®

1:1 Piston Separator

Installation and Maintenance Manual

TM-517 TM
Part Number Edition Date

TM-517 First June 2005

Copyright © 2005 Acadiana Oilfield Instruments, Inc. All rights reserved.

AOI Instrumentation is a registered trademark of Acadiana Oilfield Instruments, Inc.

The AOI logo is a trademark of Acadiana Oilfield Instruments, Inc.
All other brand names and product names are trademarks or registered trademarks
of their respective companies.

AOI Instrumentation
105 Bonin Road
Lafayette, Louisiana 70508 USA
www.aoiinstrumentation.com

Printed in the U.S.A.

4 TM-517 1:1 Piston Separator Installation and Maintenance Manual

Contents

1 Introduction 7
Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Installation 9

3 Maintenance 15
Making periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Charging the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing piston separator seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A Illustrated Parts List 27

Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Parts and part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Recommended spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1:1 Piston Separator Installation and Maintenance Manual TM-517 5

6 1:1 Piston Separator Installation and Maintenance Manual
1 Introduction
This manual explains how to install, operate, and maintain the
AOI Instrumentation® 1:1 Piston Separator.

The piston separator is a device that transfers pressure in a 1:1 ratio from well
fluids such as cement, acid, and mud to a remotely located gauge or recorder.

Caution Before installing or operating a piston separator, carefully

read the warnings, instructions, and cautions in the
associated sections of this book.

Principle of operation

The piston separator is installed in a vertical position at the location where the
pressure is to be measured. As mud pumps push the fluid through the line, the
pressure changes are transmitted from the piston separator through a
hydraulic hose to the gauge or recorder. The ratio of mud pump pressure to
instrument fluid pressure is 1:1.

hydraulic hose
between piston piston
separator and gauge separator
or recorder assembly

fluid line

1:1 Piston Separator Installation and Maintenance Manual TM-517 7

Chapter 1. Introduction

Main components

Main components

Figure 1 shows the main components of the 1:1 Piston Separator.

Note:
The piston separator is
available in six different Figure 1. Piston separator main components
configurations. See
“Configurations” on page 27.

cylinder

wing nut

seal ring

sub

Specifications

Table 1. Piston Separator specifications

Description Specification

Working pressure maximum 15,000 psi

Proof test pressure ratings 150% of working pressure ratings

Volumetric capacity (full stroke) 13.4 in3 (220 cm3 )

Mounting pipe size 2-inch

Dimensions Height: 13.25 in (33.6 cm)

Width: 7.50 in (19.0 cm)

Weight 29 pounds (13.15 kg) (with fluid)

8 TM-517 1:1 Piston Separator Installation and Maintenance Manual

2 Installation
Note
The piston separator is filled with hydraulic fluid at the factory.

Figure 2. Piston separator dimensions

7.50 in
(19 cm)

13.25 in
(33.6 cm)

2.50 in
(6.35 cm)

1:1 Piston Separator Installation and Maintenance Manual TM-517 9

Chapter 2. Installation

1. Install the gauge or drilling recorder. (See the instructions included with
the gauge or recorder.)

2. Install a shut-off valve between the flowline and the piston separator, to
enable inspection of and/or repairs to the piston separator and pressure
gauge system.

3. Install a 2-inch inline butt-weld or tee connection and nipple as shown in

Figure 3.

Figure 3. Installing the piston separator

wing nut
check valve

sub

shut-off valve

Inline weld Inline tee

10 TM-517 1:1 Piston Separator Installation and Maintenance Manual

 Chapter 2. Installation

4. On the piston separator, loosen the wing nut; then turn the sub and remove
it from the wing nut.

cylinder

wing nut

seal ring

sub

Caution When the sub is removed, handle the cylinder with care to
prevent contamination and damage.

5. Screw the sub to the flowline, or butt-weld the sub to the flowline
according to API welding practices.

1:1 Piston Separator Installation and Maintenance Manual TM-517 11

Chapter 2. Installation

6. Use a clean, soft, lint-free cloth to wipe the inside of the sub until it is
clean; then insert the seal ring with the metal ring facing up, toward the
inside of the cylinder.
check valve

wing nut

cylinder

seal ring, with metal ring

facing up

sub

7. Lower the cylinder onto the sub, engaging the seal. Tighten the
wing nut to secure the connection.

12 TM-517 1:1 Piston Separator Installation and Maintenance Manual

 Chapter 2. Installation

8. Route the hose between the gauge or recorder and the piston separator so
the hose will not be crushed, cut, or otherwise damaged.

Caution Allow sufficient slack in the hose to prevent the hose from being
pulled out of the equipment the hose is connected to. Excess
tension can cause fittings or connectors to fail.

9. With the piston separator installed on the riser, remove the plastic plug
from the hole opposite the check valve, and connect the hydraulic hose at
that location.

hydraulic hose
between
piston separator and
gauge or recorder check valve

10. Fill the system with fluid according to the instructions in “Charging the
system” on page 15.

Note
The first time the piston separator is used, closely observe the piston
separator and all the pump pressure gauge system connections for leaks.

1:1 Piston Separator Installation and Maintenance Manual TM-517 13

14 TM-517 1:1 Piston Separator Installation and Maintenance Manual
3 Maintenance

Making periodic inspections

Visually inspect the piston separator for cracks, cuts, dents, leaks, and fluid
load.

Check the hydraulic hose for cuts, cracks, and kinks. Make sure all
connections are tight.

Table 2. Periodic inspections

Component Clean Inspect Service

Piston During Daily. As required.

separator maintenance,
clean residue
build-up.

Hydraulic hose Clean residue Daily. Anytime connection is

build-up. broken, apply pipe sealant.

Charging the system

When you first install the piston separator and whenever necessary, add fluid
to the system according to the instructions in this section.

Warning To prevent injury to personnel and to avoid damaging equipment,

remove pressure from the piston separator before you loosen
the piston separator wing nut.

1. Remove pressure from the piston separator.

1:1 Piston Separator Installation and Maintenance Manual TM-517 15

Chapter 3. Maintenance

Charging the system

2. Remove the piston separator body from the sub by unscrewing

the wing nut.

hydraulic hose
between
piston separator and
gauge or recorder
body

wing nut

sub

flowline

3. Raise the piston separator body to a position slightly higher than the
gauge or recorder.

piston separator
body (raised to a
position higher
damper than the gauge or
recorder)
stem

2500
2000
3000
1500 PUMP P
RESSUR
PSI E
3500

1000
AOI
INSTR
UMEN
TATIO
N 4000
500

0
5000 4500

16 TM-517 1:1 Piston Separator Installation and Maintenance Manual

 Chapter 3. Maintenance

Charging the system

4. On the piston separator, remove the bleed plug.

hose to bleed hand pump

gauge or plug
recorder

swivel nut

check valve

5. On the piston separator, remove the check valve cap and connect a hand
pump (p/n 101349-102) to the check valve.

6. Fill the hand pump reservoir with hydraulic fluid (p/n A-11).

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

7. Pump the hand pump to bleed air from the pump at the check valve. When
bubbles cease, tighten the swivel nut.

8. Bleed air from the bleed hole located at the top of the piston separator
until no bubbles appear; then replace the bleed plug.

bleed plug

bleed hole

1:1 Piston Separator Installation and Maintenance Manual TM-517 17

Chapter 3. Maintenance

Charging the system

9. If the system includes a gauge:

Remove the hex plug.

hex plug

2500
2000
3000
1500 PUMP P
RESSUR
PSI E
3500

1000
AOI
INSTR
UMEN
TATIO
N 4000
500

0
5000 4500

If the system includes a recorder:

Inside the recorder, loosen the tubing connection on the pressure tube
socket.

inside wall
tubing of recorder case

tubing
connection
nut

18 TM-517 1:1 Piston Separator Installation and Maintenance Manual

 Chapter 3. Maintenance

Charging the system

10. At the gauge and/or recorder, open the damper at least 1-1/2 to 2 turns.

Turn the stem

counterclockwise.

2500
2000
3000
1500 PUMP PR
ESSURE
PSI
3500

1000
AOI
4000
INSTRUM
ENTAT
ION

500
0
5000 4500

11. Repeat the bleed process until the air bubbles stop appearing at the gauge
or recorder.
12. If the system includes a gauge:
Replace the hex plug you removed in step 9.
If the system includes a recorder:

Tighten the tubing connection you loosened in step 9.

13. Pump the hand pump until the gauge shows a slight preload or until the
piston inside the piston separator is at its lowest position.

Piston position anywhere above

lowest position indicates a partial
preload. You can add fluid.

Piston in lowest position indicates

a full preload. No need to add fluid.

1:1 Piston Separator Installation and Maintenance Manual TM-517 19

Chapter 3. Maintenance

Charging the system

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

15. Replace the piston separator onto the sub and tighten the wing nut.

Note
After you charge the system, closely observe the piston separator and
all pump pressure gauge system connections for leaks.

20 TM-517 1:1 Piston Separator Installation and Maintenance Manual


Troubleshooting
Table 3. Troubleshooting
Problem
Erratic or sluggish
indications
No gauge indication
Gauge indication too
high at zero
1:1 Piston Separator Installation and Maintenance Manual
Chapter 3. Maintenance
Troubleshooting
Most initial operating problems are caused by improper installation of system
components. See Chapter 2 to make sure the installation was correctly
performed. Then, if necessary, refer to Table 3 for more help.
Probable Cause Corrective Action Refer to ...
Improper damper setting Correct the damper setting. Gauge or recorder
documentation
Air in hydraulic system Purge the system. “Charging the system” on
page 15
Insufficient instrument fluid Check all system components to “Charging the system” on
make sure they are not page 15
damaged. Repair or replace any
damaged components; then add
fluid (p/n A-11).
Faulty piston seals Replace the seals. “Replacing piston separator
seals” on page 23
Broken or plugged hose Clean or replace the hose. page 13
Damper closed Correct the damper setting. Gauge documentation
No hydraulic fluid Check all system components to “Charging the system” on
make sure they are not page 15
damaged. Repair or replace any
damaged components; then add
fluid (p/n A-11).
Gauge internal mechanism Replace gauge. Contact AOI.
damaged
Gauge out of calibration Send gauge to AOI for Contact AOI.
re-calibration.
Too much instrument fluid Bleed off some fluid. “Charging the system” on
page 15
Gauge internal mechanism Replace gauge. Contact AOI.
damaged
TM-517 21
Chapter 3. Maintenance

Troubleshooting

Table 3. Troubleshooting (continued)

Problem Probable Cause Corrective Action Refer to ...

Gauge indication too Insufficient instrument fluid Check all system components to “Charging the system” on
low make sure they are not page 15
damaged. Repair or replace any
damaged components; then add
fluid (p/n A-11).

Gauge internal mechanism Replace gauge. Contact AOI.

damaged

Air in hydraulic system Purge the system. “Charging the system” on

page 15

Gauge out of calibration Send gauge to AOI for Contact AOI.

re-calibration.

22 TM-517 1:1 Piston Separator Installation and Maintenance Manual

 Chapter 3. Maintenance

Replacing piston separator seals

Replacing piston separator seals

Before you begin, have the following equipment at hand:

■ 3/8–16 x 4-inch bolt, which you will use to remove the piston
■ Seal lubricant
■ Thread-locking compound
■ Spanner wrench (p/n 517094-1)
■ Hydraulic fluid (p/n A-11)

Note
The piston separator includes Belleville spring washers. When you
replace the seals, you must retain the washers exactly as they were
installed at the factory (see Figure 4 on page 24).

Warning To prevent injury to personnel and to avoid damaging equipment,

remove pressure from the piston separator before you loosen
the piston separator wing nut.

1. Turn the piston separator upside down so that the retainer nut is visible
(see Figure 4, on the next page). Remove the retainer nut.

1:1 Piston Separator Installation and Maintenance Manual TM-517 23

Chapter 3. Maintenance

Replacing piston separator seals

Figure 4. Piston separator – exploded view

hose connector bleed plug

hole

piston

UP piston seals (2) flat washer

and
Belleville
washers
DOWN

BEVEL

BEVEL

retainer nut BEVEL

BEVEL

alternate sub
sub

24 TM-517 1:1 Piston Separator Installation and Maintenance Manual

 Chapter 3. Maintenance

Replacing piston separator seals

2. Remove the Belleville washers and the flat washer.

Note
Take care to note the placement of each Belleville washer. When you
put the piston separator back together again, you will need to replace
the washers exactly as they were installed at the factory.

3. In this step, you will remove the piston from the cylinder. When the piston
is removed, fluid will drain out through the hose connector hole.

Insert a 3/8–16 x 4-inch bolt in the hole on the bottom of the piston and
carefully pull the piston out of the cylinder.

4. Note how the two piston seals are installed on the piston; then remove
the seals.

5. Use seal lubricant to thoroughly grease the piston.

6. Install the new piston seals (p/n 517037).

7. Use seal lubricant to again grease the piston and the seals.

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

9. Carefully reinstall the piston in the cylinder, replacing the Belleville

washers exactly as they were originally installed.

10. Replace the retainer nut, using thread-locking compound. Torque the nut
with the spanner wrench (p/n 517094-1) to 85 + 10 foot/pounds.

1:1 Piston Separator Installation and Maintenance Manual TM-517 25

26 TM-517 1:1 Piston Separator Installation and Maintenance Manual
A Illustrated Parts List
This appendix contains information about the main components of the
1:1 Piston Separator.

Configurations

The piston separator is available in six configurations, as shown in Table 4.

Note
Configurations without subs are for use when the piston separator will
replace an existing gauge protector. When the separator replaces a
gauge protector, the sub from the gauge protector is used on the
separator. (A seal ring, p/n 98-2665, is furnished.)

Table 4. Piston Separator configurations

Maximum Working
Configuration Description Pressure

517038-1 Separator with welded sub 15,000 psi

517038-2 Separator with threaded sub 10,000 psi

517038-3 Separator without sub 15,000 psi

517038-4 Separator with welded sub; 10,000 psi

with H2S wing nut

517038-5 Separator without sub; 10,000 psi

with H2S wing nut

517038-6 Separator only, with wing nut and sub Depends on the
of your choice wing nut and sub
you choose.

1:1 Piston Separator Installation and Maintenance Manual TM-517 27

Appendix A. Illustrated Parts List

Parts and part numbers

Parts and part numbers

Figure 5. Piston separator main parts

3
2
1
4

6 17

18 19

AOI INSTRUMENTATION

8
UP
9
15

8
DOWN

BEVEL

BEVEL
10
11 BEVEL

12 BEVEL

14
13 16

28 TM-517 1:1 Piston Separator Installation and Maintenance Manual

 Appendix A. Illustrated Parts List

Parts and part numbers

Table 5. Piston separator part numbers

Model/Quantity Required

Figure No.-
Item No. Part Number Description -1 -2 -3 -4 -5 -6

5 517038 PISTON SEPARATOR

- 1 98P-21 . CHECK VALVE, with cap 1 1 1 1 1 1

- 2 9811490 . CROSS, 1/4 NPT 1 1 1 1 1 1

- 3 98-689 . PLUG, 1/4 NPT 1 1 1 1 1 1

- 4 98-1292 . PLUG, Plastic, 1/4 NPT (used for 1 1 1 1 1 1

shipping and storage only)

- 5 98-808 . BUSHING, 1/2 x 1/4 NPT 1 1 1 1 1 1

- 6 98-2685 . NUT, 2-inch union, 1502 1 1 1 - - -

- 7 517035 . CYLINDER 1 1 1 1 1 1

- 8 517037 . SEAL, Piston (Viton) 2 2 2 2 2 2

- 9 517036 . PISTON 1 1 1 1 1 1

- 10 51726A-02 . WASHER, Belleville 4 4 4 4 4 4

- 11 517432 . NUT, Retainer 1 1 1 1 1 1

- 12 98-2665 . RING, Seal, 2-inch union 1 1 1 1 1 -

- 13 98-073 . SUB, Female, welded, 1502 1 - - - - -

- 14 98-2675 . SUB, Female, threaded, 1502 - 1 - - - -

- 15 517076A . WASHER, Flat, special 1 1 1 1 1 1

- 16 98-073A-1 . SUB, Female, welded, H2S, 1502 - - - 1 - -

- 17 98-2688 . NUT, 2-inch union, H2S, 1502 - - - 1 1 -

- 18 517361 . NAMEPLATE 1 1 1 1 1 1

- 19 517831 . SCREW, Drive 2 2 2 2 2 2

not shown 517094-1 . SPANNER WRENCH 1 1 1 1 1 1

1:1 Piston Separator Installation and Maintenance Manual TM-517 29

Appendix A. Illustrated Parts List

Recommended spares

Recommended spares

The following items are recommended for field maintenance of the piston
separator:

Table 6. Piston Separator spares

Part Number Description Quantity

517037 SEAL, Piston (Viton) 2

98-2665 RING, Seal 1

51726A-02 WASHER, Belleville 4

517432 RETAINER NUT 1

517094-1 SPANNER WRENCH 1

30 TM-517 1:1 Piston Separator Installation and Maintenance Manual