P.O.

BOX 718
1927 HWY 90 WEST
JENNINGS, LA 70546
P 337.616.3300
F 337.616.3299

MAINTENANCE AND OPERATION MANUAL

HYDRAULIC CHOKE AND CONTROL CONSOLE

"Q U A L I T Y

C R E A T E S

T R U S T "

INTRODUCTION
The Quality Oil Tools, Inc. remote operated Hydraulic Choke has been field proven to be a
reliable choke for the drilling industry. Like all mechanical and pressure containing equipment
there are certain fundamental rules which operators should observe.
The basic mechanical operation of the QOT Hydraulic Choke is very simple. However, the
applications for which this type of equipment is used may be complex enough to require specific
training and experience to complete an operation successfully. The QOT Hydraulic Choke
should be operated by, or under the supervision of qualified operators only.
All mechanical equipment is subject to wear caused by either use or abuse. The QOT Hydraulic
Choke and Control Console should be inspected on a regular basic by qualified personnel. Any
repairs should be made before undertaking any operations involving the QOT Hydraulic Choke.
In the event of any problems please contact:
Quality Oil Tools, Inc.
1927 Highway 90 West
P.O.Box 718
Jennings, Louisiana 70546
Phone:
(337) 616-3300
Fax:
(337) 616-3299
Email:
sales@qualityoiltools.com

I. GENERAL INFORMATION
A. CHOKE
The Quality Oil Tools, Inc. Hydraulic Choke is a hydraulically operated valve with an
adjustable orifice. In the fully open position the maximum orifice size is 1.9 square inches (12
cm2) to complete closed. The orifice size is controlled by means of rotating the 'Front'
(upstream) disc from 00 to 180 while the 'Back' (downstream) disc remains stationary. The
'Front' disc is rotated by a hydraulically-driven rotary actuator. The discs, constructed of
Tungsten Carbide, are precision ground and lapped to a mirror like finish. (See Figure 1)

Figure 1
The Quality Oil Tools, Inc. Hydraulic Choke was designed primarily to control high pressure
gas kicks and various fluid flows during drilling operations but can be used in a variety of
applications.
B. CONTROL PANEL
The control panel is normally used to operate the QOT Hydraulic Choke from a remote
location. The panel is portable and may be located at any safe location to satisfy specific
needs or requirements that the customer may have. In cases where more than one panel is
required to satisfy needs or requirements, additional panels may be added with only minor
adjustments to hose and fittings, etc.

Figure 2.

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The control panel is a completely self-contained unit with the exception of an air
supply. The air input requirements are a minimum of30 PSI, however 50-125 PSI with
an available 10 cubic ft/min. (CFM) is recommended for maximum performance. There
are no electrical requirements for the panel or choke. The stroke counter assembly has a
6 Volt battery pack located inside the counter box. The battery pack is a
replaceable/expendable item that should last approximately 36 months under normal
conditions.
Should the air operated hydraulic pump fail, the choke may still be operated by using
the manual hydraulic pump located on the control panel base. This method of operation
will work only if the remaining hydraulic systems are intact. If air pressure is lost the
position indicator gauge will not work. Should the hydraulic system have a complete
failure, provisions have been made for manual choke operation by inserting a bar into
the indicator head. The indicator head features an indicator band so adjustment of the
orifice size is still possible.
For multiple choke installations, QOT also offers a Dual Choke Control Console
(Figure 3). Two chokes can be operated with this console without the need for an
auxiliary panel or two single consoles.

Figure 3

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2. INSTALLATION
A. INSTALLING THE CHOKE
The standard inlet and outlet connections supplied on the QOT Hydraulic Choke are API
Type 2-9/16" 10,000 psi WP with a BX-153 ring groove or a 3-1/16" 10,000 psi WP with a BX154 ring groove.
All Hydraulic Choke assemblies have a series of solid Tungsten Carbide wear sleeves and a flange
protector. The flange protector when installed extends 1/8" ( 4mm) from the face of the outlet
flange. This will protect the ring groove and flange from 'washing out'.
NOTE: MAKE SURE THAT THE MATING FLANGE BEING BOLTED TO THE
HYDRAULIC CHOKE OUTLET SPOOL DOES NOT INTERFERE WITH THE FLANGE
PROTECTOR. THIS COULD CRUSH THE CARBIDE PARTS INSIDE THE CHOKE.
Always check all bolting studs and nuts for cracks, damages, and wear to threads before installing.
Any damaged parts should be replaced.
Always use new gaskets when installing the choke. (Refer to API Specification 6A for Wellhead
and Christmas Tree Equipment).
The nuts should be evenly torqued and have full engagement onto the stud. The stud should have 3
to 4 threads showing for best results. After torquing the nuts, the flange raised faces should come
together and be parallel to the companion or adapter flanges.
Whenever possible, two gate or positive sealing valves should be installed upstream of the choke
(between the Blowout Preventer and the choke) and one downstream of the choke to permit
isolation for maintenance while other sections of the manifold are in use.
When using a flare line from the choke it must be securely anchored according to API
Specifications. (Refer to API Bulletin RP 53).
Whenever the choke is reassembled or installed/reinstalled in the manifold the choke should be
retested. Refer to -Section 5- of this manual for test procedure.
B. REPOSITIONING THE ACTUATOR
After installing the Hydraulic Choke assembly in the manifold, it may be necessary to reposition
the hydraulic actuator. The actuator assembly should have the open area facing down or to the side
to facilitate excess water drain -off. Should the actuator assembly not be positioned properly the
following procedure should be followed to rotate it to the proper position.
1)
2)

Remove the four mounting bolts which attach the Actuator Assembly to the
mounting bracket.
Pull the Actuator Assembly away from the choke body until the square shaft clears
the Indicator Head.

NOTE: DO NOT ROTATE THE SQUARE SHAFT OR INDICATOR HEAD DURING THIS
OPERATION. DOING SO WILL CHANGE THE ALIGNMENT OF THE DISC OR CHANGE
THE POSITION INDICATOR AND THE CHOKE WILL NOT FUNCTION PROPERLY;
3)

Rotate the entire actuator assembly 90 or 180 to the desired position.

4)

Clean and grease the square shaft and push the actuator assembly into the indicator
head.

5)

Install the four bolts removed previously and tighten them to 27 ft-lbs.
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C.

HYDRAULIC CONTROL LINES

Connect the two 3/16"3,000 psi hydraulic hoses (with 1/4" Male and Female Couplings) to the
choke control panel and the Hydraulic Choke actuator assembly using the quick disconnects. (See
Figure 4) They should be placed in such a manner as to prevent damage by sharp edges and
hazards for rig personnel.
D.

CHOKE POSITION INDICATOR

The panel is equipped with 1/4" O.D. vinyl poly flow tubing. Connect the 1/4" O.D. vinyl tubing
from the fitting on the position indicator regulator (located inside the actuator box assembly) to
the position indicator gauge (located on the control console face).
1)
2)

3)
4)

Layout and cut 1/4" tubing to the desired length.

Connect the tubing to the rear of the panel labeled "Air to Transmitter" and "Air
Return from Transmitter." Note: Tubing connectors provided on the panel and
actuator are a "Push On" type. Simply push the tubing onto the connector and pull
back to insure connection. To release: Push the ring into the fitting and pullout the
hose.
The fittings on the position indicator regulator are not labeled. Check the arrow
located on the position indicator regulator to determine the direction of flow.
Turn the air supply valve on the control panel to the on position. Operate the choke
valve to the full open position by holding the controls lever in the choke open
position until the pump stalls. The position indicator gauge should show open, if
the gauge is not calibrated correctly, recalibrate per procedures described in
Section 4.8.

NOTE: THE CONTROL P ANEL AND CHOKE VALVE ARE SHIPPED FROM QUALITY OIL
TOOLS FULLY CALIBRATED.
Push the control lever to the right toward the choke close position. The hydraulic pump should
start / stroking and the needle of the Position Indicator Gauge should begin moving. Hold the
lever in this position until the choke is fully closed and the hydraulic pump stalls; then release the
lever. The control valve lever should return to the center position.
If there are any problems with any of these operations, refer to -Section 6- of this manual.
E.

INSTALLING THE CONTROL PANEL

Place the panel in a desired location on the rig floor or in a safe working area designated by the
customer. Normally, the best location for the Control Console is against the hand rail nearest the
mud tanks and the choke manifold. This location provides the choke operator with a view of the
fluid level in the mud tanks and other equipment related to a well killing operation.
1)

AIR SUPPLY
Connect a rig air supply to the rear of the panel. The inlet for the rig air is labeled
"Rig Air Supply." (See Figure 5) The air supply should be capable of supplying a
constant moisture-free 50-120 psi of air. Trash or moisture in the air supply can
cause a malfunction in the air operated hydraulic pump or in the position indicator
assembly. The air supply should be connected to a source that will not be
disconnected from the panel.
Care should be taken when routing the air supply to avoid damage to the hose by
crimping, cutting or from excessive heat. A hose of diameter should be capable
of supplying an adequate amount of air for proper operation up to 50 feet. Should a
longer hose be required, a diameter hose is recommended. The panel is
equipped with a 1/2" NPT male connection for installing the air supply line.
-6-

2)

PUMP STROKE COUNTER

The QOT pump stroke counter is a digital readout type, which is powered by a
built in battery pack located inside the pump stroke counter box. No external
electrical power supply is required. The meter comes complete with a 125' limit
switch assembly (magnetic proximity switches optional).
The limit switch assemblies mount to the mud pump frame near the exposed
portion of the pump rods so that the pump rod collar or "splash guard" will
contact the limit switch "whisker rod". Mount the limit switch assemblies to the
pump frame using the C-Clamp bolted to the switch. There should be one full
deflection and release of the "whisker rod" for each pump stroke to assure proper
operation of the stroke counter and to avoid double counting. Route the cable
from the switch assembly to the panel so that it will not be cut or damaged.
(NOTE: The panel and switch assemblies are pre-wired and no further
connections are required.)
Operate the pump stroke counter switch assemblies by hand to determine Pump
#1, #2 or #3. There is a pump selector switch located on the bottom of the pump
stroke counter box inside the panel. This switch is used to select the desired pump
stroke count and rate being displayed.

3)

GAUGE PROTECTOR
Two gauge protectors have been provided with the panel. Connect the drill pipe
pressure gauge protector (See Figure 5) assembly to the rig standpipe and the
casing pressure gauge assembly to the choke manifold. Whenever possible mount
the assembly in the upright position with the hammer nut down, this will allow
the mud and drilling fluids to drain from the unit when no pressure is in the
manifold Connect the hose from the gauge protector to the drill pipe pressure or
casing pressure gauge on the panel Use caution when running the hose so that it
does not get cut, crimped, worn, or burned by other equipment.
The gauge protectors are rated for 10,000 psi WP and may be mounted to a 2"
Figure 1502 female hammer union hub on the standpipe and choke manifold. The
gauge protector lines should be filled with hydraulic fluid prior to leaving Quality
Oil Tools. If the lines are not filled see -Section 4.7 .B- of this manual for the
hydraulic line filling procedure.

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F.

MULTIPLE CHOKE INSTALLATION

Dual Panel
If two QOT Hydraulic Choke valves are used in the manifold, they both may be operated
from a Dual QOT control panel. The Dual panel is installed in the same manner as the
Single panel. On the rear of the Dual panel there are OPEN and CLOSE connection ports
for each choke. There are also "air to" and "air return" lines for each choke. It is very
important not to interchange the lines from Choke 1 with the lines from Choke 2. It is
recommended to install one set of lines at a time. The OPEN and CLOSE lines for Choke 1
and Choke 2 are clearly marked adjacent to the connections.
The gauge protector assemblies and supply air are installed in the same manner as a Single
Control Console.
3.

OPERATION
The choke discs should remain in the full OPEN position when the choke is not in use.
Operation of the QOT Hydraulic Choke should always begin with the choke in the OPEN
position. (Closed choke discs may result in hydraulic shock in the well bore and if the mud
pumps are running can result in lost returns and a downhole blowout.) For example: at the
start of a well control procedure, the choke e. should not be closed until after the blowout
preventer has been closed and drilling fluid is flowing through the manifold and Hydraulic
Choke. This helps to seat the discs and prevents mud particles from getting between the
discs. The choke should be closed slowly to avoid hydraulic shock on the surface pressure
control equipment and the casing seat.
A.

NORMAL OPERATING METHOD (FAST)

1)

Move master AIR SUPPLY valve to the ON position (See Figure 2).

2)
3)

Open the HYDRAULIC REGULATOR all the way.

The Control Console displays the following information that is typically used
in well control procedures.

Drill pipe pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 kPa increments).
Casing pressure 0-10,000 psi in 20 psi increments (0-68950 kPa in 138 kPa increments).
Choke position (full OPEN to full CLOSE).
Mud pumps stroke rate and stroke count.
4)

Be prepared to shift the CONTROL LEVER in either direction to maintain

the desired casing or drill pipe pressure.

NOTE:
A PLUGGED CHOKE MAY RESULT IN EXCESS PRESSURE BUILD-UP IN THE
SYSTEM THAT MAY EXCEED THE CASING PRESSURE LIMIT. IN CASE OF CHOKE
PLUGGING, SHIFT THE MAIN CONTROL LEVER TO OPEN AND OPEN THE
HYDRAULIC REGULATOR FOR FAST RESPONSE AS SOON AS THE PLUG IS
CLEARED. THE CONTROL LEVER MUST BE SHIFTED TO CLOSE LONG ENOUGH
TO RETURN TO THE DESIRED PRESSURE. THE HYDRAULIC REGULATOR VALVE
MAY THEN BE ADJUSTED FOR A SLOWER RESPONSE.
5) When the well control operation is complete, open the choke and turn master AIR SUPPLY
valve OFF to remove all pressure on the hydraulic system.
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B.

C.

ALTERNATE OPERATING METHOD (SLOW)

1)

If slow operation is desired, close the HYDRAULIC REGULA TOR all the
way. Then to adjust the choke disc speed, hold the CONTROL LEVER in the
CLOSE position and slowly open the HYDRAULIC REGULATOR valve.
This allows only a very slow movement of the choke disc. When the desired
pressure is reached, the CONTROL LEVER should be released.

2)

Open the HYDRAULIC REGULATOR valve if a faster response is needed.

EMERGENCYOPERATION
1)

Failure of air supply to air pump.

a)
b)

2)

Install PUMP HANDLE on the HAND PUMP which is mounted on the

base of the Control Console skid. (Be sure pump BLEED-OFF valve
on the HAND PUMP is closed).
To change choke opening, hold the CONTROL LEVER in the desired
position while stroking the HAND PUMP .

Rupture in Hydraulic line or connection.

a)
b)

If either hydraulic line is cut or ruptures, cut both lines at the choke.
The hoses must be cut and NOT DISCONNECTED. If they are
disconnected, check valves in the fittings will prevent operation.
Insert 5/8" (16mm) diameter rod into one of the holes in the
INDICATOR HEAD (See Figure 5) and manually position the choke
as desired.

Figure 5.
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4. SERVICE AND MAINTENANCE

A.

PROCEDURES
1)

ROUTINE INSPECTION
The QOT Hydraulic Choke is a key element of the pressure control
system used to prevent rig blowouts. Therefore, it is important that the
Hydraulic Choke and Control Console be maintained in good operating
condition at all times (See Figure 6).

Figure 6
2)

DAILY VISUAL CHECKS

heck the presence of a hand pump (Item 2 ), a manual choke operating
bar, and all panel labels.
Check fluid level in the hydraulic oil reservoir (Item I ). fill with the
correct hydraulic oil. Keep a supply of oil at the choke panel or close by.
See that all connections fit tight. Make sure the hydraulic hoses, pump
switch cable, and air-lines are properly connected and not cut or
pinched.
Check the Pump Stroke/Rate Meter (Item 8). Place the selector switch
on "TEST". The meter should be counting and should show 128 SPM,
Select Pump l or Pump 2 and observe counter and rate display. Reset
counter to zero after test.
-10-

See that the pump stroke counter switches (Item 3 ) are properly attached to the mud
pump and counting the correct number of strokes.
3)

DAILY OPERATIONAL CHECKS

Turn the master air supply valve (Item 5) on. The hydraulic pressure gauge (Item 12 )
should show 1000-1100 psi (6895-7584 kPa).
Close the hydraulic regulator (Item II) and then open I-I/2 turns. Operate the control
lever (Item 6 ). Complete a full cycle of the choke discs from full OPEN, to full
CLOSE, back to full OPEN. The position indicator (Item l0) should track the choke
disc movement according to the choke lever selection.
To operate the hand pump (Item 2 ) to close or open the choke discs, shut the air
supply off. Hold the choke control lever in desired position and operate the hand
pump. Make sure the bleed valve on the hand pump is closed. Leave the pump piston
in the DOWN position to avoid rust or corrosion.
Observe the Drill Pipe and Casing Pressure gauges (Item 7 ). The pressure value
should be approximately the same as the rig gauges. Gauge faces should be clean and
visible.

4)

REMOVING THE QOT HYDRAULIC CHOKE FROM THE MANIFOLD

CAUTION:
BEFORE ATTEMPTING TO WORK ON A ULTRAFLOW CHOKE IN A MANIFOLD,
EXTREME CAUTION SHOULD BE EXCERCISED TO ASSURE THAT THERE IS NO
PRESSURE TRAPPED IN THE CHOKE VAL YE OR CHOKE MANIFOLD. AL WAYS
USE PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAYBE TRAPPED IN THE
CHOKE VAL YE OR MANIFOLD. ONLY PERSONNEL WHO HA YE RECEIVED
INSTRUCTION ON THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT AND
PROCEDURES FOR WORKING IN AREAS WHERE H2S MAY BE PRESENT SHOULD
BE PERMITED TO WORK ON THE HYDRAULIC CHOKE. FAILURE TO FOLLOW
THESE INSTRUCTIONS COULD RESULT IN INJURY.
Rotate the choke discs to the full OPEN position. Allow the pressure in the choke
valve to be relieved before continuing with this procedure.
Carefully loosen the outlet flange nuts one turn each until seal or ring gasket is
broken but do not remove the nuts on the outlet flanges of the choke valve. After all
the nuts are loosened, break the seal on the ring gasket by separating the outlet flange
from the manifold flange. Stand on either side of the flange gap, never over it, when
breaking the seal to avoid possible severe personal injury. Once the seal is broken and
all pressure inside the choke is relieved, the nuts and studs may be safely removed.
Do not use a pry bar to remove flange because of possibly damaging the extended
wear sleeve.
Provide some manner of support for the valve then carefully loosen the upstream
flange nuts one turn until seal is broken and any trapped pressure is released, then
remove the nuts and studs on the inlet flange.
-11-

CAUTION:
THE ULTRAFLOW CHOKE IS RATED FOR H2S SERVICE THEREFORE THE
MATERIALS USED TO MANUFACTURE THE FLANGES, NUTS, AND STUDS ARE
RELA TIVEL Y SOFT AND SUBJECT TO SURFACE DISTORTION AND DENTS FROM
POOR WORK PRACTICES. CARE SHOULD BE EXCERCISED IN THE HANDELING
PROCEDURES AND USE OF TOOLS WHEN WORKING ON THE UL TRAFLOW
CHOKE TO A VOID DAMAGING THESE PARTS. DAMAGED PARTS WILL
ADVERSELY AFFECT THE STRUCTURAL INTEGRITY OF THE UL TRAFLOW
CHOKE AND MA Y RESULT IN INJURY.
1.
5)

Refer to -Section 2.A- of this manual for reinstalling the

choke in the manifold-

CHANGING THE DISC ASSEMBLIES

This section describes the procedure for removing the discs from the outlet end of
the valve body for inspection and or replacement and removal of the wear sleeves.

CAUTION
BEFORE ATTEMPTING TO WORK ON A ULTRAFLOW CHOKE, EXTREME
CAUTION SHOULD BE EXCERCISED TO ASSURE THAT THERE IS NO PRESSURE
TRAPPED IN THE CHOKE VALVE. AL WAYS USE PROPER SAFETY PRECAUTIONS
WHERE H2S GAS MAY BE TRAPPED IN THE CHOKE VALVE. ONLY PERSONNEL
WHO HA VE RECEIVED INSTRUCITON ON THE HAZARDS OF H2S, THE PROPER
SAFETY EQUIPMENT AND PROCEDURES FOR WORKING IN AREAS WHERE H2S
MAYBE PRESENT SHOULD BE PERMITTED TO WORK ON THE HYDRAULIC
CHOKE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
INJURY.
Carefully loosen the outlet-spool bolts on turn each. After all the bolts are loosened,
break the o-ring seal and unbolt the outlet spool, carefully separating it from the
body. The spool is fastened to the choke body with 7/8" ferry head cap screws. .
1.

To remove the choke discs, first rotate the front disc to the full
OPEN position if this has not been previously done. Wash any
sand, grit or weight material from around the exposed portion
of the back disc and disc opening.

2.

Insert the hook end of the disc puller in the disc opening as
illustrated in Figure 6a. and gently remove both discs using
the sliding weight on the puller.

CAUTION
TO AVOID INJURY, CAUTION SHOULD BE TAKEN TO AVOID GETTING ANY PART OF
THE HAND CAUGHT BETWEEN THE SLIDING WEIGHT AND THE STOP ON THE END
OF THE PULLER SHAFT.
Maintain the position of the hook on the puller to avoid chipping the corners of the disc orifice.
Even if the discs are worn they may be repairable if not damaged from this procedure. When the
discs have been removed, locate and inspect the stationary disc locking pin. Replace if damaged.
-12-

Figure 6a.
3.

Clean both disc assemblies thoroughly and inspect for wear or damage.
The primary criteria for determining whether or not the choke discs are
reusable is that they can provide a positive seal under pressure when
installed in the choke. See -Section 5.2- of this manual for Hydrostatic
Disc Test Procedure.

4.

Wash out and clean the interior of the choke body and the O-ring
sealing surfaces.

Remove the O-rings on the back disc carrier and the choke body flange
and replace these O-rings.

CAUTION
THE O-RINGS USED IN THE ULTRAFLOW CHOKE ARE MADE OF A SPECIAL
RESISTANT MATERIAL. USE ONLY O-RINGS SPECIFIED IN PARTS LIST
INCLUDED AT REAR OR THIS MANUAL
6.

Thoroughly clean the disc assemblies and apply a light film of silicone
grease to the O-ring groove on the rear disc carrier. Avoid getting
grease on the polished disc faces because this can cause the choke to
leak when tested.

7.

Insert the front disc assembly into the body so that the half-moon
opening side is facing the choke inlet flange. Be sure that the turning
fork fingers and the locating pin in one of the fingers align properly
with the slots and locating pin hole in the front disc assembly. The
front disc should fit loosely into the body and into the turning fork
fingers.
-13-

8.

Position the back disc locking pin in the groove on the inside diameter
of the choke body. Align the matching pin groove in the back disc
assembly and insert the back disc. Note: The moon-shaped opening
must be facing the inlet flange of the choke valve. (See Figure 7).

Figure 7

9.

To remove the outlet spool wear sleeves carefully press them out
through the end which bolts to the body. There are three identical large
internal diameter wear sleeves and one with a smaller opening that
protects the outlet flange seal.

10.

Inspect the wear sleeves for wear and replace as necessary.

11.

Before reinserting the wear sleeves, clean and inspect the bore of the
spool. Be especially careful to remove any dirt, rust or debris from the
shoulder where the extended wear sleeve makes contact. Failure to do
so may cause the wear sleeves to break the choke discs when the spool
is bolted to the valve body.

12.

Remove any dirt, rust or debris from the ends of the wear sleeves and
the shoulder on the extended wear sleeve. Apply a light film of silicone
grease on the outside of the wear sleeves and insert them into the
spool.

13.

Reassemble the outlet spool to the valve body using the alignment pins
and the ferry head cap screws. Check to be sure the O-rings are
properly positioned. Use only the screws and bolts specified in Parts
Listing at rear of this manual to assemble. Discard and replace any
damaged screws. Tighten these screws uniformly. The bolts should be
torqued to 165 Mbs (224 Nm). Over-torquing the bolts will cause them
to stretch and reduce their strength which can result in premature
failure.
-14-

14. Clean and inspect the inlet and outlet flange faces and ring grooves.
Apply a light film of general purpose grease or rust inhibitor to the face
and ring groove for corrosion protection.
6)

BONNET END DISASSEMBLY

This section describes the procedure for removal of the Actuator Assembly and
Bonnet from the Choke Valve. It also covers the removal and inspection of the
turning fork. These procedures may be done with the Hydraulic Choke either
installed in the choke manifold or removed.

CAUTION
BEFORE ATTEMPTING TO WORK ON AN HYDRAULIC CHOKE IN A MANIFOLD,
EXTREME CAUTION SHOULD BE EXERCISED TO ASSURE THAT THERE IS NO
PRESSURE TRAPPED IN THE CHOKE VALVE OR CHOKE MANIFOLD. ALWAYS
USE PROPER SAFETY PRECAUTIONS WHERE H2S GAS MAY BE TRAPPED IN THE
CHOKE VALVE OR MANIFOLD. ONLY PERSONNEL WHO HAVE RECEIVED
INSTRUCTIONS ON THE HAZARDS OF H2S, THE PROPER SAFETY EQUIPMENT,
AND PROCEDURES FOR WOKING IN AREAS WHERE H2S MAY BE PRESENT
SHOULD BE PERMITED TO WORK ON THE HYDRAULIC CHOKE. FAILURE TO
FOLLOW THESE INSTRUCTIONS COULD RESULT IN INJURY.
I.

The first step in disassembling the Bonnet from the Choke is to

remove the Actuator Assembly. Before doing this, position the choke
discs in the full OPEN position. To remove the Actuator Assembly
from the Choke Valve, remove the four bolts attaching the adapter to
the Actuator. This exposes the four bolts that attach the adapter to
the Choke Valve. Remove these bolts and proceed to the next step.

2.

Remove the cap screw attaching the Indicator Head to the Turning
Fork. Remove the Indicator Head from the Turning Fork shaft.

3.

Before removing the Bonnet, mark the Valve Body and Bonnet so
they can be reassembled with the same orientation. Remove the
remaining ferry head cap screw attaching the Bonnet to the body.
Inspect these screws for damage or distortion and replace as
necessary. Use only bolts specified in parts list at the rear of this
manual. Remove the Bonnet from the Valve Body.

CAUTION
MOST COMMON BOLTS, STUDS AND NUTS AVAILABLE DO NOT MEET THE
REQUIEMENTS FOR H2S SERVICE AND WILL FAIL FROM HYDROGENT
EMBRITTLEMENT. REPLACE BOLTS, STUDS AND NUTS WITH AUTHORIZED
REPLACEMENT PARTS.
4.

Push the Turning Fork out of the Bonnet being careful not to damage
the shaft surfaces that rotate inside the Bonnet.

5.

Clean the Turning Fork and inspect for wear or damage. The Thrust
Bearing and O-ring seal areas should be smooth. The hex should not
be rounded, cracked or deformed. Replace the Turning Fork if any of
these conditions exist. Lubricate the Turning Fork shaft with a light
application of silicone grease before reassembly.
-15-

7)

6.

Replace the Thrust Bearing, Shaft Bushing, all O-rings and backup
rings on the Bonnet. The parts that are used in the UltraFlow Choke
are made of special material for exposure to H2S gas. Use only parts
specified in parts list at rear of this manual to replace components in
the Hydraulic Choke.

7.

Reinsert the Turning Fork in the Bonnet being careful not to damage
the 0- rings or bushing. The Bonnet should be clean and have a light
application of silicone grease on the surfaces where there is contact or
close proximity to the Valve Body and Turning Fork.

8.

If the Outlet Spool is not to be removed from the body, the front disc
assembly must be properly positioned on the turning fork prior to
installation. Be sure to properly align the locating pin in the Turning
Fork finger with the alignment hole in the front disc assembly. The
polished surfaces on both the front and back disc must be completely
clean, dry and free of grease to assure proper seating.

9.

Clean the Indicator Head and apply a light film of grease to the
square and hex sockets. Check that the Indicator Head socket will fit
freely on the Actuator Assembly shaft. This will eliminate problem:;
when assembling the Actuator Assembly to the valve.

10.

When inserting the Bonnet assembly into the valve body, position the
half moon opening on the front disc toward the inlet flange and align
the marks described in Step 3 on the Bonnet and Valve Body.

11.

Reinsert and uniformly tighten the bolts securing the Bonnet to the
Valve Body and the Actuator Assembly to the Bonnet. Note: Four of
the bolts are longer than the rest. The longer bolts are used to attach
the Actuator Assembly to the Bonnet. The Actuator Assembly may be
positioned in three possible positions, but never up-side down. Care
should be exercised to assure that both the Actuator Assembly shaft
and the choke discs are in the OPEN position when these two
components are reassembled. Evenly torque these bolts to 165 ft./lbs
(224 Nm.) Over-torquing the bolts will cause them to stretch and
reduce their strength which can result in premature failure.

GAUGE PROTECTOR
The purpose of the Gauge Protector is to transmit fluid pressure from the drill pipe
or the casing to the Control Console and isolate the gauges from the drilling mud.
A.

Gauge Protector Repair

1.

If the hydraulic hose is to remain attached to the gauge protector,

remove the plug from the side of the body. This will permit air to
enter the body when the piston is removed.

2.

Remove the body from the female hub by removing the wing nut.

3.

Remove the stainless steel internal snap ring from the bore of the
gauge protector body.

-16-

4.

Insert a 1/2"-13NC bolt in the tapped hole at the bottom of the piston.
Use the bolt as a handle to extract the piston.

5.

Clean the piston and replace the O-rings on the piston. Use only the
size and type O-ring called for in the parts list at the rear of this
manual.

PISTONSTYLE GAUGE PROTECTOR

CAUTION
THE O-RINGS USED IN THE GUAGE PROTECTOR ARE MADE OF A SPECIAL H2S
RESISTANT MATERIAL. USE ONLY THE O-RINGS SPECIFIED IN THE PARTS LIST
AT THE REAR OF THIS MANUAL.

B.

6.

Clean and inspect the bore of the gauge protector body for corrosion,
wear and pitting. Replace the body if these conditions exist.

7.

Before reinstalling the piston apply an ample film of silicone grease on

the piston and O-rings. Manually insert the piston all the way into the
body. The piston should move in the body with only moderate physical
effort. If the piston sticks, replace the piston. Do not file or grind the
bore of the gauge protection body or O.D. of the piston.

Reinstall the stainless steel internal snap ring. Refer to -Section 4.7 Bof this manual for refilling the gauge protector with hydraulic fluid.
The body plug is replaced during the line filling procedure.

Filling Gauge Protector Lines

After assembly, the gauge protector, signal line and gauge lines on the Control Console
should be filled with hydraulic oil and purged of air. A few drops of oil will be lost each time
the line is coupled or uncoupled. It is, therefore, advisable to avoid disconnection these lines
once the system has been purged. Loss of hydraulic fluid in the lines may cause the gauge to
read incorrectly. The hydraulic fluid in the system must be free of air or full pressure cannot
be transmitted to the gauge.
-17-

1.

Place the gauge protector in a vertical position near the Control

Console. The signal line should be connected tightly to the gauge
protector and the Control Console manifold.

2.

Remove the check valve cap on the back of the Control Console
manifold and attach the hand pump loosely to the check valve (See
Figure 8). Do not tighten this connection yet.

3.

Fill the manual hand pump reservoir with hydraulic fluid. While
purging, keep the hand pump reservoir at least 1/2 full to avoid
pumping air into the line.

4.

Pump slowly, purging air from the pump at the loose connection.
When the pump is purged of air, tighten the connection between
the pump and the check valve.

5.

Turn the damper valve on the gauge counterclockwise several

turns to relieve the dampening effect.

6.

Remove the pipe plug on top of the gauge to allow air to bleed
from the system.
RESERVOIR COVER

HAND PUMP
Figure 8
7.

Pump fluid into the system until no air bubbles appear at the plug
on the gauge. Tighten the plug and push the damper valve in,
turning clockwise to engage the threads.

8.

Lay the hydraulic hose out as straight and flat as possible, below
the level of the gauge.

9.

Remove the plug from the gauge protector body.

10.

Pump hydraulic fluid into the system to purge all air from the
signal line and the gauge protector. Bleed air out at the gauge
protector plug opening.
-18-

8)

11.

When the signal line and gauge protector appear to be purged or air, continue
pumping slowly and rock the gauge protector slightly to help pass any
remaining air through the vent holes. Rotate the gauge protector plug end up,
to displace any air from the passage.

12.

When all the air has been purged from the system, replace the plug on the
gauge protector and tighten.

13.

Once the plug in the gauge protector is replaced, continue to pump

hydraulic fluid into the system until the piston contact the internal snap ring in
the bore of the gauge protector.

14.

Close the hand pump cover and remove the pump from the check valve.

15.

Replace the check valve cap.

POSITION INDICATOR SYSTEM

This system utilizes a 3 to 15 psi (21 to 103 kPa) air signal to operate an indicator gauge
on the Control Console. The signal comes from a plunger type regulator. As the choke is
rotated toward the "CLOSE" position, a cam connected to the Control Console shaft moves
the pivot arm assembly. The pivot arm assembly pushes on the regulator plunger and
increases the air signal. At the full OPEN position, the signal is 3 psi (21 kPa), at the full
CLOSED position the signal is 15 psi (103 kPa).
The Position Indicator gauge is labeled OPEN and CLOSE with a mark at the middle
position to indicate Y2 or 50% open. The Position Indicator serves as an aid in observing the
direction and speed of changes being made in the choke opening.
Calibration and Adjustment
Connect the supply air from the Control Console to the left tubing fitting, and connect the
signal return air to the right tubing fitting. Turn the air supply on (See figure 9).

-19-

Figure 9.
A.

To Zero the "Position the Indicator" Gauge

1.

Completely OPEN the choke.

2.

Loosen the 1/4" nut and set screws on the camshaft so the cam
turns on the shaft.

3.

Rotate the cam so the scribe mark on the short side of the cam lines
up with cam follower.

4.

Tighten shaft nut and set screws.

5.

Loosen the pivot block locking screw on rear of mounting plate

and turn the "zero" adjustment screw until signal output is 3 psi (21
kPa) on a test gauge, or "OPEN" on the position indicator gauge.

6.

Tighten pivot block locking screws.

7.

Be sure the output is 3 psi (21 kPa) when the the locking screw is
tight. Movement during tightening may slightly change the setting.
This can result in inaccurate readings of the position indicator. If
output is not 3 psi (21 kPa), adjust pivot block as indicated in Step
5 above to obtain the required 3 psi (21 kPa).

8.

Completely CLOSE the choke. The test gauge should read 15 psi
(103 kPa), or "CLOSED" on the position indicator gauge. If not, it
will be necessary to adjust the span of the Indicator Gauge.
-20-

B.

To Zero the "Span" of the Indicator Gauge

1.

Completely CLOSE the choke. This puts the scribe mark on the long side of
the cam at the cam follower. Output should be near 15 psi (103 kPa) on the
test gauge, or "CLOSED" on the position indicator gauge.

2.

If less that 15 psi (103 kPa), loosen both socket head cap screws and move
regulator bracket slightly away from the pivot block; if more than 15 psi (103
kPa), move regulator bracket slightly toward the pivot block.

3.

Tighten both socket head cap screws.

4.

Completely OPEN the choke. If output is not 3 psi (21 kPa), re-adjust the
pivot block as in Section 5.1.12 to 3 psi (21 kPa).

5.

Completely close the choke and check 15 psi (103 kPa) signals.

6.

Repeat Steps 1 through 5 until3 and 15 psi (21 and 103 kPa) outputs are
obtained.

NOTE:
IF IT IS NOT CONVENIENT TO USE THE CONTROL PANEL TO ROTATE THE CHOKE,
USE A SHORT ADAPTER CONNECTION BETWEEN THE "OPEN" AND "CLOSED"
CONNECTORS, AND ROTATE THE CHOKE BY HAND; HOWEVER, IT IS BEST TO
CHECK THE CONTROL CONSOLE AND CHOKE VALVE TOGETHER.
9)

DIGITAL PUMP/STROKE RATE METER

The QOT Digital Stroke / Rate Meter has been designed for simple maintenance. The meter
contains three interconnected modules; a display module, a switch module and a battery
pack. Should anyone of these modules fail, they are not repairable and must be replaced.
Refer to the Troubleshooting Guide in -Section 6.5-. Parts information is given in the rear of
this manual.

10)

ACTUATORASSEMBLY
See the Appendix for the manufacturer's instructions for repair and maintenance of the
Actuator Assembly.

5. PRESSURE TESTING
This section describes how to perform a shell and disc hydrostatic test on the Hydraulic
Choke. This test is not intended to supersede or duplicate the Standard API Specification 6A
Shell and Leak Test, but provide a routine procedure to verify that the seals and discs are not
leaking and to verify the integrity of the pressure containing parts.
A. PROCEDURES
1)

SHELL HYDROSTATIC TEST PRESSURE

1.

Completely OPEN the choke discs.

-21-

2.

Connect test flanges with isolation valves to the inlet and outlet flanges of the
Hydraulic Choke.

3.

Place the Hydraulic Choke with the side of the Actuator Assembly
housing and the outlet flange resting on the ground. The inlet flange is pointing
upward.

4.

With the isolation valves on the inlet and outlet flanges open, fill the choke
with water from the outlet end. When the choke appears to be full, raise the
outlet end until the centerline of the valve is parallel to the ground.

5.

Continue filling choke with water. When all of the air has been purged from
the choke, close the isolation valve on the outlet flange and
disconnect the water line. Lower the choke outlet to ground level.

6.

Open the hydraulic inlet valve and purge any air that may be trapped in the
hydraulic feed line.

7.

It may be necessary to purge air from the hydraulic line to the pressure gauge.
Open the bleed fitting for the pressure gauge and close the
isolation valve on the inlet test flange. Pump hydraulic oil through the gauge
line until all air is removed. Close the bleed fitting for the gauge.

8.

With the inlet and outlet isolation valves closed and the hydraulic inlet valve
open, slowly raise the pressure on the choke shell to 10,000 psi (68950 kPa).
Check the valve and test flanges for leaks. If leaks occur, stop the test, take
appropriate steps to correct the problem and repeat this test procedure.

9.

If no leaks are evident at this point, close the hydraulic valve on the inlet test
flange and observe the pressure gauge for three (3) minutes. If the pressure
begins to bleed down before three minutes, inspect the choke and test flanges
for leaks. Repair leaks as required and repeat this test procedure.

10.

Open the isolation valve on the outlet test flange and remove the test flanges.

CAUTION
DO NOT BLOCK THE DISCHARGE OPENING FOR THE ISOLATION VALVES. WHEN THE
VALVES ARE OPENED UNDER PRESSURE A SMALL QUANTITY OF WATER WILL
SHOOT OUT OF THE OPENING.
2)

HYDROSTATIC DISC TEST PROCEDURE

1.

To prepare the choke for the hydrostatic disc test, fill the valve with water and
remove all of the trapped air as described in -Section 5.A.l- Steps 1-7.

2.

With the isolation valves on the inlet and outlet test flanges closed, slowly raise
the pressure in the choke to approximately 2,500 psi (17238 kPa).

3.

With the hydraulic valve open and pump on, close the choke discs. Open the
isolation valve on the outlet test flange. This should seat the choke discs.
Slowly raise the pressure in the choke to 10,000 psi (68950 kPa) leaving the
outlet isolation valve open.
-22-

4.

Watch the test gauge for three (3) minutes. If the pressure bleeds down,
disassemble the choke to determine the cause for the leakage. Replace the
discs or seals as required and repeat this test procedure.

6. TROUBLESHOOTING
A.

DIAGNOSTIC GUIDES

1.

CHOKE DISCS WILL NOT OPEN OR CLOSE

CAUTION
BEFORE DISCONNECTING AIR OR HYDRAULIC LINES, TURN THE SYSTEM OFF AND
MAKE ABSOLUTELY SURE THAT ALL PRESSURE IN THE LINES HAS BEEN RELIEVED.
FAILURE TO
DO SO MAY RESULT IN INJURY.
To locate the problem when the Control Console will not operate the Hydraulic Choke, turn the
master air supply valve "ON". The control lever should be in the neutral "HOLD" position. Fully
open the hydraulic regulator by turning the knob counterclockwise several turns. If the hydraulic
pump cycles a few times and stops, proceed to Section -6.A.I-. Step 5.
If the hydraulic pump continues to cycle, proceed with the following steps in the order listed (See
Figure 10).
1.

Check the hydraulic fluid level in the reservoir. If less than half full, add the
correct hydraulic fluid, Do not use diesel oil because this will cause some
valve seals and hydraulic hoses to deteriorate.

2.

Check the low pressure suction hose between the reservoir and the hydraulic
pump for leaks, collapse or crimping. This condition will cause the pump to
lose prime and not pump fluid. Replace this hose as needed.

3.

Check the high pressure hose from the output manifold on the hydraulic
pump to the hydraulic regulator and from the hydraulic regulator to the
control valve for leaks. Replace these hoses as needed.

Figure 10
-23-

4.

Disconnect the return line on the hydraulic relief valve. This hose must temporarily be plugged to prevent hydraulic fluid in the reservoir from
leaking out. Make certain to remove this plug before reinstalling the hydraulic
relief valve return line. If hydraulic oil is leaking from the discharge of the
relief valve when the pump is cycling, slowly tighten the pressure adjustment
screw on the relief valve while observing the pressure gauge on the output
manifold on the hydraulic pump. When the maximum reading on this pressure
gauge reaches 1800 psi (12411 kPa) stop tightening the adjustment screw on
the relief valve and lower the air pressure on the air regulator feeding the
hydraulic pump until the hydraulic pressure drops to 1500 psi (10342 kPa). At
this point, the pump should stop cycling and the relief valve should stop
leaking from the return connection. If the relief valve continues to leak, replace
it.

5.

Remove the return line from the control valve. Start the hydraulic pump and
check the return connection for leakage. If hydraulic fluid leaks from this
connection, repair or replace the control valve.

6.

Remove the pump suction and discharge check valves. Check for debris or a
frozen valve. Repair or replace as needed.

7.

Inspect the open and close hydraulic lines to the choke form crimps, pinching
and damage. Replace as needed.

8.

Connect the "Choke Open" hydraulic line to the "Choke Close" hydraulic line
using the quick-connect hose coupling on the Actuator Assembly.

Operate the control lever to both the OPEN and CLOSE positions. If the hydraulic pump
begins to cycle when the control lever is moved to the OPEN and CLOSE positions, check the
hydraulic lines for the leakage and proceed to Step 9. Reconnect the hydraulic lines to the
Actuator Assembly.
9.

Turn off the air supply to the hydraulic pump and bleed the hydraulic
system to relieve the pressure in the lines between the hydraulic pump and the
rear manifold on the Console.

Remove the high pressure hose between the hydraulic regulator and the control lever. Make
sure the hydraulic regulator is open. Turn on the air supply to the hydraulic pump. If little or
no fluid flows through the hydraulic regulator, then it is plugged and must be repaired or
replaced.
10.

At this point if the Control Console will still not operate the choke, the
problem has been isolated to either the Actuator Assembly or the Choke Valve.
Remove the Actuator Assembly (See Section 2.B.) and rotate the
Actuator using the Control Console. If the Actuator does not rotate, check the
routing of hydraulic lines inside the Actuator cover and repair or replace as
needed. If the Actuator still does not rotate, replace the Actuator. (See
Appendix D for manufacturer's instructions.)

If the Actuator rotates when the control lever is operated the problem has been isolated to the
Choke Valve. Remove the Bonnet end of the choke using the procedure beginning the Section 4.6-. Clear debris from the valve or repair the choke and reassemble.
2)

CHOKE OPENS OR CLOSES TOO SLOWLY

1.

Check for partial plugging in the hydraulic regulator needle valve and in
the check valves of the quick disconnect hose couplings.
-24-

2.

3)

If faster choke response is desired replace the standard 3/16" ID high

pressure hose with 1/4" ID hose or hard piping. DO NOT EXCEED 15
psi (103 kPa) hydraulic pressure. If the Turning Fork becomes locked,
hydraulic pressure greater than 15 psi (103 kPa) could result in overtorqing and "twisting off' the end of the Turning Fork. This condition
would make it impossible to control the position of the choke discs.

CHOKE VALVE LEAKS

1.

Determine the location of the leak. If the leak is at the Bonnet end of
the valve, remove the Bonnet and Turning Fork from the body as
described in -Section 4.6- of this manual. Clean and inspect the sealing
surface for damage and wear. Replace the seals as required and
reassemble the valve as described in -Section 4.6-.

2.

If the Choke Valve leaks between the body and outlet spool, remove the
Hydraulic Choke from the manifold and repair the outlet spool end of
the valve as described in -Section 4.5-.

If the inlet or outlet flanges leak, remove the valve and replace the seals as described in Sections 4.5 and 4.6.
4)

CHOKE DISCS LEAK

There are several conditions that will cause the choke discs to leak. The repair
procedure to stop the discs from leaking is to disassemble the choke from the outlet
end and examine the internal parts to determine the cause for the leak. -Section 4.5describes the proper disassembly and inspection procedure.
Below is a list of conditions to be checked that will cause the choke discs to leak.

5)

Dirt, rust or other debris between the discs .

Worn or cracked discs
Damaged or improperly sized O-ring around the back disc
Missing or damaged back disc locking pin .
Front disc frozen to the turning fork .
Improper alignment of the front disc on the turning fork. Alignment pin may be
damaged or missing .
Improper orientation of the indicator head on the turning fork .
Improper alignment of the actuator shaft on the indicator head .
Worn or damaged thrust bearing between the bonnet and turning fork

DIGITAL PUMP STROKE/RATE METER

The rate meter contains three modules which are not field repairable, however, they
were designed for easy field replacement. Before replacing any of the modules, make
the following check: Place the selector switch in the "Test SPM" position. If the rate is
128 and the counter counts, the problem is probably with the wiring or the pump
stroke switches. The rate meter is working properly. If neither the wiring nor the pump
switches are bad, replace the switch module and repeat this test.
-25-

If the meter does not indicate in the test position, replace the logic module.
A troubleshooting symptom-cure table can be found at the rear of this manual.
6)

PRESSURE GAUGES NOT READING CORRECTLY

The pressure gauges located on the QOT Choke Control Console will, in almost all
cases, be the gauges which are used to determine drillpipe pressure and casing
pressure during operations involving the use of the QOT Hydraulic Choke. If these
gauges are not working properly, repairs should be made before operations involving
the Hydraulic Choke are undertaken.

7)

1.

Check that the dampening valve on the gauge is not closed.

2.

Check the hydraulic hose to the gauge protector for damage or

crimping.

3.

If the gauge fails to register correctly at higher pressures, check for air
in the hydraulic lines or improperly charged lines to the gauge
protectors. See -Section 4.7.B- of this manual.

4.

If the hydraulic lines to the gauge protector are longer than 100 ft. (30
meters), hard piping or special steel braided hose will be required.

POSITION INDICATOR NOT WORKING

1.

Check the air supply gauge on air regulator attached to the hydraulic
pump for a positive reading of 3-35 psi (27-241 kPa).

2.

Check air supply and signal lines for leaks and crimping.

3.

Make sure the cam is tight on the cam shaft and the cam shaft
connected to the actuator unit is tight and straight. The cam should turn
a fu11 180 when the choke position is changed from the OPEN to
CLOSED or from CLOSED to OPEN.

4.

Check choke position, 3 psi (21 kPa) applied directly to the gauge
should indicate "OPEN" of the gauge, and 15 psi (103 kPa) should
indicate "CLOSED", if the gauge is in good condition.

If the position gauge does not agree with the calibration band on the choke, See -Section
4.8.A&B- for the correct installation and adjustment.
-26-

MAINTENANCE AND OPERATION

MANUAL
PUMP STROKE RATE METER

Quality Oil Tools, Inc.

Jennings, Louisiana

P: (337) 616-3300

F: (337) 616-3299

DISCLAIMER

Any recommendation for use, oral or written, shall be considered advisory in content and as such,
Quality Oil Tools, Inc. shall not be held liable under any warranty, expressed or implied, should this
product not perform under conditions other than its intended use as a accumulative pump stroke
counting device.
Quality Oil Tools, Inc. shall in no way be liable for damages incurred while using this product.
File copies of this manual are maintained. Revisions and/or additions will be made as deemed
necessary by Quality Oil Tools, Inc. The drawings in this book are not drawn to scale, but any
dimensions are accurate.

INTRODUCTION
As with any electronic equipment the Quality Oil Tools, Inc. Pump Stroke/Rate Meter Assembly is
subject to wear and eventual failure. Periodic disassembly and inspection is required and should be left
to a qualified repair technician.
Every precaution has been taken to ensure the highest quality product has been provided for use. Any
question or correspondence should be directed to:
Quality Oil Tools, Inc.
P. O. Box 718
Jennings, Louisiana 70546
Telephone number (337) 616-3300
Fax (337) 616-3299
Email: sales@qualityoiltools.com

*** TABLE OF CONTENTS ***

SECTION

GENERAL INFORMATION
W ARRANTY INFORMATION

SECTION

II

TROUBLE SHOOTING AND MAINTENANCE

SECTION

III

REPLACEMENT PARTS

SECTION I
GENERALINFORMATION
The Quality Oil Tools, Inc. Digital Pump Stroke Rate Meter is a intrinsically safe
Class 1, Div. 1 unit designed for simple maintenance.
Because this unit is intrinsically safe no explosion proof housing or switches are required.
The meter contains three interconnected modules. They are the display module or PCB, the switch
module and the battery pack.
Should anyone of these modules fail they will have to be replaced as they are not field repairable.
The logic module (PCB) can be repaired if returned to Quality Oil Tools, Inc. factory.
Section II provides a trouble-shooting guide to assist in the repair of the counter assembly.
Section III provides a list of replacement parts for the Quality Oil Tools, Inc. Pump Stroke/Rate
Meter .
We have made every effort to document all necessary information which will allow users to install
and operate the QOT Rate Meter.
This information has been carefully reviewed and is believed to be accurate. However, no
responsibility is assumed for inadvertent omissions or errors that may appear in this document.

-31-

WARRANTY INFORMATION
Quality Oil Tools, Inc. Pump Stroke/Rate Meter is warranted to be free of defects in material and
workmanship under normal usage for a period of one year .
This warranty applies to the original purchaser only. The warranty
period shall be for one year from the date shipped when the product is used in a manner for which it
was manufactured.
Quality Oil Tools, Inc. liability for the Meter Assembly shall be limited to replacement, free or
charge on any parts found to be defective in materials or workmanship.
This limited warranty does not include service to repair damage to the product resulting from
accident, lightning, high voltage, disaster, misuse, abuse, modification or service to the product
unauthorized by Quality Oil Tools, Inc.

SECTION II
TROUBLESHOOTING AND MAINTAINENCE
This section discusses troubleshooting and maintenance for the digital
stroke/rate meter system assembly.
The Pump Stroke/Rate Meter system is powered by a built in battery pack. No outside source or
power is required.
The meter assembly contains three modules which were designed for easy field replacement.
Before replacing any of the three modules, check the counter assembly as follows:

Place the selector switch in the "Test SPM" position.

The rate meter should read: "60 strokes / min. and count 1,2,3,4 "

Should the counter read as above it is working properly and the problem may be in
the wiring or limit switch assemblies.

If after making any necessary repairs the counter is still not working properly the
switch module should be replaced.
If there are no indications in the Test/Spill position or the readout is not working
properly, replace the Logic Module.

REMEMBER:

LIMIT SWITCHES MUST BE WIRED IN NORMALLY OPEN

FOR MAXIMUM BATTERY PACK LIFE.

-33-

Quality Oil Tools, Inc.

P. O. Box 718
Jennings, Louisiana 70546
Telephone: (337) 616-3300
Fax: (337) 616-3299
E-mail: sales@qualityoiltools.com

API-6A-0607
Q1-0036
ISO 9001:2000-0308

Hydraulic Choke Maintenance Manual Release 1.0 July, 2004

8