load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Figure 6.23 Bellows: dismantling & tightening sequence . . . . . . . . . . . . . . . . . . . . . . . . . 73Figure 6.24 Removing glass from standard CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . 77Figure 6.25 CombiGauge calibration mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Figure 6.26 Tension Calibration Tool assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Figure 6.27 Tension Calibration Tool - exploded diagram. . . . . . . . . . . . . . . . . . . . . . . . . 80Figure 6.28 Tension Calibration Tool - load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Figure 6.29 Tension calibration tool rig-up - MPxx series . . . . . . . . . . . . . . . . . . . . . . . . . 83

MP16 User Manual

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

1.1 Scope of this manualThis 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

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 manualBefore 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 MPxx. 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 MPxx maintenance.Page 6 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

MP16 User Manual

1Introduction1.3 Documentation PackageThis 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.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 7 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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fety2 SAFETYThis section describes all safety aspects required when working with NOV ASEP Elmar equipment. The safety aspect can relate to potential equipment damage or to danger to personnel working with this equipment or in the vicinity.

Preventing accidents is an objective affecting all company levels and operations. It is therefore a basic requirement that each supervisor makes the safety of all employees an integral part of their regular management function. It is equally the duty of each employee to accept and follow established safety regulations and procedures.

Every effort should be made to provide adequate training to employees. However, if an employee is ever in doubt about how to do a job or task safely, they should always ask a qualified person for assistance. Employees are expected to assist management in accident prevention activities. Unsafe conditions must be reported immediately. Fellow employees that need help should be assisted.

Every injury that occurs on the job, even a slight cut or strain, must be immediately reported to management and/or the Responsible Safety Officer. Never leave the work site without reporting an injury, except for emergency trips to the hospital.

2.1 General safety responsibilitiesHigh voltages, mechanical, chemical, thermal, noise and stored energy hazards are present in NOV ASEP Elmar systems. Therefore, pay special attention to safety when operating and maintaining each system, including:

Meet all applicable codes, laws and field regulations

Read and understand each item in this manual

Follow the operatingand maintenance procedures exactly

Perform all testing procedures exactly as specified

Ensure that only trained and qualified personnel are allowed to work on the system (please note that rigging up and rigging down are also part of unit operations.)

Ensure that adequate safety equipment is installed (fire extinguishers, escape routes, shut off valves, etc.), and that personnel are trained to use the equipment

Always use the correct tools for the job

Take recommended precautions - never take short cuts

Follow the procedures and advice in this manual closely

Never work alone if there is a possibility of an accident

Wear Personal Protection Equipment (PPE) where necessary

Do not attempt to use the equipment for other purposes outside its design scope. This may lead to damage and/or dangerous situations

Do not restart NOV ASEP Elmar equipment after an emergency stop without verifying that the cause of this stop has been removed or rectifiedPage 8 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

MP16 User Manual

2Safety2.1.1 Wireline operations During Wireline operations, consider the zone in front of the wireline unit as a danger zone. For safety reasons keep the following points in mind:

This is a constant danger zone

Never step over the wireline

Never allow spectators near the working area

If possible, restrict access to this area with signs and/or bright tape

If the wireline is rigged up but has not run for a period, clamp the wireline, reduce the tension, and flag the wire with signs

When the wireline unit is tied down on deck using rope/line/chains, attach a flag to the ropes/lines/chains to signal their location

When the wireline operation is finished, shutdown the engine(s) and close all hatches and doors.

2.1.2 Working with open doors and hatches: While opening/closing hatches and/or doors on the unit, be aware of wind conditions.

Hatches and/or doors might forcibly swing open/shut and cause damage or injury.

When open, the hinge side of most doors and hatches can create an extremely hazardous pinch point for fingers, clothing, hoses and cables. Always check the hinge side before closing any door or hatch.

Always use the built-in door or hatch retainers to anchor the door or hatch if you need to leave it open while you work. Wind or sudden movement of the unit can cause the door or hatch to swing shut with great force, resulting in possible injury or equipment damage.

2.1.3 Transport/Installation When lifting the wireline unit by crane, make sure you cannot get trapped between the

load and a wall, fixed object, etc.

If possible, position yourself so that you are visible to the crane operator. If not possible, make sure a flagman can signal the crane operator

Never walk under a hanging load

Make sure that lifting gear is sufficiently dimensioned and certified

Never leave an operation-ready unit unattended

Do not operate damaged equipment. This may lead to further damage and/or dangerous situations

Respect and maintain your working environment. Dispose of waste correctly

Keep the unit and connected components clean. Accumulated dirt can hamper unit operations and might jeopardize safety

To prevent accidents, keep all safety guards in position while operating NOV ASEP Elmar equipment

When engaged in maintenance and / or performing checks on the unit:

First consider your safety and that of others

Make sure that the equipment is switched off completely and use a decal or similar to prevent un authorized starting during maintenance or check upNOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 9 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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fety Never work on hydraulic and/or pneumatic systems under pressure. Always relieve system pressure to prevent dangerous situations

Never attempt to move heavy parts without the aid of a mechanical device

Do not allow heavy objects to rest in an unstable position

Use the correct tools for the task

2.2 Warnings and cautionsThe following alerts are used in this manual:

WARNINGS alert users of potentially dangerous situations. Failure to obey a warning can result in serious injury and/or death.

CAUTIONS alert users of potential equipment damage. Ignoring a caution can result in damage to equipment.

Warnings and cautions in this manual, are indicated by:

an icon

the text WARNING or CAUTION a textual description, which states the hazard and how to avoid it.

See following examples:

WARNINGFALLING FROM HEIGHTFalling from the top of the unit can cause serious injury or death.When working on top of the unit, make sure the roof is locked and always use an appropriate fall arrest system.

WARNINGHOT OBJECTHot oil can cause serious burns.Take care when handling hydraulic components and oil. Always wear appropriate Personal Protective Equipment (PPE), such as gloves.

CAUTIONEQUIPMENT DAMAGEFluid leaks can cause mechanical components to run dry and sieze, as well as contaminate the working area and environment. Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are properly tightened.

CAUTIONEQUIPMENT DAMAGEThe fuel tank and fuel lines can be damaged if the fuel tank breather is capped (blocked).Never block (cap) the fuel tank breather.Page 10 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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2Safety

f 2.2.1 Warning and caution iconsThis manual uses the following icons to highlight safety aspects during operating and maintenance steps. These same icons are attached to NOV ASEP Elmar systems at appropriate locations to warn of a safety aspect.

General Caution or Warning Hot object

Corrosive liquids or adhesive Moving parts

Dangerous voltage Automatically starting and stopping of machine parts

Grounding required Lifting with forklift - beware ofalling loads

Potentially explosive substances or environments Danger of falling from height

Inflammable substances Hoisted object that can fall

Crushing dangerNOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 11 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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fety2.2.2 Restriction iconsOther icons may be used on your machine and in the manual to indicate that restrictions are in place. For example the following PPE (Personal Protection Equipment) may be required:

Eye protectionWear protective glasses to prevent eye damage

Breathing protectionWear a full respiratory mask if working with toxic vapours

Ear protectionWear ear protection during this procedure

Wear protective glovesWear latex gloves to protect your skin when performing this procedure

Electro-Static Discharge (ESD)Make sure you are sufficiently equipped to prevent ESD hazards

Wear protective helmetAlways wear a helmet to protect your head when performing this procedure

Wear protective shoesAlways wear protective shoes to protect your ankles and feet when performing this procedurePage 12 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

MP16 User ManualNOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 13 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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3 PHYSICAL DESCRIPTION3.1 MP16II

Figure 3.1 MP16II measuring head

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3Physical description1 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 (4x) 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, 2 on drum side.

5 measuring head guide roller (Not visible, at rear of measuring head). Roller assembly that stabilizes the drum-side of the measuring head in a horizontal guide rail mounted on the winch levelwind arms.

6 upper subframe Rigid upper section of the measuring head.

7 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.

8 wireline retainer (2x) Spring-loaded roller at the front and rear that press wireline into the (upper) guide wheels and prevent the wire from jumping out of the guide wheel grooves. Can be lifted to ease rig-up/rig-down.

9 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 (see drawing) or dual-bellows type (see inset). Optionally, a digital pressure transducer can be connected to supply tension data to an electronic depth and tension monitoring system, such as the ASEP Elmar SmartMonitor.

10 tension measurement hydraulic line

Hose to CombiGauge tension display in winch control panel.

11 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.

12 lower subframe retainer/adjuster (See inset, on left side of measuring head). Used to keep the measuring head from falling open, and to adjust the critical distance between the upper and lower subframe for tension measurement.

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

14 depth measurement wheel Turns with wireline travel, transfers rotation via shaft to depth counter mechanical drive and optional digital encoder.

15 depth counter angle drive Turns the mechanical drive through 90 degrees, with a fixed reduction ratio.

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

17 optional digital depth encoder (On opposite side to depth counter, optional): Transfers a digital depth signal to an electronic depth and tension monitoring system, such as the ASEP Elmar SmartMonitor.

18 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.l

19 optional wireline oiler tank Supplies oil to the wireline during operations.

20 wireline oiler drip valve Manual valve to start/stop the oil flow. Should be closed when not in use to avoid unnecessary spillage.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 15 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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Figure 3.2 MP16II additional options


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3Physical description1 Autospooling option Replaces the drum side roller set. Enables automatic head positioning by signalling when the head needs to move laterally. The wireline winch must be equipped with an electronic control system (e.g. SmartMonitor) that can translate signals from the sensors (see below) into the correct amount of movement of the measuring head.

2 autospooling assembly baseplate Bolted to the upper subframe in place of the rear (drum side) guide rollers.

3 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.

4 lateral deflection cam When the cam is tilted by pressure against a roller, the cam lobe presses against the plunger of the sensor on the opposite side to the roller.

5 lateral deflection sensor When the sensor plunger is pressed sufficiently by the cam, the switch closes and the levelwind motor is given a signal to move the measuring head one step towards the side that the wire is pressing.

6 Tension load pin option Option for fully-digital depth & tension system (without CombiGauge). Used in combination with depth shaft encoder. The standard mechanical drive system and hydraulic load cell are not present.

7 hinge load pin 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.

8 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.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 17 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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3.2 CombiGauge 3.2.1 CombiGauge standard (classic model)

Figure 3.3 Overview - standard CombiGauge


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3Physical description1 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.

7 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 rig-up using the zero pull-knob. Units (feet or metres) specified at time of ordering.

12 depth odometer zero pull-knob

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 correlating depth CombiGauge

Shown with glass and dial plate removed. This type of CombiGauge includes a secondary Correlating depth odometer.

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

16 correlating depth odometer zero pull-knob

Pull to zero the correlating odometer.

17 correlating depth odo set knob

Pull and turn to set the correlating odometer to a specific value.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 19 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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3.2.2 CombiGauge II

Figure 3.4 Overview - CombiGauge II


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3Physical description1 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

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

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 rig-up using the zero pull-knob. Units (feet or metres) specified at time of ordering.

9 depth odometer zero pull-knob

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.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 21 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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4Functional D

escription4 FUNCTIONAL DESCRIPTION4.1 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.

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

Figure 4.1 Measuring head working principle

tension signal

depth signal

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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 transducer in the pressure circuit transmits a digital signal to the control system and/or display. The optional presure transducer 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 single or 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 and the (lower) measuring wheel are of composite material.

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.

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 by electronic 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.

NOTE: A detailed description of how to combine drive components for specific wireline sizes is provided in Appendix 4: MP16II and CombiGauge depth calculation on page 92. Page 24 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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4Functional D

escription4.2 CombiGaugeThe 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.

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.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 25 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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5 SETUP & TRANSPORT5.1 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 head

5.1.1 Release head from transport lock and mount for operationsRefer to your winch manual for instructions.

5.1.2 Prepare depth measurement systemRelated topics:

6.9 Remove/install upper wheels and bearings on page 50

6.10 Remove/install measuring wheel and bearings on page 53

6.11 Remove/install drive splitter on page 55

6.12 Remove/install depth counter drive cable on page 58

6.13 Remove/install angle drive on page 59

Appendix 4: MP16II and CombiGauge depth calculation on page 92

Proceed as follows to prepare the depth measurement system of the MP16II 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 MPxx measuring head. These are examples only, and the corresponding components on your measuring head may be assembled differently..

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

2. Disable all mechanical movement of the winch, e.g. by operating the units 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

WARNINGMOVING PARTSMoving 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. Page 26 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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5Setup &

transportattached 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 MP16II.

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.

Figure 5.1 Depth measurement mechanical parts

MP16BS/HD

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, 0.108 or 7/32.

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.

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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.

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

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 re-peat 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.Page 28 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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5Setup &

transportNOTE: If the MP16II 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 systemRelated topics:

6.15 Check/adjust critical tension measurement distances on page 63

6.18 Service tension measurement hydraulic load cell on page 70

Proceed as follows to prepare the tension measurement system of the MP16II measuring head for operations.

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

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

3. Ensure that there is no wireline installed in the MP16II 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: 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.

6. 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.

WARNINGMOVING PARTSMoving 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. NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 29 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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8. 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.

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

1. 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 units 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.

WARNINGMOVING PARTSMoving 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.

WARNINGRISK 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.Page 30 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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transporte) 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 units 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.

Figure 5.2 Threading the wireline

to wellhead

drum

wireline

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 wheelF measuring wheel wire pressure wheels (2x)

A BCD D

E

F FNOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 31 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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tup

& tr

ansp

ort

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-downTo rig-down the MP16II measuring head after operations, there are two procedures:

Unthread wireline from the 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.

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.


WARNINGRISK 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.Page 32 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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transport5. Starting from the well side of the MP16II, unthread the wireline from the measuring head as follows:

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 units 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 transportRefer to your winch manual for instructions.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 33 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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ce6 MAINTENANCEIntroduction to MP16II maintenance

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.

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.

WARNINGMOVING PARTSMoving parts (drum, gearbox, chain) can cause serious injury or death.Make sure the winch cannot be operated during maintenance or rig-up activity. Page 34 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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aintenance6.1 Periodic maintenance schedule

Maintenance procedure Page

Service interval

daily

300

hrs

600

hrs

900

hrs

1200

hrs

1500

hrs

1800

hrs

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

6.6 Lubricate measuring head 42

6.7 Service measuring head support bearing 44 6.9 Remove/install upper wheels and bearings 50 6.10 Remove/install measuring wheel and bearings 53

6.18 Service tension measurement hydraulic load cell 70

6.4 Safe maintenance shutdown 38 As required6.5 Remove/install measuring head in winch 40 As required6.8 Check/adjust autospooling 46 As required6.11 Remove/install drive splitter 55 As required6.12 Remove/install depth counter drive cable 58 As required6.13 Remove/install angle drive 59 As required6.14 Remove/install depth encoder 61 As required6.15 Check/adjust critical tension measurement distances 63 As required6.16 Fill and bleed tension measurement hydraulic system 65 As required6.17 Drain excess tension measurement hydraulic fluid 68 As required6.19 Check/calibrate tension measurement system 74 As required6.20 Rig-up and use of Tension Calibration Tool 79 As required

Table 6.1 MP16II maintenance scheduleNOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 35 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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ce6.2 Special notes on measuring head measurement precision

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).

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.

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 Page 36 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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aintenancedisplay, 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 anodal 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

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 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 37 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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cegreased using a special type of grease gun. See Figure 6.1.

For proper MP16II functioning, the bearings must be lubricated using a high quality grease. During manufacturing of the MP16II, the bearings are lubricated with sufficient grease to ensure correct MP16II operation until the next complete overhaul of the measuring head.

However, if for any reason re-lubrication is required (e.g. cleaning with a high pressure tool, extreme contamination), MP16II bearings and contact surfaces can be lubricated using the grease nipples fitted to all moving parts.

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 shutdownRelated topics:

Wireline winch shutdown (see winch documentation)

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.

Proceed as follows to shutdown the winch for safe maintenance.

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.

Figure 6.1 Recommended grease gun


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aintenance2. 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.).NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 39 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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ce6.5 Remove/install measuring head in winchRelated topic:

6.4 Safe maintenance shutdown on page 38

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.

1. Ensure that the winch is in the following safe state:



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


Figure 6.2 Levelwind shaft mountings

direct shaft drive hydraulic motor drive

1 levelwind shaft Must be removed complete with measuring head.

2 shaft retaining bolt There may also be a bolt in the ends of the levelwind shaft (on units with a hydraulic motor drive). This bolt must first be loosened and removed.

3 shaft mounting block The mounting at each end of the shaft is a split block clamp held by two bolts. Loosen and remove these bolts. NOTE: On units with a hydraulic motor drive, on one side the same bolts are used to attach the motor and set the chain tension.

3

3

2

11


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aintenance 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. Referring to Figure 6.2, loosen and remove the bolts of the levelwind shaft mountings.

NOTE: The figure shows two possible levelwind shaft mountings. The mountings in your winch may also be different to those shown here.

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.

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.

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

17. Restore all adjustments, including tightening levelwind chain.

18. Test that the measuring head performs correctly.NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 41 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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ce6.6 Lubricate measuring headRelated topics:

6.3 Special notes on cleaning and lubrication of the measuring head on page 37

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.

2. If applicable, disable all mechanical movement e.g. by operating the units 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 6.10.

A: Measuring head support bearing

B: Upper wheel bearings

C: Measuring wheel bearings (one on each side)

D: 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)


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aintenanceFigure 6.3 Measuring head lubrication points

measuring head support bearing upper wheel bearings

measuring wheel nipple 1 measuring wheel nipple 2

wireline guide rollers (4 in total)

A B

C C

DDNOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 43 of 100NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Revision A


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ce6.7 Service measuring head support bearingRelated procedures:

6.4 Safe maintenance shutdown on page 38

6.5 Remove/install measuring head in winch on page 40

MP16II, ALSO APPLIES TO MP20

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;

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.

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

Figure 6.4 Measuring head support bearing and ball cagePage 44 of 100 NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012 Original Instructions

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aintenance1. :Ensure that the winch is in the following safe state:



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.

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)

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