Cement Head Manual

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JET Manual 08

Cement Heads andCasing Hardware


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JET Manual 08 Cement Heads and Casing HardwareInTouch Content ID# 4127832

Version: 1.1Release Date: July 31, 2006Owner: Well Services Training & Development, IPC

Schlumberger private

Document Control

Revision HistoryRev. Effective Date Description Prepared by

Copyright 2006 Schlumberger, Unpublished Work. All rights reserved.

This work contains the con dential and proprietary trade secrets of Schlumberger and may notbe copied or stored in an information retrieval system, transferred, used, distributed, translated, orretransmitted in any form or by any means, electronic or mechanical, in whole or in part, withoutthe express written permission of the copyright owner.

Trademarks & service marksSchlumberger, the Schlumberger logotype, and other words or symbols used to identify theproducts and services described herein are either trademarks, trade names, or service marks ofSchlumberger and its licensors, or are the property of their respective owners. These marks maynot be copied, imitated or used, in whole or in part, without the express prior written permission

of Schlumberger. In addition, covers, page headers, custom graphics, icons, and other designelements may be service marks, trademarks, and/or trade dress of Schlumberger, and may notbe copied, imitated, or used, in whole or in part, without the express prior written permission ofSchlumberger. A complete list of Schlumberger marks may be viewed at the Schlumberger Oil eldServices Marks page: http://www.hub.slb.com/index.cfm?id=id32083

An asterisk (*) is used throughout this document to designate a mark of Schlumberger.

Other company, product, and service names are the properties of their respective owners.


3/100iiiJET 08 Cement Heads and Casing Hardware |

Table of Contents

1.0 Introduction 71.1 Learning objectives 71.2 Safety warnings 7

2.0 Cementing Overview 92.1 Preparing the casing 102.2 Pumping the cement slurry 112.3 Displacement 122.4 End of job 13

3.0 Cementing Techniques 153.1 Primary cementing 15

3.1.1 Single-stage cementing 153.1.2 Two-stage cementing 153.1.3 Stab-in cementing 173.1.4 Liner cementing 18

3.2 Plug cementing 193.3 Remedial cementing 19

4.0 Plugs 21

4.1 Plug functions 214.1.1 Botom plugs 214.1.2 Top wiper plug 22

4.3 Nonrotating and rotating wiper plugs 224.4 Wiper plug manufacturers 234.5 Cementing wiper plug sequence 24

5.0 Overview of Cement Heads 275.1 Conventional cement heads 27

5.1.1 Conventional cement heads 295.2 Cement head pressure ratings 29

5.2.1 IRI fabricated cement head (305 and 306 series) 295.2.2 IRI integral cement head (307 and 308 series) 30

5.3 Single-plug cement head 305.4 Double-plug cement head 30

6.0 Cement Head Components 336.1 Manifolds 33


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6.2 Caps 346.3 Pull pin assembly 346.4 Tattletale 356.5 Casing nipple 356.6 Bull plug 35

6.7 Quick-connect coupling 367.0 Cement Head Job Execution 437.1 Cement head prejob checklist 43

7.1.1 General job inspection procedure for cement heads 457.1.2 Safety 487.1.3 Before attaching the cement head 487.1.4 Loading the wiper plugs 487.1.5 Setting the tattletale 507.1.6 Connecting the cement head 507.1.7 Pressure testing 527.1.8 Excessive pressure testing 52

7.2 Single-stage job 537.2.1 Dropping plugs in a single-stage job 537.2.2 Troubleshooting 54

7.3 Two-stage job 567.4 Non-standard cement plug 57

7.4.1 At district 57

7.4.2 On location 577.5 Postjob 578.0 Maintenance and Inspections 59

8.1 12-month inspection 598.1.1 Cap and O-ring inspection guideline 618.1.2 O-ring inspection 628.1.3 Inside cement head inspection 628.1.4 Pull pin inspection 628.1.5 Manifold valves 648.1.6 Maintenance bulletins 64

9.0 Casing Adapters 659.1 Casing threads 659.2 Crossovers 669.3 Quick coupler 669.4 Fast-latch couplers (FLC) 67

9.4.1 Fast-latch coupler 67

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5/100vJET 08 Cement Heads and Casing Hardware |

9.4.2 Operation 689.4.3 Adjustment operation 699.4.4 Rig-down 719.4.5 Pressure test 739.4.6 Preventive maintenance 73

9.4.7 Disassembly 749.4.8 Assembly 759.4.9 Troubleshooting 75

9.5 Circulating swages 7510.0 Hardware 77

10.1 Shoes 7710.1.1 Guide shoes 77

10.2 Float collars 7810.3 Two-stage cementing collars 7910.4 External casing packers (ECP) 8010.5 Baskets and centralizers 8010.6 Scratchers and collars 8310.7 Liner hardware 8310.8 Squeeze and top-out cementing equipment 8410.9 Squeeze manifold 8510.10 Packer 86

11.0 References 87

12.0 Appendix 9112.1 Rig-up from ground to rig floor and to the cement head 9112.2 Cement head tables 9212.3 Prejob check-list 9312.4 Rig-up and rig-down checklist 94

12.4.1 Prejob checks 9412.4.2 Installation procedure 9412.4.3 Pressure testing 9412.4.4 Launching the bottom plug 9512.4.5 Launching the top plug 9512.4.6 Launching two-stage plugs 9512.4.7 Postjob 9512.4.8 Additional information/precautions 96

13.0 Check Your Understanding 97


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7/1007JET 08 Cement Heads and Casing Hardware |

In this manual you will be introduced toequipment related to the casing in the well,including peripheral equipment, such as cementheads, plugs, casing hardware, squeezemanifolds, casing couplers and adapters, andcirculating swedges.

The manual will

name the types of equipment, and explaintheir functions

explain operational procedures for thedifferent equipment

explain the maintenance procedures

explain the pre- and postjob checksrequired

1.1 Learning objectivesUpon completion of this training, you will be

able to do the following:

Describe the types of cement heads usedby Schlumberger

Describe the applications for each type ofcement head

Name the components of the conventionalcement head, as well as any associatedequipment

Name the options for connecting thecement head to the casing

Describe the different types of threadsgenerally found in casings and tubings

Explain the prejob checklist for aconventional cement head

Describe the STEM I process for a cementhead and manifold

Describe the pressure test interval andprocedure for cement heads and manifolds

Describe what MAWP (maximum allowablepressure) is and how it applies to thecement head

Explain the correct procedure for droppingthe top and bottom plugs

Explain how the pressure equalizes insidethe loaded cement head

Explain what a tattletale is and why it isused

Explain what dropping the plug on the ymeans

Identify the different kinds of casinghardware available and their uses

1.2 Safety warningsProper supervision is required during hands-on training and normal operation. Requestassistance from your supervisor if you areunfamiliar or uncomfortable with the operation.

Ensure that all safety devices are in place andoperational before using the cement head.

When operating the cement head on location,follow the procedures in Well Services SafetyStandard (WSSS) 5: Pressure Pumping andLocation Safety, InTouch Content ID# 3313681.

1.0 Introduction


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Cementing is the process of hydraulicallysealing the casing within the wellbore prior toperforation and hydrocarbon extraction. Theannulus (the space between the casing andthe formation) is lled with cement by pumpingliquid cement slurry down through the casingand forcing it back up the annulus surrounding

Figure 2-1. Preparing the Casing and Mud

the casing. Wiper plugs are dropped ahead ofand behind the slurry to keep it separate frompre ushes (washer or spacer) pumped in frontof the cement slurry, and the displacement uid(mud or drilling uid) pumped behind.

2.0 Cementing Overview


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Cementing is performed for the following mainreasons:

to provide complete isolation of zones(hydraulic bond)

to support the casing (shear bond)

to protect the casing string.

2.1 Preparing the casingFirst, a drilling mud (also referred to as drillingfluid) is circulated down through the casing to

condition and clean the well. A pressure testchecks that there are no leaks in the lines thatconnect the pumping unit to the well.

Then a chemical wash and/or a spacer arepumped in. The chemical wash is a fluid that

helps thin and disperse the drilling mud aheadof the cement slurry.

The spacer is a weighted uid with controlledrheological properties designed to keep cementslurry and mud separate

Figure 2-2. Dropping Bottom Plug



Next, a bottom plug, also called a wiper plug,is dropped from the cement head. This bottomplug cleans (wipes) the sides of the casing asit descends and provides a barrier between themud and the cement slurry, which is pumpednext.

2.2 Pumping the cement slurryOnce the bottom wiper plug is released, cementslurry is pumped from the cement unit and intothe casing through the cement head which is

mounted on the top of the casing. The cementhead is a pressure-rated container whichholds the cement wiper plug(s) and allowstheir controlled release in a predeterminedsequence.

In the case of continuous mixing, mixingwhile pumping can continue according to therequirements of the job. The cement head is acontainer mounted on the casing. It is attachedto the cementing unit and allows for therelease of uids and plugs in a predeterminedsequence.

Figure 2-3. Dropping Top Plug



The cement slurry pushes the wash and/orspacer and bottom plug ahead of it into thecasing. When the bottom plug reaches the oatcollar, the plug's diaphgram ruptures and thewash, spacer, and slurry can ow to the casingshoe.

2.3 DisplacementOnce mixing and pumping of the designedcement slurry or slurries is completed, the topwiper plug is released from the cement head.

Figure 2-4. End of Job

The top plug separates and protects the slurryagainst contaminants from the displacement

uid that will be pumped. The displacementuid, typically drilling mud, pushes the top plugand slurry down into the casing. The slurry is

forced out of the bottom of the casing and upinto the annulus.

When the top plug reaches the bottom plugit is seald or "bumped" with the bottom plugby a presssure increase. When there is a


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There are three main types of cementingapplications, which can be differentiated fromone another by their objectives. These are

primary cementing

plug cementing

remedial cementing.

A summary of cementing techniques isprovided in this chapter. Please refer to the

InTouch and the Well Services Training andDevelopment web page for more details.

3.1 Primary cementingPrimary cementing is the placement of cementslurry in the annulus between the casing andthe wellbore. The four major techniques ofprimary cementing are

single-stage

two-stage

stab-in

liner.

3.1.1 Single-stage cementingIn single-stage cementing, cement slurryis placed in the annulus in one stage. Thistechnique uses two plugs to prevent the

intermixing of cement with other uids used inthe operation.

3.1.2 Two-stage cementingTwo-stage cementing refers to the placement ofslurry around a lower and an upper portion of acasing string.

The main pupose of two-stage cementing is toisolate two problem zones within one open holesection.

Two-stage cementing may be performed asone operation or two, depending on speci ccircumstances at the well.

The process for the rst stage in two-stagecementing is as follows:

Circulate mud

Pressure test

Pump washer and spacer

Pump slurry

Drop rst-stage plug

Bleed-off and check returns.

1.

2.

3.

4.

5.

6.

3.0 Cementing Techniques


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Figure 3-1. Two-Stage Components

After the rst-stage is completed, an openingbomb is dropped. This bomb opens the ports

of the two-stage collar, a device that allows theopening of ow to the second stage of the job.The process for the second stage in two-stagecementing is as follows:

Drop opening bomb

Establish circulation

1.

2.

Pump washer

Pump slurry

Drop a closing plug similar to the topplug

Begin displacement

Bleed off and check returns.

3.

4.

5.

6.

7.



3.1.3 Stab-in cementingStab-in cementing is performed throughdrillpipe.

Figure 3-2. Stab-In Cementing Components

The pupose is to prevent problems associatedwith cementing large casing, such as.contamination and channeling inside thecasing.

Stab-in cementing is used for large casing sizes(generally bigger than 13 3/8 in) and at depthsup to 3,000 ft.

Two additional advantages are that it reducesexcess cement and can reduce job time (byreducing displacement volume.

The procedures for this technique are

Mud circulation

Pressure testing

Mixing and pumping slurry

1.

2.

3.



Displacement

Releasing the stinger to remove thedrillpipe from the inside of the casing.

3.1.4 Liner cementing A liner is a string of casing that does not extendto the top of the wellbore. The liner is attachedto casing by a liner hanger.

Figure 3-3. Liner Components

4.

5.

Liners also

cover corroded or damaged casing

cover lost circulation zones, shales, plasticformations, and salt zones

reduce the weight of the casing string.The liner cementing process consists of

mud circulation

pressure testing

1.

2.



pumping washer

pumping slurry

dropping the dart

displacement

bleeding off

releasing the setting tool from thepacker

reverse circulation.

3.2 Plug cementingPlug cementing is the placement of a relativelysmall volume of slurry anywhere in thewellbore.

3.3 Remedial cementingRemedial cementing is the process of forcingslurry under pressure through holes or splits inthe casing or wellbore annular space. Remedialcementing is often referred to as squeezecementing.

3.

4.

5.

6.

7.

8.

9.

Figure 3-4. Plug Cementing

The objectives of remedial cementing includethe following:

Repair improper zonal isolation.

Raise the top of the cement.

Plug perforations.

Repair corroded casing.

This remedial work is performed with some ofthe tools described in this manual.



4.1 Plug functionsPlugs have the following functions:

separate uids and prevent contamination

clean inner casing wall

provide surface indication whendisplacement is complete.

Cementing plugs are semi-rigid barriers usedto separate cement from drilling uids, wipe thecasing, and indicate when cement placementis complete. Both top and bottom plugs areconstructed of various types of elastomers,including natural rubber, polyurethane, nitrile,etc., molded over drillable aluminum, plastic,or wooden cores. Although similar in externalappearance, top and bottom plugs differconsiderably in internal design and operation.

Top and bottom plugs are recommended for

every primary cementing job, when possible.The bottom plug minimizes contaminationof the cement as it is pumped. The top plugprevents contamination of the cement slurry bythe displacement uid, and provides a positiveindication that the cement has been displaced.

Plugs need to be compatible with the oatcollars. Inserts can be used in addition to theoat collar to make plug and collar compatible.

Figure 4-1. Plugs

Note:The pressure to rupture adiaphragm is approximately150-500 psi. Do not rupture thediaphragm on purpose at surface.

4.1.1 Botom plugsBottom plugs are developed to precede thecement, requiring an internal bypass or ow-through feature. This feature uses a hollowcore and a thin membrane that is designedto rupture and permit ow once the plug hasseated and a differential pressure is exertedacross the membrane.

A bottom wiper plug accomplishes thefollowing:

cleans the casing wall

provides a seat for the top plugs.

4.0 Plugs


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Figure 4-2. Bottom Plug

4.1.2 Top wiper plugTop plugs are often used alone and aredesigned to withstand the pressures and forcesgenerated when they land abruptly. Top plugsdo not have a thin membrane and are designedto prevent any uid bypass. Top plugs can look

very similar to bottom plugs (especially if theyare the same color), and often the only way todetermine one from another is to turn the plugsupside down and check the inside of the plugs .

The top wiper plug

cleans the casing wall

indicates end of displacement

follows the slurry to prevent contamination.

Figure 4-3. Top Plug

The following gure shows the last fewmoments of a wiper plug's displacement andthe position of the various uids (mud, cement,etc.) in the annulus of the wellbore.

Figure 4-4. Position of Various Fluids in Annulus

4.3 Nonrotating and rotating wiper plugs

The following three types of wiper plugs do notrotate at the oat collar depth.

Figure 4-5. Plug Types

A: nonrotating TOP plug

B: standard BOTTOM plug

C: standard TOP plug

Figure 4-6 shows a simulated wellbore in whichthe top and bottom non-rotating plugs havelanded at the oat collar.

At the bottom of the gure is a magni ed viewof the top of the bottom plug showing the nonrotating pro le. Weatherford typically suppliesplugs of this design.



Figure 4-6. Nonrotating Wiper Plugs in Well

4.4 Wiper plug manufacturersSchlumberger uses three preferred vendorsfor wiper plugs: Industrial Rubber, Inc. (IRI),Weatherford International Ltd., and WichitaFalls Manufacturing, Inc.

Weatherford

Typical polyurethane cement wiper plugssupplied by Weatherford are shown in bothstandard and non-rotational con gurations.

Weatherford bottom wiper plug is shown in red,the top wiper plug is shown in yellow.

Figure 4-7. Weatherford Standard Plug

Figure 4-8. Weatherford Non-Rotating Plug

Wichita Falls Manufacturing, Inc.

Typical cement wiper plugs supplied by WichitaFalls are shown in the standard con guration.

Figure 4-9. Wichita Falls Top and Bottom Plugs

Wichita Falls plugs have distinguishing featuresbetween the top and bottom plugs. The bottom


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plug is orange and has a large hollow inside,whereas the top plug is black and has a smallhollow inside.

Industrial Rubber, Inc. (IRI)

Four types of plugs supplied from IRI areshown from left to right: rubber top (solid)plug, wooden top (solid) plug, orange rubber(hollow) bottom plug, and black rubber (hollow)bottom plug.

Figure 4-10. Top and Bottom Plugs Manufactured by IRI

Table 4-1. Sequence of Fluids and Pumps

Sequence of uids and plugs starting with rst uid pumped and ending with displacement uid

One top plug only (liners):

Mud Wash Spacer Cement slurry Top plug Mud

HP-HT cases (when additional spacer behind the plug is required):Mud Spacer Cement slurry Top plug Spacer behind Mud

One bottom plug only (might be either of the sequences):

Mud Wash Bottom plug Cement slurry Top plug Mud

Mud Bottom plug Spacer Cement slurry Top plug Mud

Mud Wash Bottom plug Spacer Cement slurry Top plug Mud

4.5 Cementing wiper plug sequenceGeneric sequence

Cementing plugs should be used wheneverpossible within the casing and the drillpipe toprevent the intermixing of uids of differentdensities inside the casing and to wipe theinternal casing walls clean of mud.

The number of plugs to be used dependslargely on the method of releasing them; that is,whether they are surface-released or subsea-launched, the type of casing run, and thecasing hardware used ( oat equipment, casingrunning system, etc.).

To minimize the contamination of uidsinside the casing, the shutdown time (timewhen equipment is idle and cement remainsunpumped) for dropping the plugs must bekept to a minimum. The following placementsequences should be used. If at all possible,it is recommended that two bottom plugs beused on critical jobs (critical is de ned by thecustomer).

The sequences in Table 4-2 start with the rst

uid pumped and end with the displacementuid. The following alternative is recommendedif the spacer is in turbulent ow inside the



casing and the density difference between thecement slurry and the spacer is signi cantlyhigher than that between the spacer and themud.

Table 4-2. Alternative Sequence of Fluids and Plugs

Alternative sequence of uids and plugs

Bottom and top plugs:

Mud Spacer Bottom plug Cement slurry Top plug Mud

Two bottom plugs:

Mud Bottom 1 Wash Bottom 2 Cement slurry Top plug Mud

Mud Bottom 1 Spacer Bottom 2 Cement slurry Top plug Mud

Mud Wash Bottom 1 Spacer Bottom 2 Cement slurry Top plug Mud


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Note:The EXPRES* extrusion plugrelease system (cementing head)is very rarley used and is no longersupported by the Product Centers.

Conventional cement heads range in size

from 2-7/8 to 20 in and range in pressure from10,000 psi to 1,500 psi. Two constructionmethods are used to create cement heads.These methods are covered in detail in thefollowing chapters.

Deepsea EXPRES* is a system for launchingplugs with subsea wellheads. InTouch has avariety of resources for the use of DeepSeaEXPRES. The reference page for the DeepSeaEXPRES is in InTouch Content ID# 3280457,DeepSea EXPRES CUH-332 subsea cementhead.

Figure 5-1. DeepSEA EXPRES

5.1 Conventional cement headsTwo styles of cement heads are approved foruse. Fabricated heads, which can be used upto a maximum of 5,000 psi, depending on thesize of the head, and integral heads, whichcan be used up to a maximum of 10,000 psi,depending on the size of the head. Integralheads have higher-pressure ratings thanfabricated heads and therefore require extracare when they are used.

The fabricated head is of approved weldedconstruction, and the manifold has an approvedthreaded design. The integral head is machinedout of one piece of stock, with female ACME

5.0 Overview of Cement Heads


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threads provided in case a changeover to the1502 unions is required.

Integral manifolds come in two styles. Oneis the FMC adjustable manifold that uses the2-in integral tee style valve. The other is an

integral manifold machined out of one piece ofstock with female ACME threads provided forcases in which changeover to 1502 unions isrequired. This integral manifold uses standard2x2-in integral FMC valves.

OCT cement heads still in use are 15 to 25years old. Any other heads that are made outof cast steel and are not marked with the OCTdiamond are older. Many of these heads aremarked with the size (e.g, 9 5/8 in) welded ontothe OD of the head. OCT (FMC) cement headsshould have been removed from service byMarch 31, 2002 as they are at least 20 yearsold and no longer approved for operations.

To address conventional cement headequipment requirements, Schlumberger usesof fabricated and integral heads designed andmanufactured by Industrial Rubber, Inc. (IRI)in Oklahoma City, Oklahoma this company is

the primary and preferred supplier. (For more

information on cement heads, refer to their Website: http://www.iri-oiltool.com.) The cementheads distributed by IRI have been selectedby OSP (Operations SupportWell Services)as the preferred product for Schlumberger.

Alternative suppliers may be used if they are

speci ed contractually or if the nal destinationis UIE in France and/or Hybrid (in California).Hybrid cement heads in the eld that werepurchased to meet North Sea or contractrequirements will remain in service.

The standard associated over-the-collar coupleris the Fast Latch Coupler, which is designedand manufactured by FMC Technologies inHouston, Texas.

A tattle-tale assembly signals that thecementing wiper plug has left the head. Theinterior of the head is machined to allowequalization of pressure around the cementingwiper plug. The plug is held in place duringcementing by a continuous-type pin assembly.

The manifold is composed of FMCs DR5OWplug valves and 1502 Weco unions.

Table 5-1. Integral versus Fabricated Cement Heads



The complete assembly is machined usingalloy steel with traceability for each componentand in compliance with ASME and APIspeci cations.

5.1.1 Conventional cement headsThe Conventional cement heads come in asingle-plug and a double-plug cement head, IRImanufactures both types.

Figure 5-2. Conventional Cement Head Types

5.2 Cement head pressure ratings5.2.1 IRI fabricated cement head (305 and

306 series)The IRI fabricated cement head is the latestdesign. Connections on the body are integraltype with #8 ACME threads and PolyPak seals.

The design eliminates the line-pipe connectionsthat were used in the past. The costs aremuch less than for the integral head. The 305series is a single-plug cement head assemblyfabricated type, while the 306 is the double-plug cement head fabricated type.

Singleplug

head

Figure 5-3. Fabricated Single Plug

Safe working pressures are given in the tablebelow. Note that the bigger the internal diameterof the cement head, the lower the safe workingpressure (SWP).

Pressure rating (psi)

From 2 7/8-in to 9 5/8-in (inclusive) 5,000

From 10 3/4-in to 13 3/8-in (inclusive)

Cement head size(internal diameter)

3,000From 16-in to 20-in (inclusive) 1,500

Table 5-2. Safe Working Pressures

Each head is equipped with continuous pinassemblies, tattle-tale assembly (to signal that

the plug has left the head), an extra pump truckconnection, and a high-pressure manifold.

The complete assembly is machined, usingalloy steel, to ASME and API speci cations.

The standard pressure (fabricated) cementheads can be identi ed by the straight exteriorof the body.


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Figure 5-6. Double-Plug Cement Head Components


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32 | Overview of Cement Heads


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34/10034 | Cement Head Components

All manifolds currently supplied by IRI cementheads are now considered integral becausethey use the same thread for assembly. Thiscovers both fabricated and integral cementheads.

Figure 6-3. Threaded and Acme Unions Used for Manifolds

6.2 CapsThe cap is the top-sealing device of the cementhead.

Figure 6-4. Cap and Threads

Figure 6-5. Cap

6.3 Pull pin assemblyIn a double-plug cement head, both top andbottom plugs are loaded into the cementhead before starting the job. These plugs arereleased by different methods.

The pull pin plug release assembly is the mostcommon type of release. The pull pin must beretracted a speci c number of turns to allow thewiper plug to move downward.

The following maintenance bulletins andtechnical alerts provide information about thepull pin assembly:

Maintenance Bulletin 1056, InTouchContent ID# 2023239, Cementing HeadPull Pin Maintenance

Technical Alert 2000-09, InTouch ContentID# 2040682, Pull Pins in Cement Heads

Technical Alert 2001-16, InTouch ContentID# 2062482

Technical Alert 2001-24, InTouch ContentID# 3036444 Part numbers for pull pinassemblies in Industrial Rubber Inc.cement heads.



Figure 6-6. Cement Head Pin

Figure 6-7. Cement Head Pin Assembly

6.4 TattletaleThe tattletale is a lever device that indicatesthat the plug has left the cement head.

The tattletale points towards the body of thecement head when the plug is in the head,and it points away from the body of the cementhead when the plug has been dropped.

335-1033BODY

335-1433SNAP RING,SHAFT

335-7033SEAT, SUPPORT BALL,TEFLON

335-8033LOCK RING,SUPPORT BALL

335-2033HANDLE,SIGNAL

335-3033SENSING ARM

1. Prior to plug departurethe tattletail lever will pointtowards the cement head body

2. After plug departurethe tattletail lever will pointaway from the cement head body

335-8033SUPPORT BALL, ARM

335-1333THREAD SEAL, O-RING (2-330)

335-2033HANDLE, SIGNAL

335-9405FLATHEAD SOCKETCAP SCREW (1024X5/3)

335-4033MAIN SHAFT

335-1133O-RINGS, SHAFT(4 required)

335-8000LOCK RING,INTEGRAL THREAD

Figure 6-8. Tattletale Components (above) and Operation(below)

6.5 Casing nippleThe casing nipple attaches the cement headto the casing that protrudes above the rig oor.Usually an over-the-coupler fast latch type isused.

6.6 Bull plug A bull plug is used to connect an extra linewhen high pumping rates (more than 8 bbl/min,connecting another pump) or displacementrates are required.



Figure 6-9. Bull Plug

6.7 Quick-connect couplingThe quick-connect coupling is a device thatconnects easily and securely to the casing. Itsuse and characteristics are detailed further inthe next sections.

The use of twin-path slings to securecement heads to the elevators or bails are arequirement in Standard 5.

Cement heads through size 13-3/8 in aresecured by using the TPXC 1500 sling and theCrosby 3-ton hook.

Slings have three main advantages over cable:

They increase the safety margin. A wirerope such as 1/2-in 6x19 IWRC EIP ropecan support a 960-lb 2 force load when itdrops from 3 ft but fails at a drop of 5 ft.With a twin-path sling the weight is safelysupported, even with a 5-ft fall.

Twin-path slings provide three visiblemeans of identifying damage, which willbe explained further. The integrity of wireropes is often dif cult to assess, especiallyin the presence of dirt and oil.

The synthetic slings are lightweight andexible, making them user-friendly in termsof handling at heights and securing theload.

Figure 6-10. Tattletale for Slings

The black line indicates thelimit to which the yellowber cord can be pulled tobefore the sling should beremoved from service.

Black limit line

Fiber cord

Fiber optic

Twin-path slings (patented by Slingmax) usetwo hi-tech ber rope cores that provide eachother with backup protection. The two cores arephysically separated within the sling. Each coreforms a continuous loop, so two conductingpaths share the load.



The slings have a dual cover. If the outer coveris cut, the red inner cover is revealed, whichindicates that the slings integrity has beencompromised. When this happens, the twotattletales built into the sling must be examined.

One of these is a solid ber chord (Fig. 6-10)that extends outside the sling cover for eachload path. When the cord is pulled partiallyunder the cover or disappears, the sling isoverloaded.

The other tattletale consists of ber-optic linesthat follow the complete loop inside the sling,one ber for each side. Each optical ber iscontinuous and emerges from the sling at themid-point, as shown below.

Figure 6-11. Optic Lines

Fiber optic

If light can be transmitted from one end of theber optic cable to the other, the sling has notbeen overloaded or damaged and can remainin service.

However, if light cannot be transmitted from oneend to the other, the sling must be removedfrom service.

Note:The ends of the optical cablemay be dirty from use. Whenperforming the light continuity testalways ensure that the ends are

clean. It may be necessary to cuta very small piece off each endbefore testing.

For detailed information on the types, costs,order numbers, and weight limits of the slingsrefer to Maintenance Bulletin 1062-BRestrainingSlings for Cement Heads InTouch ContentID# 3562542.

Locations that already have the slings in usecan continue to use them on the 16-in through20 in-heads (TPXC 3000-12 ft). The TPXC1000 (8 ft with 5-ton hook) can be used on allcement heads up through the 9 5/8-in singleor double cement head. This applies to bothstandard pressure and integral cement heads.

A durable carrying case is provided with eachset of slings. After each use, the slings shouldbe cleaned, inspected, and placed in the bag.

Before inspecting the sling, wash it with soapand water. The slings are approved for washingwith a high-pressure washer.

Inspection of twin-path slings

Tattletales should extend to the black linemarked across both paths of the sling.If neither tattletale is visible or if neither

extends past the black line, remove thesling from service (see Fig. 6-12). If Tell-Tailsshow evidence of chemical degradation,remove the sling from service and send it tothe manufacturer for evaluation and repair.



Slings should be inspected to see whetherthe outer cover is cut or torn. Slings mustbe removed from service if the white coreyarns become exposed. If cuts to the innerred jacket are visible, remove the slingfrom service immediately and send it back

to the manufacturer for repair if possible.Damage to the cover may indicate loadcore damage.

Inspect the slings for evidence of heatdamage. Slings with polyester or Covermaxcovers should not be exposed to temperaturesabove 82 degC (180 degF). Cold temperatureexposure down to 40 degC (40 degF)does not affect the strength of the products.

Any other temperature to which the

equipment will be exposed should be referredto the manufacturer for approval.

Fiber-optic light transfer determines coreintegrity. If light cannot be transmittedfrom one end of the ber-optic cable to theother end, the sling has been overloadedor damaged (see Fig. 6-12). If deteriorationis found, the sling must be removed fromservice and returned to the manufacturerfor evaluation. Test both optic bers.

Figure 6-12. Sling Inspection

Tell-tails

Black line

Slingoverloaded

Slings removed from service that cannot berepaired should be destroyed so that theyare completely un t for future use.

Abrasion, heat damage, or cuts to thecover may indicate a loss of strength tothe load core. These slings should not beused until they have been evaluated by themanufacturer.

Slings should be examined throughouttheir entire length for abrasions, cuts, heatdamage, and tting distortion. If thereis any doubt whatsoever about the slingintegrity, remove the sling from service.

Slings must be visually inspected beforeevery cementing job.

After the job, slings should be packed inthe bag provided.



Figure 6-13. Slings Bag

Figure 6-14. Slings Fiber Check

Optic ber

Reection of lightfrom this end

A ashlight shoneinto this end

Inspection of Crosby synthetic sling savershackles (S-253)

Check for wear, deformation, cracks, sharpnicks, and modi cations on all Crosbyshackles.

The two major wear points on the CrosbyS-235 sling saver shackles are at the pull ofthe bow (D) and the pull of the pin (B) (seediagram). No more than 10 percent of wear

of the original dimensions is acceptableon any Crosby shackles, as shown inFig. 6-15.

Deformation of the Crosby S-253 slingsaver shackle can be measured by theoverall length of the shackle (A), the widthbetween the ears of the shackle (C), andwhether the pin seats fully in the shackle(see Fig. 6-15).

Cracks can show anywhere on the shackle,but the pulling surfaces tend to show mostdeterioration. Sharp nicks on the shackleshould be removed to avoid sling damageand failure.

No modi cation should be made toCrosby ttings without the consent of themanufacturer.

If any indications are observed, the shacklemust be removed from service.

A 3.06 in

D - width

Dim. Tot.+ 0.25- 0.00

+ 0.00- 0.12+ 0.18- 0.18+ 0.00- 0.14

B 1.25 in

C 1.62 in

D 1.38 inwidth

A

B

C

Figure 6-15. Shackle Inspection

D-width

Inspection of Crosby hooks (5-ton WS-320)

Crosby hooks are a part of the sling assemblyused for lifting the cement head.

Check for wear, deformation, cracks, nicks,and gouges on all Crosby hooks.

The two major wear points on the CrosbyWS-320 synthetic sling saver hooks are atthe pull of the eye (B) and the bowl of thehook (D). No more than 5 percent of wearof the original dimension is acceptable (seeFigs. 6-16 and 6-17).



A 1.47 in

B - width

D - width

Dim. Tot.+ 0.25- 0.25

+ 0.08- 0.08

+ 0.25- 0.25+ 0.06- 0.06

B 1.63 inwidth

C 2.00 in

D 1.13 inwidth

A

C

Figure 6-16. Crosby Hook Inspection

B-width

D-width

Figure 6-17. Hook Deformation Indicators

Deformationindicators

Never use a hook whose throat openinghas been widened (which indicates abuseor overload) or whose tip has been bentmore than 10 degrees out of plane fromthe hook body, which is in any other waydistorted or bent.

To check for deformations, refer to twostrategically placed marks, one just belowthe shank or eye and the other on the hooktip, to see whether the throat opening has

changed.

Use a tape measure to measure thedistance between the marks. The marksshould align to either an inch or a half-inchincrement on the tape measure (see Fig.6-17). If the measurement does not meetthis criterion, the hook should be inspectedfurther for possible damage.

Remove any hook with a crack, nick,or gouge from service, and repair it bygrinding lengthwise, following the contourof the hook (no more than 5 percent of theoriginal dimension, as determined in table.)

For the WS-320 hook, the reference is2.5 inches.

No modi cations should be made toCrosby ttings without the consent of themanufacturer.

If any modi cation or wear is found, removethe hook from service.

Inspection of Crosby hooks (3-ton WS-320AN)

Check for wear, deformation, cracks, nicks,and gouges on all Crosby hooks.

The two major wear points on CrosbyWS-320AN synthetic sling saver hook areat the pull of the eye (B) and the bowl ofthe hook (D). Acceptable wear on a Crosbyhook is no more than 5 percent of theoriginal dimensions. (see Figure 6-18).

Never use a hook whose throat openinghas increased, whose tip has been bentmore than 10 degrees out of plane fromthe hook body, or which is in any other waydistorted or bent.

Note: A latch will not work properly on ahook with a bent or worn tip.

Remove any hook with a crack, nick,or gouge from service and repair itby grinding lengthwise, following thecontour of the hook (no more than5 percent of the original dimensions).

4.



A 1.47 in

B - width

D - width

Dim. Tot.+ 0.25- 0.25

+ 0.08- 0.08

+ 0.25- 0.25+ 0.06- 0.06

B 1.63 inwidth

C 2.00 in

D 1.13 inwidth

A

C

Figure 6-18. Hook Widths

B-width

D-width



7.1 Cement head prejob checklist

Pre-job checklist

Table 1-1. Prejob Checklist

Use the following cement head prejob checklistto ensure that the cement head job progressessmoothly. (The appendix of this manual provideschecklists also for prejob, rig-up, rig-down, andSTEM I procedures.) Complete each of the tasksbefore going to the job location.

STEP01 Check the size, weight, andthread of the casing. These provide informationabout the size of the cement head and theadapter to use.

STEP02 Check the adapter thread typeand thread gauge quality to make sure they areappropiate for the job.

STEP03 Check the bail size to determinewhether to use a single- or double-plug cementhead.

STEP04 Determine the expected workingpressure of the well as speci ed in theCementing Minimum Service Quality Standardsthat can be found in InTouch.

STEP05 Make sure the plug type iscompatible with the cement head and in goodcondition.

STEP06 Con rm that the plugs meet therequirements for well pressure, temperature,casing weight, and size requirements.

STEP07 Review the maintenancedocumentation to con rm that the cementhead has been pressure tested and inspectedin the last 12 months. Cement heads must bepressure tested and threads checked at leastonce a year as speci ed in Safety Standard

7.0 Cement Head Job Execution


44/10044 | Cement Head Job Execution

5: Pressure Pumping and Location Safety,InTouch Content ID# 3313681.

STEP08 Inspect the green tagged cementhead with the following procedure:

Disassemble the manifold from thecement head.

Open each of the hammer valves (makesure they open easily and that they areclean).

The thread-halves should be checkedfor good seals on all 1502 threadhalves.

Pass a bar or run water through each ofthe thread halves to make sure there isno cement or mud clogging the valves.

Do the same for the manifold.

Check the threads of the cement head.If there is mud or cement residue, cleanthe threads with a wire brush.

Clean the pinhole of the wire tattletale, ifone is being used.

Make sure the pull pins open, close,and turn easily. Note the number ofturns needed to fully extract. Check thatretract and engage fully by checkingthem visually inside the cement head.

1.

2.

3.

4.

5.

6.

7.

8.

Figure 7-1. Correct Pull Pin Assembly

Cement headOD

Pull pin assembly

Thread

Pull pin

Cement headmajor ID

If the head is a quick-connect, set thequick coupler on the oor and check theO-ring to be sure it is in good condition.Screw the head on, and make sure thet is correct.

Make sure the thread protector isinstalled.

Have a spare set of O-rings available.

Ensure that there are back up plugs(one top and one bottom).

Once the head is in the pick-up or before the job, always remove the cap and check theO-ring to be sure it is in good condition. Withthe cap off, check the pin from inside thecement head. Check for full movement and tosee if the pins feel loose. If the pin is in workingcondition, set it in the CLOSED position. If a

plug is loaded at this time, follow the stepsdetailed in 7.1.4 Loading the wiper plug sectionof this manual.

9.

10.

11.

12.


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threads with solvent and check the threads withcasing thread gauge (P/N 518218000).

STEP02 Remove and clean all caps andcheck all O-rings. Replace the O-ring in the topcap before beginning the job if it is damaged.

Figure 7-3. Damaged Hammer Ears and O-Ring

Figure 7-4. Hammer Ears

STEP03 Grease all valves and check thatthey operate properly.

STEP04 Check the plug releasemechanism to see that it operates properly.Ensure that the pin is not bent or damaged.Replace any bent or damaged pin.

STEP05 Put thread protector on any threads.STEP06 Verify that the tattletale functionsproperly and moves freely.

STEP07 Green-tag the cement head withthe date serviced and the initials of the personperforming the maintenance.

STEP08 Put additional O-rings for the cap,quick connection, and pin in a container with apressure test chart.

STEP09 Make sure that the cement head'spaint is undamaged and make touch-ups asneeded.


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7.1.2 SafetyBefore every cement job, make sure youknow and understand all appropriate safetyprocedures. The following key documentsdescribe the required safety procedures:

Safety Standard 5: Pressure Pumpingand Location Safety, InTouch ContentID# 3313681

Standard S013: Mechanical Lifting, InTouchContent ID# 3260276

Standard 14: Power Winches, InTouchContent ID# 3313689

Pressure Management/Planning: Checklistand Data Sheet for Well Services SafetyStandard 28, InTouch Content ID# 4090045

7.1.3 Before attaching the cement head

STEP01 Set the quick-connect couplinginto the casing before the casing is raised onthe derrick.

STEP02 Clean any mud off the threads ofthe cement heads. Mud can be picked up bythe head while it is moving.

STEP03 Using the winch of the crane (ifavailable) and the help of an operator, unloadthe head from the truck.

Figure 7-6. Loading the Bottom Plug

STEP04 Make sure that the safety slings, avalve bar, and safety chains are ready for use,if necessary. Also have ready a tee and a valvein case you are not going to wash the on top ofthe plug.

7.1.4 Loading the wiper plugsMake sure that the pull pins are functioningbefore loading each wiper plug. Recon rm thenumber of turns required to fully retract thebottom and top pull pins.

Follow this procedure when loading top andbottom wiper plugs into the cement head.

STEP01 Ensure that both wiper plugs arepresent and undamaged.

STEP02 If both plugs are the same color,ensure that the top and bottom plugs are kept

apart and are clearly labeled.


49/100



7.1.5 Setting the tattletale

2. After plug departure thetattle tail lever will point awayfrom the cement head body.

1. Prior to plug departure thetattletail lever will point towards

the cement head body.

Figure 7-10. Tattletale

Before dropping the wiper plugs into the cementhead set the tattletale to evaluate when and ifthe wiper plugs have dropped. A malfunctioningcement head can result in serious damage tothe well.

STEP01 Make sure that the tattletale (wireor mechanical) mechanism is not stuck andthat the seal is in place and undamaged. Ifa tattletale cap is available and wire is used,follow these guidelines:

For small plugs, wrap a piece of bailingwire around the middle wipers of the plugand push the plug into the head. Set thetattletale and tighten the rubber on the wire.

For a ex-plug or a ex-latch in the plug(the ex plug is used on a two-stage job asthe rst plug), do not load the plug a longtime ahead of the job. The ex plug canslip in the cement head and become hungin the pin. For best results, load the plug inthe head just before displacing.

Set the mechanical tattletale:

STEP02 Before the wiper plug is released,the tattletale lever arm (inside the cement head)should be pointing up, and the external indicatorshould be pointing up towards the body of thecement head.

Whether the plug has departed can bedetermined by the tattletale lever:

Prior to plug departure, the tattletale leverwill point toward the cement head.

After the plug departure, the tattletale leverwill point away from the cement head.

7.1.6 Connecting the cement head

Warning:When attaching the cement head,be careful not to drop any toolsinside the casing or around the rigoor.

Always follow these guidelines when takingtools to connect the cement head:

Do not carry any tools that are extremelyheavy or big. Tools must be easy to handle.

Do not carry any tools or objects in pocketswhile aloft that could be dropped intothe casing. Make sure that you have achinstrap on your hard hat.



These combinations areavailable for both fabricatedand integral heads

IRI cement head male ACME thread

IRI Quick coupler ACME thread

Casingthread

IRI cementhead male

ACMEthread


FMC fast-latch ACME threadStandard casing pin

IRI quick coupler ACME thread/FMC Fast-Latch

ACME thread

FMC Fast-Latch

Coupler FMCFast-Latch

Cementhead

Figure 7-11. Connection Combinations for Heads

Note: After the cement head is inposition and stabbed into thecasing; the supervisor can ask fortools to complete the connection

of the cement head. The tools canbe delivered to the supervisor ina basket or bag attached to themanifold.

STEP01 After the casing is in place,connect the head to the quick coupling. If aquick coupling is not being used, connect thehead to the casing. When connecting the head,be sure that the plug pin on the head can bebacked off because the pin is occasionallytrapped in the rigs elevator bails. Before themanifold is sent up in the derrick make surethe chiksan (swivel), safety cable, and valvebar (used to open and close the cement headvalves) are attached to the manifold.

Note:When using a screw-in head, makesure the rig sets the slips and slacksoff on the elevators before the headis screwed in. Otherwise, the collar

may not t correctly on the head; apoor t will result in a poor seal.

STEP02 Attach the manifold to the head.Be sure that the top valve is shut if there is aplug in the head.

7.1.6.1 Securing the cement head

The cement head must be secured whilecement is being pumped during a job. However,if the head separates from the casing, thesecuring cables will prevent the head fromfalling and damaging equipment or injuringpersonnel. The Safety Standards now allow theuse of two small slings on single-plug cementheads that are 8-5/8 in and smaller.


52/100



Figure 7-13. Pressure Testing

7.2 Single-stage job

7.2.1 Dropping plugs in a single-stage jobUnless instructed otherwise, all plugs should bereleased with the cement unit in standby mode(engines idling and pumps out of gear).If a explug or latch-in plug is used, load the plug justbefore displacement begins (stuff the plug)while washing up to the pit.

Figure 7-14. Loaded Plugs

To drop a preloaded plug:

When the spacer and washer have beenpumped and the pump unit stopped, open themiddle valve, release the bottom plug, andclose the bottom valve. Resume pumping thecement slurry.

Figure 7-15. Dropping the Bottom Plug, Valves Open in Green

Figure 7-16. Dropping the Top Plug, Valves Open in Green

When the cement pumping is complete, ensurethat the pumps on the unit are stopped.

STEP01 Loosen the tattletale wire seal nut.

STEP02 Turn the pin the required numberof turns to release the plug.

STEP03 If necessary, wash the lines.

STEP04 Open the top valve.



STEP05 Close the middle or bottom valve.

STEP06 Start pumping the displacementmud or uid slowly.

STEP07 Check the tattletale for plugdeparture. If in doubt of the departure,review the contingency plan with a companyrepresentative; then remove the cement headcap, and check for plug departure.

STEP08 After pumping about 5 bbl (800L)of displacement, open all the valves on thecement head to wash out any cement.

Note:Special permission and instructionsfrom management are requiredwhen dropping plugs on the y(while the cement pump is pumping).

Load plugs by hand:

STEP01 To load a plug, the valves onthe cement head should be closed (you areprobably pumping to the pit and washing up).The plug pin should be open. Knock the bullplug off the top of the cap to relieve any suctionthe cement has on the cap. (If you do not dothis, the cement U-tube effect will probably suckthe O-ring off the cap down the hole.) Once thebull plug is off you can knock the cap off.

STEP02 Place the plug in the head; usea valve bar to push the plug all the way intothe casing or as far into the head as possible(be sure to chain the valve bar securely to thecement head). Then put the cap and bull plugback on the cement head.

STEP03 Repeat these steps to load thenext plug.

7.2.2 Troubleshooting

7.2.2.1 Top plug fails to bumpThe top plug may fail to bump because of anincorrect displacement calculation or poor mud

displacement ef ciency. If the top plug does notbump:

Figure 7-17. Top Plug Fails to Bump

Check the displacement calculation,including the casing tally and pumpef ciency (having the correct pumpef ciency before the cement job startsis recommended).

Do not over-displace more than half ofthe shoe track volume. If the plug is stillnot bumped, stop pumping and checkreturns.

1.

2.



7.2.2.2 Tattletale malfunction

2. After plug departure thetattle tail lever will point awayfrom the cement head body.

1. Prior to plug departure thetattletail lever will point towards

the cement head body.

Figure 7-18. Tattletale

After the wiper plug is released, the tattletalepoints down and the indicator points awayfrom the cement head body. If this fails tooccur, notify the client immediately. The correctsequence of events should always be thefollowing:

Prior to plug departure, the tattletalelever points towards the cement headbody.

After the plug departure, the tattletalelever points away from the cement headbody.

7.2.1.3 Pin pull is stiffIf the pull pin is too stiff to move or if it has beenbent, when the wiper plug is launched removethe head and place the plugs in the casing (asneeded). Then, replace either the head or thecirculating swedge. Then nish the displacingprocedure.

Figure 7-19. Pull Pin is Stiff

1.

2.

7.2.1.4 Manifold valve is stiffIf any of the high-pressure manifold plugvalves are too stiff or cannot be moved, stopthe job. Remove the cement head and attacha circulating swedge or water bushing to the

casing while the plug valve is being repaired.

Figure 7-20. Leaking Pin Puller

7.2.1.5 Pressure spikesIf the area around the lower pull-pin begins toleak after the bottom plug had been droppedand while pumping cement slurry, screw thepin back in. Make sure the plug has dropped bychecking the tattletale position.


56/100



Open the valve to the wash-up line. Thiswill drain all uid from the head andallow a visibility check.

Visually check to see that the plug pin isworking and that it is closed.

The plug can then be loaded. Make surethe plug ts rmly against the pin.

Release the plug as for a typical cement job.

With non-standard plugs (for example,tapered plugs), it is critical that they tproperly in the cement heads. Someplugs are too long or too wide. When sucha problem arises, follow this procedure:

7.4 Non-standard cement plug

7.4.1 At district

STEP01 Con rm all speci cations anddimensions for the cement head and plug(outer diameter, length, etc.).

STEP02 Test the actual plug manually toverify that it passes freely through the cementhead and bowl (check clearance).

7.4.2 On location

STEP01 Visually check the cement headon location and count the number of turns toopen/close the retaining pin.

STEP02 Rig up with some means ofrelieving the U-tube (e.g., using a tee and valve)before beginning pumping.

STEP03 To load a plug, relieve the U-tubevacuum. Close the valves on the cementhead if pumping to the pit and washing up are

4.

5.

6.

7.

8.

required. After the vacuum is off, remove thecap.

STEP04 Inspect the inside of the cementhead. If it is full of cement slurry, drain it,opening the lower valve on the manifold to seethe retaining pin and the lower port.

STEP05 Open the pin, visually checkingthat it is 100 percent open. If it is not possibleto check visually, count the number of turnsneeded to open the pin at the beginning of theprocedure and compare.

STEP06 Load the plug into the cementhead and push it down below the retaining pin.Reinstall the cap.

STEP07 Open the top valve.

STEP08 Pump half a shoe track volume,which is the volume between the oat collarand one oat shoe.

STEP09 Shut down the pump and releasethe pressure and vacuum.

STEP10 Remove the cap. Visually inspectthat the plug is gone. If the plug has not left,pull out the cement head, pull the plug fromthe head, and drop the plug manually intothe casing. Reinstall the cap and resumedisplacement.

7.5 Postjob

STEP01 Either on location or upon returnto the District, prepare the head for the next job(perform a STEM).

STEP02 If the plug did not bump duringdisplacement, open the head to make sure thatthe plug is not there.



STEP03 Open all the valves, with fullyinserted pull pins. If the head is to be lefton location, leave the pins inserted to avoiddamage during movement by the rig crew.

STEP04 Clean the head both inside andoutside.

STEP05 Run water through all the valveson the manifold. (This should also have beendone during the displacement stage of thecement job when the plug valves were cycledopen and closed.)

STEP06 Grease the head, sealing area,and manifold plug valves. During the greasingprocess, the valve cap should be in the openposition to allow the grease to escape underpressure; otherwise, the grease may force theseals out of their segments. Between greasestrokes, move the valve from open to closedand back to open to ensure good coverage withgrease within the valve.

STEP07 Check that all O-rings and sealrings are in place and not damaged.

STEP08 Green-tag the head if everythingis in order. If there is still a problem, red-tag it.

General maintenance for cement heads isdiscussed in the Well Services Safety Standard23: Testing and Inspection of Treating EquipmentTBT (Multi-language), InTouch ContentID# 3675503.



Cement heads should be painted Schlumbergerblue, with the working pressure (clearly statedunits) and size painted in white, at least 1 inhigh; the valve indicators should also be paintedwhite (to clearly show the direction of the valve).

Chaining the valve bar to the manifold isrecommended to prevent the bar from beingdropped into the hole or annulus or onto the rigoor.

If there is a change in plug supplier, ensure thatthe new plugs completely pass through the headwith a minimum force and that they cannot passby the extended pins.

As a minimum, the cement head should bepressure-tested to its working pressure oncea year. The manifold and body should bethickness-tested as speci ed in Standard 14Section VI.

Review Maintenance Bulletin 1062-BRestraining Slings for Cement Heads, InTouchContent ID# 3562542, for twin-path slings.

Review Maintenance Bulletin 1100 MUSTDO, InTouch Content ID# 2023276, for issuesregarding the internal chamber on some IRIcement heads.

Review Technical Alert 2000-09, InTouch

Content ID# 2040682, and Maintenance Bulletin1056, InTouch Content ID# 2023239, for pull pinchecks and maintenance.

Periodically, the reference page for CementHeads, InTouch Content ID# 3266798, forupdated Technical Alerts, MaintenanceBulletins, and content related to cement heads.

8.1 12-month inspectionFor optimum performance and to ensure safety,cement heads and quick couplings must bethoroughly tested and pressure tested at leastonce a year. This 12-month check is describedin detail in the WSSS 23: Testing and Inspectionof Treating Equipment TBT (Multi-language),InTouch Content ID# 3675503. For additionalinformation refer to the Treating EquipmentManual, Version B, InTouch Content ID# 3013931,

Section 8.

Cement head inspection

The following list identi es the speci c mandatorycement head inspections and maintenancechecks that are required at a minimum of every12 months. In some locations the client orcontact may require additional testing. If you areresponsible for the maintenance of cement heads,make sure that you understand and perform the

procedure accurately.

To determine the pressure integrity of the cementhead, complete the following steps:

STEP01 Perform an ultrasonic thicknesstest on the head and manifold (refer to Fig. 8-1).

STEP02 Check all 1502 unions with a gaugekit.

STEP03 Pressure-test to the workingpressure of the head as indicated in theTreating Equipment Manual, Version B, InTouchContent ID #3013931, Section 8.

STEP04 Hold the stabilized pressure testfor a minimum of 3 minutes.

8.0 Maintenance and Inspections


60/10060 | Maintenance and Inspections

STEP05 Pressure-test the valves in themanifold from both sides.

STEP06 Identify the head and manifoldwith a serial number and tag the equipment in

such a way that is permanent.

STEP07 Document the results of theinspection and tests.

STEP08 Remove from service any head orcomponent that does not pass any part of theinspection or test. If possible, repair it; if not,destroy it.

STEP09 Remove and disassemble the pullpin assembly. Inspect the pull pin for corrosion,bending, and cracks. Subject each pull pin tomagnetic particle or dye inspection. Any pinsshowing cracks must be removed from serviceand repaired.



Figure 8-1. Measuring Erosion as Part of 12-Month Inspection

Ultrasonic thickness

Perform an ultrasonic thickness test on thehead and manifold as indicated in Fig. 8-1above.

8.1.1 Cap and O-ring inspection guidelineCheck that the top cap and O-ring are insatisfactory condition for use. Check that thehammer ears are in good condition for knockingthe cap to a suitable tightness. This top capdoes not need to be hammered to tighten it.

Figure 8-2. Cap and O-Ring Inspection



8.1.2 O-ring inspection

Figure 8-3. O-Ring Inspection

Inspect the condition of the sealing O-ring andthe locating groove. This is critical because theO-ring provides the sealing mechanism for thetop of the cement head.

For example, the cement head will not sealif the O-ring is missing, even if the top cap ishammered as tight as possible. Rubber O-ringsshould be clean, have no cuts, and t thegroove uniformly. The groove itself should beclean and free of cement or other residues.

Extra top cap O-rings should always be suppliedwith the cement head.

Keep them in the plastic bag until you needthem; the plastic bag protects O-rings from UVlight, increasing their lifespan.

8.1.3 Inside cement head inspectionCheck the inside of the cement head wherethe O-ring seals against the bore of the cementhead body. This area should be smooth andfree from scratches and other marks that could

affect how effectively the O-ring is able to sealagainst the cement head.

8.1.4 Pull pin inspection

Figure 8-4. Pull Pin Inspection

Check the pull pin visually to ensure that itretracts and engages fully; do not rely solely oncounting the turns. As an additional inspectionmeasure, count the number of turns before thecement head is loaded and stabbed (moved tothe rig oor). Be sure that the correct pin is ttedto the head. Install the pin before departure to a

job, as the pin can only be changed before.



Correct pull pin installation

Figure 8-5. Correct Pull Pin Installation

Cement headOD

Pull pin assembly

Thread

Pull pin

Cement headmajor ID

It is essential that pin puller assemblies arecorrectly installed to ensure safe operation andaccurate performance. Figures 8-5 and 8-6provide examples of correct and incorrect pininstallation.

Correct pin installation

The cement head shown in Figure 8-5 is a7-in fabricated type with only the body and pullpin shown. Note that the pull pin is now fullyretracted (maximum travel achieved) and nolonger protrudes into the bore of the cementhead.

Incorrect pin installation

Figure 8-6. Incorrect Pull Pin Installation

Cement headOD

Pull pin assembly

Thread

Pull pin

Cement headmajor ID

Note how the pull pin is still protruding beyondthe bore of the cement head when it has beenfully retracted. This is not how the pull pinshould appear. The job supervisor must checkthe pins operation before leaving the base forthe job location.



8.1.5 Manifold valves

Figure 8-7. Manifold Valve

While the cement head is in transit, and beforestabbing in, all the plug valves on the manifoldshould be open.

Pressure-testing the high-pressuremanifolds

All plug valves on the cement head should beoperational. It should be possible to turn themwith relative ease and they should not becomeincreasingly stiff when turned in either direction.

Make sure that the plug valve caps are in placeand tight to allow effective turning of the plug. Avalid pressure test certi cate (or COP) shouldbe attached to or travel with the cement headon the way to location.

8.1.6 Maintenance bulletins A listing of the maintenance and technicalbulletins with which you should be familiar isavailable in Section II, References of this JETmanual. These and future bulletins can be

found at http://intouchsupport.com.



9.1 Casing threads

These combinations areavailable for both fabricatedand integral heads

IRI cement head male

ACME thread

IRI Quick coupler ACME thread

Casingthread

IRI cementhead male

ACMEthread


FMC fast-latch ACME threadStandard casing pin

IRI quick coupler ACME thread/FMC Fast-Latch

ACME thread

FMC Fast-LatchCoupler FMC

Fast-Latch

Cementhead

Figure 9-1. Casing Adapters

Casing threads are typically tapered. Two basictypes of casing threads are shown (Fig. 9-2).round and buttress. There are two kinds of roundcasing threads: long and short.

A short male thread can be mated with along thread collar, but not vice-versa. See

API Speci cation 5B for more details, APIPublications, InTouch Content ID# 3853152,

Access to API Publications.

Figure 9-2. Typical Round and Buttress Threads

Round casing threads Buttress casing threads

The gure above shows typical round and buttresscasing threads. For inspection information,see Well Services Safety Standard 23: Testing

9.0 Casing Adapters


66/10066 | Casing Adapters

and Inspection of Treating Equipment TBT(Multi-language), InTouch Content ID# 3675503.

The nominal size of the threads corresponds tothe pipe's outside diameter.

All round casing thread is 8 threads per inch. Allbuttress casing thread is 5 threads per inch.

Note:Premium threads are available byspecial request. Contact regionaltechnical resources for information.

9.2 CrossoversCrossovers are adapters used to enable twocomponents with different thread types or sizesto be connected.

A list of authorized adapters can be found in theTreating Equipment Manual, Version B, InTouchContent ID# 3013931.

Schlumberger provides executable software,the Treating Adapter Selection program, thatwill identify the appropiate adapter and its partnumber. This program is available athttp://www.rd.oil eld.slb.com/emwd/tedb.htm.

When necessary, FMC will manufacturespecialty connections on a regional basisthrough FMC-approved machine shops forSchlumberger. The nished adapters mustconform to FMC's quality standards.

9.3 Quick couplerQuick couplers for standard pressure cementheads (5,000 psi) do not t the Acme threads inan integral cement head.

Identication of conventional and extra-high-pressurecouplings

IRI conventional and extra-high-pressure (XHP)quick-coupling nuts have different widths. Allconventional quick-coupling nuts are 5-1/2 inwide and all XHP quick coupling nuts are 7 inwide.

Figure 9-3. Quick Coupler

Casing End

O-Ring

Female subNutMale sub

CementHead End E

D A

B

Figure 9-4. IRI Quick Coupling

321 Series design parameters

All IRI 321 series quick couplers are designedfor exclusive use with conventional cementheads. For safety reasons, the 321 serieswill not mate correctly with Schlumberger's

extra-high-pressure cement heads.

321XH Series design parameters

All IRIs 321XH Series quick couplers aredesigned for exclusive use with Schlumbergerextra-high-pressure (XHP) cement heads.

As with the 321 Series, for safety reasons



the 321XH series will not mate correctly withSchlumberger conventional cement heads.

IRI recommends several inspection proceduresand checks, for jobs that involve our quickcouplers.

The following checks should be performedbefore and after each job to ensure safety andproper operation.

Make sure that the male sub is fully engagedin the head. Also, ensure that the lock ring istightly secured.

Check all seals and seal ring surfaces for anydamage.

Figure 9-5. Do Not Damage Threads

Protect the seal surface on subs at all times tomaintain secure tight connections.

Inspect the casing threads before each job.The threads must be free of damage to workproperly and safely.

Note: Any abrasions or nicks may causethe seal to leak.

Note:Never use a pipe wrench or allowany other type of tightening deviceon the threads or sealbore ofthe female sub. This can cause

damage and leakage. Use eitherpower tongs or a chain wrench onthe tong space provided.

Note: Any nicks or damage may preventthe sub threads from fully engaging.Leaking or arti cial torque-up mayoccur if the threads are damaged.

9.4 Fast-latch couplers (FLC)

9.4.1 Fast-latch couplerThe fast latch coupler is a manually operateddevice that decreases rig-up time and increasessafety during the operation of a cement head.It can also be used as a circulating head usinga dedicated swedge. The fast latch coupler isintended to provide a safer and more ef cientalternative to a threaded casing adapter.

Figure 9-6. FLC Basic Principle



The fast latch coupler has three basic functions:sealing, latching, and unlatching (see Fig. 9-7).

The fast latch coupler seals to the top of anytype of casing coupling that conforms to API8-round, short or long, buttress, and VAM,

while a set of split dogs latches the FLCunderneath the casing collar. Activating twoexternal handles simultaneously does thelatching and unlatching. These handles rotatecams that push the dogs against the casing, bymoving a piston down. A locking pin preventsany unlatching (see Fig. 9-7).

The coupling seal is highly pressure-energizedby a wave spring and has been speci callydesigned to seal to the casing collar end, evenif the end has some damage.

Because of the wave spring, the coupling sealis always in contact with the top of the collar,ensuring a seal even under vacuum conditions.When the casing is pressurized, the differencein the surface area between the coupling

Figure 9-7. FLC Locking Pin

FLC bodyWave spring

Coupling seal

Casing collar ID

Casing seal ID

Load F = (Areacoupling seal OD Areacollar ID) x Pressure

Figure 9-8. Coupling Seal

seal outer diameter and the casing collar innerdiameter is multiplied by the pressure to createa force F applied to the coupling seal body. Theforce pushes the coupling seal onto the topface of the casing collar to form a perfect seal(see Fig. 9-8).

To unlatch the system, ensure that the pressurehas been released, remove the locking pin, andsimultaneously push the two handles backward.

The internal piston moves up, and the dogsretract into the lower body of the fast latch withthe aid of springs.

Warning:To avoid damage when handlingthe cable, always position thelocking pin ring on the handle whenthe locking pin is not connected..

9.4.2 OperationThe fast-latch coupler seals on the top of thecasing collar and latches underneath the collar.

Because there are different types of casingcollars, the length of the fast latch coupler has



to be adjusted before making any connection(see Table 9-1).

Table 9-1. Casing Collar Length Range

Material Collar Length (in/mm)

Size (in) Minimum Maximum

4 1/2 6.25/159 9.50/241

5 1/2 6.75/171.5 9.50

7 7.25/184 12.5/317

7 5/8 7.5/190 12.8/325

8 5/8 7.75/197 13.25/337

9 5/8 7.75/197 13.1/333

10 3/4 8/203 13.2/335

11 3/4 8.00/203 13.25/337

13 3/8 8/203 13.2/335

16 9/229 10.7/272

4 1/2 9.00/229 11.75/298

4 1/2 9/229 11.6/292

Note:In the following description, each partis identied by its name and itemnumber as listed in the assemblydrawing (see FMC Fast-Latch Coupler(FLC) Operators Manual InTouchContent ID# 3582955, Fig. 9-9 and

Appendix A).

Figure 9-9. Exploded View of Fast-Latch Coupler

1

2

139

7 11

8 56

12 14

17

12

410 15

163

4x

2x

2x 2x

2x3x

9.4.3 Adjustment operationMeasure (in inches) the length of the casingcollar of the last casing joint. Display this

measured length on the engraved rule of thefast-latch couplers body (#1) (see Fig. 9-9)according to the adjustment procedure. Therule has 0.125-in (1/8-in) increments.

Warning:The FLC only works in the rangede ned in the Table 9-1.

Adjustment procedure

STEP01 Loosen the three hexagonal-socketset screws (#12) located on the top of the lowerbody (#3).

STEP02 Rotate the body (#1) clockwiseto decrease the length or counter clockwise toincrease it.

STEP03 Adjust to the measured length.The number displayed on the engraved rule atthe top of the lower housing (#3) must matchthe measured casing collar length.

STEP04 Tighten all three set screwsevenly.


70/100



STEP06 Latch the fast-latch couplersystem by pulling the two handles (#14) downand securing them with the locking pin (#17).

STEP07 Try to push the handles back.If they are properly secured they will remainlatched.

STEP08 The equipment is now ready forthe treating lines to be hooked up.

Having a bowl available is recommended incase the fast-latch coupler fails. If this happens,an exemption is necessary. Call your FSM andexplain job details before using the bowl.

9.4.4 Rig-down

STEP01 Ensure that all pressure is bledoff.

STEP02 Remove all safety cables.

STEP03 Ensure that the elevators are notapplying a load to the fast-latch coupler.

The entire system can be removed at once orthe cement head can be removed before thefast-latch coupler assembly.

STEP04 To remove the entire assembly,remove the locking pin (#17) from the fast-latchcoupler and simultaneously push back the twohandles (#14) to unlatch the device.

Lift the assembly with the elevatorswhile pulling it with the cat line (seeFig. 9-12).

Install the assembly on the fast-latchcoupler support assembly.

When transporting the fast-latch coupler,remove it from its support.

1.

2.

3.

Figure 9-12. Rig Down Entire Assembly

Warning:To avoid any coupling sealdamage, do not transport thefast-latch coupler installedon the support assembly. Tofacilitate preventive maintenance,immediately clean all parts withwater.

STEP05 To rst remove the cement head,disconnect it from the fast-latch coupler. Hookup the cat line to the cement head and lift it up.Lower the cement head to the rig oor.

Remove the locking pin (#17) from the

fast -atch coupler and simultaneouslypush back the two handles (#14) tounlatch the device.

Connect a lifting chain to both lift eyesthat have been installed in the body ofthe fast latch coupler, then hook up thecat line to the chain ring.

1.

2.



Lift the fast-latch coupler assembly offthe casing and lower it to the rig oor.

Latch the fast-latch coupler and secureit with the locking pin in preparation forits transportation.

With a swage, the fast-latch coupler can beused as a circulating head. The fast-latchcoupler has to be adjusted to t the casingcollar (see the FMC Fast-Latch Coupler (FLC)Operators Manual, InTouch Content ID#3582955, Section 4.1).

STEP01 Install the swage on top ofthe FLC. A 2-in. 1502 female Weco sub

provides the connection to the treating line(see Fig. 9-13).

STEP02 Tighten all three hexagon-socketset screws evenly.

STEP03 Hook up the cat line to the Wecolifting connection, lift the assembly, and lower itover the casing collar.

STEP04 Latch the FLC system by pullingthe two handles (#14) down and securing themwith the locking pin (#17).

3.

4.

Figure 9-13. Circulating Head Preparation

STEP05 Try to unlatch the fast latchcoupler. If it is properly secured, you will not beable to unlatch it.

STEP06 Connect the treating line andperform the pumping operation.

STEP07 Before rigging down the assembly,ensure that all pressure is bled off.

STEP08 Ensure that the elevators are notapplying a load onto the fast-latch coupler.

STEP09 Remove the treating line and hookup the cat line to the Weco lifting connection.

STEP10 Remove the locking pin (#17)from the fast-latch coupler and simultaneouslypush back the two handles (#14) to unlatch thedevice.



STEP11 Lift the fast-latch coupler/swageassembly off the casing and lower it to the rigoor.

STEP12 Either latch the fast-latchcoupler and secure it with the locking pin fortransportation, or install the cement head forthe cement job.

To facilitate preventive maintenance,immediately clean all parts with water.

9.4.5 Pressure testThe complete fast-latch coupler assemblyis pressurized using an external pumpingdevice. The fast latch coupler is tested bymeans of a test cap positioned inside a casingcollar that is mounted on a fast-latch couplersupport assembly. Refer to the pressure testprocedure in the FMC Fast-Latch Coupler(FLC) Operators Manual, InTouch contentID# 3582955, Appendix E.

9.4.6 Preventive maintenance

The fast-latch coupler must be maintained ingood condition to ensure reliable operation.Preventive maintenance enhances its life,performance, and reliability by minimizingcorrosion, wear, and dirt problems. Forassembly and disassembly instructions seethe FMC Fast Latch Coupler (FLC) OperatorsManual, InTouch Content ID# 3582955,Section 7, Maintenance.

9.4.6.1 Routine maintenanceRoutine maintenance must be performed aftereach job.

STEP01 Wash the entire fast-latch couplerwith water to remove all mud and cementdebris. Thoroughly clean the coupling seal (#9)and wave spring (#13) area to ensure that all

residual dirt is completely removed. Operatethe fast-latch coupler several times during thecleaning operation to ensure that all dirt isremoved from the locking dogs area.

STEP02 Grease the dogs (#5) and theirhousing.

STEP03 Inspect the locking pin and itscable; replace them if necessary.

Operate the fast-latch coupler a couple of timesto ensure that it is working properly.

9.4.6.2 Periodic maintenance

Periodic maintenance must be performed everysix jobs or every six months, whichever comesrst.

STEP01 Remove the coupling seal (#9)from the body (#1) and inspect it. Replace theO-ring and/or backup ring if wear or scratchescan be seen. With slight scratches or cuts,the rubber seal will still function as designed;however, if there is any doubt about the

condition, replace the part. Remove and inspectthe wave spring (#13). Clean its housing andgrease it before reassembly.

STEP02 Inspect the ACME threads on theouter and inner (if applicable) diameters of thebody (#1) and on the inner diameter of the lowerhousing (#3). These threads must be free ofmud and cement (see Section 7).



Note:The body is equipped with a weephole that is used to detect leakageof mud or cement past the angeO-ring seal. If a large amount of

mud or cement has collected inthe threads, the O-ring seal on thecement head may be damagedand need to be replaced.

STEP03 Inspect the cam mechanism.Operate the cams to verify that the systemis operating smoothly. If necessary, removethe cam assemblies from the lower housing.Inspect the cam pins for signs of excessivewear or brinelling. If necessary, a cam pin canbe removed using a 7-32-in diameter x 3-in-long drift punch and a new cam pin installed.

STEP04 Inspect the piston ring (#4). Verifythat the ring slides freely inside the lowerhousing (#3). Inspect the cam pin groove onthe outer diameter of the piston ring for burrs orbrinelling from the cam pins. Small marks can

be removed with a hand grinder.

STEP05 Remove the lock dog springs (#8).Verify that the springs can form a circle and arenot excessively deformed.

STEP06 Remove the lock dogs (#5). Cleanthem and their housing. Inspect the dogs forexcessive deformation or corrosion.

STEP07 Reassemble the fast-latchcoupler.

9.4.6.3 MaintenanceThis section describes the disassembly andassembly of the fast-latch coupler.

The fast-latch coupler is a heavy device. Itsdisassembly requires the use of a crane orforklift. Place the fast-latch coupler in a cleanand clear area. No speci c tools are required toperform the maintenance.

9.4.7 DisassemblyThe FLC consists of two major assembliesthe body assembly, which contains the sealingdevice, and the lower housing assembly, whichhouses the locking device mechanism.

Body assembly/disassembly

STEP01 Remove the four hexagonal-socket set screws (#12).

STEP02 Unscrew the body (#1) from thelower housing (#3).

Use a crane or forklift to lift the body whileunscrewing it.

When the body is completely unscrewed,remove it from the lower housing and place thebody upside-down on the oor.

Coupling seal removal

STEP01 Using a screwdriver, remove thering retainer (#11) and pull out the spacer ring(#7).

If it is dif cult to remove the coupling seal, usea bearing puller.

STEP02 Remove the wave spring (#13).STEP03 Visually inspect the coupling sealassembly. Check the O-ring and backup ring;there should be no visible wear or scratches.With slight scratches or cuts, the rubber sealwill still function as designed. However, replacethe part if there is any doubt about its condition.



STEP04 Store the parts in a safe andclean area.

STEP05 Clean each part carefully.

Lower housing disassembly

STEP01 Cams (#6 and #16) removal:Remove the ring retainer (#10) using a smallscrewdriver and pull out the cam assembly.Repeat this procedure for the second cam.

STEP02 Locking dogs (#5) removal: Usinga screwdriver, remove the two spring rings (#8)followed by the locking dogs.

STEP03 Upper housing (#2) removal:Loosen the four hexagonal-socket set screws(#12). Unscrew the upper housing using thehexagonal-socket set screws to rotate thehousing. Remove the piston (#4) by carefullypulling it out.

STEP04 Clean each part carefully.

9.4.8 AssemblyTo assemble the unit, reverse the disassemblyprocedure.

STEP01 All parts must be greased usingbearing grease. The locking dogs (#5) havea sequence number stamped on the top face(1-2, 2-3, 3-4, 4-5, 5-6, 6-1). Install the lockingdogs matching the sequence order.

STEP02 Install the piston (#4).

STEP03 Screw in the upper housing (#2).

Warning:When near the end of the threads,rotate the upper housing slowlyand gently. DO NOT TIGHTENTHE THREADS. Secure the upper

housing with the four set screws(#12).

STEP04 Put the wave spring (#13) in place.

STEP05 Install the coupling seal (#9) andthe spacer ring (#7).

STEP06 Install the ring retainer (#11). Usea wooden or plastic spacer and a hammerto force the ring retainer into the groove.Make sure that the ring retainer is positionedcompletely in the groove.

STEP07 Install the body assembly onto thelower housing assembly.

After completing the assembly, adjust theFLC to a casing collar

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