Section 3 Wellhead Control Test and Injection Units

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Section 3: Wellhead Control, Test and Injection Units
Contents S3
Copyright National Oilwell Varco, Inc. 2008
www.nov.com/Elmar
HYDRAULIC CONTROL UNITS:
Portable Hydraulic BOP Unit ................................................ 49
Portable Hydraulic Actuator .................................................. 50
Dual Output 10,000 psi Control Unit ..................................... 51
DHSV/MV/2-BOP/SB Control Unit ....................................... 52
Mini Series 2 or 3-BOP Hydraulic Module ............................ 53
15 Series 3-BOP Hydraulic Module ...................................... 54
Smart Control Module ........................................................ 55
GREASE CONTROL UNITS:
Single Pump Grease Unit ..................................................... 56
Mini Series Grease Module .................................................. 57
15 Series Grease Module ..................................................... 58
+ 5D+ Control Module ............................................................. 59
+ 20,000 - 30,000 psi Diesel Driven Grease
Intensifier Module ................................................................. 60
COMBINED GREASE AND
HYDRAULIC CONTROL UNITS:
5 Series 2-BOP Control Module ........................................... 61
10 Series 3-BOP Control Module ......................................... 62
5 Series E-Lite Control Module .......................................... 63
+ Smart Inject Control Module ............................................... 64
Truck Mounted 5 Series Control Module .............................. 65
N.B. The technical data contained within these pages was correct at the
time of publication but should not be used as operational guidelines.
For operational guidelines please refer to the operation and maintenance
manual supplied with the equipment.
+ Indicates new product.
PRESSURE TESTING WORKSHOPS:
+ Containerised Pressure Testing Workshop (Mobile) ............ 66
TEST AND INJECTION UNITS:
Portable Glycol Injection and Pressure Test Unit ................. 67
Portable 10,000 psi Pressure Test Unit ................................ 68
700 Series Pressure Test Unit ............................................. 69
Maxsafe Workshop Pressure Test Unit ............................. 72
Wall Mounted Pressure Test Unit ......................................... 73
Gas Booster Unit ................................................................. 74
ACCESSORIES:
Air Driven Grease Injection Pumps and Accessories .......... 75/6
Hand Pump Assemblies ....................................................... 77
Stand Alone Mechanical
and Electronic Chart Recorders ........................................... 78
Stand Alone "Wet Centre" Reels
and Remote Emergency Shutdown Units ............................ 79
Hose End Fittings and Accessories ..................................... 80
Grease Line Connectors and Accessories ........................... 81
Portable Hydraulic BOP Unit
This compact unit is ideal for opening and closing all sizes
from single to quad hydraulic BOPs.
Hydraulic Control Units 49
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PART NUMBER L-691050
WEIGHTS AND DIMENSIONS
Weights Dry 38kg (84lbs) Wet 52kg (114lbs) Dimensions cm (in) L 40 (16) W 47 (19) H 40 (16)
FEATURES:
Lightweight and economical
Positive control - leaves no doubt whether BOP is
open or closed
Air driven hydraulic pump
Machine engraved, stainless steel, colour coded
panel
High quality valves, gauges and fittings used
throughout
All stainless steel construction
OPTIONS:
Choice of hoses and fittings
Choice of pump ratios
Choice of controls from single to quad BOPs
Steel frame and tank
CE marked, ATEX approved
HOSE OPTIONS
Part Number Working Pressure Description
L-691000 5,000 psi 1 x 1/4 I.D. (6.4mm) Y Hose BOP Open
L-691100 5,000 psi 1 x 1/4 I.D. (6.4mm) Y Hose BOP Close
L-690760 5,000 psi 2 x 50ft (15.2m) 1/4 I.D. (6.4mm) Hose
UNIT OPTIONS
Part Number Description
L-691050 Single BOP
L-691060 Dual BOP
L-690778 Dual BOP accumulator plus hand pump back-up
L-6901010891 Quad BOP accumulator plus hand pump back-up
Control panel for part number L-691050 single BOP
Control panel for part number L-691060 dual BOP
Dual BOP part number L-690778
Part number L-690778
Portable Hydraulic Actuator
This portable hydraulic actuator is designed for those wireline pressure operations which do not require larger and more
expensive Elmar units.
Hydraulic Control Units
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50
Weights 95kg (210lbs) Dimensions cm (in) L 84 (33) W 33 (12) H 66 (26)
FEATURES:
5 gallon reservoir
2.6 gallon (10 litre) accumulator
Machine engraved, stainless steel, colour
coded panel
Air driven hydraulic pump with back-up manual pump
High quality valves, gauges and fittings used
throughout
OPTIONS:
Choice of panel controls
Choice of hoses and fittings
Choice of pump ratios
Stainless steel back-up hand pump
This package offers a flexible, lightweight and cost effective means of
controlling various combinations of wireline pressure control equipment.
HOSE OPTIONS
L-690586 5,000 psi 1 x 50ft (15.2) 1/4 I.D. (6.4mm) Hose
L-690740L075 5,000 psi 1 x 75ft (22.8m) 1/4 I.D. (6.4mm) Hose
L-691000 5,000 psi 1 x 1/4 I.D. (6.4mm) Y Hose BOP Open
L-691100 5,000 psi 1 x 1/4 I.D. (6.4mm) Y Hose BOP Close
TYPICAL PANELS (more available on request)
L-690160 L-690170
Line Wiper Line Wiper
Tool Catcher Stuffing Box
BOP 3 Tool Catcher
BOP 2 BOP 2
BOP 1 BOP 1
L-690190 L-691110
Line Wiper Line Wiper
Tool Catcher Tool Catcher
Tool Trap BOP 3
BOP 2 BOP 2
BOP 1 BOP 1
L-691120 L-691130
Stuffing Box Line Wiper
Tool Catcher Stuffing Box
Tool Trap Tool Catcher
BOP 2 Tool Trap
BOP 1 BOP 1
L-690341
Stuffing Box
Tool Catcher
Tool Trap
Line Wiper
BOP 3
BOP 2
BOP 1
Control panel
for part number
L-690170
Dual Output 10,000 psi Control Unit
These multipurpose control units are used to actuate or pressure test master valves, sub surface safety valves, downhole
safety valves and other hydraulically actuated equipment.
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FEATURES:
Dual outlets
Two air driven hydraulic pumps
10,000 psi maximum output pressure
Adjustable relief valves on each circuit
Tank mounted return filter with bypass valve
External drain facility to eliminate contaminated
hydraulic fluid
Stainless steel back-up hand pumps
OPTIONS:
All required connectors can be supplied
All hose configurations/pressures can be
accommodated
HOSE ASSEMBLY OPTIONS
HOSE REEL OPTION
Control panel c/w stainless steel back-up hand pumps
Stand alone reel assembly L-690674
These stand alone reel assemblies can be used to
connect hydraulic lines between equipment.
Side view
DHSV/MV/2-BOP/SB Control Unit
This Elmar hydraulic unit has been developed to control a downhole safety valve, a master valve, two wireline BOPs,
test line and stuffing box.
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52
Weights 855kg (1,881lbs) Dimensions cm (in) L 120 (47) W 85 (33) H 154 (61)
FEATURES:
Alarm system
Large hydraulic oil reservoir
Relief valves on each circuit
panel
Two 5 gallon (20 litre) accumulators
Air driven hydraulic pumps with back-up stainless
steel hand pumps
Emergency shutdown facility
Test line facility
Hoses on Elmar wet centre reels
OPTIONS:
Remote ESD system
CE marked, ATEX approved for use in a Category 2
(Zone 1) hazardous area
3-BOP version part number L-6901010507
The unit features an audible warning air horn which operates whenever the DHSV,
MV or air lines fall below their preset pressures.
Rear view
Control panel
Typical reel assembly
Mini Series 2 or 3-BOP Hydraulic Module
This module and the mini-series hydraulic control module form the controls for the mini-series pressure equipment system.
Either module may be used separately.
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This hydraulic module has been designed to operate various combinations of 2 or 3
wireline BOPs, a tool trap, tool catcher, line wiper and stuffing box. This module is
suitable for well pressure up to 10,000 psi.
Side view
Control panel
FEATURES:
Machine engraved stainless steel colour
coded panel
Back-up stainless steel hand pumps
Lightweight compact unit
Multiple choice of controls
Storage locker
OPTIONS:
Transport frame for pressure equipment
Glycol/chemical injection facility/pressure test facility
15 Series 3-BOP Hydraulic Control Module
This module and the 15 series grease control module form the controls for the 15 series pressure equipment system for up to
15,000 psi maximum wellhead pressure.
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54
Control panel
Rear view
FEATURES:
Machine engraved stainless steel, colour
coded panel
Glycol/chemical injection facility
Pressure test facility
Compliments 15 Series Grease Module
(part number L-695740 page 3/58 )
OPTIONS:
(page 4/125)
Single stuffing box control and air reel
(part number L-695800)
This hydraulic module has been designed to
operate 3 wireline BOPs, a tool trap, tool
catcher, line wiper and a dual stuffing box.
Smart Control Module
Well Control Module and Remote Control Unit with central processing unit and monitor. To operate (1) shear/seal BOP, (2)
wireline BOP's and grease injection to BOP.
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Weights 3,400kg (7,480lbs) Dimensions cm (in) L 200 (79) W 180 (71) H 193 (76)
FEATURES:
Remote electronic operation and process monitoring
based on a Zone 1 membrane keypad P.C. with
hard wire connector
Full override operation of module using conventional
valves
Certified to DNV 2.7-1, Norsok and NPD require
ments, with CE marking and ATEX approval for use
in a Category 2 (Zone 1) hazardous area
(2) Air-hydraulic pumps, 35:1 and 60:1
(1) Air-grease pump 175:1
(4) x 37 litre Accumulators to control a 6 3/8 ID 10k
Triple BOP
Back-up hand pump
Forklift pockets
Storage locker
Hoses on Elmar Wet Centre reels
OPTIONS:
Primary Well Control for Grease Injection Head/Line
Wiper/Stuffing Box/ Tool Catcher/Tool Trap etc
L-690579 Air rewind tool for hose reels
Control panel
Note: UK pat. 2337545B
US pat. 6 305 471
Australia pat. 30/10/3959
Europe pat EPO959225B
Norway pat. 317364
Singapore pat. 90051
Zone 1 membrane keypad P.C
with hard wire connector
Single Pump Grease Unit
This Elmar air powered single pump grease injection unit supplies
grease at up to 10,000 psi to the grease head and BOP.
Grease Control Units
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56
FEATURES:
Bulkhead mounted outlet for grease injection to BOP
Storage facility for spare grease barrel
96 gallon (363 litre) grease tank
120ft (36.5m) grease supply and grease return
hoses mounted on Elmar wet centre reels
coded panel
Either 175:1 or 85:1 grease pumps
OPTIONS:
Grease transfer pump (part number L-698420
page 3/75)
Storage for spare grease barrel
Control panel
Typical Reel assembly
Mini Series Grease Control Module
This module and the mini-series hydraulic control module form the controls for the mini-series pressure equipment system.
Either module may be used separately.
Grease Control Units 57
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Control panel
Rear view
FEATURES:
Two air driven grease pumps 175:1
coded panel
Large grease tank with divider
Lightweight compact unit
Multiple choice of controls
OPTIONS:
Wellhead pressure monitoring facility
Two air driven 85:1 grease injection pumps
page 3/75)
The grease module has been designed to
operate 2 grease pumps. This module is
suitable for well pressure up to 10,000 psi.
15 Series Grease Module
This module and the 15 series hydraulic control module form the controls for the 15 series pressure equipment system for up to
15,000 psi wellhead pressure. Either module may be used separately.
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58
FEATURES:
Maximum grease output pressure 22,500 psi
coded panel
Large grease tank
Two Grease Head and one BOP grease
injection lines
Individual pump stroke counters
Storage locker
Compliments 15 Series Hydraulic Module
(part number L-697830 page 3/54 )
OPTIONS:
(page 4/125)
page 3/75)
It has been developed to eliminate problems which conventional
diesel driven intensifiers present when used on an offshore
installation.
Control panel
5D+ Control Module
This diesel driven grease and hydraulic control module is designed to operate 3 BOPs, tool trap, tool catcher, stuffing box, line
wiper, grease injection and optional water/glycol pressure test.
Grease Control Units 59
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Control panel with throttle control lever
Typical reel assembly complete with optional test line
PART NUMBER L-690693-V03
This module is suitable for well pressure up to 10,000 psi.
Throttle control lever
FEATURES FOR L-690693-V03:
Rigsafe, air cooled, electric start diesel engine
Two Elmar hydraulically driven grease intensifiers
each capable of delivering 0.6 US gal/min (2.3 l/min)
at 40 strokes/min
5.3 gallon (20 litre) accumulator for BOP
back-up supply
Twin x 60 gallon (2 x 225 litres) grease tank for
different viscosities
Low fuel consumption
coded panel
Cupboard for accessory storage
OPTIONS:
60 gallon (225 litre) water/glycol pressure test
unit with hydraulically driven volume and
pressure pumps
Stainless steel panel covers with sound
deadening material
Back-up air driven grease pump in place of one
intensifier
Variant V04: As V03 but including (1) air driven
grease pump and (1) hydraulically
driven grease intensifier
Variant V05: As V03 but including a hydraulically
driven PTU and no cupboard
Variant V06: As V04 but including a hydraulically
driven PTU and no cupboard
Part Number L-6901017786-V01
Part Numbers L-6901017786-V02/V03/V04/V05
Weights V02: 2,775kg (6,118lbs) V03: 2,650kg (5,842lbs) V04: 3,000kg (6,614lbs) V05: 3,000kg (6,614lbs)
Part Numbers L-6901017786-V02/V03/V04/V05
Dimensions cm (in) L 250 (98) W 132 (52) H 190 (75)
20,000 - 30,000 psi Diesel Driven Grease Intensifier Module
This diesel driven grease control module features an Elmar high pressure grease intensifier pump in a compact package.
The intensifier delivers high flow rates at high pressures.
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60
FEATURES FOR L-6901017786-V01:
Maximum working pressure 30,000 psi
(limit can be specified)
Rigsafe, air cooled, electric start 44hp Deutz
diesel engine
Elmar hydraulically driven grease intensifier pump
capable of delivering 1.6 US gal/min (6 l/min) at 50
strokes/min
Air driven back-up 235:1 grease pump
(2) grease supply outlets, 1 grease to BOP outlet,
1 grease return outlet
120 USgal (454 litre) grease capacity in twin tanks
53 USgal (200 litre) fuel tank capacity
Elmar mimic control panel for easy logical control
BS EN12079 frame with full drip pan
Operating temperature range -20C to +50C
OPTIONS:
Low temperature kit (-40C)
Sound deadening panels for power pack
Variant V02: As standard but including powered
grease hose reels and storage
cupboard
Variant V03: As standard but including hydraulic
control facility for quad BOP control,
tooltrap, toolcatcher, dual stuffing box
and line wiper. Accumulator storage
for emergency BOP operation
Variant V04: As V03 but including powered grease
hose reels and manual hydraulic
hose reels
Variant V05: As V04 but suitable for use in
hazardous areas up to ATEX category
II (Zone 2)
Electronic switching and seal-less liquid ends ensure that the pump delivers
superior performance, reliability and longevity. The main intensifier is primed
using a charge pump.
The module features dual 60USgal (227litre) grease tanks or a single
120USgal (454litre) tank and a 53 USgal (200litre) fuel tank giving stand
alone grease control capacity for prolonged well site operations.
The compact dimensions allow transport on smaller vehicles reducing
transport and handling costs.
This module is suitable for controlling well pressures up to 25,000psi.
Part number L-6901017786-V04
Control panel
Standard Module
Part number L-6901017786-V01
5 Series 2-BOP Control Module
This combination module is designed to operate 2 wireline BOPs, a tool trap, tool catcher, stuffing box, line wiper and grease
injection. It is suitable for well pressure up to 10,000 psi.
Combined Grease and Hydraulic Control Units 61
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Control panel showing optional accumulator panel (left)
Optional chemical injection control panel
Rear view
FEATURES:
panel
Large grease tank with divider
OPTIONS:
(page 4/122)
Glycol/chemical injection facility
Galvanised base skid (part number L-696670)
page 3/75 )
85:1 grease pumps
OPTIONS - PUMP AND GLYCOL/CHEMICAL INJECTION
Part Number Pump Type Glycol/Chemical Injection Facility
L-690299 175:1 Pump No
L-696950 85:1 Pump No
L-690369 175:1 Pump Yes
L-690309 85:1 Pump Yes
10 Series 3-BOP Control Module
This combination module is designed to operate 3 wireline BOPs, a tool trap, tool catcher, stuffing box, line wiper and grease
injection. It is suitable for well pressure up to 10,000 psi.
Combined Grease and Hydraulic Control Units
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FEATURES:
coded panel
OPTIONS:
(page 4/123)
L-697210 c/w glycol/chemical injection
Galvanised base skid (part number L-699050)
page 3/75)
Rear view
Optional chemical injection control panel
Control panel
5 Series E-Lite Control Module
This combination grease and hydraulic control module is designed to operate 3 wireline BOPs, a tool trap, tool catcher, stuffing
box, line wiper and grease injection during wireline intervention up to 10,000 psi maximum wellhead pressure.
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s Control panel
Rear view
Weights Dry 920kg (2,024lbs) Wet 1,300kg (2,860lbs) Dimensions cm (in) L 146 (58) W 82 (32) H 147 (59)
FEATURES:
Two x 10 litre accumulator
coded panel
Large grease tank with divider for use with two
grease types
Large bore grease return valve
Frame designed to BS EN 12079-1 (2006)
OPTIONS:
(page 4/124). Note: L-6901010860-V02 not
suitable for transport frames L-690598/690665
Grease transfer pump (L-698420 Wiwa 4:1 page
3/75 or L-840689 Alemite 5:1)
Smart Inject Control Module
Allows Automatic Grease Control during wireline operations. Primarily designed to be a bolt on feature to the
Elmar 5 Series E-lite Control Module.
Combined Grease and Hydraulic Control Units
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64
5 Series E-Lite Control Module Control panel
5 Series E-Lite Control Module
FEATURES:
Well pressure monitoring
Automatic grease injection
System automatically maintains grease pressure at
specified level above well pressure
Inject grease at 5-30% above well pressure
Instant reaction to changes in well pressure and
line speed
Auto control of individual or both grease pumps
Alarm system
Battery back up for power supply
Normal manual control of control module can be
taken at any time
Monitors well pressure at BOP and Injected Grease
pressure at grease control head
5 Series E-Lite Control Module reel assembly
Note: UK pat. 2337545B
US pat. 6 305 471
Australia pat. 30/10/3959
Europe pat EPO959225B
Norway pat. 317364
Singapore pat. 90051
Smart Inject
Control Module
L-6901020153
5 Series E-LiteControl Module
Option: Control via remote PC
Bolt on design
LCD screen to show system status
Automatic data logging - internal SD card
records job
Rated for Zone 1 and ATEX compliant
OPTION:
Control via remote PC - could be in logging cabin
Truck Mounted 5 Series Control Module
This combination module is designed to operate 3 wireline BOPs, a tool trap, tool catcher, stuffing box, line wiper, grease
injection and glycol injection.
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FEATURES:
coded panel
OPTION:
(part number L-840880 page 3/75)
HOSES SUPPLIED LOOSE C/W QUICK COUPLINGS
BOP Hose (L-651192) Tool Trap Hose (L-651192)
25ft Twin Hose (7.6m) 25ft Twin Hose (7.6m)
2 x 3/16 I.D. (4.8mm) 2 x 3/16 I.D. (4.8mm)
5,000 psi W.P. (345 bar) 5,000 psi W.P. (345 bar)
Control panel
Accumulator control panel
It is specifically designed for use on a wireline
mast truck and the control panel on the unit
replaces an existing cupboard on the truck,
with the module located on the rear bed.
It is suitable for well pressure up to 10,000 psi.
Glycol injection control panel
Truck mounted wireline mast
(section 2 page 47)
Truck mounted module in position
Containerised Pressure Testing Workshop (Mobile)
This Elmar Pressure Testing Workshop has been designed to provide a safe and controlled environment for pressure testing
and maintenance operations.
Pressure Testing Workshops
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Weights 18,000kg (39,672lbs) Dimensions m (ft) L 9.15 (30.01) W 2.44 (8.00) H 2.85 (9.35)
The workshop allows testing to be carried out on
location or on a company base. The cabin gives
the operator full control of testing and monitoring
up to maximum 24,000 psi working pressure.
FEATURES:
Max-Safe (24,000 psi WP) pressure test unit
(4) x colour camera CCTV system and DVD
recorder
(3) x roof mounted air conditioners
10ft work bench complete with vice
Removable Baker vice
Chain hoist rated to (1) tonne
220V/110V electrical system
Removable steel blast panels (internal)
Door locks when pressure applied
Warning light
Operators control cabin
Designed, built and certified in accordance with
DNV.2.7-1 (2007)
Floor mounted test stump (removable)
Internals lined with wood
Fully load tested
Max-Safe pressure test unit
(24,000 psi) wall mounted panel
FEATURES:
Air driven high volume and high pressure pump
systems
56.8 gallon (215 litre) stainless steel reservoir
Wall mounted Elmar wet centre reel
Diaphragm pump to return drained fluid to tank
Electronic chart recorder
MONITORING SYSTEM:
(4) x colour camera CCTV system
24 hour DVD recorder
Flat screen monitor
Roof mounted air conditioners CCTV camera Wall mounted Max-Safe pressure test unit
Flat screen monitor and CCTV controls
Workshop with test unit, Baker vice and chain hoist
Portable Glycol Injection and Pressure Test Unit
This Elmar com pact stand-alone port able press ure test unit has been designed for gly col injec tion, or to pump water for
press ure test ing up to 10,000 psi.
Test and Injection Units 67
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PART NUMBER L-697240-V02-001 (European CE compliant)
FEATURES:
5.3 gal lon (20 litre) stain less steel test fluid tank
Machine engraved, stain less steel, col our
coded panel
Air driven high press ure pump
Stroke counter to moni tor injec tion rate
OPTIONS:
Non CE marked and non ATEX approved version
50ft hose assembly (part number L-690183-L050)
Typical 10,000 psi pump chart
Control panel for CE marked and ATEX approved version
Portable 10,000 psi Pressure Test Unit
This Elmar com pact stand-alone port able press ure test unit has been designed to pump water, or gly col for press ure test ing
up to 10,000 psi.
Test and Injection Units
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FEATURES:
54 gal lon (200 litre) stain less steel test fluid tank
coded panel
100ft test line hose on Elmar wet centre reel
Air driven high press ure pump
OPTION:
15,000 psi unit (part number L-696830)
Rear view
Control panel
Test fluid tank and reel assembly
Control panel
Typical 10,000 psi pump chart
700 Series Pressure Test Unit
This Elmar 700 series press ure test unit has been designed for press ure test ing up to 22,500 psi. Two air driven pumps are
provided; a vol ume pump for rapid fill ing and a high press ure pump. A chart recorder allows the press ure test to be rec orded.
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Side view
Control panel for part number L-690240 CE marked
PART NUMBER L-690240 (European CE compliant option)
Part Numbers L-690268/L-690240/L-690250
FEATURES:
Machine engraved, stainless steel, col our
coded panel
8 chart recorder with 2/8 hour mech anical clock
Air driven high vol ume and high press ure pumps
Hoses mounted on Elmar wet centre reels
14 gal lon (53 litre) stain less steel res er voir tank
Stainless steel front pro tec tive covers
OPTIONS:
0-10,000 and 0-22,500 psi high press ure pump
Galvanised 4 wheel trol ley
UNIT OPTIONS
Part Number Working Pressure Reservoir
L-690268 10,000 psi (690 bar) 52 Litre Tank
L-690240 15,000 psi (1,035 bar) 52 Litre Tank
L-690250 22,500 psi (1,552 bar) 52 Litre Tank
CHART OPTIONS
L-570040 0-15,000 psi
L-570030 0-20,000 psi
L-571490 0-30,000 psi
CONVERSION FACTORS
277 cu. in. = 1 Imp gallon
231 cu. in. = 1 U.S. gallon
This compact air driven pressure test unit is designed to operate horizontally or vertically in workshop or field environments
and will stow into a logging truck compartment.
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Rear view
Part Number L-690646-V02
FEATURES:
Stainless steel frame
Lightweight, 110 pounds (50 kg)
Vertical or hori zon tal oper ation
5 gal lon (19 litre) stain less steel res er voir tank
Air driven high vol ume and high press ure pumps
coded panel
OPTIONS:
30ft long press ure hose
Free standing chart recorder with 10ft long hose
External suction
These units feature a high volume pump for
fast filling and a high pressure pump for testing
up to a maximum 10,000 psi (690 bar), 15,000
psi (1,035 bar) or 22,500 psi (1,550 bar).
UNIT OPTIONS
Part Number Working Pressure Reservoir Features
L-690535-V01 0-10,000 psi (690 bar) 19 Litre Tank
L-690535-V02 0-10,000 psi (690 bar) 30 Litre Tank CE
L-690646-V01 0-15,000 psi (1,035 bar) 30 Litre Tank
L-690646-V02 0-15,000 psi (1,035 bar) 30 Litre Tank CE/ATEX
L-690801 0-22,500 psi (1,552 bar) 19 Litre Tank
L-690802 0-22,500 psi (1,552 bar) 19 Litre Tank with chart recorder
L-692610-V01 0-15,000 psi (1,035 bar) 19 Litre Tank
L-692610-V02 0-15,000 psi (1,035 bar) 19 Litre Tank with external suction
L-697850 0-20,000 psi (1,379 bar) 19 Litre Tank with chart recorder
CONVERSION FACTORS
277 cu. in. = 1 Imp gallon
231 cu. in. = 1 U.S. gallon
OPTIONAL EXTRAS
L-690538 10,000 psi 6mm ID hose assembly x 50 ft, 10,000 psi WP, with quick couplings and (1) 1/2 NPT (M) adapter
L-691220 15,000 psi 8mm ID hose assembly x 30ft, 18,850 psi WP, with quick couplingsand (1) 1/2 NPT (M) adapter
L-691221 22,500 psi 8mm ID hose assembly x 30ft, 30,450 psi WP, with quick couplings and (1) 9/16 AE (M) adapter
Control panel CE marked version
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These systems have been developed for oil or service company use. Each pumping unit has a large reservoir for injection fluids
such as water and glycol. The high volume and high pressure pumps allow rapid fill and pressure build up.
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Control panel for part number L-696902
Reel assembly for part number L-696902
Rear view
Part Numbers L-696902/L-696905
Part Numbers L-696903/L-696904
FEATURES:
6,000 psi, 10,000 psi, 15,000 psi or 22,500 psi W.P.
Air driven high volume and high pressure pumps
Choice of reservoir capacity (1,000 litre/1,500 litre)
Stroke counter switchable between pumps
Output hose and reel
Air supply hose and reel
OPTIONS:
Free standing chart recorder c/w hose
Stainless steel frame
Stainless steel protective covers
Forklift runners
Methanol service
Gas driven
Reduced height version (part number L-696913)
suitable for use with mast truck
Test fluid return pump
Test fluid return pump for part number L-696902-V04
UNIT OPTIONS
Part Number Working Pressure Reservoir
L-696902 10,000 psi (690 bar) 1,000 Litre Tank
L-690546 15,000 psi (1,035 bar) 1,000 Litre Tank
L-690554 22,500 psi (1,552 bar) 1,500 Litre Tank
Maxsafe Workshop Pressure Test Unit
This Elmar Maxsafe two piece workshop pressure test unit has been designed for mounting either side of a workshop
pressure test bay wall.
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Control Panel Unit
Tank Pump Unit
Reel/Bracket
Typical Hose Installation Kit
Weights 70kg (154lbs)
FEATURES:
Air driven high volume and high pressure
pump systems
Diaphragm pump to return fluid (drained from test
piece) back to tank
56.8 gal lon (215 litre) stain less steel res er voir tank
15,000 psi electronic strip chart recorder
Wall mounted Elmar wet centre reel with 12mm ID
x 75ft (23m) long hose
Installation kit options to suit clients test bay design
and dimensions
Safety features include:
- Flashing lights indicate when unit is in use
- Door interlock relays prevent pressure build up
when personnel or test bay door is open
- Automatic bleed-off if door is opened
OPTIONS:
(4) x Camera colour CCTV system
24 hour VCR
Data aquisition software for PC or laptop
0-24,000 psi unit (1,632 bar) (part number
L-6901003825-VO3)
CE marked, ATEX
approved
Pressure transducers have been used to remove all
fluid pressure from behind the operator panel making
this the safest most efficient hydrostatic pressure test
unit available.
Control panel
Reel assembly
Note: Installation kit needs to be confirmed at time of
order. Client to supply pressure test bay dimensions.
Rewind Mechanism
Wall Bracket Crank Handle
Complete assembly
Tank pump unit
Control panel unit
Wall Mounted Pressure Test Unit
This Elmar two piece pressure test unit has been designed for mounting either side of a workshop pressure test bay wall,
and includes features essential for safe and efficient hydrostatic pressure testing up to 22,500 psi.
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Weights Overall 140kg (309lbs)
Dimensions Frame and Reel cm (in) L 63 (25) W 77 (30) H 125 (49)
Dimensions Control Panel cm (in) L 28 (11) W 61 (24) H 61 (24)
FEATURES:
Air driven high volume and high pressure
pump systems
Diaphragm pump to return fluid (drained from test
piece) back to tank
Adjustable gauge cut-off pump at preset
test pressure
0-30,000 psi 8 2/8 hour chart recorder
Wall mounted Elmar wet centre reel with 8mm ID
x 82ft (25m) long hose
Installation kit options to suit clients test bay design
and dimensions
Safety features include:
- Flashing lights indicate when unit is in use
- Door interlock relays prevent pressure build up
when personnel or test bay door is open
- Automatic bleed-off if door is opened
OPTIONS:
(4) x Camera colour CCTV system
Electronic pressure recorder and digital display
24 hour VCR
8mm I.D. x 40ft (12m) hose
Charts (part number L-571490)
Control panel
Note: Installation kit needs to be confirmed at time of
order. Client to supply pressure test bay dimensions.
Gas Booster Unit
The Elmar compact, stand-alone, portable gas booster unit has been designed for pressure testing/charging up to 5,000 psi
using nitrogen gas.
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FEATURES:
coded panel
Air driven gas booster pump
Stainless steel protective covers
Emergency shutdown and exhaust function
Supply hoses for air and gas, output gas hose
Control panel
Test Line Pressure
Start Button
Emergency Stop Button
Gas Inlet Pressure
Air Supply Pressure
Machine engraved, stainless steel,
colour coded panel
Air Driven Grease Injection Pumps and Accessories
Elmar air-operated Grease Pumps, developed in conjunction with WIWA, are designed for use in Elmar's Grease Control
Modules. Elmar high-pressure Grease Pumps consist of a reciprocating air drive, coupled to a piston fluid pump.
Accessories 75
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There are three pumps ratios available: 85:1, 175:1, and 235:1. With an air input of 100 psi the maximum
output pressure is respectively 8,500 psi, 17,500 psi and 22,500 psi, to suit well operations to 5,000, 10,000
and 15,000 psi. A 4:1 ratio pump is also available for fast transfers from a drum to grease reservoir on Elmar
modules. Driving the pump through an air regulator allows an infinitely variable control of the grease flow rate
and pump stall pressure. An Air Line Lubricator is required at the pump air input for reliable performance.
ELMAR WIRELINE GREASE
Elmar Wireline Greases are polybutene base fluids,
specially formulated for effective pressure control and
wireline lubrication. Elmar Wireline greases contain
inhibitors, and provide protection during wireline
operations against corrosion from hydrogen sulphide
(H2S), acids, caustics and saline brines. Elmar
Wireline Greases have a clear amber colour, and
because of their cohesive and adhesive properties
minimise drip and spatter, thus reducing well site
contaminations. Elmar Wireline Greases are supplied
in 55 US gallon (205 litres) drums and are available in
a range of viscosities to cover applications in ambient
temperatures ranging from -20C to in excess of
+60C. A Bio-Degradable version is available in
selected viscosities. On special request, greases are
available for temperatures down to -40C, and
specially inhibited for well fluids with high CO2
content.
GREASE FOR WIRELINE GREASE INJECTION SYSTEMS
Part Number Grease Type Operating Temp. Range (C) Biodegradeable Grease Type Part Number
L-8871010730 OCR 767-VIS 10 -40C to -15C
L-8871010731 OCR 768-VIS 12 -23C to +7C OCR 780-VIS 12 L-8871010729
L-880194 OCR 770-VIS 16 +7C to +30C OCR 780-VIS 16 L-880284
L-880103 OCR 778-VIS 28 +32C to >+55C OCR 780-VIS 28 L-880101
L-880217 OCR 779-VIS 30 +35C to >+60C OCR 780-VIS 30 L-880286
L-880247 Poly Multi K -20C to +5C
L-882800 Poly Multi -5C to +20C
L-882802 Poly Multi HP-HT +5C to +35C
WIWA Pump Ratio: 175:1 Ratio: 85:1 Ratio: 235:1 Ratio: 4:1
WIWA GREASE INJECTION AND TRANSFER PUMPS
Part Number Ratio Air Motor Size Output per Cycle Max Cycles per Min. Max Air Pressure Maximum Pressure
L-840890 235:1 12 (30cm) 2.6 cu.in. (43cc) 75 100 psi (6.9 bar) 23,500 psi (1,621 bar)
L-840750 175:1 8 (20cm) 2.6 cu.in. (43cc) 75 100 psi (6.9 bar) 17,500 psi (1,207 bar)
L-8401005837* 175:1 8 (20cm) 2.6 cu.in. (43cc) 75 100 psi (6.9 bar) 17,500 psi (1,207 bar)
L-840880 85:1 6 (15cm) 2.6 cu.in. (43cc) 75 115 psi (8 bar) 8,500 psi (586 bar)
L-698420 4:1 3 (7.5cm) 1.8 cu.in. (29cc) 75 100 psi (6.9 bar) 460 psi (32 bar)
FEATURES:
Relief valve on air motor to set maximum
working pressure
Oil bath above upper packing for long service life
Large built-in air silencer
High pressure pump tube of rugged construction
Replaceable packing sets in pump tube
Foot valve can be examined/replaced without pump
strip-down
ATEX approved versions are available*
L-840888 L-840890 L-698420
Filter
Air Lubricator
Air Driven Grease Injection Pumps
and Accessories Continued
Accessories
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AIR MOTOR KITS FOR 175:1 WIWA GREASE INJECTION PUMP L-840750
L-660770 Air Motor Seal Kit
L-660340 Air Motor Repair Kit (includes items in above seal kit)
FLUID SECTION KITS
L-660350 Fluid Section Repair Kit
L-838750 Upper Packing Mixed Assembly
L-838930 Lower Packing Mixed Assembly
L-838890 Bottom Valve Assembly
FLUID SECTION KITS
GENERAL ITEMS
L-661470 85:1 Pump Repair Kit (Kits L-661440 and L-660350 combined)
L-837241 Engineering Adhesive for Air Motor
L-837242 Lubricator Grease for Air Motor
L-880000 Killfrost Airline Lubricant
L-690207 Flow Test Unit for Grease Pump
FLUID SECTION KITS
Ratio: 235:1
WIWA Pump Ratio: 175:1
WIWA Pump Ratio: 85:1
Hand Pump Assemblies
Elmar lightweight portable hand pumps have been designed to
be used with wireline pressure control equipment.
Accessories 77
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FEATURES:
3,000 psi maximum working pressure on BOP
hand pump
6,500 psi maximum working pressure on stuffing
box hand pump
10,000 psi maximum working pressure on Quick
Test Sub and Wireline Cable Cutter hand pump
Lightweight portable construction
Aluminium base channel
Integral hydraulic reservoir
OPTIONS:
15,000 psi maximum working pressure on Q.T.S.
FEATURES:
Naval brass cylinder
All other parts stainless steel
O ring and PolyPak Seals
Improved check valve
Dust seal on top of cylinder
Easy to maintain
No more seized-up hand pumps
PART NUMBERS
Part Number Output Pressure Output Volume In Port Out Port
L-793400 0-3,000 psi 0.66 cu.in./stroke 1/4 N.P.T.-F 1/4 N.P.T.-F
Service Kit L-663820 (0-207 bar) (11cc)/stroke
Service Kit L-663830 (0-414 bar) (5.9cc)/stroke
Service Kit L-663810 (0-690 bar) (4.6cc)/stroke
L-790008 0-15,000 psi 0.13 cu.in./stroke 1/4 N.P.T.-F 3/8 A.E.S.L.
Service Kit L-660487 (0-1,035 bar) (2.1cc)/stroke
STUFFING BOX OR PACK-OFF HAND PUMP
L-690730 Hand Pump Assembly 6,000 psi Working Pressure
HYDRAULIC HOSE ASSEMBLY
QUICK TEST SUB & WIRELINE CABLE CUTTER HAND PUMP
HYDRAULIC HOSE ASSEMBLY
SINGLE BOP HAND PUMP
HYDRAULIC HOSE ASSEMBLIES
Stuffing box or
pack-off hand pump
Single BOP hand pump
part number L-690750
L-691080
L-690760
L-690740
25ft
50ft
100ft
Hose Assembly
1/4 ID 100 R2AT Hose with 1/4 NPT Male Hose Ends
and Snaptite Male and Female Connectors
L-690587
L-690586
L-6901004505
25ft
50ft
100ft
Hose Assembly
6mm ID, 10,000 psi Hose with
Quick Connectors and Dust Covers
L-691000
L-691100
Y Hose Assembly for BOP Opening
Y Hose Assembly for BOP Closing
L-691080
L-690760
L-690740
25ft
50ft
100ft
Hose Assembly
1/4 ID 100 R2AT Hose with 1/4 NPT Male Hose Ends
and Snaptite Male and Female Connectors
STAINLESS STEEL HYDRAULIC HAND PUMP
Elmar-designed, stainless steel, modular hand pumps. These are now fitted to all our
hydraulic modules. They are completely interchangeable with the former steel hand
pumps.
Stainless steel hydraulic
hand pump
Stand Alone Mechanical and Electronic Chart Recorders
These chart recorders are designed as an Add on to existing Pressure Test Units to produce a paper or paper and
electronic pressure test record.
Accessories
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UNIT OPTIONS
L-690772 for 6,000 psi Pressure Test Unit
FEATURES:
Mechanical Chart Recorder
Paper type output
Mounted on anti-vibration mounts within a hand
portable stainless steel frame
Suitable for up to 22,500 psi test pressure
Complete with 10ft hose and quick connectors
OPTIONS:
Transport Peli case (fully water proof)
Full range of adapters for connection to equipment
Electronic chart recorder
part number L-6901004669
ELECTRONIC CHART RECORDER
FEATURES:
Electronic Chart Recorder
Digital display
Record to memory function
Supplied c/w computer software for viewing
collected data
Anti tamper file transfer
CE marked
Supplied in stainless steel trimmed flight case
Suitable for up to 22,500 psi test pressure
30,000 psi test pressure transducer included
OPTION:
Full range of adapters for connection to equipment
Mechanical chart recorder
Stand Alone Wet Centre Reels
and Remote Emergency Shutdown Units
Accessories 79
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PART NUMBERS
L-690147 10,000 psi 3 x 150ft (45.7m) 1/4 I.D. (6.4mm) Hose 120 psi
1 x 60ft (18.2m) 1/2 I.D. (12.7mm) Air Hose
L-690166 5,000 psi 3 Reel No Hose
10,000 psi 1 x 150ft (45.7m) 1/4 I.D. (6.4mm) Hose
120 psi 1 x 60ft (18.2m) 1/2 I.D. (12.7mm) Air Hose
L-690588 150 psi 1 x 150ft (45.7m) 3/8 I.D. (9.5mm) Hose
PART NUMBERS
L-690131 120 psi 1 x 150ft (45.7m) 3/8 I.D. (9.5.mm) Hose
L-690219 120 psi 1 x 100ft (30.4m) 3/8 I.D. (9.5mm) Hose
L-690319* 120 psi 1 x 82ft (25m) 3/8 I.D. (9.5mm) Hose
*Note: Positive shutdown version.
Remote ESD Unit
Stand Alone 4 x Wet Centre
Reel Assembly
OPTIONS:
accomodated
CE marked
These stand alone reel assemblies can be used to connect air/hydraulic lines
between equipment.
OPTIONS:
accomodated
CE marked
REMOTE EMERGENCY SHUTDOWN (ESD) UNIT
The ESD System can be operated during an emergency either
by a pilot operated manual reset valve on the control panel of
the hydraulic control module, or by a push button valve on a
Remote Emergency Shut Down System.
Hose End Fittings and Accessories
The fittings shown are types of fittings most commonly used on Elmar equipment. Other fittings as specified by a client can
also be supplied.
Accessories
www.nov.com/Elmar
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80
Air Line Connectors
CHICAGO CONNECTORS 250 PSI WORKING PRESSURE
L-580200 1/2 I.D. 1/2 N.P.T. M
L-583400 1/2 I.D. 1/2 N.P.T. F
L-580300 3/4 I.D. 3/4 N.P.T. M
L-583300 3/4 I.D. 3/4 N.P.T. F
ARO CONNECTORS 250 PSI WORKING PRESSURE
L-582800 1/4 I.D. 1/4 N.P.T. - M, Nipple
L-582700 1/4 I.D. 1/4 N.P.T. - F, Nipple
L-582900 1/4 I.D. 1/4 N.P.T. - F, Coupling
L-580100 1/2 I.D. 1/2 N.P.T. - M, Nipple
L-585400 1/2 I.D. 1/2 N.P.T. - F, Nipple
Hydraulic Line Connectors - Steel and Stainless Steel
SNAPTITE H SERIES 6,500 PSI WORKING PRESSURE
L-585200 1/4 I.D. 1/4 N.P.T. - M, Nipple
L-586800 1/4 I.D. 1/4 N.P.T. - M, Stainless Steel Nipple
L-585300 1/4 I.D. 1/4 N.P.T. - M, Coupling
L-586700 1/4 I.D. 1/4 N.P.T. - M, Stainless Steel Coupling
L-581000 1/4 I.D. 1/4 N.P.T. - F, Nipple
L-583800 1/4 I.D. 1/4 N.P.T. - F, Stainless Steel Nipple
L-583700 1/4 I.D. 1/4 N.P.T. - F, Stainless Steel Coupling
WALTHER CONNECTORS
L-500165 6mm I.D. 3/4 Type - M, Nipple 30,000 psi Working Pressure - without check valve
L-580129 6mm I.D. 3/4 Type - M, Coupling 30,000 psi Working Pressure
L-582100 6mm I.D. 1/4 N.P.T. - F, Nipple 10,000 psi Working Pressure - with check valve
L-581870 6mm I.D. 1/4 N.P.T. - M, Nipple 10,000 psi Working Pressure - without check valve
L-582000 6mm I.D. 1/4 N.P.T. - F, Coupling 10,000 psi Working Pressure
BAYONET CONNECTORS 10,000 PSI WORKING PRESSURE
L-580800 1/2 N.P.T. - F, Upper Element
L-580700 1/2 N.P.T. - M, Lower Element
Chicago Connectors
Aro Connectors
Snaptite H Series Connectors
Walther Connectors
Walther Connectors
Grease Line Connectors
and Accessories
Accessories 81
www.nov.com/Elmar
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SNAPTITE STAINLESS STEEL COUPLINGS
L-585700 1/2 I.D. 1/2 N.P.T. - F, Nipple
L-585800 3/4 I.D. 3/4 N.P.T. - M, Nipple
PIONEER COUPLINGS 10,000 PSI WORKING PRESSURE
L-587940 3/8 I.D. 3/8 N.P.T. - M, Coupling
L-587930 3/8 I.D. 3/8 N.P.T. - M, Nipple
HEX UNION ASSEMBLY 10,000 PSI WORKING PRESSURE
L-580900 Complete Assembly
L-587300 1/2 I.D. 1/2 N.P.T. - F, Insert
L-587500 2 1/4 Hex Nut
L-587400 1/2 I.D. 1/2 N.P.T. - F, Adapter
L-871500 Adapter O Ring
HIGH PRESSURE ADAPTERS 10,000 PSI WORKING PRESSURE
L-202500 1/2 N.P.T. - M, Adapter
L-204900 1/2 - 1/4 N.P.T. - M, Reducing Adapter
L-202300 1/4 N.P.T. - M, Adapter
MANIFOLD VALVE AND CHECK VALVE
L-500060 1/2 N.P.T. - M - F, 10,000 psi Working Pressure Manifold Valve
L-505590 1/2 N.P.T. - F, 10,000 psi Working Pressure Check Valve
MANIFOLD BLOCKS 10,000 PSI WORKING PRESSURE
L-740300 4 Port 1/2 N.P.T. F
L-740410 3 Port 1/2 N.P.T. F
L-740510 2 Port 1/2 N.P.T. - F
WALTHER CONNECTORS 10,000 PSI WORKING PRESSURE
L-582300 10mm I.D. 1/2 N.P.T. - F, Coupling
L-582400 10mm I.D. 1/2 N.P.T. - F, Nipple
Snaptite Stainless Steel Couplings
Pioneer Couplings
Hex Union Assembly
High Pressure Adapters
Manifold Blocks
Manifold Valve Check Valve
Walther Connectors

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