Part Number TW714

Revision A

INSTALLATION, OPERATION, AND MAINTENANCE

WITH
ILLUSTRATED PARTS LIST

PISTON SEPARATOR
MODEL P10038A

Manufacturers of Precision Instruments

Printed in U.S.A. December 1983

 Manual TW714 contains 12 pages, divided as follows:

Cover. ....................... December 1983

ii through iv. .................. December 1983
Pages l-8 .................... December 1983

All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.

Information in this manual is subject to change without notice.

 IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

December 1983 Page iii

M/D TOTCO
 LIMITED PRODUCT WARRANTY
THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company’s judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility,

B. Any product which has, in the Company’s judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company’s obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company’s standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY’S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

Page iv December 1983

M/D TOTCO
MARTIN-DECKER TW714

SECRON 1.0 SECI’ION 2.0

XNTRODUC‘ITON DESCRIPTION
1.1 INTRODUCTION. This manual 2.1 PHYSICAL DESCRIPTION. The
contains the description, installation, and P10038A 1:l Piston Separator consists of
maintenance information for four major components as shown in Figure
MARTIN-DECKER. P10038A 1:l Piston 2-l.
Separator. Included is information relative to
the use of the Piston Separator with pressure a. Cylinder - Manufactured from 17-4 PH
fwfw and recorders. Instructions are stainless steel to operate at pressures up
included for using the P10038A Piston to 15,000 psi (Tested to 22,500 psi).
Separator as a direct replacement for the
Martin-Decker El7 Gauge Protector. Review b. Wing Nut - Designed to union the Female
this manual before ins&Ration and operation Sub and Cylinder into an assembly.
of the 1:l Piston Seperator.
c. Seal Ring - Designed to seal the the union
1.2 PRECAUTIONARY INFORMATION. of Female Sub and Cylinder for pressures
Precautionary information included in up to 15,000 psi.
Martin-Decker manuals, where applicable, is
for aid in operation, protection of equipment, d. Female Sub - Designed to fasten to a 2-
and safety to personnel. inch pressure pipe that holds the Piston
Separator assembly.
Application is as follows:
a. NOTE. Used to caII special attention
to specific procedures or requirements
associated with the text.
b. CAUTION. Used where malfunction of
equipment or damage to equipment
may cause interruption of service.
C. WARNING. Used where malfunction
of equipment or damage to equipment
could result in serious or fatal injury
to personnel or major property loss.
Location of the precautionary notices used in
this manual are shown on Page i. Ensure aR
personnel who will be performing the
procedures in this manual have read the
IMPORTANT SAFETY NOTICE on page A.
1.3 UNPACKING AND INSPECTION. The
shipping container is constructed to protect
the Piston Separator from normal shocks and
vibration encountered during shipment.
Unpack the system carefuRy and perform the
f 0IIowingz /EMALEsuB

a. Carefully check al.I items shipped against

the packing list, and examine for hydraulic
leaks and damaged parts.
b. Notify the shipping agency and
MARTIN-DECKER immediately in the Figure 2-l. Piston Separator Major
event of damaged or missing parts. Components
12A3 page1
 TW714
2.2 ORDERING INFORMATION. The
Piston Separator is available in six
configurations:
P10038A-01 Separator with Welded Female
Sub
P10038AdI2 Separator with Threaded Female
Sub
P10038A-03 Separator without Sub
P10038A-04 Separator with Welded Female
Sub (H2S Service)
P10038A-05 Separator without Sub, with Nut
for H2S Service
P10038A-06 Separator only, without Sub or
Nut (Xust be used with Lug Nut and
Female Sub of user’s choice)
2.3 The Piston Separator may be furnished
without a female sub when used as a
replacement for the El7 Gauge Protector
(See Table 8-l), in which case the existing
El7 Sub is used. SeaI ring (B10252A) is
furnished.
2.4 OPERATIONAL DESCRIPTION. The
PlO938A Piston Separator is a 1:l ratio
piston device which transfers pressure from
welI fluids (mud, cement, acid, etc) to a
remotely located gauge or recorder. The
Piston Separator is used for working
pressures up to 15,000 psi, with a l/4 inch
high presssure hydraulic hose.
2.5 SPECIFICATIONS:
l Working pressure Ratings:
P10038A-01 - 15,000 psi
P10038A-02 - 10,000 psi
P10038A-03 - 15,000 psi
P10038A-04 - 10,000 psi
P10938A-95 - 19,000 psi
P10038A-96 - See Para. 2.2
l Proof Test Pressure Ratings:
150% of working pressure ratings
l Volumetric Capacity: (FulI Stroke)
13.4 cu. in. (220 cc)
l Mounting Pipe size: 2 inch
l Dimensions:
Height: 13.25 in. (336 mm)
Width: 7.50 in. (190 mm)
l Weight: 29 lb.(with fluid)
page2
MARTIN-DECKER
SECI'ION 3.0
INSTALLATION
- WARNING -
Do not attempt to remove the
Separator from the flow line
untiI aR pressure has been
removed from the Separator.
Personal injury could result.
NOTE: A shut-off valve should
be instailed between the flow
line and the Piston Separator for
inspection and/or repair of the
Separator and gauge (or
recorder).
NOTE: The Piston Separator is
usually mounted in the vertical
position to aRow well fluids to
drain out of the cylinder when it
is not operating.
3.1 REPLACING THE El7 GAUGE
PR0l'ECM)R WITH THE P10038A PJSTON
SEPARATOR
a. Shut down the pumps or close the shut-off
valve to remove aR pressure from the
flow line.
b. Check the gauge or recorder for preload;
bleed if required.
c. Disconnect the hydraulic hose from the
El7 Gauge Protector.
d. Loosen the wing nut until disengaged
from the female sub. Lift the El7 and
wing nut from the female sub.
NGTE: If the P10038-06 Separator
is replacing the El7 Protector,
continue with step e. If the
P10038A-03 Separator is used, skip
to step f.
e. Remove the check valve from the El7
Gauge Protector in order to remove the
wing nut. This wing nut will be used on
the P10038A-06 Separator when installed.
12A3
MARTIN-DECKER
f. Wipe the inside of the female sub clean
and remove the old seal ring. When the
female sub is clean, insert the new seal
ring (P/N B10252A) with the metal ring
facing out.
g. Install the P10038A Piston Separator
(with wing nut) on the female sub and
tighten down.
NOTE: The check valve will have
to be removed from the P10038A
Separator in order to place the
wing nut on the Separator.
Replace the check valve after
installing wing nut.
h. Remove the plastic plug opposite the
check valve. Connect the hydraulic hose
to the Seoarator.
I.. Charge the system per Paragraph 5.1.
CAUTION
Closely observe the Piston
Separator and all connections
for leaks the first time the
system is made operational,
j. Turn on the pumps or open the shut-off
valve.
3.2 INITIAL INSl'ALLATION OF THE
P10038APISTONSEPARATOR.
a. Referring to Figure 2-1, loosen Wing Nut
(item 21, then turn the Female Sub (item
4) from the wing nut.
CAUTION
With the female sub removed,
handle the Cylinder (item 1)
with care to prevent
contamination or damage.
12A3
TW714
NOTE: The Seal Ring (item 3) is
shipped loose from the factory.
b. Screw the female sub to the flow line; or,
if using a welded female sub, carefully
butt weld to the flow line per accepted
API welding practices.
c. With a clean, soft, lint-free cloth wipe
the inside of the female sub clean; then
insert the seal ring with the metal ring
facing out.
d. Lower the cylinder into the female sub,
engage the seal. Tighten the wing nut to
secure the connection.
NOT& The Piston Separator is
filled with hydraulic fluid prior
to shipment from the factory.
e. With the cylinder installed on the riser,
remove the plastic plug opposite the
check valve and connect the hydraulic
hose from the gauge or recorder.
I. Charge the system per Paragraph 5.1.
CAUTION
Closely observe the Piston
Separator and all connections
for leaks the first time the
system is made operational.
g* Turn on the pumps or open the shut-off
valve.
SECllON 4.0
CALIBRATION
4.1 The Piston Separator has been tested at
the factory before shipment, and requires no
calibration prior to operation.
page3
TWVl4 MARTIN-DECKER

SECIION 5.0
MAINTENANCE

5.1 PERIODIC RECHARGE. Periodically

attach the hand pump and recharge the HAND PUMP CHECK VALVE
system. Experience with the Piston \ \
Separator will determine the time span for
fluid recharge. Purge and recharge the
system as follows (Refer to Figure 5-l):

NOT& It is recommended that the

Separator be positioned vertically
during recharging to insure proper
P@ng.

a. Check system co~ections for integrity.

b. Close the damper on the gauge.

Figure 5-l. System Purging and Recharging
c. Remove check valve cap and secure the
YA2 hand pump to the check valve. Do
not tighten swivel nut,
g. Remove hand pump from the check valve
and replace check valve cap.
d. Fill hand iwmp reservoir with
MARTIN-DECKER WlS/WlS Hydraulic
Fluid.
h. Adjust pointer sensitivity to operator’s
preference.
e. Stroke hand pump to bleed air from pump
and swivel at check valve. When bubbles
cease tighten swivel nut.
CAUTION

CAUTION Closely observe the Piston

Separator,
-- gauge (or recorder) and
Keep hand pump reservoir half full all connections for leaks the first
at all times to avoid introducing time the system is operated after
air into the system. recharge.

f. Open the damper at the gauge l-1/2 to 2

turns and stroke hand pump until the 5.2 SEAL RXPIACEMENT. Seal
gauge (or recorder) shows a slight replacement is determined through
preload, then bleed air at bleed plug on experience with respect to well fluids,
top of cylinder. Repeat preload and bleed pressures and use time. See Paragraph 7.2
process at plug until no bubbles appear. for seal replacement procedures.

mF4 12A3
 MARTIN-DECKRR TOOT14

SECI’ION 6.0
TROUBLESHOOTING
6.1 START-UP PROBLEMS. Mast initial
operating problems are caused by improper
facility preparation and/or incorrect product
installation. Verify proper installation per
Section 3.0 of this manual before performing
the troubleshooting procedures in this
section.
6.2 Most common system malfunctions can
be remedied by using Table 6-l.
SEcnON 7.0
REPAIR
7.1 REMOVING CYLlNDER ASSEMBLY
FROM FJMALB SUB AND FLOW LINE
(Refer to Figure 8-l).
a. Shut down the pumps or close shut off
valve to remove all pressure from the
flow line.
b. Check the gauge or recorder for preload,
bleed if required.
c. Loosen Wing Nut (item 6) until disengaged
from the Female Sub (item 13). Lift the
cylinder and the wing nut off the female
sub.
d. If the Piston Separator is to be removed
from the site, there is the option of
including the gauge (or recorder), or to
disengage the hydraulic hose at the Piston
Separator. If the hose is disengaged at
the Piston Separator, close the damper
stem at the gauge. When reinstalling the
Piston Separator always use a new seal
ring (P/N B10252A) and refer to
Paragraph 5.1 for recharge information.
7.2 REPLACEMENT OF PISI’ON WEAR
SEAIS (Refer to Figure 8-l).
CAUTION
All Piston Separators have
temperature compensating
Belleville Spring Washers (item
10) installed under the piston.
These washers must be retained
exactly as installed at the
factory (See Figure 8-l).
a. Disconnect hydraulic hose from the
Piston Separator.
b. Remove Piston Separator from female
sub per paragraph 7.1 and slide off wing
nut.

TABLE 6-l. Malfunction Isolation Chart

I MALPUNCTXON I PROBABLE CAUSE I CORRECI’IVE ACTION I
Erratic or Sluggish Improper Damper Setting Correct Damper Setting
Indications
Air in Hydraulic System Purge System per Para. 5.1
Faulty Piston Seals Replace seals

II No Gauge Indication I Broken or Plugged Hose

t
II Clean or Replace Hose
I 4
I
I 1Damper Closed I Correct Damper Setting
I I
I t I I
INo Hydraulic Fluid I Recharge per para. 5.1 I
la/I33 Page5
TW714 MARTIN-DECKER

c. Turn Piston Separator upside down so
Retainer Nut (item 11) is visible.
Remove retainer nut.
d. Remove the Belleville washers and the
flat washer. See CAUTION note above.
j. Carefully reinstall the piston in the
cylinder, replace the Belleville washers
exactly as removed from the cylinder
(see Figure 8-l). Replace the retainer
nut using thread locking compound.
Torque it with assembly tool (Para. 8.3)
to 85& 10 foot/pounds.
k. Reinstall the cylinder on the female sub.

L Reconnect the hydraulic hose.

NOTE: When the piston is
removed, fluid in the cylinder
will drain through the hose
connector hole.
m. Remove the Bleed Plug (item 3) and fill
the cylinder with hydraulic fluid.
Replace the bleed plug.

e. Insert a 3/8 - 16 x 4 IN. bolt in the n. Recharge the system per paragraph 5.1.
tapped hole on the bottom of the piston
(see Figure 8-1, item 91, ‘and carefully
pull the piston out of the cylinder. Fluid
will drain off. SECI’XON 8.0
PARTS LIST

8.1 P10038A 1:l Piston Separator Parts

Breakdown is shown in Table 8-l and Figure
f. Note how the Piston Seals (item 8, two 8-l.
places) are installed on the piston,
remove the old seals.
a.2 RRCOMMENDED SPAR=. The
following items are recommended for field
maintenance:
g. Using seal lubricant (P/N X10107A)
grease the piston thoroughly. InstaR the l P/N P10037A Seal, Piston (Viton), quantity
new piston seals (P/N P10037A) with the 2 each
grooved side of the seals facing outward
of the piston. l P/N B10252A Ring, Seal, quantity, 1 each
l G10026A-000002 Belleville Washers,
quantity, 4 each
h. Regrease the piston and the seals using l J10432A Retainer Nut, quantity, 1 each.
the seal lubricant.
8.3 TOOLING. The following special
tooling is recommended for field
maintenance:
I.. Wipe the cylinder clean and inspect for
surface damage such as scoring or
pitting. 0 T10094A Spanner Wrench

Page6 l2B3
 MARTIN-DECKER TW714

TABLE 8-l. P10038A Piston Separator Parts List

(Reference Figure
- 8-l)
rITEM WY.REQ&
NO. PARTNO. DESCRIPTION .dl -62 -63 -64 45 -66

1 F350-1 CHECK VALVE, with Cap 1 1 1 1 1 1

2 51490 CROSS, l/4 NPT 1 1 1 1 1 1
3 J826-2HS PLUG, l/4 NPT 1 1 1 1 1 1

4 51292-2 02 PLUG, Plastic, l/4 NPT 1 1 1 1 1 1

5 5808-425 BUSHING, l/2 x l/4 NPT 1 1 1 1 1 1
6 5753-152 NUT, 2” Union 1 1 1 - - -

7 P10035A CYLINDER 1 1 1 1 1 1
8 P10037A SEAL, Piston 2 2 2 2 2 2
9 P10036A PISTON 1 1 1 1 1 1

10 G10026A-000002 WASHER, Belleville 4 4 4 4 4 4

11 J10432A NUT, Retainer 1 1 1 1 1 1
12 B10252A RING, Seal, 2” Union 1 1 1 1 1 -
13 J10073A SUB, Female, Welded 1 - - - - -
14 5754-152 SUB, Female, Threaded 1 - - - -
15 G10076A WASHER, Flat, Special 1 1 1 1 1 1

16 J10073A-01 SUB, Female, Welded, H2S - - - 1 - -

17 5753-153 NUT, 2” Union,H2S 1 1 -
18 B10361A NAMEPLATE lklll

19 5831-21 SCREW, Drive 2 2 2 2 2 2

01 Reference paragraph 2.2

@ Used for shipping and storage only

Page7
 I I
I
I
I

13,16

Figure 8-l. P10038A Piston Separator, Exploded View (Reference Table 8-l)
-4~8 12183