Printed in U.S.A. December 1983

Manufacturers of Precision Instruments

INSTALLATION, OPERATION, AND MAINTENANCEWITH

ILLUSTRATED PARTS LIST

PISTON SEPARATORMODEL P10038A

Part Number TW714

Revision A

Manual TW714 contains 12 pages, divided as follows:

Cover. ....................... December 1983 ii through iv. .................. December 1983 Pages l-8 .................... December 1983

All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners.

Information in this manual is subject to change without notice.

IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment. The service procedures recommended by M/D TOTCO and described in the technical manuals are recommended methods of performing service operations. When these service operations require the use of tools specially designed for the purpose, those special tools should be used as recom- mended. Warnings against the use of specific service methods that can damage equipment or render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO could not possibly know, evaluate and advise service people of all conceivable ways in which ser- vice might be done or of all possible associated hazardous consequences. Accordingly, anyone who uses service procedures or tools which are not recommended by M/D TOTCO must first sat- isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized by the method selected.

December 1983 M/D TOTCO

Page iii

LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company’s judgement, as to affect the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company authorized facility,

B. Any product which has, in the Company’s judgement, been subject to negligence, accident, or improper storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit warranty claims directly to the manufacturer thereof.

The Company’s obligation under this warranty is limited to repairing, or at its option, replacing any products which in its judgement proved not to be as warranted within the applicable warranty period. All costs of transportation of products claimed not to be as warranted to authorized Company service facility shall be borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company may, at its sole option elect to refund the purchase price of the products, and Company shall have no further obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts provided under the terms of this warranty are warranted for the remainder of the warranty period of the product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company’s standard warranty terms or period as stated herein will be honored unless agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR BREACH OF ANY OF COMPANY’S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER, WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

Page iv M/D TOTCO

December 1983

MARTIN-DECKER TW714

SECRON 1.0 XNTRODUC‘ITON

1.1 INTRODUCTION. This manual contains the description, installation, and maintenance information for MARTIN-DECKER. P10038A 1:l Piston Separator. Included is information relative to the use of the Piston Separator with pressure fwfw and recorders. Instructions are included for using the P10038A Piston Separator as a direct replacement for the Martin-Decker El7 Gauge Protector. Review this manual before ins&Ration and operation of the 1:l Piston Seperator.

1.2 PRECAUTIONARY INFORMATION. Precautionary information included in Martin-Decker manuals, where applicable, is for aid in operation, protection of equipment, and safety to personnel.

Application is as follows: a. NOTE. Used to caII special attention

to specific procedures or requirements associated with the text.

b. CAUTION. Used where malfunction of equipment or damage to equipment may cause interruption of service.

C. WARNING. Used where malfunction of equipment or damage to equipment could result in serious or fatal injury to personnel or major property loss.

Location of the precautionary notices used in this manual are shown on Page i. Ensure aR personnel who will be performing the procedures in this manual have read the IMPORTANT SAFETY NOTICE on page A.

1.3 UNPACKING AND INSPECTION. The shipping container is constructed to protect the Piston Separator from normal shocks and vibration encountered during shipment. Unpack the system carefuRy and perform the f 0IIowingz

a. Carefully check al.I items shipped against the packing list, and examine for hydraulic leaks and damaged parts.

b. Notify the shipping agency and MARTIN-DECKER immediately in the event of damaged or missing parts.

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SECI’ION 2.0 DESCRIPTION

2.1 PHYSICAL DESCRIPTION. The P10038A 1:l Piston Separator consists of four major components as shown in Figure 2-l.

a. Cylinder - Manufactured from 17-4 PH stainless steel to operate at pressures up to 15,000 psi (Tested to 22,500 psi).

b. Wing Nut - Designed to union the Female Sub and Cylinder into an assembly.

c. Seal Ring - Designed to seal the the union of Female Sub and Cylinder for pressures up to 15,000 psi.

d. Female Sub - Designed to fasten to a 2- inch pressure pipe that holds the Piston Separator assembly.

/EMALEsuB

Figure 2-l. Piston Separator Major Components

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TW714 MARTIN-DECKER

2.2 ORDERING INFORMATION. The Piston Separator is available in six configurations:

P10038A-01 Separator with Welded Female Sub

P10038AdI2 Separator with Threaded Female Sub

P10038A-03 Separator without Sub P10038A-04 Separator with Welded Female

Sub (H2S Service) P10038A-05 Separator without Sub, with Nut

for H2S Service P10038A-06 Separator only, without Sub or

Nut (Xust be used with Lug Nut and Female Sub of user’s choice)

2.3 The Piston Separator may be furnished without a female sub when used as a replacement for the El7 Gauge Protector (See Table 8-l), in which case the existing El7 Sub is used. SeaI ring (B10252A) is furnished.

2.4 OPERATIONAL DESCRIPTION. The PlO938A Piston Separator is a 1:l ratio piston device which transfers pressure from welI fluids (mud, cement, acid, etc) to a remotely located gauge or recorder. The Piston Separator is used for working pressures up to 15,000 psi, with a l/4 inch high presssure hydraulic hose.

2.5 SPECIFICATIONS:

l Working pressure Ratings: P10038A-01 - 15,000 psi P10038A-02 - 10,000 psi P10038A-03 - 15,000 psi P10038A-04 - 10,000 psi P10938A-95 - 19,000 psi P10038A-96 - See Para. 2.2

l Proof Test Pressure Ratings: 150% of working pressure ratings

l Volumetric Capacity: (FulI Stroke) 13.4 cu. in. (220 cc)

l Mounting Pipe size: 2 inch l Dimensions:

Height: 13.25 in. (336 mm) Width: 7.50 in. (190 mm)

l Weight: 29 lb.(with fluid)

page2

SECI'ION 3.0 INSTALLATION

- WARNING -

Do not attempt to remove the Separator from the flow line untiI aR pressure has been removed from the Separator. Personal injury could result.

NOTE: A shut-off valve should be instailed between the flow line and the Piston Separator for inspection and/or repair of the Separator and gauge (or recorder).

NOTE: The Piston Separator is usually mounted in the vertical position to aRow well fluids to drain out of the cylinder when it is not operating.

3.1 REPLACING THE El7 GAUGE PR0l'ECM)R WITH THE P10038A PJSTON SEPARATOR

a. Shut down the pumps or close the shut-off valve to remove aR pressure from the flow line.

b. Check the gauge or recorder for preload; bleed if required.

c. Disconnect the hydraulic hose from the El7 Gauge Protector.

d. Loosen the wing nut until disengaged from the female sub. Lift the El7 and wing nut from the female sub.

NGTE: If the P10038-06 Separator is replacing the El7 Protector, continue with step e. If the P10038A-03 Separator is used, skip to step f.

e. Remove the check valve from the El7 Gauge Protector in order to remove the wing nut. This wing nut will be used on the P10038A-06 Separator when installed.

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MARTIN-DECKER TW714

f. Wipe the inside of the female sub clean and remove the old seal ring. When the female sub is clean, insert the new seal ring (P/N B10252A) with the metal ring facing out.

g. Install the P10038A Piston Separator (with wing nut) on the female sub and tighten down.

NOTE: The check valve will have to be removed from the P10038A Separator in order to place the wing nut on the Separator. Replace the check valve after installing wing nut.

h. Remove the plastic plug opposite the check valve. Connect the hydraulic hose to the Seoarator.

. I. Charge the system per Paragraph 5.1.

CAUTION

Closely observe the Piston Separator and all connections for leaks the first time the system is made operational,

j. Turn on the pumps or open the shut-off valve.

3.2 INITIAL INSl'ALLATION OF THE P10038APISTONSEPARATOR.

a. Referring to Figure 2-1, loosen Wing Nut (item 21, then turn the Female Sub (item 4) from the wing nut.

CAUTION

With the female sub removed, handle the Cylinder (item 1) with care to prevent contamination or damage.

12A3

b.

c.

d.

e.

I.

g*

NOTE: The Seal Ring (item 3) is shipped loose from the factory.

Screw the female sub to the flow line; or, if using a welded female sub, carefully butt weld to the flow line per accepted API welding practices.

With a clean, soft, lint-free cloth wipe the inside of the female sub clean; then insert the seal ring with the metal ring facing out.

Lower the cylinder into the female sub, engage the seal. Tighten the wing nut to secure the connection.

NOT& The Piston Separator is filled with hydraulic fluid prior to shipment from the factory.

With the cylinder installed on the riser, remove the plastic plug opposite the check valve and connect the hydraulic hose from the gauge or recorder.

Charge the system per Paragraph 5.1.

CAUTION

Closely observe the Piston Separator and all connections for leaks the first time the system is made operational.

Turn on the pumps or open the shut-off valve.

SECllON 4.0 CALIBRATION

4.1 The Piston Separator has been tested at the factory before shipment, and requires no calibration prior to operation.

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TWVl4 MARTIN-DECKER

SECIION 5.0 MAINTENANCE

5.1 PERIODIC RECHARGE. Periodically attach the hand pump and recharge the system. Experience with the Piston Separator will determine the time span for fluid recharge. Purge and recharge the system as follows (Refer to Figure 5-l):

NOT& It is recommended that the Separator be positioned vertically during recharging to insure proper P@ng.

a. Check system co~ections for integrity.

b. Close the damper on the gauge.

c. Remove check valve cap and secure the YA2 hand pump to the check valve. Do not tighten swivel nut,

d. Fill hand iwmp reservoir with MARTIN-DECKER WlS/WlS Hydraulic Fluid.

e. Stroke hand pump to bleed air from pump and swivel at check valve. When bubbles cease tighten swivel nut.

CAUTION

Keep hand pump reservoir half full at all times to avoid introducing air into the system.

f. Open the damper at the gauge l-1/2 to 2 turns and stroke hand pump until the gauge (or recorder) shows a slight preload, then bleed air at bleed plug on top of cylinder. Repeat preload and bleed process at plug until no bubbles appear.

HAND PUMP \

CHECK VALVE \

Figure 5-l. System Purging and Recharging

g. Remove hand pump from the check valve and replace check valve cap.

h. Adjust pointer sensitivity to operator’s preference.

CAUTION

Closely Separator, --

observe the Piston gauge (or recorder) and

all connections for leaks the first time the system is operated after recharge.

5.2 SEAL RXPIACEMENT. Seal replacement is determined through experience with respect to well fluids, pressures and use time. See Paragraph 7.2 for seal replacement procedures.

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MARTIN-DECKRR TOOT14

SECI’ION 6.0 TROUBLESHOOTING

6.1 START-UP PROBLEMS. Mast initial operating problems are caused by improper facility preparation and/or incorrect product installation. Verify proper installation per Section 3.0 of this manual before performing the troubleshooting procedures in this section.

6.2 Most common system malfunctions can be remedied by using Table 6-l.

SEcnON 7.0 REPAIR

7.1 REMOVING CYLlNDER ASSEMBLY FROM FJMALB SUB AND FLOW LINE (Refer to Figure 8-l).

a. Shut down the pumps or close shut off valve to remove all pressure from the flow line.

b. Check the gauge or recorder for preload, bleed if required.

c. Loosen Wing Nut (item 6) until disengaged from the Female Sub (item 13). Lift the cylinder and the wing nut off the female sub.

d. If the Piston Separator is to be removed from the site, there is the option of including the gauge (or recorder), or to disengage the hydraulic hose at the Piston Separator. If the hose is disengaged at the Piston Separator, close the damper stem at the gauge. When reinstalling the Piston Separator always use a new seal ring (P/N B10252A) and refer to Paragraph 5.1 for recharge information.

7.2 REPLACEMENT OF PISI’ON WEAR SEAIS (Refer to Figure 8-l).

CAUTION

All Piston Separators have temperature compensating Belleville Spring Washers (item 10) installed under the piston. These washers must be retained exactly as installed at the factory (See Figure 8-l).

a. Disconnect hydraulic hose from the Piston Separator.

b. Remove Piston Separator from female sub per paragraph 7.1 and slide off wing nut.

TABLE 6-l. Malfunction Isolation Chart

I MALPUNCTXON I PROBABLE CAUSE I CORRECI’IVE ACTION I

Erratic or Sluggish Improper Damper Setting Correct Damper Setting Indications

Air in Hydraulic System Purge System per Para. 5.1

Faulty Piston Seals Replace seals

I No Gauge Indication I Broken or Plugged Hose I Clean or Replace Hose I I t I I 4 I 1 Damper Closed I Correct Damper Setting I I t

I I I

I No Hydraulic Fluid I Recharge per para. 5.1 I

la/I33 Page5

TW714 MARTIN-DECKER

c. Turn Piston Separator upside down so Retainer Nut (item 11) is visible. Remove retainer nut.

j. Carefully reinstall the piston in the cylinder, replace the Belleville washers exactly as removed from the cylinder (see Figure 8-l). Replace the retainer nut using thread locking compound. Torque it with assembly tool (Para. 8.3) to 85& 10 foot/pounds.

d. Remove the Belleville washers and the flat washer. See CAUTION note above.

k. Reinstall the cylinder on the female sub.

NOTE: When the piston is removed, fluid in the cylinder will drain through the hose connector hole.

e. Insert a 3/8 - 16 x 4 IN. bolt in the tapped hole on the bottom of the piston (see Figure 8-1, item 91, ‘and carefully pull the piston out of the cylinder. Fluid will drain off.

f. Note how the Piston Seals (item 8, two places) are installed on the piston, remove the old seals.

g. Using seal lubricant (P/N X10107A) grease the piston thoroughly. InstaR the new piston seals (P/N P10037A) with the grooved side of the seals facing outward of the piston.

h. Regrease the piston and the seals using the seal lubricant.

. I. Wipe the cylinder clean and inspect for surface damage such as scoring or pitting.

Page6

L Reconnect the hydraulic hose.

m. Remove the Bleed Plug (item 3) and fill the cylinder with hydraulic fluid. Replace the bleed plug.

n. Recharge the system per paragraph 5.1.

SECI’XON 8.0 PARTS LIST

8.1 P10038A 1:l Piston Separator Parts Breakdown is shown in Table 8-l and Figure 8-l.

a.2 RRCOMMENDED SPAR=. The following items are recommended for field maintenance:

l P/N P10037A Seal, Piston (Viton), quantity 2 each

l P/N B10252A Ring, Seal, quantity, 1 each

l G10026A-000002 Belleville Washers, quantity, 4 each

l J10432A Retainer Nut, quantity, 1 each.

8.3 TOOLING. The following special tooling is recommended for field maintenance:

0 T10094A Spanner Wrench

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MARTIN-DECKER TW714

TABLE 8-l. P10038A Piston Separator Parts List (Reference Figure 8-l)

r -

ITEM NO. PARTNO.

WY.REQ& DESCRIPTION .dl -62 -63 -64 45 -66

1 F350-1 CHECK VALVE, with Cap 1 1 1 1 1 1 2 51490 CROSS, l/4 NPT 1 1 1 1 1 1 3 J826-2HS PLUG, l/4 NPT 1 1 1 1 1 1

4 51292-2 0 2 PLUG, Plastic, l/4 NPT 1 1 1 1 1 1 5 5808-425 BUSHING, l/2 x l/4 NPT 1 1 1 1 1 1 6 5753-152 NUT, 2” Union 1 1 1 - - -

7 P10035A CYLINDER 1 1 1 1 1 1 8 P10037A SEAL, Piston 2 2 2 2 2 2 9 P10036A PISTON 1 1 1 1 1 1

10 G10026A-000002 WASHER, Belleville 4 4 4 4 4 4 11 J10432A NUT, Retainer 1 1 1 1 1 1 12 B10252A RING, Seal, 2” Union 1 1 1 1 1 -

13 J10073A SUB, Female, Welded 1 - - - - - 14 5754-152 SUB, Female, Threaded 1 - - - - 15 G10076A WASHER, Flat, Special 1 1 1 1 1 1

16 J10073A-01 SUB, Female, Welded, H2S - - - 1 - - 17 5753-153 NUT, 2” Union,H2S 1 1 - 18 B10361A NAMEPLATE lklll

19 5831-21 SCREW, Drive 2 2 2 2 2 2

0 1 Reference paragraph 2.2

@ Used for shipping and storage only

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I I

I I

I

13,16

Figure 8-l. P10038A Piston Separator, Exploded View (Reference Table 8-l)

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