Professional Documents
Culture Documents
Standard CombiGauge
CombiGauge II
DRAFT - FOR
User Manual
INFORMATION ONLY
ORIGINAL INSTRUCTIONS
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
Tel: +31 184 608 700, Fax: +31 184 608 790, www.nov.com
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 1 of 100
Revision A
MEASUREHEAD MP16II
A1114113
A1083290
L-6501034275
L-6501034295
L-6501034294
L-6501034293
L-6501037002
L-6501038038
WARNING
REVISION HISTORY
DANGEROUS MACHINERY
Ignoring 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.
Published by:
NOV ASEP Elmar
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
2012 No part of this document may be reproduced by any means without
the written consent of the publisher.
Whilst every care has been taken to ensure that the information in this
document is correct, no liability can be accepted by NOV ASEP Elmar for
loss, damage or injury caused by any errors or omissions in this document.
Revision
Date
Amendments
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
2.00
8 March 2010
REVISION HISTORY
Page 2 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
TABLE OF CONTENTS
1
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 3 of 100
Revision A
Original Instructions
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Scope of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 How to use this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Documentation Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 General safety responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1
Wireline operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.2
Working with open doors and hatches: . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.3
Transport/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1
Warning and caution icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2
Restriction icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 MP16II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.1
CombiGauge standard (classic model) . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.2
CombiGauge II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 MP16II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SETUP & TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Measuring head rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.1
Release head from transport lock and mount for operations . . . . . . . . 26
5.1.2
Prepare depth measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.3
Prepare tension measurement system . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.4
Thread wireline through the measuring head . . . . . . . . . . . . . . . . . . . . 30
5.2 Measuring head rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2.1
Unthread wireline from the measuring head . . . . . . . . . . . . . . . . . . . . . 32
5.2.2
Lock measuring head for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1 Periodic maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Special notes on measuring head measurement precision . . . . . . . . . . . . . . . . 36
6.3 Special notes on cleaning and lubrication of the measuring head . . . . . . . . . . . 37
6.4 Safe maintenance shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.5 Remove/install measuring head in winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.6 Lubricate measuring head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.7 Service measuring head support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.8 Check/adjust autospooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.9 Remove/install upper wheels and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.10 Remove/install measuring wheel and bearings. . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.11 Remove/install drive splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.12 Remove/install depth counter drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.13 Remove/install angle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.14 Remove/install depth encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.15 Check/adjust critical tension measurement distances . . . . . . . . . . . . . . . . . . . . 63
6.16 Fill and bleed tension measurement hydraulic system . . . . . . . . . . . . . . . . . . . . 65
6.17 Drain excess tension measurement hydraulic fluid. . . . . . . . . . . . . . . . . . . . . . . 68
6.18 Service tension measurement hydraulic load cell . . . . . . . . . . . . . . . . . . . . . . . 70
6.19 Check/calibrate tension measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.19.1 Rig-up the measuring head to check tension . . . . . . . . . . . . . . . . . . . . 74
APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Appendix 1: MP16II measuring head specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Appendix 2: CombiGauge specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Appendix 3: Tension measurement hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Appendix 4: MP16II and CombiGauge depth calculation . . . . . . . . . . . . . . . . . . . . . . 92
Appendix 5: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Table of Contents
CUSTOMER NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Page 4 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
LIST OF FIGURES
MP16II measuring head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MP16II additional options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - standard CombiGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - CombiGauge II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring head working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth measurement mechanical parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Threading the wireline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended grease gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Levelwind shaft mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring head lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring head support bearing and ball cage . . . . . . . . . . . . . . . . . . . . . . .
Autospooling assembly with electric sensors . . . . . . . . . . . . . . . . . . . . . . . . .
Creating access for upper wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper wheel centre with bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of measuring wheel & shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .
measuring wheel shaft, depth counter side . . . . . . . . . . . . . . . . . . . . . . . . . .
Angle drive and drive splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth counter drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth counter assembly and mounting plate . . . . . . . . . . . . . . . . . . . . . . . . .
Angle drive, link key, measuring wheel shaft . . . . . . . . . . . . . . . . . . . . . . . . .
Depth encoder mounted on lower subframe . . . . . . . . . . . . . . . . . . . . . . . . .
Critical distances at load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CombiGauge bleed point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure transducer & bleed point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hand pump, bleed key, and connection point . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary bleed point on CombiGauge (classic model only) . . . . . . . . . . . . . .
Hand pump and connection point on load cell . . . . . . . . . . . . . . . . . . . . . . . .
Dual-bellows load cell and cross-section of a bellows . . . . . . . . . . . . . . . . . .
Gaining access to the load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bellows: dismantling & tightening sequence . . . . . . . . . . . . . . . . . . . . . . . . .
Removing glass from standard CombiGauge . . . . . . . . . . . . . . . . . . . . . . . .
CombiGauge calibration mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension Calibration Tool assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension Calibration Tool - exploded diagram. . . . . . . . . . . . . . . . . . . . . . . . .
Tension Calibration Tool - load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension calibration tool rig-up - MPxx series . . . . . . . . . . . . . . . . . . . . . . . . .
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
14
16
18
20
23
27
31
38
40
43
44
47
50
51
54
54
56
58
60
61
62
63
65
66
67
68
69
70
71
73
77
77
79
80
81
83
Page 5 of 100
Revision A
Original Instructions
List of Figures
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4
Figure 4.1
Figure 5.1
Figure 5.2
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
Figure 6.5
Figure 6.6
Figure 6.7
Figure 6.9
Figure 6.8
Figure 6.10
Figure 6.11
Figure 6.12
Figure 6.13
Figure 6.14
Figure 6.15
Figure 6.16
Figure 6.17
Figure 6.18
Figure 6.19
Figure 6.20
Figure 6.21
Figure 6.22
Figure 6.23
Figure 6.24
Figure 6.25
Figure 6.26
Figure 6.27
Figure 6.28
Figure 6.29
INTRODUCTION
The MP16II measuring head is one of the many NOV ASEP Elmar products used in the well
servicing industry.
1.1
1 Introduction
1.2
Page 6 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
1.3
Documentation Package
This User Manual is part of a comprehensive Documentation Package that is supplied as an
integral part of your measuring head. The Documentation Packet includes:
Certificates and Reports
Drawings Packet with schematics
Parts List
Supplier Documentation
Refer to the Parts List when ordering replacement components during maintenance.
Use the supplier documentation as reference for further information on OEM components.
1 Introduction
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 7 of 100
Revision A
Original Instructions
SAFETY
This 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
2 Safety
High 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 rectified
Page 8 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
2.1.1
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
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 up
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 9 of 100
Revision A
Original Instructions
2 Safety
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.
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
2 Safety
WARNING
FALLING FROM HEIGHT
Falling 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.
WARNING
HOT OBJECT
Hot oil can cause serious burns.
Take care when handling hydraulic components and oil. Always wear appropriate Personal
Protective Equipment (PPE), such as gloves.
CAUTION
EQUIPMENT DAMAGE
Fluid 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.
CAUTION
EQUIPMENT DAMAGE
The 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
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
2.2.1
Hot object
Moving parts
Dangerous voltage
Grounding required
Inflammable substances
Crushing danger
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 11 of 100
Revision A
Original Instructions
2 Safety
2.2.2
Restriction icons
Other 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 protection
Wear protective glasses to prevent eye damage
Breathing protection
Wear a full respiratory mask if working with toxic vapours
Ear protection
Wear ear protection during this procedure
2 Safety
Page 12 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 13 of 100
Revision A
Original Instructions
PHYSICAL DESCRIPTION
3.1
MP16II
3
drum side
2
well side
3 Physical description
19
7
7
5
20
9
13
10
11
16
12
17
15
14
18
18
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
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.
Slider bearing for smooth motion of the measuring head on the levelwind shaft.
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.
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.
(Not visible, at rear of measuring head). Roller assembly that stabilizes the drumside of the measuring head in a horizontal guide rail mounted on the winch
levelwind arms.
upper subframe
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.
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.
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
11
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
(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
Turns with wireline travel, transfers rotation via shaft to depth counter mechanical
drive and optional digital encoder.
15
Turns the mechanical drive through 90 degrees, with a fixed reduction ratio.
16
(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
(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
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
20
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
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 15 of 100
Revision A
Original Instructions
3 Physical description
2
5
3 Physical description
8
7
6
See legend next page
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
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.
autospooling assembly baseplate Bolted to the upper subframe in place of the rear (drum side) guide rollers.
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.
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.
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.
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.
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.
spacer block
This block is mounted in the open side (well side) of the MP16II to maintain the
spacing between the upper and lower subframe. The spacer is attached to one
subframe only.
3 Physical description
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 17 of 100
Revision A
Original Instructions
3.2
CombiGauge
3.2.1
17
16
15
14
7
3
3 Physical description
6
12
11
4
5
13
10
Page 18 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
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.
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.
wireline tension zero knob Turn to zero tension measurement during rig-up.
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.
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
10
Mechanical drive cable from the depth measurement wheel of the measuring head.
11
depth odometer
Shows well servicing tool depth in the hole, referring to the zero point set during rigup using the zero pull-knob. Units (feet or metres) specified at time of ordering.
12
13
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
17
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 19 of 100
Revision A
Original Instructions
3 Physical description
3.2.2
CombiGauge II
10
3 Physical description
1
2
8
9
3
See legend next page
Page 20 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
wireline tension zero knob Turn to zero tension measurement during rig-up.
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.
tension system bleed point For removal of air from highest point in tension hydraulic system.
depth odometer
Shows well servicing tool depth in the hole, referring to the zero point set during rigup using the zero pull-knob. Units (feet or metres) specified at time of ordering.
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
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 21 of 100
Revision A
Original Instructions
3 Physical description
10
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
3 Physical description
Page 22 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
FUNCTIONAL DESCRIPTION
4.1
MP16II
The MP16II is a combined depth and tension measuring head, that supplies analogue and/or
digital signals to a display device in a wireline winch cabin. The MP16II is mainly intended for
slickline and light braided or monoconductor wireline operations, and can be used with a wide
range of wireline sizes with only very minor modification. Furthermore, the design of the MP16II
enables the user to thread the head without using any tools, and without needing to remove the
rope socket or attached wireline tools.
Please refer to the specifications for a comprehensive overview of the features, dimensions and
capabilities of the MP16II.
Working principle
See Figure 4.1.
levelwind carriage on levelwind shaft
wireline
to wellhead
upper wheels
wire
retainer
measuring head
guide wheel
load
cell
hinge
drum
depth
counter
drive
measuring wheel
tension signal
depth signal
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 23 of 100
Revision A
Original Instructions
4 Functional Description
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
4 Functional Description
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
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
4.2
CombiGauge
The CombiGauge is a hydro-mechanical gauge that displays both wireline depth and tension
simultaneously on a single gauge. When used in conjunction with any ASEP Elmar measuring
head with an integral hydraulic load cell and a wireline depth measuring wheel with rotary output,
this device can display depth and tension with great precision.
Depth
Depth measurement is recorded on a bidirectional odometer, driven by a rotary drive cable that
transmits the rotations of a measuring wheel from the measuring head to the CombiGauge.
In the Correlating Depth models, there is an additional depth counter that is synchronized to the
main odometer, but can be individually set to record depth changes relative to a set depth.
Between the measuring wheel shaft of the measuring head and the drive cable there are
additional drive components - an angle drive and optional splitter - that convert the measuring
wheel rotations to depth units. The gear ratios in these components are dependent on the
measuring wheel diameter and wireline thickness, and convert one depth unit (foot or meter) of
wireline travel into the same unit at the CombiGauge.
Tension
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
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 25 of 100
Revision A
Original Instructions
4 Functional Description
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.
5.1
5.1.1
5.1.2
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
Ensure that the 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
Page 26 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
1
5
2
2
3
6
MP16II
5
4
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.
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.
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.
Threaded nut. Used to secure the drive cable to the angle drive or drive splitter
output.
protective cap
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 27 of 100
Revision A
Original Instructions
MP16BS/HD
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 repeat the screwdriver test. If the cable now does not turn smoothly, then the
CombiGauge must be replaced or repaired. Contact NOV ASEP Elmar.
b) Detach the drive splitter, and again spin the measuring wheel.
If the measuring wheel now turns smoothly and the output tongue of the angle drive turns,
then the problem is in the drive splitter. Install a new drive splitter, then continue with
step 8. See related topic.
c) Detach the angle drive, and again spin the measuring wheel.
If it now turns smoothly, then the problem is in the angle drive. Install a new angle drive,
then continue with step 8.
d) If the measuring wheel still does not turn smoothly, then the measuring wheel bearings
will need to be serviced or replaced. See related topic.
8.
Page 28 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
NOTE: If the MP16II is equipped with digital depth and tension output, make certain also to
select the correct wireline size in your control software.
5.1.3
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
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.
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.
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.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 29 of 100
Revision A
Original Instructions
1.
8.
5.1.4
Inspect the load cell for leakage of hydraulic oil. If there is evidence of leakage from the load
cell, then the hydraulic bellows of the load cell must be serviced. See related topic.
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
WARNING
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.
Page 30 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
wireline
to wellhead
drum
E
5 Setup & transport
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.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 31 of 100
Revision A
Original Instructions
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
5.2.1
WARNING
5 Setup & transport
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
WARNING
RISK OF INJURY FROM WIRELINE.
1. Wirelines can have sharp points caused by snags and wear.
2. Small pieces of wire can be ejected from a wireline moving at high speed.
Always wear suitable gloves and eye protection, when handling or working around wireline.
1.
2.
3.
4.
Position yourself on the open side of the MP16II, so that the vertical subframe members are
behind the wheels.
Page 32 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
5.
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
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 33 of 100
Revision A
Original Instructions
MAINTENANCE
Introduction 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.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
6 Maintenance
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.
Page 34 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6.1
1800hrs
1500hrs
1200 hrs
900 hrs
600 hrs
Page
daily
Maintenance procedure
300 hrs
Service interval
6.6
42
6.7
6.9
6.10
44
50
53
6.18
70
6.4
6.5
6.8
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.19
6.20
38
40
46
55
58
59
61
63
65
68
74
79
6 Maintenance
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 35 of 100
Revision A
Original Instructions
6.2
6 Maintenance
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
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
display, the CombiGauge. With digital recording, a transducer hydraulically connected to the load
cell supplies a digital pressure signal to a digital control system, e.g. ASEP Elmar SmartMonitor.
Failure to record tension precisely (causing both 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
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
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 37 of 100
Revision A
Original Instructions
6 Maintenance
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.
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
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
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.
Page 38 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
2.
3.
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.).
6 Maintenance
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 39 of 100
Revision A
Original Instructions
6.5
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1
2
6 Maintenance
3
direct shaft drive
levelwind shaft
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.
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.
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
Page 40 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
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.
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.
8.
Slide the levelwind shaft out of the measuring head support bearing.
9.
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
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 41 of 100
Revision A
Original Instructions
6 Maintenance
6.
6.6
Ensure that the MP16II is properly mounted for operations or servicing, and released from
any transport locks.
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
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
6 Maintenance
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)
Page 42 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6 Maintenance
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 43 of 100
Revision A
Original Instructions
6.7
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),
6 Maintenance
At regular intervals (see maintenance schedule), the bearing should be completely serviced. This
entails removal and cleaning of the bearing.
Proceed as follows.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
Page 44 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
1.
The levelwind support arms are in the operating position with the MP16II positioned
roughly opposite the centre of the drum.
The winch is in manual mode, if applicable, i.e. the automatic control program (e.g.
SmartMonitor) has been disabled.
There is no wireline in the MP16II measuring head.
2.
Shut down the wireline winch unit for safe maintenance. See related topic.
3.
Remove the measuring head from the winch. See related topic.
4.
Slide the levelwind shaft out of the measuring head support bearing.
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.
7.
Clean the levelwind shaft, and apply thin film of grease to the shaft.
8.
9.
Using a grease gun, pump grease into the bearing through the grease nipple until grease can
be seen emerging from both sides.
10. Install the measuring head in the winch. See related topic.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 45 of 100
Revision A
Original Instructions
6.8
Check/adjust autospooling
Related topics:
6.4 Safe maintenance shutdown on page 38
Introduction
Autospooling is an automatic repositioning of the measuring head during outhole or inhole
spooling, ensuring the straightest possible path from the drum to the hay pulley for greatest
measurement precision, and smooth buildup of wireline wraps on the drum during outhole
spooling. It also leaves the operators hands free for drum control and other activities when
spooling over large distances in safe depth zones.
Correct autospooling depends on the adjustment of the lateral deflection sensors on the drum
side of the measuring head. The deflection sensors are tripped by pressure of the moving wireline
against the left or right side rear guide rollers. The sensitivity on each side is independently
adjusted.
Note that the sensitivity of autospooling is influenced by several factors:
6 Maintenance
Wireline tension: wire under high tension will trip a sensor more quickly than wire under
low tension.
Levelwind chain tension: ensure that this is correctly adjusted. When the chain is too
slack, the response when changing direction (at the sides of the drum) will be slower.
Wire gauge: a thicker wire is less flexible, and will trip the sensor more quickly than a
thinner wire.
Wire path from drum to upper guide wheel: when the drum is fully loaded, the wire will
enter the rollers high up. When the drum is almost unloaded, the wire will enter the rollers
low down. The lever effect means the sensors are tripped more quickly when the wire is
high up (drum full) than when the wire is low down (drum empty).
Levelwind assembly type: This depends on the winch model. On winches with the ability
to raise and lower the measuring head, the wireline path can sometimes be adjusted to
maintain a constant point of contact with the rear guide rollers. This has the advantage
that the operator can compensate for the changing wire path as the wire is spooled
further on or off.
There are several types of autospooling assembly in use on the MPxx series of measuring heads.
Autospooling is an option that is not present on every measuring head. Before continuing with this
procedure, verify whether autospooling is present, and if so, what type.
Inspect the rear (drum side) guide rollers of your MP16II measuring head.
If the guide rollers have a movable mounting with sensors (electric or pneumatic), then
your measuring head has autospooling. If not, then you should skip this procedure, there
is nothing to adjust.
If the assembly is identical to that in Figure 6.5 on page 47, then you can continue with
the check/adjust procedure instructions below.
If you have an autospooling assembly of a different type, then please contact
NOV ASEP Elmar for advice.
Page 46 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
NOTE: On this autospooling assembly, the levelwind movement is triggered by the lateral
deflection sensor on the opposite side, i.e. for levelwind movement left, you must adjust
the sensor on the right, and vice versa.
Proceed as follows to check the settings, and adjust if necessary. Refer to Figure 6.5.
1
6
7
6 Maintenance
sensor body
sensor plunger
centreline
inner screw
outer screw
guide roller
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 47 of 100
Revision A
Original Instructions
Check autospooling
1.
2.
Ensure that the MP16II is in operational state and positioned roughly opposite the centre of
the drum.
3.
If there is no wireline in the measuring head, thread the measuring head with wireline.
4.
5.
6.
7.
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
8.
Take steps to ensure that the winch cannot be operated, e.g. have all personnel leave the
cabin, and lock the cabin door.
9.
6 Maintenance
Page 48 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 49 of 100
Revision A
Original Instructions
6 Maintenance
25. When both sensors have been set, repeat the autospooling check on both sides.
6.9
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
6 Maintenance
B
A
D
C
2.
Shut down the wireline winch unit for safe maintenance. See related topic.
3.
If present, loosen the mounting bolts and remove the wireline oiler tank and drip valve from
the measuring head.
4.
Fully loosen the upper wireline retainer rollers, and remove the rollers.
Page 50 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
5.
Remove the measuring head from the winch. See related topic.
6.
Lay the measuring head on a suitable clean workbench, with the open side on top, and with
a block of wood under each of the upper and lower subframes, so that there is a clearance
for the shaft to be pressed downwards and out of the frame.
Place a cushioning layer between the measuring head and the workbench and wooden
blocks.
7.
.Create access for removal of the upper wheels (see Figure 6.6):
a) Remove the wireline guide roller mounting plates A (4 bolts each) from the wellhead and
drum sides, and remove each complete roller assembly from the measuring head.
b) Unscrew the support bearing retainer grub screw B in the top of the upper subframe (on
the closed side of the measuring head).
c) Carefully lift the levelwind carriage side plate C and support bearing D out of the upper
subframe.
8.
9.
Separate the wheels, and place the wheels and shaft on a clean workbench.
10. Clean all old grease and residue from the upper subframe. Make use of the access with the
wheels removed to inspect and clean the rest of the measuring head frame.
11. Clean the shaft and wheels thoroughly, and inspect each wheel on both sides. See
Figure 6.17):.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 51 of 100
Revision A
Original Instructions
6 Maintenance
c) Using a drift and soft hammer, carefully tap the bearing out of the centre of the wheel.
d) Press a new bearing into the wheel, and secure it using the circlips
14. Apply a small amount of grease to the area around the bearing on each side.
15. Turn the measuring head over, so that the closed side is upwards.
16. Place the wheels together at the flat side, and insert then into position in the upper subframe.
17. Insert the shaft through the subframe and the wheels, with the flanged end on the closed side
of the upper subframe.
If you need to use a little force to press the shaft home, first remove the grease nipple. Use
a soft hammer.
18. Using a suitable grease gun, inject plenty of grease into the grease nipple on the upper wheel
shaft until the grease is seen to emerge around the bearings. Wipe off any excess grease
around the shaft area.
19. Turn the measuring head over and fit the retaining ring to the open side, tightening the shaft
with the Allen bolt.
20. Fit the levelwind carriage side plate and support bearing back into the upper subframe. Do
not yet tighten the grub screw.
6 Maintenance
21. Mount the wireline guide rollers back on each side of the levelwind carriage.
22. Tighten the support bearing retaining grub screw in the top of the upper subframe (on the
closed side of the measuring head).
23. Spin the upper wheels and check that they turn freely.
24. Install the measuring head in the winch. See related topic.
25. Mount the wireline retainer rollers.
26. Fit the wireline oiler tank and drip valve.
27. Restore all adjustments.
28. Test that the measuring head performs correctly.
Page 52 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6.10
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
The winch is in manual mode, if applicable, i.e. the automatic control program (e.g.
SmartMonitor) has been disabled.
There is no wireline in the MP16II measuring head.
2.
Shut down the wireline winch unit for safe maintenance. See related topic.
3.
4.
Remove the complete depth counter assembly from the opposite end of teh measuring
wheel shaft. See related topic.
5.
Remove the two wireline pressure wheels from the lower subframe.
6.
Remove the circlip from the measuring wheel shaft on the depth counter side. See
Figure 6.8.
7.
While supporting the wheel, slide the measuring wheel shaft out of the bearings in the lower
frame.
You may need to use a drift and a soft hammer to tap the shaft out of the bearings. The
bearing on the opposite side may also come out. The key will stay in the keyway in the
measuring wheel.
8.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 53 of 100
Revision A
Original Instructions
6 Maintenance
The levelwind support arms are in the operating position with the MP16II positioned
roughly opposite the centre of the drum.
1
1
measuring wheel
bearing
circlip
6 Maintenance
Using a bearing puller or a drift and soft hammer, remove the bearings from the lower
subframe.
10. Clean all old grease and residue from the lower subframe. Make use of the access with the
wheel removed to inspect and clean the rest of the measuring head frame.
11. Carefully clean all the removed parts and inspect them for damage or wear. Replace any
worn parts, in particular the bearings.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
a) Fit the (new) bearings into each side of the lower subframe.
b) Insert the key into the measuring wheel, and tap it carefully in until it is precisely centred
(A).
c) Check that the shaft can fit into the measuring wheel centre.
d) Insert the shaft from the encoder side through the bearing until it just extends inside the
subframe.
e) Fit one synthetic ring over the shaft.
f) Support the measuring wheel in the lower subframe, and press the shaft further through
the bearing and the nylon ring until just before it emerges through the measuring wheel.
This will require more force, as the key in the measuring wheel will now engage in the
keyway of the shaft.
g) Carefully insert the second synthetic ring between the measuring wheel and the lower
subframe, and press the shaft all the way through the lower subframe until it is tight
against the bearing on the encoder side.
h) Ensure that the bearing on the depth counter side is properly seated, and fit the circlip
onto the shaft.
13. Inject grease into the bearing on each side of the measuring wheel, and check that sufficient
grease has penetrated the bearing (the grease will emerge from the bearing).
15. Mount the two wireline pressure wheels on each side of the lower subframe.
16. Mount the complete depth counter assembly on the lower subframe, by proceeding through
the removal in reverse. See related topic.
Make certain to insert the link key in the coupling between the shaft and the angle drive,
taking care to align the two sides first by turning the measuring wheel.
17. If applicable, install the depth encoder removed in step 3, otherwise fit the encoder mounting
plate, and tighten the bolts.
18. Check that the measuring wheel turns freely, and that the depth measurement is correctly
registered at the CombiGauge and (if applicable) digital control system.
6.11
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 55 of 100
Revision A
Original Instructions
6 Maintenance
NOTE: The illustrations in this procedure are examples only, and may not appear exactly the
same as the corresponding components on your measuring head.
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
3
4
6 Maintenance
6
5
9
8
7
MP16
1
angle drive
Connected to the end of the depth measurement drive shaft, this device provides a
drive reduction while turning the rotary movement axis through 90 degrees. The
reduction ratio is stamped on the body (circled).
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.
drive splitter ring nut and retaining The retaining wire ensures that the ring nut cannot become loosened during
operation. The ring nut must not be overtightened, otherwise the assembly can be
wire
damaged.
Threaded nut. Used to secure the drive cable to the angle drive or drive splitter
output.
protective cap
Page 56 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
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.
NOTE: The depth counter drive cable is attached to a drive splitter mounted on the angle drive,
that has two outputs. The angle drive and splitter are calibrated to work together.
3.
4.
b) Carefully engage the drive splitter input to the angle drive output.
c) Ensure that the lug on the input side of the drive splitter is properly seated in the hole in
the drive splitter mounting bracket.
d) Gently hand-tighten the drive splitter ring nut, to the point where the retaining wire is
aligned with the hole in the ring nut.
If necessary to align the wire to the hole, loosen the nut one turn or less.
e) Using the needlenose pliers, fit the retaining wire into the ring nut hole.
5.
Carefully engage the drive cable input to the correct drive splitter output for the wireline size
to be used.
6.
Firmly tighten the drive cable ring nut, without applying excessive force to the drive splitter.
7.
Ensure that the unused drive splitter output is fitted with a protective cap.
NOTE: If the MP16II is equipped with digital depth and tension output, make certain also to
select the correct wireline size in your control software.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 57 of 100
Revision A
Original Instructions
6 Maintenance
a) Ensure that the input and output tongues and grooves are clean and lightly lubricated
with fresh grease.
6.12
WARNING
6 Maintenance
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
2.
Shut down the wireline winch unit for safe maintenance. See related topic.
3.
4.
Cut any tie-wraps fastening the old cable to the winch, fastening the new cable with new tiewraps at the same point.
5.
Page 58 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6.13
6.
7.
Prepare the depth measurement section to ensure that the depth measurement is now
working correctly. See related topic.
Proceed as follows.
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
2.
Shut down the wireline winch unit for safe maintenance. See related topic.
3.
As applicable, remove the drive cable, plus drive splitter or gearbox attached to the angle
drive. See related topic.
4.
5.
To remove the angle drive at the measuring wheel shaft of the measuring head, you must
first remove the complete depth counter assembly (see Figure 6.17):
a) Note the mounting position of all parts.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 59 of 100
Revision A
Original Instructions
measuring wheel
angle drive
To install the (new) angle drive at the CombiGauge, proceed through step 4 above in
reverse.
Make sure to turn the angle drive and locknut counterclockwise to tighten them.
7.
To install the (new) angle drive at the measuring wheel shaft of the measuring head, proceed
through step 5 above in reverse.
Make sure to turn the angle drive and locknut counterclockwise to tighten them.
NOTE: Make certain to insert the link key in the coupling between the shaft and the angle
drive, taking care to align the two sides first by turning the measuring wheel.
Page 60 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6.14
8.
If you have installed a new angle drive to match a different wire size for your winch, make
sure all other depth counter drive components between the measuring head and
CombiGauge are properly matched. See related topic.
9.
As applicable, attach the drive cable, drive splitter or gearbox attached to the angle drive.
See related topic.
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
2.
Shut down the wireline winch unit for safe maintenance. See related topic.
3.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 61 of 100
Revision A
Original Instructions
6 Maintenance
measuring wheel
depth encoder
d) Cut or remove all tie-wraps from the depth encoder cables, so that the cables are
completely free.
e) Completely loosen the four encoder mounting bolts from the lower subframe of the
MP16II.
f) Carefully withdraw the encoder with mounting plate from the lower subframe.
g) Unscrew the four Allen screws holding the encoder to the encoder mounting plate, and
separate the encoder from the mounting plate.
4.
5.
Page 62 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6.15
6.
Using the automatic control system, check that the depth encoder is working correctly by
spinning the measuring wheel without any wireline in the measuring head.
7.
First zero both systems, then check that the analogue (CombiGauge) and automatic control
system both register the same depth difference after a certain number of turns of the
measuring wheel.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
6 Maintenance
WRPP
=
WRPP
WRPP
Ensure that the MP16II is properly mounted for operations or servicing, and released from
any transport locks.
2.
Shut down the unit for safe maintenance. See related topic.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 63 of 100
Revision A
Original Instructions
3.
Using an internal calliper and a feeler gauge, check the following three critical distances at
the load cell of the non-loaded MP16II tension measurement system. See Figure 6.15.
A: subframe separation = distance between load cell base plate (above) and lower subframe
(below). MAXIMUM 40 mm.
B: piston extension = exposed length of piston (above) when in contact with lower subframe
(below). APPROXIMATELY 5-7 mm.
C: piston/subframe gap = distance between piston (above) and lower subframe (below).
MINIMUM 1 mm, MAXIMUM 2 mm. Measure approximately using a 1 to 2 mm feeler gauge
or a piece of card of about 1.5 mm thickness.
Explanation:
There must always be a minimum gap (C) between the extended piston and the lower
subframe of 1 to 2 mm to make certain that the tension system always reads zero when
there is no tension on the wireline. In that situation, the weight of the lower subframe will
cause it to drop down against the retainer.
The piston extension (B) is necessary to ensure that the load cell body can never interfere
with the tension measurement.by contacting the lower subframe. It is however important
that there is no air in the load cell hydraulic circuit, otherwise the piston extension will not
be sufficient to prevent interference.
6 Maintenance
The subframe separation (A) is a way to help set the normal, unloaded position of the
subframe at the subframe retainer.
4.
NOTE: The measured distances can be significantly affected when the ambient temperature
varies greatly. In particular, expansion of the hydraulic fluid can affect the piston
extension. When temperatures vary greatly, routinely check that the settings are still in
order.
5.
6.
Page 64 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6.16
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
6 Maintenance
standard CombiGauge
CombiGauge II
2.
Shut down the unit for safe maintenance. See related topic.
3.
Using the method described in the procedure for checking the critical distances, set the
separation between the lower subframe and the base plate of the load cell to 38 mm. See
related topic.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 65 of 100
Revision A
Original Instructions
NOTE: The lower subframe must be suspended on the lower subframe retainer.
4.
Place a piece of card or a feeler gauge between the lower subframe and the piston (1 - 2
mm).
5.
At the winch control panel, obtain access to the CombiGauge hydraulic connections.
Every winch control panel has a different layout. You may need to withdraw the CombiGauge
from the winch control panel in order to gain access to the hydraulic connector.
6.
Ensure that the hydraulic hose connections at the load cell bellows and the CombiGauge are
tight, and there is no sign of leakage at any point in the system.
7.
If a pressure transducer is present on the MP16II, ensure that the bleed point is closed using
the supplied key. See Figure 6.17.
NOTE: On some wireline units, the pressure transducer may be mounted in the winch control
panel, beside the CombiGauge.
6 Maintenance
2
1
3
1
pressure transducer
bleed point
MP16 BS
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
8.
Page 66 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
At the winch control panel, locate the bleed point on the hydraulic connector of the
CombiGauge. See Figure 6.16.
10. Wrap a clean rag around the fittings below the bleed point to catch fluid released from the
bleed point.
11. Locate the hand pump connection on the load cell of the MP16II.
6 Maintenance
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 67 of 100
Revision A
Original Instructions
18. If no other maintenance is required at the CombiGauge, re-fit any panels removed for
access.
19. If a pressure transducer is present on the MP16II, repeat steps 15 through 17 at the bleed
point on the transducer.
20. Close the valve on the hand pump connection.
21. Disconnect the hand pump.
22. Check and if necessary adjust the critical distances in the tension measurement system. See
related topic.
23. Calibrate the tension measurement system. See related topic.
6 Maintenance
NOTE: There is an additional (auxiliary) bleed point at the bottom of the standard CombiGauge
(Figure 6.19). This point is used to bleed air during manufacturing of the CombiGauge.
If required, it can be used after maintenance on the bourdon tube of the CombiGauge.
However, it should not be used during routine servicing.
6.17
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
Page 68 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Shut down the wireline winch unit for safe maintenance. See related topic.
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
3.
Make sure there is room in the hand pump to collect excess fluid.
4.
Locate the hand pump connection point on the load cell of the MP16II.
5.
Wipe the hand pump nozzle and the connection point with a clean rag to remove any dust or
grit.
6.
7.
8.
9.
Place a piece of card or a feeler gauge (1 - 2 mm) between the piston and the lower
subframe.
10. Using the retainer bolt, carefully raise the lower subframe against the piston until the piston
extension is at the correct length of approximately 7 mm.
The excess fluid will drain into the hand pump.
11. Close the valve on the hand pump connection.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 69 of 100
Revision A
Original Instructions
6 Maintenance
The winch is in manual mode, if applicable, i.e. the automatic control program (e.g.
SmartMonitor) has been disabled.
6.18
6 Maintenance
If there is leakage from or damage to the hydraulic load cell, you will need to dismantle the load
cell, and possibly replace the piston membrane and O-rings. This can be done without removing
the MP16II from the winch. Figure 6.21 gives an overview of the construction of a load cell.
Page 70 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Proceed as follows to service the hydraulic load cell of the MP16II measuring head tension
measurement section.
WARNING
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1
1
lower subframe
load cell(s)
hydraulic connector
2.
Shut down the wireline winch unit for safe maintenance. See related topic.
3.
Fully loosen the locknut and the bolt of the lower subframe retainer(s), and swing the lower
subframe away from the upper subframe, so that you have clear access to the load cell. See
Figure 6.10.
4.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 71 of 100
Revision A
Original Instructions
6 Maintenance
MP16II
shown
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
a) Place a container below the measuring head to catch any hydraulic fluid leaking from the
system.
b) Using a wrench, loosen the hydraulic connector from the load cell.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
6 Maintenance
c) With the hose loosened, attach an end-cap to the hose and elevate the hose opening to
avoid further leakage. If a pressure transducer is present, remove the transducer
connection.
d) Working from below, unscrew each of the Allen key bolts that fasten the load cell base
plate to the upper subframe.
Support the load cell with one hand as you remove the last bolts.
e) Move the load cell to a clean work bench
NOTE: For a dual-bellows load cell, repeat the following instructions for dismantling, cleaning
and reassembling the load cell bellows.
5.
6.
7.
Re-assemble bellows.
Page 72 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
F
6 Maintenance
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 73 of 100
Revision A
Original Instructions
This is essential to ensuring that the membrane and O-ring are evenly sandwiched
between the top ring and the body. Failure to do so can cause leakage from the
membrane joint.
j) Following the same sequence, tighten the screws to the final tightness.
k) Check that the piston is approximately centred and can move freely in the body of the
bellows.
8.
Mount the load cell on the upper subframe, firmly tightening the Allen key bolts.
9.
10. Remove the dust cap from the hydraulic hose, and attach the hydraulic hose.
11. Raise the lower subframe and re-mount the lower subframe retainer, until the distance
between the lower subframe and the base plate of the load cell is approximately 38mm.
12. Fill and bleed the hydraulic system. See related topic.
13. Adjust the critical tension measurement distances. See related topic.
6.19
6 Maintenance
NOTE: The CombiGauge is preset at the factory to provide a full scale deflection at 25, 30, 40,
45 or 60 bar (scale dependent). This corresponds to the 360 degrees of travel of the
CombiGauge scale. Recalibration of this setting is not a recommended field
maintenance activity, and should only be undertaken by personnel trained and familiar
with fine mechanical instrumentation. Incorrect handling of the CombiGauge will result
in instrument damage necessitating factory repair and recalibration.
NOTE: This procedure requires the use of an auxiliary reliable and precise tension
measurement device with sufficient range to match that of the MP16II and the installed
CombiGauge. Use either a second wireline winch with accurate tension measurement,
or a special purpose tool such as the NOV ASEP Elmar Tension Calibration Tool.
NOTE: This procedure requires at least two people. One person must control the tension on the
auxiliary tension measurement device, while the other adjusts the CombiGauge.
Page 74 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
3.
Prepare the tension measurement system as described in the setup and transport chapter.
See related topic.
4.
Rig the measuring head for tension measurement calibration by either of the following
methods:
Second winch
NOTE: Use only wireline of a breaking strength higher than the maximum range of the
CombiGauge.
a) Position your winch opposite a second, reliably calibrated winch, with identical wireline to
the current rigging of your MP16II
c) Spool several wraps to ensure good attachment, then apply the winch brake.
d) Shut down the winch for safe maintenance. See related topic.
e) Continue with section 6.19.2, using the controls of the second winch to tension the
wireline when instructed.
NOV ASEP Elmar Tension Calibration Tool
a) Shut down the winch for safe maintenance. See related topic.
b) Rig-up the Tension Calibration Tool. See related topic.
c) Continue with section 6.19.2, using the adjustment features of the tool to tension the
wireline when instructed.
2.
Zero the CombiGauge needle for the slack wireline, using the tension zero-set knob.
3.
On a notepad, create a two-column table for the test values for the wireline tension.
The left column is the test tension (indicated on the second winch or calibration tool).
The right column is the value indicated on the CombiGauge.
You will be testing in specific increments up to 90 % of the maximum breaking strength of
the wire used during this test. Recommended increments: 0, 25 %, 50 %, 75 %, 90 %.
NOTE: Never exceed the maximum tension range on the scale of the CombiGauge!
4.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 75 of 100
Revision A
Original Instructions
6 Maintenance
b) Thread the free end of the wireline through your MP16II, and fasten it in a suitable
manner to your winch drum.
a) Carefully increase the test tension to the percentage of maximum tension for your
CombiGauge.
Example: If the maximum range is 1000 kg, apply an approximately 250 kg tension.
b) Record the test tension in the left column, and the CombiGauge tension value in the right
column.
NOTE: Provided the tension measurement hydraulic system is completely free of trapped
air, the difference between the CombiGauge value and the test tension must be
linear.
5.
6.
6 Maintenance
If the CombiGauge is showing the correct tension through the full range of test values, then
it is correctly calibrated. No further action is required, and the test set-up can be rigged
down. The procedure is complete.
If the CombiGauge shows a deviation from the test values (reading too low or too high),
then continue with section 6.19.3.
NOTE:
If the difference between the CombiGauge and test values is non-linear, the most
likely cause is air in the MP16II tension measurement hydraulic system, from the
load cell to the CombiGauge. In this case you must bleed the air from the system
and re-adjust the critical distances. See related topics.
Establish the model of CombiGauge installed in your winch, referring to the physical
description pages of this manual. See related topic.
NOTE: The adjustment mechanism is in a different position on the standard CombiGauge
and CombiGauge II.
2.
Remove the glass from the CombiGauge as follows. See Figure 6.24.
NOTE: Every winch control panel has a different layout. You may need to withdraw the
CombiGauge from the winch control panel in order to remove the glass.
a) Remove each of the knobs from the face plate and centre of the dial.
NOTE: Some of the knobs are held by a nut below the cap on the knob. Use a knife or
screwdriver to lift the cap for access to the nut. Take care to keep all parts together!
b) Loosen the four (4) screws in the face plate and lift the face plate and glass off the gauge.
3.
4.
Page 76 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
-..........+
6 Maintenance
standard CombiGauge
+..........-
CombiGauge II
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 77 of 100
Revision A
Original Instructions
NOTE: The calibration set screw itself does not make the actual adjustment; it simply
fastens the adjustment. The actual adjustment is made by shifting the position of
the screw in the slot in the linkage.
5.
lower (-)
higher (+)
6 Maintenance
Repeat the tension measurement check of section 6.19.2, and if necessary adjust the
calibration again in the above steps until the tension measurement at the CombiGauge
corresponds to the test values on the second winch or tension calibration tool.
6.19.4 Finalize
1.
2.
Reduce the wireline tension to zero (the wireline is slack) and shutdown the winch.
3.
4.
Remove the tension zero-set knob, re-install the glass in the CombiGauge, re-fit the removed
knobs, and (if necessary) re-mount the CombiGauge in the winch control panel.
Page 78 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6.20
MP20 setup
6 Maintenance
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 79 of 100
Revision A
Original Instructions
1
2
7
6 Maintenance
main frame
These hooks support the main frame during testing. The main frame can be
repositioned up or down on the hooks to enable a straight-through test cable path.
piston subframe
Detachable frame end, enables easy frame installation. Secured by retaining clips.
Measures tension in test cable up to max. 5000 kg (11000 lb). Anchored to frame by
vertical pin with retaining clip. See also Figure 6.28 on page 81.
NOTE: Transmits signal wireless to handheld unit. Mounting direction is important!
Attaches cable to load cell. Cable end screws into connector. Anchored to load cell
by vertical pin with retaining clip.
test cable
Specially manufactured cable for each measuring head type and wireline gauge.
Screws into load cell cable connector at one end, attached to piston by nut and
washer. (SmartHead test cable shown).
NOTE: The cable is longer for wrap-around type heads than for straight-through
heads (as shown).
piston
Applies tension to test cable. Test cable end passes through hollow piston, and is
anchored by nut and washer.
Supplies pressure to extend piston and tension the test cable. Connects to piston by
hydraulic quick coupling.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
3
6 Maintenance
5
4
2
radio signal
load cell
Digital load cell. Started, stopped and read out using the wireless handheld unit.
handheld unit
Wireless remote control/display for load cell. The units of measurement are shown
on the label (this example shows tonne, see item 3).
display
Shows measured force and status of the handheld and load cell (indicated by small
bar above labels below display). The units of measurement cannot be changed.
power button
tare button
Press to set tare load (zero the display) or gross mode. The display will indicate the
mode (G or N).
NOTE: Configuration and use of the load cell is briefly described in 6.20.3 Using the Tension Calibration Tool on page 84. For
detailed operation and maintenance information, please refer to the suppliers documentation, provided in your documentation
package.
Page 81 of 100
Revision A
Original Instructions
Position the levelwind support arms in the operating position with the measuring head
positioned roughly opposite the centre of the drum.
2.
3.
Unthread the wireline from the measuring head, and fasten it to the drum.
4.
Prepare the tension measurement system as described in the setup and transport chapter
for the wireline winch.
5.
Dismantle the tension calibration tool, and set the components ready for installation,
approximately as shown in the exploded diagram in Figure 6.27 on page 80.
6.
Check that all parts are present, and that the load cell and handheld unit batteries have
sufficient charge. See 6.20.3 Using the Tension Calibration Tool.
7.
If necessary, reposition the side members of the tool on the levelwind shaft hooks, in order
to achieve the straightest possible wireline path from the load cell into the measuring head,
and from the measuring head to the piston. To do this, simply unscrew the mounting bolts of
the hooks, position the bolt-holes against a different slot, and re-tighten the bolts.
8.
Install the tension measurement tool on the measuring head as shown in Figure 6.29. The
following steps correspond to the illustrations in the figure.
6 Maintenance
a) Bring the main frame down over the measuring head from the winch drum side, with the
hooks on the top side.
b) Lay the frame horizontal, and insert the anchor pins, securing them with the retaining
clips.
c) Thread the test cable through the measuring head in the usual way. See related topic.
Ensure that the long threaded end of the cable is on the well side of the measuring head.
d) Mount the piston subframe onto the ends of the main frame, and fasten it with the
retaining clips.
e) Mount the load cell in the main frame at the winch drum end, using the anchor pin and
retaining clip.
Insert the load cell cable connector into the frame, screw it onto the end of the test cable
until the cable threaded end just emerges from the inner side of the connector, and link
the cable connector to the load cell using the anchor pin and retaining clip.
NOTE: The wireless communication between the load cell and handheld unit is strongest
in the direction of the bottom of the load cell. If you intend to read the measured
load in the winch cabin, then position the bottom end of the load cell towards the
cabin.
f) Mount the piston onto the piston subframe, and anchor the free end of the test cable
through the piston with the nut and washer. Tighten the nut hand tight only.
9.
10. Test the setup by applying pressure sufficient to cause the measuring head to react, then
release the pressure using the control knob on the pump.
11. Hand-tighten the test cable nut once more (if necessary) to take up the slack.
12. Inspect the complete setup to check that all parts are properly settled and ready for the test
procedure.
Page 82 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
6 Maintenance
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 83 of 100
Revision A
Original Instructions
6 Maintenance
If the unit has been stored for a longer period or the batteries are suspected to be old, open
the battery compartment and insert new batteries.
2.
Switch the handheld and load cell ON by pressing and holding the power button until BUSY
displayed.
3.
The display will initialize, then show the current measurement value 0.0. You should start
with a slack test cable, and zero load.
Determine the target tension you want to test at, e.g. 250 kg or 600 lb (depending the of your
load cell).
You will normally be taking a series of readings over a range to calibrate the tension
measurement system of a wireline winch.
2.
3.
4.
Manually pump pressure into the calibration tool piston to tension the wireline.
5.
While observing the display of the load cell, continue pumping until the approximate target
value is reached.
6.
Allow the test setup to stabilize for several minutes, or if necessary longer.
7.
The test cable will stretch when first placed under tension. It will stretch further as higher
tensions are applied.
8.
If necessary, pump again until you have a stable tension force close to your target value. If
you overshoot the target value, carefully release a little pressure using the release valve.
It is not essential to arrive at exactly the target value. The main objective is to compare the
calibration tension with the tension measured at the measuring head and displayed on the
tension display of the winch.
Page 84 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
9.
Once the value in the load cell display is stable, record this value and the value given by the
winch tension measurement system.
Finalize
1.
Open the release valve to relieve the tension on the load cell.
2.
3.
Switch the handheld and load cell off by pressing and holding the power button until BUSY
displayed.
6 Maintenance
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 85 of 100
Revision A
Original Instructions
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
No depth measurement at
CombiGauge (but measuring wheel
rotates)
MP16II troubleshooting
7 Troubleshooting
DEPTH
TENSION
No tension measurement at
CombiGauge when load cell under
compression
Page 86 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
PROBLEM
SUGGESTED REMEDY
Defective CombiGauge
Defective bearings
Replace rollers
Bearings fouled
Replace sensor
Replace bearing
Replace/repair as applicable
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 87 of 100
Revision A
Original Instructions
7 Troubleshooting
POSSIBLE CAUSE
APPENDICES
Appendix 1: MP16II measuring head specifications
Appendix 2: CombiGauge specifications
Appendix 3: Tension measurement hydraulic fluid
Appendix 4: MP16II and CombiGauge depth calculation
APPENDICES
Appendix 5: Contact us
Page 88 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Dimensions (L x W x H)
Wheel diameters
54 kg (119 lb)
Frame material
Plate aluminium
High grade composite upper (guide) wheels
Stainless steel lower wheel (measuring wheel)
Hollow wheel grooves
Depth measurement
Angle drive with rotary drive cable connector for use with ASEP Elmar K-Winch
CombiGauge
Optional single or dual-output gearbox (splitter) for one or two wire sizes
Optional optical encoder for use with automated monitoring system (e.g. ASEP
Elmar SmartMonitor) independent of analogue output
Autospooling (optional)
Optional lateral deflection sensors (left, right) coupled to automated control system
0.092 - 0.135
-20C to +50C
(-4F to +122F)
Transportation
Further options
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 89 of 100
Revision A
Original Instructions
Depth measurement
Tension measurement
Large dial (360) display with black needle and clear tension increments
Bourdon type pressure measurement (C-form)
Tension scale 0 to 900, 1500, 2000, 4400 or 7000 kg
(0 to 2000, 3200, 4400, 8800 or 15400 lb)
Specified at time of ordering
Red maximum tension setpoint needle
Hydraulic hose connector for use with ASEP Elmar K-Winch MP series
measuring heads
Zero tension reset knob
Hydraulic damping valve to reduce needle jitter
Options
Page 90 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
ATF D-3
Alternative:
DEXRON III
ARAL
ATF 55
BP
AUTRAN DXIII
CASTROL
TQ DEXTRON III
ELF
ELFMATIC G3
FINA
FINAMATIC HP
KPC / Q8
AUTO 15
MOBIL
ATF
SHELL
DONAX TX
TEXACO
TEXAMATIC 7045
TOTALFINAELF
FLUIDE AT42
NOV ASEP Elmar recommended oil types for the ASEP Elmar MPxx measuring head family
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 91 of 100
Revision A
Original Instructions
AGIP
Diameter calculation
Wireline distance travelled with one turn of the wheel = 414.583 * = 1302.45 mm
The counter inside the CombiGauge is connected to the measuring wheel. When connected
directly, one rotation of the measuring wheel is indicated with one unit on the counter. We have
calculated that one rotation of the measuring wheel equates to 1.30245 metres.
If our CombiGauge is to record depth in metres, then we need to accelerate the depth odometer
to register the same depth from a single turn of the measuring wheel. This is accomplished by the
combinations of gears in the angle drives (at the measuring head and CombiGauge) and
(optional) drive splitter on the measuring head.
ASEP Elmar has a variety of angle drives and drive splitters to accomplish the required
conversion for various wireline sizes.
Returning to the example above:
measuring head angle drive ratio = 0.658 :1 (step-up)
CombiGauge angle drive ratio = 1 : 0.857 (step-down)
Resulting overall ratio = 1/0.6758 * 0.857/1 = 1.30243
One turn of the measuring wheel therefore registers 1.30243 metres at the CombiGauge.
Page 92 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
You may notice that there is a difference of 0.00002 metres between these figures. Over 10,000
metres of depth, this equates to 0.00002/1.30245 * 10,000 = 0.15 metres (15 cm). This is
negligible for normal purposes.
Combining different wireline sizes
Most slickline winch units have either a dual drum or split drum, allowing the use of two or more
different wireline sizes. Referring to the calculation above, this means that the drive ratio must be
adjusted for the different wireline thicknesses (diameters). The measuring wheel diameter of
course remains the same.
This adjustment is achieved using a drive splitter with two internal drive ratios. The splitter has
one input and two outputs. When switching the winch to a different wireline size, you must also
connect the depth counter drive cable to the correct splitter outlet.
With:
wire size=
If the 0.108 output is a 1:1 (straight-through) drive in the splitter, then the 0.125 output must have
a different ratio, calculated as follows:
second output ratio = 1303.808 / 1302.450 = 1.001
You do not need to remember the ratio. The output is labelled for the correct wireline size.
Combining drive components
No more than 2 gearboxes (angle drive, splitter) may be connected directly to each other, and no
more than 3 gears may be used in the external counter system. (The internal ratio of the odometer
inside the CombiGauge is ignored).
Imperial units
Taking the example above, one turn of the measuring wheel equates to 1.30245 m = 4.273 ft.
So one rotation of the measuring wheel needs to indicate 4.273 feet.
To avoid needing to accelerate the depth counter drive cable to more than 4 times the normal
(metric) speed, which could create service and performance problems, CombiGauges with
imperial units have an internal step-up ratio of 1 : 5, i.e. the counter is accelerated by 5 turns for
every incoming turn. This needs to be reduced to 4.273 by the external drive components.
The required overall deceleration is therefore 4.273 / 5 = 1 : 0.855. This is achieved by using drive
components with the internal ratios 1.002 :1 and 1 : 1.166 (= 0.857 : 1) as follows:
(1/1.002) x (1/1.166)= 0.855
For an overview of the typical drive ratios available for various wireline sizes, see the table below.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 93 of 100
Revision A
Original Instructions
Wireline distance travelled with one turn of the wheel = (411.84+3.175) * = 1303.808 mm
Page 94 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Appendix 5: Contact us
Facilities
Address
Corporate
Headquarters
Sales
Manufacturing
Service
Sales
Manufacturing
Service
Energieweg 26,
2964 LE Groot-Ammers,
The Netherlands
Sales
Manufacturing
Service
11993 FM 539,
Houston, TX77041,
United States of America
Manufacturing
Dubai,
United Arab Emirates
Manufacturing
Singapore
Location
Australia
Mexico
Veracruz, Mexico
Brazil
Maca, Brazil
Representative Offices
Location
Telephone
USA
Louisiana, USA
Canada
Edmonton, Canada
China
Beijing, China
Colombia
Bogota, Colombia
Malaysia
Moscow, Russia
Turkey
Istanbul, Turkey
Belarus
Minsk, Belarus
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 95 of 100
Revision A
Original Instructions
Appendix 5: Contact us
Organization
INDEX
drive cable 19
drive cable, remove/install 58
drive splitter 15
drive splitter, remove/install 55
dynafor, load cell 81
dynamometer 80
a
adjustment mechanism, CombiGauge 77
adjustment, wire gauge 89
angle drive 15, 57
angle drive, depth counter 19
ASEP Measuring Head Calibration Tool 74
ATEX 89, 90
Autospooling 24
autospooling 89
autospooling problems 87
autospooling, adjust 48
autospooling, check 48
autospooling, introduction 46
autospooling, option 17
autospooling, sensitivity 46
e
earth cable 40
encoder mounting plate 62
encoder, depth 53
Enerpac hydraulic pump 84
f
fill & bleed 65
fleet angle 87
frame, MP16 89
INDEX
b
ball cages, measuring head support bearing 45
bearing replacement, upper wheels 51
bellows 70, 87
bellows, disassembly 72
bleed 65
bleed point 19, 21
bleed point, Bourdon tube 19
bleed point, CombiGauge 68
Bourdon tube 25
gauges, braided 89
gauges, monoconductor 89
gauges, slickline 89
gear ratios 25
grease gun 38
grease nipples 37
grub screw, support bearing 51
guide rollers, wireline 87
guide wheel, measuring head 41
guide wheel, upper 15
calibration mechanism 77
calibration screw, CombiGauge 78
cautions 10
chain attachment point, levelwind 15
cleaning and lubrication, special notes 37
CombiGauge 25
Correlating Depth 25
Correlating depth display 90
critical distances 87
critical distances, tension measurement 63
Page 96 of 100
Revision A
Original Instructions
icons 11, 12
l
lateral deflection cam 17
lateral deflection sensor 17
lateral deflection sensors 41, 87, 89
levelwind carriage 15, 40, 51
levelwind chain 40
Levelwind drive chain 87
levelwind drive chain 87
levelwind drive sprocket 87
levelwind motor 87
levelwind problems 87
Levelwind shaft 87
levelwind shaft 41
levelwind shaft, clean/lubricate 44
link key 61
load cell 36, 63, 89
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
m
material, MP16 wheels 89
measurement precision 36
measuring head general problems 87
Measuring head guide wheel 87
measuring head, lubrication 42
measuring head, remove/install 40
measuring wheel 15, 86
measuring wheel and bearings, remove/install 53
measuring wheel bearings, lubrication 42
mounting plate, encoder 62
u
unthreading, wireline 32
upper wheel bearings, lubrication 42
upper wheels and bearings, remove/install 50
odometer 25
odometer, Correlating Depth 19
oiler 24
scale 90
sensor, autospooling 47
set knob, Correlating Depth 19, 25
setpoint knob, tension 19, 21
setpoint needle, tension 19, 21, 25
slickline 23
slip 36
slip in depth measurement system 86
SmartMonitor 79
subframe separation 64
subframe, lower 15
subframe, upper 15
support bearing 15, 87
support bearing retainer grub screw 51
support bearing, lubrication 42
support bearing, servicing 44
t
tank, wireline oiler 15
temperature 89, 90
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 97 of 100
Revision A
Original Instructions
INDEX
Warnings 10
weight 89
wire size 93
wireline guide roller bearings, lubrication 42
wireline guide rollers 15
wireline oiler 15, 24
wireline oiler, MP16 measuring head 89
wireline pressure wheel 53
wireline size 26
wireline sizes, combining 93
wireline tension dial 19
Wireline tension zero knob 25
wireline unthreading 32
wireline, threading 30
CUSTOMER NOTES
CUSTOMER NOTES
Page 98 of 100
Revision A
Original Instructions
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
CUSTOMER NOTES
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012
Page 99 of 100
Revision A
Original Instructions
Published by:
NOV ASEP Elmar
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
2012 No part of this document may be reproduced by any means without
the written consent of the publisher.
Whilst every care has been taken to ensure that the information in this
document is correct, no liability can be accepted by NOV ASEP Elmar for
loss, damage or injury caused by any errors or omissions in this document.
NOV ASEP Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV ASEP Elmar K-Winch MP16II, MAN-10003445, 20 January 2012