SWACO Operating & Service Manual Super Choke

OPERATING & SERVICE
MANUAL
SUPER CHOKE
2-9/16 AND 3-1/16
For
2-9/16 Choke Assembly - 9611630 & 9611421
3-1/16 Choke Assembly - 9611608 & 9611613
Single Choke Console - 9611371-01 Thru -04
Dual Choke Console - 9611405-01 Thru -04
Dual HDI Console - 9612207-01 Thru -04
P. O. Box 42842
Houston, TX 77242-2842
Global Sales/Technical Support

Tel: 281-988-1866
Fax: 281-988-1889
1-800-654-0660
MANUAL PART # 90-90-080 (REV. C)
DISCLAIMER
Recommendations made by M-I SWACO are advisory only. M-I SWACO shall not be
liable under any guarantees or warranties, expressed or implied, in any manner or
form, AND ALL WARRANTIES, EXPRESSED OR IMPLIED, ARE HEREBY
SPECIFICALLY EXCLUDED, and M-I SWACO shall not be liable for the failure to
obtain any particular results from the use of any recommendation made by it or from
the use of this material. In no event shall M-I SWACO be liable for incidental or
consequential damages.
ii
TABLE OF CONTENTS
SECTION 1 INTRODUCTION..................................................................................... 1
SECTION 1.1 SYMBOLS............................................................................................... 2
SECTION 1.2 GENERAL PRECAUTIONS .................................................................... 3
SECTION 2 GENERAL INFORMATION ..................................................................... 4
SECTION 2.1 CHOKE VALVE....................................................................................... 4
FIGURE 1. CHOKE VALVE VIEW............................................................................. 4
SECTION 2.2 CONTROL CONSOLE ............................................................................ 4
FIGURE 2. SINGLE CHOKE CONSOLE VIEW......................................................... 6
FIGURE 3. DUAL CHOKE CONSOLE VIEW ............................................................ 7
FIGURE 4. HDI CHOKE CONSOLE VIEW................................................................ 8
SECTION 3 INSTALLATION....................................................................................... 9
SECTION 3.1 CHOKE VALVE....................................................................................... 9
SECTION 3.1.1 INSTALLING THE CHOKE VALVE......................................................... 9
FIGURE 5. SUPER CHOKE VIEW............................................................................ 9
SECTION 3.1.2 REPOSITIONING THE ACTUATOR ASSEMBLY................................. 10
SECTION 3.1.3 CONTROL LINES ................................................................................. 11
SECTION 3.1.4 CHOKE DISC POSITION TRANSMITTER ........................................... 11
SECTION 3.2 CONTROL CONSOLE .......................................................................... 12
SECTION 3.2.1 INSTALLING THE CONTROL CONSOLE ............................................ 12
FIGURE 6. M-I SWACO SINGLE CHOKE CONSOLE VIEW .................................. 12
SECTION 3.2.2 AIR SUPPLY ......................................................................................... 12
SECTION 3.2.3 STROKE/RATE METER ....................................................................... 13
SECTION 3.2.4 GAUGE PROTECTOR.......................................................................... 14
SECTION 3.3 MULTIPLE CHOKE INSTALLATION .................................................... 14
SECTION 3.3.1 DUAL CONTROL CONSOLE ASSEMBLY ........................................... 14
FIGURE 7. DUAL CHOKE CONTROL CONSOLE VIEW........................................ 15
SECTION 3.3.2 AUXILIARY CONTROL PANEL ............................................................ 16
SECTION 3.3.3 MULTIPLE CONTROL CONSOLE INSTALLATION ............................. 16
SECTION 4 OPERATION ......................................................................................... 17
SECTION 4.1 PROCEDURES..................................................................................... 17
SECTION 4.1.1 NORMAL OPERATING METHOD (FAST)............................................ 17
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SECTION 4.1.2 ALTERNATE OPERATING METHOD (SLOW)..................................... 18
SECTION 4.1.3 EMERGENCY OPERATION ................................................................. 18
FIGURE 8. HYDRAULIC LINE OR CONNECTION VIEW ....................................... 19
SECTION 5 SERVICE AND MAINTENANCE........................................................... 20
SECTION 5.1 PROCEDURES..................................................................................... 20
SECTION 5.1.1 ROUTINE INSPECTION ....................................................................... 20
FIGURE 9. SUPER CHOKE AND CONTROL CONSOLE....................................... 20
SECTION 5.1.2 DAILY VISUAL CHECKS ...................................................................... 20
SECTION 5.1.3 DAILY OPERATIONAL CHECKS ......................................................... 21
SECTION 5.1.4 REMOVING CHOKE VALVE FROM MANIFOLD ................................. 21
SECTION 5.1.5 CHANGING THE DISC ASSEMBLIES ................................................. 22
FIGURE 10. SUPER CHOKE DISC REMOVAL VIEW .............................................. 23
FIGURE 11. SUPER CHOKE DISC ORIENTATION VIEW ....................................... 25
SECTION 5.1.6 BONNET END DISASSEMBLY ............................................................ 25
SECTION 5.1.7 GAUGE PROTECTOR.......................................................................... 27
SECTION 5.1.8 GAUGE PROTECTOR DISASSEMBLY ............................................... 27
FIGURE 12. GAUGE PROTECTOR.......................................................................... 28
SECTION 5.1.9 FILLING GAUGE PROTECTOR LINES................................................ 29
FIGURE 13. CHECK VALVE ..................................................................................... 29
SECTION 5.1.10 POSITION INDICATOR SYSTEM......................................................... 30
SECTION 5.1.11 CALIBRATION AND ADJUSTMENT..................................................... 30
FIGURE 14. CALIBRATION AND ADJUSTMENT..................................................... 31
SECTION 5.1.12 DIGITAL STROKE/RATE METER ........................................................ 32
SECTION 5.1.13 ACTUATOR ASSEMBLY ...................................................................... 32
SECTION 6 PRESSURE TESTING.......................................................................... 33
SECTION 6.1 PROCEDURE ....................................................................................... 33
SECTION 6.1.1 HYDROSTATIC TEST PROCEDURE .................................................. 33
FIGURE 15. SUPER CHOKE INLET/OUTLET TEST FLANGES .............................. 33
FIGURE 16. SUPER CHOKE VALVES AND GAUGE CONNECTOR....................... 34
SECTION 6.1.2 HYDROSTATIC SEAT TEST PROCEDURE ........................................ 35
SECTION 7 TROUBLESHOOTING .......................................................................... 36
SECTION 7.1 CONSOLE WILL NOT OPEN OR CLOSE CHOKE .............................. 36
iv
FIGURE 17. SUPER CHOKE AIR PUMP.................................................................. 36
SECTION 7.2 CHOKE OPENS AND CLOSES TOO SLOWLY ................................... 38
SECTION 7.3 SUPER CHOKE LEAKS ....................................................................... 38
SECTION 7.4 SUPER CHOKE DISCS LEAK .............................................................. 38
SECTION 7.5 DIGITAL STROKE/RATE METER ........................................................ 39
SECTION 7.6 PRESSURE GAUGE NOT READING CORRECTLY............................ 39
SECTION 7.7 POSITION INDICATOR NOT WORKING ............................................. 40
SECTION 8 DRAWINGS AND PARTS LIST ............................................................ 41
FIGURE 18. 2-9/16 SUPER CHOKE......................................................................... 41
FIGURE 19. 2-9/16 SUPER CHOKE ASSEMBLY PARTS LIST ............................... 42
FIGURE 20. 2-9/16 SUPER CHOKE ASSEMBLY..................................................... 43
FIGURE 21. 2-9/16 SUPER CHOKE PARTS LIST ................................................... 45
FIGURE 22. 3-1/16 SUPER CHOKE ASSEMBLY..................................................... 46
FIGURE 23. 3-1/16 SUPER CHOKE PARTS LIST ................................................... 47
FIGURE 24. 3-1/16 SUPER CHOKE ASSEMBLY DRAWING .................................. 48
FIGURE 25. 3-1/16 SUPER CHOKE ASSEMBLY PARTS LIST ............................... 50
FIGURE 26. ACTUATOR ASSEMBLY ...................................................................... 51
FIGURE 27. ACTUATOR ASSEMBLY PARTS LIST................................................. 53
FIGURE 28. SINGLE CONSOLE DIMENSIONAL VIEWS ........................................ 54
FIGURE 29. SINGLE CONSOLE FRONT/BACK VIEWS .......................................... 55
FIGURE 30. SINGLE CONSOLE SIDE VIEW ........................................................... 56
FIGURE 31. SINGLE CONSOLE HOSE ASSEMBLY ............................................... 57
FIGURE 32. SINGLE CONSOLE (9611154) PARTS LIST........................................ 59
FIGURE 33. SINGLE PANEL ASSY. (9611155) TOP/BOTTOM VIEW..................... 60
FIGURE 34. SINGLE PANEL ASSEMBLY (9611155) PARTS LIST ......................... 61
FIGURE 35. SINGLE PUMP ASSEMBLY (9611153) VIEWS.................................... 62
FIGURE 36. SINGLE PUMP ASSEMBLY (9611153) PARTS LIST........................... 63
FIGURE 37. SINGLE MANIFOLD ASSEMBLY (9611156) TOP VIEW ..................... 64
FIGURE 38. SINGLE MANIFOLD ASSEMBLY (9611156) SIDE VIEW .................... 65
FIGURE 39. SINGLE MANIFOLD ASSY (9611156) PARTS LIST ............................ 66
FIGURE 40. SINGLE TANK ASSEMBLY (9611157)................................................. 67
FIGURE 41. SINGLE TANK ASSEMBLY (9611157) PARTS LIST ........................... 68
v
FIGURE 42. SINGLE CONTROL CONSOLE PANEL SCHEMATIC ......................... 69
FIGURE 43. SINGLE CONTROL CONSOLE TUBING SCHEMATIC ....................... 70
FIGURE 44. DUAL CONSOLE SYSTEM (9611405) VIEW ....................................... 71
FIGURE 45. DUAL CONSOLE SYSTEM (9611405) PARTS LIST............................ 72
FIGURE 46. DUAL CONSOLE SYSTEM HDI (9612207) VIEW................................ 73
FIGURE 47. DUAL CONSOLE SYSTEM HDI (9612207) PARTS LIST .................... 74
FIGURE 48. DUAL CONSOLE FRONT/BACK (9611489) VIEWS ............................ 75
FIGURE 49. DUAL CONSOLE SIDE/HOSE (9611489) VIEWS................................ 76
FIGURE 50. DUAL CONSOLE (9611489) PARTS LIST ........................................... 78
FIGURE 51. DUAL CONSOLE HDI FRONT/BACK (9612206) VIEWS ..................... 79
FIGURE 52. DUAL CHOKE CONSOLE SIDE (9612206) VIEW................................ 80
FIGURE 53. HDI GAUGE FASTENER DETAIL (9612206) ....................................... 81
FIGURE 54. DUAL CONSOLE HDI (9612206) PARTS LIST .................................... 83
FIGURE 55. DUAL PANEL ASSEMBLY CONSOLE (9611415)................................ 84
FIGURE 56. DUAL PANEL ASSEMBLY (9611415) PARTS LIST............................. 85
FIGURE 57. DUAL PANEL ASSEMBLY HDI (9612205) ........................................... 86
FIGURE 58. DUAL PANEL ASSEMBLY (9612205) PARTS LIST............................. 87
FIGURE 59. DUAL MANIFOLD ASSY REAR (9611410) .......................................... 88
FIGURE 60. DUAL MANIFOLD REAR (9611410) SECTION VIEW......................... 89
FIGURE 61. DUAL MANIFOLD ASSY REAR (9611410) PARTS LIST..................... 90
FIGURE 62. DUAL PUMP ASSEMBLY (9611413) VIEW ......................................... 91
FIGURE 63. DUAL PUMP ASSEMBLY SECTION A-A ............................................. 92
FIGURE 64. DUAL PUMP ASSEMBLY SECTION B-B ............................................. 93
FIGURE 65. DUAL PUMP ASSEMBLY (9611413) PARTS LIST .............................. 94
FIGURE 66. DUAL CONTROL CONSOLE TUBING SCHEMATIC ........................... 95
FIGURE 67. DUAL CONTROL CONSOLE PANEL SCHEMATIC............................. 96
FIGURE 68. GAUGE PROTECTOR ASSEMBLY ..................................................... 97
FIGURE 69. GAUGE PROTECTOR ASSEMBLY PARTS LIST ................................ 98
SECTION 8.1 STROKE/RATE METER CONFIGURATIONS ...................................... 99
FIGURE 70. METER 2 PUMP WITH LIMIT (9611626).............................................. 99
FIGURE 71. METER 2 PUMP W/LIMIT (9611626) PARTS LIST ............................ 100
FIGURE 72. METER 3 PUMP WITH LIMIT SWITCH (9611625)............................. 101
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FIGURE 73. METER 3 PUMP W/LIMIT (9611625) PARTS LIST ............................ 102
FIGURE 74. METER 2 PUMP W/MAGNETIC SWITCH (9611641)......................... 103
FIGURE 75. METER 2 PUMP W/MAG. (9611641) PARTS LIST ............................ 104
FIGURE 76. METER 3 PUMP W/MAG. SWITCH (9611633) VIEW ........................ 105
FIGURE 77. METER 3 PUMP W/MAG. (9611633) PARTS LIST ............................ 106
FIGURE 78. STROKE/RATE METER ASSY. 2 PUMP (9611321) .......................... 107
FIGURE 79. STROKE/RATE METER 2 PUMP (9611321) PARTS LIST ................ 108
FIGURE 80. STROKE/RATE METER ASSY. 3 PUMP (9611612) .......................... 109
FIGURE 81. RATE METER ASSY. 3 PUMP (9611612) PARTS LIST .................... 110
FIGURE 82. PUMP STROKE W/LIMIT SWITCH (9611049) ................................... 111
FIGURE 83. PUMP STROKE W/LIMIT SWITCH (9611049) PARTS LIST.............. 112
FIGURE 84. PUMP STROKE MAG. SWITCH (9611635) ....................................... 113
FIGURE 85. PUMP STROKE MAG. SWITCH (9611635) PARTS LIST .................. 114
FIGURE 86. EQUIVALENT BEAN SIZE CHART .................................................... 115
FIGURE 87. MULTIPLE CHOKE INSTALLATION DIAGRAM................................. 116
APPENDIX A BARKSDALE VALVE .......................................................................... 117
APPENDIX B HDI GAUGE DELETED – NOT INCLUDED IN THIS DOCUMENT .... 119
APPENDIX C SC HYDRAULIC PUMP ...................................................................... 120
APPENDIX D PINE SIMPLEX PUMP........................................................................ 131
APPENDIX E FLO-TORK ACTUATOR ..................................................................... 134
APPENDIX F TECHNICAL BULLETINS DELETED – NOT INCLUDED IN THIS
DOCUMENT ....................................................................................... 140
TB 003 RENOLD 275N COUPLING P.N. 3105265 ................................................... 140
TB 019 10K CONTROL CONSOLE JUNCTION BOX ASSEMBLY CHANGES ........ 140
TB 023 10K GAUGE PROTECTOR........................................................................... 140
TB 032 10K CHOKE SINGLE AND DUAL CONSOLE PRESSURE GAUGES.......... 140
TB 053 10K EXTENDED WEAR SLEEVE WITH O-RING......................................... 140
TB 066 10K NON H2S CHOKE BLEEDER VALVE ................................................... 140
TB 069 GAUGE PROTECTOR ASSEMBLY.............................................................. 140
TB 087 BONNET-END-LOADING (BEL) BACK DISC ASSEMBLY........................... 140
TB 094 4-WAY 3-POSITION CONTROL VALVES .................................................... 140
TB 096 INCONEL 625 VS. AUSTENITIC STAINLESS STEEL ................................. 140
vii
TB 111 GAUGE PROTECTOR NIPPLE INSTALLATION.......................................... 140
TB 114 10K CHOKE PANEL DIGITAL GAUGE INSTALLATION .............................. 140
TB 123 10K SUPER CHOKE BODY MODIFICATION FOR DOWEL PIN ................. 140
TB 134 SUPER AUTOCHOKE CONSOLE AIR-OPERATED HYDRAULIC PUMP
REPAIR KIT................................................................................................... 140
TB 142 SUPER CHOKE SHEAR PIN ........................................................................ 140
TB 153 M-I SWACO CHOKE PANEL DIGITAL GAUGE INSTALLATION ................. 140
TB 163 SUPER CHOKE REPAIR PROCEDURE ...................................................... 140
TB 171 GAUGE PROTECTOR CAUTION................................................................. 140
viii
SECTION 1 INTRODUCTION
The remote operated M-I SWACO Super Choke is proven by experience to be a

reliable choke for the drilling industry. The basic mechanical operation of the M-I
SWACO Super Choke is simple. However, the applications for which this type of
equipment is used may require specific training and experience to complete an
operation successfully.
The M-I SWACO Super Choke should be operated by, or under the supervision of
qualified operators.
All mechanical equipment is subject to wear caused by either use or abuse. For this
reason, the M-I SWACO Super Choke and Control Console should be inspected on
a regular basis by qualified personnel. Repairs should be completed before
undertaking any operations involving the M-I SWACO Super Choke and Control
Console.
Contact the nearest M-I SWACO service center in the event the Super Choke or
Control Console does not operate correctly.
1
SECTION 1.1 SYMBOLS
Instructions in the operating & service manual that concern operating safety are
emphasized as follows.
This symbols draws attention to the safety measures to prevent

personal injury.
ATTENTION!
This symbol draws attention to the safety measures that must be
observed to prevent damage to the equipment.
NOTE:
This note draws attention to the general operating notes that
should be especially observed.
The symbols shown on the packing are as follows.
2
SECTION 1.2 GENERAL PRECAUTIONS
THIS EQUIPMENT OPERATES UNDER HIGH PRESSURE. NEVER

ATTEMPT TO DISASSEMBLE UNTIL ALL PRESSURE HAS BEEN
RELEASED.
PROPER MAINTENANCE TOOLS SHOULD BE USED AND NO

UNAUTHORIZED MODIFICATIONS ARE TO BE MADE.
USE ONLY AUTHORIZED REPLACEMENT PARTS.
WHILE PRESSURE TESTING, ASSURE THAT ALL AIR HAS BEEN

PURGED FROM THE SYSTEM. APPROACH THE UNIT ONLY AFTER
THE DESIRED PRESSURE HAS BEEN OBTAINED AND STABILIZED.
EYE PROTECTION IS REQUIRED WHILE PERFORMING
MAINTENANCE AND PRESSURE TESTING.
ALWAYS USE PROPER SAFETY PRECAUTIONS IF H2S GAS COULD

BE TRAPPED IN THE CHOKE OR MANIFOLD.
3
SECTION 2 GENERAL INFORMATION
SECTION 2.1 CHOKE VALVE

The M-I SWACO Super Choke is a hydraulically operated valve providing an
adjustable orifice size from a maximum area of 1.9 square inches (12 cm²) to
complete shutoff. The working pressure of this choke is 10,000 psi (68950 kPa).
The size of the choke orifice is determined by the overlapping portion of two off-
center half-moon openings in two highly polished tungsten carbide discs. The
downstream disc is fixed while the upstream disc may be rotated up to 180º by a
hydraulically driven rotary actuator (see FIGURE 1)
FIGURE 1. CHOKE VALVE VIEW
The Super Choke was designed primarily to control high pressure gas kicks and
salt water flows during drilling operations. However, because of its long life, high
capacity, ease and simplicity of operation the Super Choke is commonly used in
the following:
• Stripping-in under pressure (controlled displacement)

• Spotting light fluids, particularly in freeing stuck pipe
• Volume "calipering" specific hole sections
• Spotting heavy slugs (barite, cement, etc.)
• Drilling under pressure
• Displacing fluids in wells before and after work over
• Testing and clean up of new completion's where sand, lost circulation
material, or perforating debris are present.
SECTION 2.2 CONTROL CONSOLE

The Super Choke in normally operated from the Control Console located on the
rig floor. However, the Control Console may be placed in a remote location or
any safe working area designated by the customer. In special installations,
several Control Consoles may be placed at different locations, where any
Control Console can provide full control.
4
The Control Console panel has a control lever, master air supply valve, choke
disc position indicator, drill pipe gauge, casing pressure gauge and a pump
stroke counter with rate meter. Mounted below the Control Console panel is the
air-operated hydraulic pump, hydraulic fluid reservoir and a manually operated
hydraulic pump to be used in case the air supply fails (see FIGURE 2).
The control lever normally remains in the HOLD position, and is rotated to the
OPEN or CLOSE position to open or close the choke, respectively. The control
lever is spring loaded to return to the HOLD position when released.
A needle valve, labeled HYDRAULIC REGULATOR, can be adjusted to control

the opening and closing speed of the choke discs. The hydraulic regulator valve
should normally be rotated at least 1-1/2 turns to provide a suitable speed for the
choke discs during operation.
The AIR SUPPLY valve controls the air supply to the air-operated hydraulic
pump and the position indicator system. The recommended air pressure is 50-
125 psi (342-862 kPa).
5
FIGURE 2. SINGLE CHOKE CONSOLE VIEW
For multiple choke installations, M-I SWACO has a Dual Choke Control Console
(See FIGURE 3). Two chokes can be operated with this console without the
need for an auxiliary panel or two single consoles.
The Dual Control Console panel consists of two choke control levers, two choke
disc position indicators and two hydraulic regulators. There are also pressure
gauges and a master air supply valve for use in operation of either or both choke
valves.
The operation of the Dual Control Console is identical to that of a single Control
Console. Located below the panel is a hydraulic reservoir, which supplies both
systems with the required hydraulic fluid. Each system has a separate air-
operated hydraulic pump and a manually operated hydraulic pump to be used in
case the air supply fails.
6
FIGURE 3. DUAL CHOKE CONSOLE VIEW
7
FIGURE 4. HDI CHOKE CONSOLE VIEW
8
SECTION 3 INSTALLATION
SECTION 3.1 Choke Valve
SECTION 3.1.1 Installing the Choke Valve
ATTENTION!
Most common bolts, studs and nuts do not meet the requirements for H2S
service and will fail from hydrogen embrittlement. Replace bolts, studs and
nuts with authorized replacement parts.
All M-I SWACO Super Chokes contain a tungsten carbide wear sleeve that
extends 1/8 inch (4 mm) beyond the face of the outlet flange and protects the
ring gasket groove from erosion. The internal diameter of the companion flange
or adapter must have a minimum 2-9/16 inch bore to prevent the wear sleeve
from damaging the back choke disc when the flange is installed.
The flange studs and nuts should be checked for cracks, damage, wear and
thread distortion before installation. If any of these conditions are observed the
part should be replaced.
FIGURE 5. SUPER CHOKE VIEW
9
The standard inlet and outlet flanges are API Type 6BX, 2-9/16, 10,000 psi
(68950 kPa) and 3-9/16, 10,000 psi.
Companion flanges and adapter flanges can be furnished with the choke and
must be made from specially heat treated material. Zinc plated BX ring
gaskets suitable for H2S service is also available.
New ring gaskets should be used on each installation and each time the
flanges are disconnected. Used gaskets are deformed and may not seal
properly. Torque should be evenly applied to the fasteners. The nut threads
must fully engage the stud threads. It is recommended that each stud have at
least three threads exposed beyond the nut.
When the nuts are fully tightened, the faces of the choke flanges should be
parallel to the companion or adapter flanges. The material used to fabricate
the choke is relatively soft. When fitting the choke to the manifold caution
should be exercised to not damage the flanges.
The choke manifold should have at least two positive shutoff valves between
the blowout preventer and Super Choke. There should also be one valve
downstream of the Super Choke to permit isolation for servicing of the choke
while other sections of the manifold are in use (refer to API Bulletin RP 53,
Blowout Prevention Equipment Systems).
The discharge line from the choke must be securely anchored according to
API specifications (refer to API Bulletin RP 53).
The Super Choke should be pressure tested after installation and a notation
regarding the test made on the drilling report. This test may be done when
the choke manifold is being tested. Refer to SECTION 6 of this manual for
pressure test procedures.
SECTION 3.1.2 Repositioning the Actuator Assembly
When installing the M-I SWACO Super Choke in the manifold, the actuator
assembly should be installed with the open area of the actuator cover facing
down or to one side (see FIGURE 5). If the actuator assembly is not
positioned properly, the following procedures should be followed to rotate it
to the correct position.
10
NOTE:
Do not rotate the indicator head when removing and turning the actuator
assembly because this will cause misalignment of the choke discs. Make
sure the actuator assembly shaft is not rotated. When the actuator
assembly is reinstalled the position indicator cam must be the same
position as it was when the actuator assembly was removed or the choke
will not operate properly.
• Remove the four bolts, which fasten the actuator assembly to the
mounting adapter.
• Pull the actuator assembly away from the adapter until the square
shaft is clear of the indicator head.
• Turn the actuator assembly 90º to 180º to the desired position.
• Push the actuator assembly shaft into the indicator head. A light
application of grease on the actuator assembly shaft is recommended
to ease installation and future changes.
• Replace the four bolts and tighten them to 27 ft-lbs. (366 Nm).
SECTION 3.1.3 Control Lines
Connect the two 3/16 inch, low pressure hydraulic hoses from the Super
Choke to the rear manifold on the Control Console (see FIGURE 6). The two
(2) hoses are provided with quick disconnect fittings that are matched with
male and female ends so that it is impossible to reverse and install the hoses
incorrectly.
SECTION 3.1.4 Choke Disc Position Transmitter
Connect 1/4 inch O.D. vinyl tubing from fittings on the position transmitter,
located on the choke valve to the corresponding fittings on the Control
Console (see FIGURE 6).
The two (2) fittings on the Control Console manifold are labeled "Air to
Transmitter" and "Air Return from Transmitter."
The fittings on the position transmitter are not labeled. Check the arrow
located on the position transmitter regulator to determine the direction of the
air flow.
11
SECTION 3.2 Control Console
SECTION 3.2.1 Installing the Control Console
Place the Control Console in the desired location on the rig floor or in a safe
working area. Normally, the best location for the Control Console is near 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.
FIGURE 6. M-I SWACO SINGLE CHOKE CONSOLE VIEW
SECTION 3.2.2 Air Supply
Connect the air supply hose from the manifold on the Control Console to the
air supply (see FIGURE 6). The air hose should be connected to an outlet
where clean, dry air may be obtained. Trash or moisture in the air supply can
cause a malfunction of the air-operated hydraulic pump. This air outlet should
not be used for any other purpose which might cause the supply to be
disconnected from the Control Console.
12
The recommended air supply pressure for the Control Console is 50-125 psi
(345-862 kPa). A 1/2 inch diameter hose is adequate for hoses up to 50 feet
long. For longer lengths of hose a 3/4 inch diameter hose is desirable. The
air hose supplied with the Control Console has 1/2 inch NPT male
connection which can be adapted to the air outlet on the rig.
Turn the master air supply valve on the Control Console to the ON position.
The pointer of the position indicator gauge should show OPEN if the choke
was installed in the open position. If it shows CLOSED or partially closed,
check to determine if the Super Choke is fully closed or if the position
transmitter is properly calibrated.
NOTE:
The Control Console and Super Choke should be calibrated
simultaneously at the service center. Refer to Section 5.1.11 of this
manual for proper calibration procedures.
Push the control lever to the right toward the choke CLOSE label. The
hydraulic pump should start stroking and the needle of the position indicator
gauge should move. Hold the lever in this position until the choke is fully
closed and the hydraulic pump stops stroking; then release the lever. The
control valve should open.
Push the control lever to the left toward the choke OPEN label until the choke
is fully open.
If there is any problem with these operations, refer to SECTION 7 of this

manual.
SECTION 3.2.3 Stroke/Rate Meter
The M-I SWACO Digital Pump Stroke/Rate Meter, located on the Control
Console, is powered by a built-in battery pack. The meter comes with either
limit or magnetic proximity switches.
• Limit switch: Each pump stroke switch assembly mounts to the mud
pump frame near the exposed pump rods. Position each switch
assembly so the switch actuator rod moves when contacted by the
pump rod collar or splash guard. There should be one full deflection
and release of the actuator rod for each pump stroke to assure proper
operation of the stroke counter and to avoid double counting.
• Magnetic switch: Locate a large mass of metal on the pump and
position the switch so that it can detect the metal mass. Do not allow
the mass to pass completely past the sensor or it will double count.
Route the cable from the Digital Pump Stroke/Rater Meter to the junction box
and connect the wires. Use wire nuts to connect the wires inside the junction
13
box. The strain relief connections on the meter, junction box and pump
switches should be used. Shielded cable is recommended between the
Stroke/Rate Meter and the limit switch assembly. Ground the shielding on
one end of the cable. This will prevent electrical noise from the power cables
adjacent to the Stroke/Rate Meter from causing an inaccurate count. The
case of the Stroke/Rate Meter and the console itself should also be grounded
to a proper earth ground to prevent erroneous stroke resets.
Operate each pump stroke assembly by hand to determine Pump 1, 2, or 3.

The pump select switch is located on the bottom of the Stroke/Rate Meter is
used to display the desired pump stroke count and rate being displayed.
SECTION 3.2.4 Gauge Protector

Connect the drill pipe pressure gauge protector assembly (FIGURE 6) to the
rig standpipe. The assembly should be mounted in an upright position to
allow mud to drain when there is no pressure in the standpipe. The hydraulic
hose is connected to the drill pipe pressure gauge connection located on the
Control Console manifold. Make sure the hose will not interfere with
pedestrian or vehicle traffic or be cut, crimped, worn by rig structures or
burned by other equipment.
Connect the casing pressure gauge protector assembly (FIGURE 6) to a
suitable place on the choke manifold. This assembly should be mounted
upright and have a valve below it that can be closed off to allow repair of the
gauge protector. The hydraulic hose is connected to the casing pressure
gauge connection located on the Control Console manifold. Make sure the
hose is routed in the same manner as described above.
The gauge protectors are rated for 10,000 psi (68950 kPa) working pressure
and may be mounted to a 2 inch female hammer union hub or a 2 inch NPT
female connection. The gauge protector lines should be filled with hydraulic
fluid at the service center prior to the Control Console being delivered to the
rig site. If this is not possible, refer to Section 5.1.9 of this manual for the
hydraulic line filling procedure.
SECTION 3.3 Multiple Choke Installation
SECTION 3.3.1 Dual Control Console Assembly
If two Super Choke valves are to be used in the choke manifold, they may
both be controlled from the dual Control Console assembly (FIGURE 7). On
the rear manifold of the dual Control Console (FIGURE 59) there are OPEN
and CLOSE lines for each choke and air to and air return lines for each
choke. Do not interchange the lines for choke A with the lines from choke B.
Improperly installed lines will cause choke B to operate when choke A
controls are actuated and vice versa. Therefore, it is recommended to install
14
one set of lines (choke A or choke B) at a time. The OPEN and CLOSE lines
for choke A are located next to the drill pipe pressure fitting. The open and
close lines for choke B are located next to the casing pressure fitting. Facing
the back of the dual Control Console, the air lines for choke A are on the right
side of the unit and the air lines for choke B are located on the left side.
The supply air and gauge protector assemblies are installed in the same
manner as they are for the single Control Console.
FIGURE 7. DUAL CHOKE CONTROL CONSOLE VIEW
15
SECTION 3.3.2 Auxiliary Control Panel
If a Dual Control Console is not available, the Auxiliary control panel may be
used with the single Control Console for the operation of the two Super
Chokes.
The Auxiliary Control Panel is mounted on the right side of the Control
Console. Two hose connections tie the Auxiliary Control Panel to the Control
Console hydraulic system. One connection is located at the output of the air
operated hydraulic pump. The connection will supply the necessary hydraulic
pressure for operating the auxiliary choke. Use high pressure hose and
fittings (minimum 3,000 psi / 20685 kPa) to make this connection. The
second connection is located between the return port on the auxiliary control
panel control valve and the hydraulic reservoir on the Control Console.
To complete the installation, connect the air supply to the position transmitter
on the second choke. This can be done by installing a 1/4 inch tubing tee in
the “Air to Transmitter” line between the Control Console and the primary
choke. Connect this air supply to the position transmitter on the second
choke. The return line from the second choke position transmitter connects
directly to the position indicator gauge on the auxiliary control panel.
SECTION 3.3.3 Multiple Control Console Installation
When using two Super Chokes it may be desirable to have more than one
Control Console in order to operate the chokes from different areas.
FIGURE 87 MULTIPLE CHOKE INSTALLATION DIAGRAM is a schematic
for installing two chokes and three Control Consoles with Auxiliary Control
Panels on each Control Console. Full operation of each choke valve is
possible from any of the three control locations. For two console operation
use consoles at Master Station 1 and Station 2 only.
The control line hoses may be replaced by 1/2 inch Schedule 40 pipe for
underground routing to remote locations. This change will improve the choke
response time and prevent the lines from being crushed.
When making these special installations, 1/8 inch copper or stainless steel
tubing should be used for the gauge lines if the total distance between the
Control Console and the gauge protectors exceeds 100 feet (30m).
For multiple panel installations with the Dual Control Console, the same
steps can be followed as for the single Control Console with an Auxiliary
Control Panel.
16
SECTION 4 OPERATION
The choke discs should remain in the fully OPEN position when the choke is not in
use. Operation of the M-I SWACO Super Choke should always begin with the choke
in the OPEN position. Closed choke discs may result in hydraulic shock on the well
bore, and if the mud pumps are running it can result in lost returns and a down hole
blowout. For example: at the start of a well control procedure, the choke should not
be closed until after the blowout preventer has been closed and drilling fluid is
flowing through the manifold and Super 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.
SECTION 4.1 PROCEDURES
SECTION 4.1.1 Normal Operating Method (Fast)
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 (0-68000 kPa in 200
kPa increments)
• Casing pressure 0-10,000 psi in 20 psi increments (0-68000 kPa in 200
kPa increments)
• Choke position (full OPEN to full CLOSE)
• Rig pump stroke rate and stroke count
To operate the Control Console in the normal operating method perform the
following.
• Move the Air Supply valve to the ON position (see FIGURE 2).
• Fully open the Hydraulic Regulator.
• Shift the Control Lever in either direction to maintain the desired casing or
drill pipe pressure.
• 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
NOTE:
A plugged choke may result in excess pressure that could exceed the
casing pressure limit. Shift the main control lever to OPEN and open
the hydraulic regulator for fast response. When the plug is cleared the
control lever must be shifted to CLOSE to return to the desired
pressure. The hydraulic regulator valve can then be adjusted to a
slower response setting.
17
SECTION 4.1.2 Alternate Operating Method (Slow)
• Fully close the Hydraulic Regulator.

• Hold the Control Lever in the CLOSE position and slowly open the
Hydraulic Regulator valve. This allows a very slow movement of the
choke disc. When the desired pressure is reached the Control Lever
should be released.
• Open the Hydraulic Regulator valve if a faster response is needed.
SECTION 4.1.3 Emergency Operation
FAILURE OF AIR SUPPLY OR AIR PUMP
• Install the Pump Handle on the Hand Pump that is mounted on the base
of the Control Console skid. Make sure the bleed 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
• Cut both lines at the choke if either hydraulic line is cut or ruptured. The
hoses must be cut and NOT DISCONNECTED. If they are disconnected
check valves in the fittings will prevent choke operation.
• Insert a 5/8 inch (16mm) diameter rod into one of the holes in the
Indicator Head (FIGURE 8) and manually position the choke as desired.
18
FIGURE 8. HYDRAULIC LINE OR CONNECTION VIEW
19
SECTION 5 SERVICE AND MAINTENANCE
SECTION 5.1 PROCEDURES
SECTION 5.1.1 Routine Inspection
The M-I SWACO Super Choke is a key element of the pressure control
system used to prevent blowouts. Therefore, it is important that the Super
Choke and Control Console be maintained in good operating condition at all
times (see FIGURE 9).
FIGURE 9. SUPER CHOKE AND CONTROL CONSOLE
SECTION 5.1.2 DAILY VISUAL CHECKS
• Check the presence of a Hand Pump handle (item 9), a manual choke
operating bar and all panel labels.
• Check fluid level in the Hydraulic Oil Reservoir (item 1). Fill with the
correct hydraulic oil. Keep a supply of oil at or near the choke panel.
• Verify that all connections tight. Verify that the hydraulic hoses, pump
switch cable and air lines are properly connected and are not damaged.
• Check the pump Stroke/Rate Meter (item 8). Place the selector switch on
TEST. The meter should count and indicate 128 SPM. Select Pump 1 or
Pump 2 and observe counter and rate display. Reset counter to zero after
test.
• Verify that the pump stroke counter switches (item 3) are properly
attached to the mud pump and count the correct number of strokes.
20
• Check the Air Line Lubricator (item 14). The bowl should be filled with the
correct hydraulic oil.
SECTION 5.1.3 DAILY OPERATIONAL CHECKS
• Turn the Air Supply Valve (item 5) to ON. The Hydraulic Pressure Gauge
(item 12) should show 1500-1750 psi (10343-12066 kPa).
• Close the Hydraulic Regulator (item 11) and then open 1-1/2 turns.
Operate the Control Lever (item 6). Complete a full cycle of the choke
discs from full OPEN to full CLOSE and back to full OPEN. The Position
Indicator (item 10) should track the choke disc movement according to
the choke lever selection.
• While the Hydraulic Pump is stroking, check the sight glass located on top
of the Air Line Lubricator (item 14). The lubricator should deliver
approximately 1 drop of oil for every 20 strokes of the Hydraulic Pump.
The adjustment screw is located on top of the lubricator.
• 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 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 valve should be approximately the same as the rig gauges. Both
gauge faces should be clean and visible.
SECTION 5.1.4 REMOVING CHOKE VALVE FROM MANIFOLD
Before working on a Super Choke installed in a manifold verify that

there is no pressure trapped in the choke valve or choke manifold.
Use appropriate safety precautions if H2S gas could be trapped in the

Super Choke or the manifold. Only personnel who have received
training on the hazards of H2S should be permitted to work on the
Super Choke. Failure to follow these instructions could result in injury.
ATTENTION!
The material used to fabricate the M-I SWACO Super Choke flanges,
nuts and studs is relatively soft and subject to localized surface
distortion and dents due to improper work practices. Care should be
exercised when working on the Super Choke to avoid damaging these
parts. Damaged parts will adversely affect the structural integrity of the
Super Choke that may result in injury.
21
• Rotate the choke discs to the full OPEN position. Allow the pressure in
the choke valve to relieve before continuing.
• Carefully loosen the outlet flange nuts one turn each until the seal or ring
gasket is relieved - do not remove the nuts. 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 and not over it when breaking the
ring gasket seal.
ATTENTION!
Do not use a pry bar to separate the flange due to the possibly of
damaging the extended wear sleeve.
• After the seal is broken and all pressure inside the Super Choke has been
relieved, remove the nuts and studs.
• Support the valve and then carefully loosen the upstream flange nuts one
turn until the gasket is relieved and any trapped pressure is released.
• Remove the nuts and studs on the inlet flange.
Refer to Section 3.1.1 of this manual for reinstalling the choke in the
manifold.
SECTION 5.1.5 CHANGING THE DISC ASSEMBLIES
This section describes the procedure for removing the Super Choke discs
from the outlet end of the valve body for inspection and/or replacement and
removal of the wear sleeves.


• Carefully loosen each outlet spool bolt one turn. After all the bolts are
loosened, break the o-ring seal and remove the outlet spool bolts.
Carefully separate the outlet spool from the choke body. Locating pins
provide alignment between the choke body and the outlet spool.
22
• To remove the choke discs, rotate the front disc to the full OPEN position
if this has not been previously done. Wash any sand, grit or other debris
from around the exposed portion of the back disc and the disc opening.
• Insert the hook end of the disc puller (M-I SWACO part number 96-11-
083) in the disc opening as illustrated in FIGURE 10 and gently remove
both discs using the sliding weight on the puller.
FIGURE 10. SUPER CHOKE DISC REMOVAL VIEW
Do not place any part of your hand 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. 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.
• Clean both disc assemblies thoroughly and inspect for wear or damage.
The primary criteria for determining whether or not the choke discs are
usable are that they can provide a positive seal under pressure when
installed in the choke. See Section 6.1.2 of this manual for the hydrostatic
disc test procedure.
• 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.
23
NOTE:
The o-rings used in the Super Choke are made of a special H2S
resistant material. Replace o-rings with authorized replacement parts.
• 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.
• Insert the front disc assembly into the choke 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.
• 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 11.
• 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.
• Inspect the wear sleeves for wear and replace as necessary.
• Before reinserting the wear sleeves, clean and inspect the bore of the
spool. 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.
24
FIGURE 11. SUPER CHOKE DISC ORIENTATION VIEW
• 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.
• Assemble 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.
• Discard and replace any damaged screws with authorized replacement
parts.
• Tighten the screws uniformly. Apply a torque of 165 ft/lb (224 Nm) to the
bolts. Applying too much torque may cause them to stretch and reduce
their strength which, can result in premature failure.
• Clean and inspect the inlet and outlet flange faces and ring grooves.
Apply a light film of general purpose grease or a rust inhibitor to the face
and ring groove for corrosion protection.
SECTION 5.1.6 BONNET END DISASSEMBLY
This section describes the procedure for removal of the actuator assembly
and bonnet from the Super Choke. It also describes removal and inspection
of the turning fork. These procedures may be done with the Super Choke
installed in the manifold or removed from the manifold.
25

• Position the choke discs in the full OPEN position.

• Remove the actuator assembly by removing the four bolts that attach the
actuator adapter to the Super Choke.
• Remove the cap screw attaching the indicator head to the turning fork.
• Remove the indicator head from the turning fork.
• Mark the valve body and bonnet so they can be reassembled in the same
position. Remove the remaining ferry head cap screws attaching the
bonnet to the Super Choke body.
• Inspect these screws for damage or distortion.
• Remove the bonnet from the choke body.
• Push the turning fork out of the bonnet being careful not to damage the
shaft surfaces that rotate inside the bonnet.
• 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.
• Replace the thrust bearing, shaft bushing, all o-rings and backup rings on
the bonnet.
• Lubricate the turning fork shaft with a light application of silicone grease
before reassembly. Install the turning fork in the bonnet being careful not
to damage the o-rings or bushing.
• Clean the bonnet and apply silicone grease on the surfaces where there
is contact or close proximity to the valve body and turning fork.
• 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.
• 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 problems when assembling
the actuator assembly to the valve.
• Insert the bonnet assembly into the choke body. Verify the half moon
opening on the front disc is toward the inlet flange and the marks made
on the bonnet and choke body are aligned.
26
• Install and uniformly tighten the bolts securing the bonnet to the choke
body and the actuator assembly to the bonnet.
NOTE:
Most common bolts, studs and nuts do not meet the requirements for
H2S service and will fail from hydrogen embrittlement. Replace bolts,
studs and nuts with authorized replacement parts.
• Evenly torque the bolts to 165 ft/lbs (224Nm). 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 upside down.
NOTE:
Verify that the actuator assembly shaft and the choke discs are in the
OPEN position when these two components are assembled.
SECTION 5.1.7 GAUGE PROTECTOR
The purpose of the gauge protector (see FIGURE 12) is to transmit fluid
pressure from the drill pipe or the casing to the Control Console and isolate
the gauges from the drilling mud.
SECTION 5.1.8 GAUGE PROTECTOR DISASSEMBLY
• 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.
• Remove the body from the female hub by removing the wing nut.
• Remove the stainless steel internal snap ring from the bore of the gauge
protector body.
• Insert a 1/2-13 UN bolt in the tapped hole at the bottom of the piston. Use
the bolt as a handle to extract the piston.
• Clean the piston and replace the o-rings on the piston. Use only the size
and type o-ring called for in FIGURE 68 GAUGE PROTECTOR
ASSEMBLY on page 97.
27
FIGURE 12. GAUGE PROTECTOR
NOTE:
The o-rings used in the gauge protector are made of a special H2S resistant
material. Use only authorized replacement parts.
• Clean and inspect the bore of the gauge protector body for corrosion,
wear and pitting. Replace the body if these conditions exist.
• Before reinstalling the piston apply a 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 outside diameter of the piston.
• Reinstall the stainless steel internal snap ring. Refer to Section 5.1.9 of
this manual for refilling the gauge protector with hydraulic fluid. The body
plug is replaced during the line filling procedure.
28
SECTION 5.1.9 FILLING GAUGE PROTECTOR LINES
After the gauge protector has been assembled, 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 recommended to avoid disconnecting 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.
• 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.
• 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 13).
Do not tighten this connection.
FIGURE 13. CHECK VALVE
• Slide the cover of the hand pump to one side and fill the reservoir with
hydraulic fluid. While pumping, keep the hand pump reservoir at least
half-full to avoid pumping air into the line.
• 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.
• Turn the damper valve on the gauge counterclockwise several times to
relieve the dampening effect.
• Remove the pipe plug on top of the gauge to allow air to bleed from the
system. Pump fluid into the system until no air bubbles appear at the plug
29
on the gauge. Tighten the plug and push the damper valve in, turning
clockwise to engage the threads.
• Lay the hydraulic hose out as straight and flat as possible below the level
of the gauge.
• Remove the plug from the gauge protector body.
• 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.
• When the signal line and gauge protector appear to be purged of 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.
• When all the air has been purged from the system, replace the plug on
the gauge protector and tighten.
• Once the plug in the gauge protector is replaced, continue to pump
hydraulic fluid into the system until the piston contacts the internal snap
ring in the bore of the gauge protector.
• Close the hand pump cover and remove the pump from the check valve.
• Replace the check valve cap.
SECTION 5.1.10 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 hydraulic actuator 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
1/2 or 50% open. The graph in FIGURE 86 on page 115 can be used to
convert the choke position to an approximate equivalent diameter opening or
choke bean size. The position indicator serves as an aid in observing the
direction and speed of changes being made in the choke opening.
SECTION 5.1.11 CALIBRATION AND ADJUSTMENT
• Connect the supply air from the Control Console to the AIR SUPPLY
fitting and connect the signal return air to the AIR SIGNAL RETURN
fitting (see FIGURE 14).
• Turn on the air supply.
30
FIGURE 14. CALIBRATION AND ADJUSTMENT
TO ZERO THE POSITION INDICATOR GAUGE
• Completely OPEN the choke.

• Loosen the 1/4 inch nut and set screws on the camshaft so the cam turns
on the shaft.
• Rotate the cam shaft so the scribe mark on the short side of the cam lines
up with the cam follower.
• Tighten shaft nut and set screws.
• 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 the OPEN on the position indicator gauge.
• Tighten pivot block locking screws.
• Be sure the output is 3 psi (21 kPa) when 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 block as previously indicated above the required 3 psi
(21 kPa).
• Completely CLOSE the choke. The test gauge should read approximately
15 psi (103 kPa), or CLOSED on the position indicator gauge.
31
TO ZERO THE SPAN OF THE INDICATOR GAUGE
• 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.
• If less than 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.
• Tighten both socket head cap screws.
• Completely OPEN the choke. If output is not 3 psi (21 kPa), re-adjust the
pivot block to 3 psi (21 kPa).
• Completely CLOSE the choke and check 15 psi (103 kPa) signals.
• Repeat steps until 3 psi 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.
SECTION 5.1.12 DIGITAL STROKE/RATE METER
The digital stroke/rate meter contains three interconnected modules; a display

module, a switch module and a battery pack. Should any one of these
modules fail, they are not repairable and must be replaced. Refer to the
troubleshooting guide in Section 7.5. Parts information is given in FIGURE 78
on page 107 and FIGURE 80 on page 109.
SECTION 5.1.13 ACTUATOR ASSEMBLY
See the appendix for the manufacturer’s instructions for repair and
maintenance of the actuator assembly.
32
SECTION 6 PRESSURE TESTING
This section describes how to perform a hydrostatic pressure test on the M-I
SWACO Super Choke. This test is not intended to supersede or duplicate the
standard API tests, but to provide a routine procedure to verify that the seals and
discs will not leak and to verify the integrity of the pressure containing parts.
SECTION 6.1 PROCEDURE
SECTION 6.1.1 HYDROSTATIC TEST PROCEDURE
• Fully OPEN the choke discs.

• Install test flanges to the inlet and outlet of the choke that use isolation
valves as shown in FIGURE 16.
• Place the Super Choke with the side of the actuator assembly housing
and the outlet flange resting on the ground. The inlet flange should point
upward (see FIGURE 15).
FIGURE 15. SUPER CHOKE INLET/OUTLET TEST FLANGES
• With the isolation valves on the inlet and outlet flanges open, fill the choke
with water from the outlet flange. When the choke is full, raise the outlet
end until the centerline of the valve is parallel to the ground (see FIGURE
16).
33
FIGURE 16. SUPER CHOKE VALVES AND GAUGE CONNECTOR
• Continue filling the 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 (see
FIGURE 15).
• Open the hydraulic inlet valve and purge any air that may be trapped in
the hydraulic feed line.
• 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.
• With the inlet flange isolation valves closed and the hydraulic inlet valve
open, slowly raise the pressure on the Super Choke 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.
• If there are no visible leaks, close the hydraulic valve on the inlet test
flange and observe the pressure gauge for three (3) minutes. If the
pressure begins to decrease inspect the choke and test flange for leaks.
Repair leaks as required and repeat this test procedure.
• Open the isolation valve on the outlet test flange and remove the test
flange.
34
Do not block the discharge opening for the isolation valves. When the
isolation valves are opened under pressure a small quantity of water will
discharge from the opening.
SECTION 6.1.2 HYDROSTATIC SEAT TEST PROCEDURE
• Fill the Super Choke with water and remove all of the trapped air as
described in Section 6.1.1.
• With the isolation valves on the inlet and outlet test flanges closed, slowly
raise the pressure in the Super Choke to approximately 2,500 psi (17238
kPa).
• With the hydraulic valve open and pump on, close the choke discs. Open
the isolation valve on the outlet test flange. Slowly raise the pressure in
the Super Choke to 10,000 psi (68950 kPa) while the outlet flange
isolation valve is open.
• Hold the pressure for three (3) minutes. If the pressure decreases,
disassemble the Super Choke to determine the cause of the leakage and
repeat this test procedure.
35
SECTION 7 TROUBLESHOOTING
SECTION 7.1 CONSOLE WILL NOT OPEN OR CLOSE CHOKE
• Verify that the Super Choke and Control Console are correctly installed
per SECTION 3.1 and SECTION 3.2.
• At the console, turn the mater air supply valve to ON. The control lever
should be in HOLD position.
• Open the hydraulic regulator by turning the knob counterclockwise
several turns. If the hydraulic pump continues to cycle, proceed with the
following steps in the order listed (see FIGURE 17).
FIGURE 17. SUPER CHOKE AIR PUMP
• Check the hydraulic fluid level in the reservoir. If it is less than half full,
add hydraulic fluid (M-I SWACO part number LSF00003-103). Do not use
diesel oil since it is not compatible with valve seals and hydraulic hoses.
• Inspect the low pressure suction hose between the reservoir and the
hydraulic pump for leaks, collapse or crimping. This will cause the pump
to lose prime and not pump fluid. Replace this hose as needed.
• Inspect 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.
36
• Disconnect the return line on the hydraulic relief valve and install a
temporary plug to prevent hydraulic fluid in the reservoir from leaking.
Make certain to remove this plug before reinstalling the return line. If
hydraulic oil leaks 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 the 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.
• Remove the return line from the control lever 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. Refer to the
APPENDIX A for more information regarding the control lever.
• Remove and inspect the pump suction and discharge check valves.
Repair or replace as needed.
• Inspect the open and close hydraulic lines to the Super Choke for crimps,
pinching or other damage. Replace as needed.
• Connect the CHOKE OPEN hydraulic line to the CHOKE CLOSE
hydraulic line using the quick-connect hose couplings 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.
Reconnect the hydraulic lines to the actuator assembly.
• 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.
If the above steps have not revealed a problem and the Control Console
will still not operate the Super Choke, the problem has been isolated to
either the actuator assembly or the Super Choke.
• Remove the actuator assembly (see Section 3.1.2).

• Operate the actuator using the Control Console.
• If the actuator does not rotate
• Inspect the routing of hydraulic lines inside the actuator cover (see
FIGURE 26 on page 51), repair or replace as needed.
• If the actuator still does not rotate, replace the actuator (see
APPENDIX E for manufacturer’s instructions).
37
• If the actuator rotates when the control lever is operated, the problem has
been isolated to the Super Choke valve. Remove the bonnet end of the
choke using the procedure beginning with Section 5.1.6. Clear debris
from the choke or repair the choke and assemble.
SECTION 7.2 CHOKE OPENS AND CLOSES TOO SLOWLY
• Check for plugging in the hydraulic regulator needle valve and in the
check valves of the quick disconnect hose couplings
• If faster choke response is desired replace the standard 3/16 inch ID high
pressure hose with 1/4 inch ID hose or hard piping.
NOTE:
If the turning fork became locked, applying hydraulic pressure greater
than 1500 psi (10342 kPa) could result in deforming the turning fork.
This condition would make it impossible to control the position of the
choke disc.
SECTION 7.3 SUPER CHOKE LEAKS
• 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 5.1.6. Clean and inspect the sealing surfaces for damage and
wear. Replace the seals as required.
• If the leak is between the choke body and outlet spool, remove the Super
Choke from the manifold as described in Section 5.1.4. Clean and inspect
the sealing surfaces for damage and wear. Replace the seals as required.
• If the inlet or outlet flanges leak, remove the Super Choke from the
manifold. Clean and inspect the ring groove sealing surfaces for damage
and wear. Replace the ring gasket seals as needed.
SECTION 7.4 SUPER CHOKE DISCS LEAK
Below is a list of conditions to be checked if the Super Choke discs will not
seal. Refer to Section 5.1.5 for disc changing and inspection procedure.
• Dirt, rust or other debris between the discs.

• Worn or cracked discs.
• Damaged or improperly sized o-ring around the back disc.
• Damaged, dirty or corroded sealing surfaces contacting the o-ring at 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.
38
• Worn or damaged thrust bearing between the bonnet and turning fork.
SECTION 7.5 DIGITAL STROKE/RATE METER
The rate meter contains three modules that cannot be repaired in the field.
However, they were designed for easy field replacement. Before replacing any of
the modules, perform the following.
• Place the selector switch in the “test SPM” position.

• If the rate is 128 and the counter counts, the rate meter is working properly
and the problem is most likely with the wiring or the pump stroke switches.
If neither the wiring nor the pump switches are bad, replace the switch
module and repeat this test.
• If the meter does not indicate in the test position, replace the logic module.
PROBLEM / SYMPTOM CURE / REMEDY

Display flashing Low or bad batteries
No display Replace batteries or check connection to
battery pack. If okay, then replace logic
module.
Display on but is not counting or Replace logic module
displaying rate, including the test
mode
Display is on but does not count or Check wiring and pump stroke switches
indicate correct rate, but works
correctly in “test” mode or for only
one pump.
Only one input (p1 or p2) works, but Check wiring and pump stroke switches
okay in “test” mode
Count display does not display all Replace logic module
digits
Erratic count and stroke rate display Cable to the pump switches are not
properly shielded or grounded.
SECTION 7.6 PRESSURE GAUGE NOT READING CORRECTLY

The pressure gauges located on the Super Choke Control Console will, in almost
all cases, be the gauges which are used to determine drill pipe pressure and
casing pressure during operations involving the use of the M-I SWACO Super
Choke. If these gauges are not working properly, repairs should be made before
operations involving the Super Choke are undertaken.
• Check that the dampening valve on the gauge is not closed.

• Check the hydraulic hose to the gauge protector for damage or crimping
39
• 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 5.1.9 of this manual.
• If the hydraulic lines to the gauge protector are longer than 100 feet. (30
meters) hard piping or special steel braided hose will be required.
If the Control Console is equipped with HDI digital pressure gauges, refer to the
appendix for the gauge operating instructions.
SECTION 7.7 POSITION INDICATOR NOT WORKING
• Check the air supply gauge on air regulator attached to the hydraulic
pump for a reading of 3-35 psi (27-241 kPa).
• Inspect the air supply and signal lines for leaks and crimping.
• Make sure the cam is correctly installed on the cam shaft connected to
the actuator. The cam should turn 180 degrees when the choke position
is changed from OPEN to CLOSED or from CLOSED to OPEN.
• Inspect the choke position indicator gauge. If the gauge is in good
condition 3 psi (21 kPa) applied directly to the gauge should indicate
OPEN and 15 psi (103 kPa) should indicate CLOSED.
• If the position gauge does not agree with the calibration band on the
choke, see Section 5.1.10 for the correct installation and adjustment.
40
SECTION 8 DRAWINGS AND PARTS LIST
FIGURE 18. 2-9/16 SUPER CHOKE
41
NO. QTY. PART NO. DESCRIPTION
1 4 1345295 WASHER, LOCK
2 4 1404164 SCREW FERRY
3 4 1408562 SCREW SOC HEAD
4 4 1492031 SCREW DRIVE
5 2 3919153 GASKET RING
6 1 8420200 DECAL M-I SWACO
7 1 9611376 ADAPTER ACTUATOR
8 1 9611421 CHOKE ASSEMBLY 10K 2-9/16
9 1 9611631 ACTUATOR
10 1 9650384 NAMEPLATE
2 9611431 FLANGE COMPANION 2-9/16 IN (NOT SHOWN)
FIGURE 19. 2-9/16 SUPER CHOKE ASSEMBLY PARTS LIST
42
FIGURE 20. 2-9/16 SUPER CHOKE ASSEMBLY
43
1 4 1305043 NUT HEX
2 4 1345127 WASHER FLAT
3 12 1404163 SCREW FERRY HEAD
6 1 1492250 SCREW SOCKET HEAD
7 1 1573243 PIN ROLL
8 2 1573273 PIN ROLL
9 1 3966338 O-RING BUNA-N 90
10 1 3967149 O-RING VITON 90
11 1 3967151 O-RING VITON 90
12 1 3967216 O-RING VITON 90
13 2 3967237 O-RING VITON 90
14 1 3967342 O-RING VITON 90
15 1 3967348 O-RING VITON 90
16 1 3967915 O-RING TEFLON
17 2 3967916 O-RING BACKUP TEFLON
18 1 5867261 PIN DOWEL
19 1 5867430 PLUG CAP
20 1 5867436 PLUG CAP
21 1 5867521 PROTECTOR 9 INCH
22 6 8087264 TIE CABLE 8 INCH (NOT SHOWN)
23 1 9360904 SPRING WAVE
24 1 9436145 HANDLE CHOKE MANUAL (NOT SHOWN)
25 3 9611111 SLEEVE WEAR 2-9/16
26 1 9611214 DISC FRONT
27 1 9611215 DISC BACK
28 1 9611216 SLEEVE WEAR FLANGE PROTECTOR
29 1 9611352 RING PROTECTOR 4 INCH
44
30 1 9611354 RING PROTECTOR 5-1/4 INCH
31 1 9611360 PROTECTOR BODY OUTLET
32 1 9611422 BODY CHOKE 2-9/16
33 1 9611423 SPOOL OUTLET 2-9/16
34 1 9611425 FORK TURNING
35 1 9611427 BUSHING SHAFT
36 1 9611428 RING THRUST
37 1 9611429 BAND CALIBRATION
38 1 9611432 INDICATOR HEAD
39 1 9611439 BONNET
40 1 9611556 COLLAR
FIGURE 21. 2-9/16 SUPER CHOKE PARTS LIST
45
FIGURE 22. 3-1/16 SUPER CHOKE ASSEMBLY
46
1 4 1345295 WASHER LOCK
2 4 1404164 SCREW FERRY
3 4 1408562 SCREW SOC HEAD
5 2 3919160 GASKET RING (NOT SHOWN)
7 1 9611376 ADAPTER ACTUATOR
8 1 9611613 CHOKE ASSEMBLY 10K 2-9/16
9 1 9611631 ACTUATOR
2 9611431 FLANGE COMPANION 2-9/16 INCH (NOT SHOWN)
FIGURE 23. 3-1/16 SUPER CHOKE PARTS LIST
47
FIGURE 24. 3-1/16 SUPER CHOKE ASSEMBLY DRAWING
48
1 4 1305043 NUT HEX
7 1 1573243 PIN ROLL
8 2 1573273 PIN ROLL
9 1 3966338 O-RING BUNA-N 90
10 1 3967149 O-RING VITON 90
11 1 3967151 O-RING VITON 90
12 1 3967216 O-RING VITON 90
13 2 3967237 O-RING VITON 90
14 1 3967342 O-RING VITON 90
15 1 3967348 O-RING VITON 90
16 1 3967915 O-RING TEFLON
17 2 3967916 O-RING BACKUP TEFLON
18 1 5867261 PIN DOWEL
19 1 5867430 PLUG CAP
20 1 5867438 PLUG CAP
21 1 5867533 PROTECTOR 11-5/16 INCH
22 6 8087255 TIE CABLE 12.5 INCH (NOT SHOWN)
23 1 9360904 SPRING WAVE
24 1 9436145 HANDLE CHOKE MANUAL (NOT SHOWN)
25 3 9611111 SLEEVE WEAR 2-9/16
26 1 9611214 DISC FRONT
27 1 9611215 DISC BACK
28 1 9611216 SLEEVE WEAR FLANGE PROTECTOR
29 1 9611352 RING PROTECTOR 4 INCH
49
30 1 9611354 RING PROTECTOR 5-1/4 INCH
31 1 9611360 PROTECTOR BODY OUTLET
32 1 9611614 BODY CHOKE 3-1/16 INCH
33 1 9611615 SPOOL OUTLET 3-1/16 INCH
34 1 9611425 FORK TURNING
35 1 9611427 BUSHING SHAFT
36 1 9611428 RING THRUST
37 1 9611429 BAND CALIBRATION
38 1 9611432 INDICATOR HEAD
39 1 9611439 BONNET
40 1 9611556 COLLAR
FIGURE 25. 3-1/16 SUPER CHOKE ASSEMBLY PARTS LIST
50
FIGURE 26. ACTUATOR ASSEMBLY
51
1 1 0402235 BEARING DOUBLE SHIELD
2 1 1220017 BOLT SPECIAL W/SHOULDER
3 2 1305037 NUT HEX
4 1 1305210 NUT HEX
6 2 1345340 WASHER LOCK SPLIT
10 2 1407083 SCREW HEX HEAD PLATED
11 3 1407154 SCREW HEX HEAD PLATED
12 2 1407460 SCREW HEX HEAD
16 2 1466339 SCREW SET HEX SOCKET
17 1 2010040 COUPLING SOCKET
18 1 2010041 COUPLING PLUG
19 1 2012021 DUST CAP QUICK DISCONNECT PLUG
20 1 2012097 DUST CAP QUICK DISCONNECT SOCKET
21 2 2032543 HOSE ASSEMBLY 10K PSI
23 4 5005151 NIPPLE HEX
24 4 5030449 ELBOW STREET
25 2 5078079 TEE PIPE
26 1 5201029 REGULATOR AIR
27 1 5401305 TUBING POLY BLACK
28 1 5401315 TUBING POLY NATURAL
29 6 5415205 ELBOW COMPRESSION 90 DEGREE
52
30 4 5417526 CONNECTOR MALE 37 DEGREE
31 1 5801016 ACTUATOR HYD
32 1 9611036 ARM FOLLOWER CAM
33 1 9611037 BLOCK ADJUSTABLE PIVOT
34 1 9611038 BRACKET REGULATOR
35 1 9611039 CAM
36 1 9611040 CLAMP PIVOT ADJUSTABLE SCREW
37 1 9611042 ARM GUIDE
38 1 9611044 SCREW ADJUSTMENT
39 1 9611046 SCREW CAM FOLLOWER
40 1 9611098 HOUSING ACTUATOR
41 1 9611099 COVER POSITION INDICATOR
42 1 9611100 GUARD
43 1 9611102 SHAFT CAM
FIGURE 27. ACTUATOR ASSEMBLY PARTS LIST
53
FIGURE 28. SINGLE CONSOLE DIMENSIONAL VIEWS
54
FIGURE 29. SINGLE CONSOLE FRONT/BACK VIEWS
55
FIGURE 30. SINGLE CONSOLE SIDE VIEW
56
FIGURE 31. SINGLE CONSOLE HOSE ASSEMBLY
57
1 1 1305035 NUT HEX
2 10 1305167 NUT HEX
11 4 1460097 SCREW HEX HEAD GR5
13 2 2010040 COUPLING SOCKET 7500 PSI
14 2 2010041 COUPLING PLUG 7500 PSI
15 2 2010060 COUPLING SOCKET 10K PSI
16 1 2010302 COUPLING PLUG 10K PSI
17 2 2012021 CAP DUST
18 1 2012035 CAP DUST
19 2 2012097 DUST CAP QUICK DISCONNECT
20 2 2032148 HOSE ASSEMBLY 250 PSI
23 1 3403052 PUMP HAND
24 1 5005502 NIPPLE HEX 10K PSI
25 2 5008518 BUSHING HEX 3000 PSI
26 1 5030449 ELBOW 90 DEGREE 3000 PSI
27 2 5057193 NIPPLE
28 50’ 5401315 TUBING POLY CLEAR (NOT SHOWN)
58
29 20 8087264 TIE CABLE
30 1 8420167 DECAL OPERATING
32 1 9111050 SKID CONSOLE
33 1 9611153 PUMP ASSEMBLY CONSOLE
34 1 9611155 BOX ASSEMBLY CONSOLE
35 1 9611156 MANIFOLD CONSOLE
36 1 9611157 TANK ASSEMBLY CONSOLE
37 2 9611643 PROTECTOR GAUGE
39 1 9650360 NAMEPLATE ID
40 1 LSAF00003- OIL HYDRAULIC 5 GAL
103
FIGURE 32. SINGLE CONSOLE (9611154) PARTS LIST
59
FIGURE 33. SINGLE PANEL ASSY. (9611155) TOP/BOTTOM VIEW
60
1 2 1305236 NUT HEX
10 2 2422244 GAUGE 0-10000 PSI 0-70 KPA
11 REF 3491100 HANDLE PUMP
12 4 5005096 NIPPLE PUSH LOC
13 1 5030196 ELBOW 90 DEGREE 150 PSI
14 2 5030352 ELBOW STREET 150 PSI
15 1 5030449 ELBOW 90 DEGREE 3000 PSI
16 2 5417526 CONNECTOR FLARED 37 DEGREE
17 4 5417567 ELBOW MALE 37 DEGREE
18 1 5603156 VALVE BALL
19 1 5603292 VALVE 4 WAY
20 1 5603368 VALVE REGULATING
21 1 9611052 BRACKET PUMP HANDLE
22 1 9611143 GAUGE POSITION INDICATOR
23 1 9611398 BOX CONTROL PANEL
FIGURE 34. SINGLE PANEL ASSEMBLY (9611155) PARTS LIST
61
FIGURE 35. SINGLE PUMP ASSEMBLY (9611153) VIEWS
62
1 2 2007059 CLAMP HOSE
2 1 2015016 NIPPLE KC
5 1 2033008 HOSE 200 PSI
6 1 2033012 HOSE 200 PSI
7 1 2422227 GAUGE 0-2000
8 1 2802100 LUBRICATOR
9 1 3403005 PUMP AIR/HYDRAULIC
10 1 3491500 MUFFLER
12 1 5005151 NIPPLE HEX
13 2 5008417 BUSHING HEX 150 PSI
14 1 5008520 BUSHING HEX 3000 PSI
15 1 5030200 ELBOW 90 DEGREE 150 PSI
16 2 5030354 ELBOW 90 DEGREE 150 PSI
17 1 5055073 NIPPLE
18 1 5055077 NIPPLE
19 1 5055123 NIPPLE
20 1 5201142 REGULATOR 125 PSI
21 1 5603225 VALVE HYDRAULIC RELIEF
22 REF 5609291 VALVE CHECK 2000 PSI
23 REF 5609293 VALVE CHECK 2000 PSI
24 1 9611063 ADAPTER MANIFOLD
FIGURE 36. SINGLE PUMP ASSEMBLY (9611153) PARTS LIST
63
FIGURE 37. SINGLE MANIFOLD ASSEMBLY (9611156) TOP VIEW
64
FIGURE 38. SINGLE MANIFOLD ASSEMBLY (9611156) SIDE VIEW
65
1 1 1602226 FILTER AIR
2 4 2002051 ADAPTER HOSE
3 1 2010040 COUPLING FEMALE
4 1 2010041 COUPLING MALE
5 1 2010301 COUPLING FEMALE
6 1 2012021 CAP DUST
7 1 2012097 PLUG DUST
8 1 2012103 PLUG DUST
10 1 2033008 HOSE 200 PSI 36 IN
11 1 2033008 HOSE 200 PSI 72 IN
12 1 2033008 HOSE 200 PSI 120 IN
15 2 5015232 COUPLING 150 PSI
16 1 5030198 ELBOW 90 DEGREE 150 PSI
19 2 5031046 ELBOW 90 DEGREE 15,000 PSI
20 2 5050116 BULKHEAD FITTING 20,000 PSI
21 1 5055077 NIPPLE
22 2 5078344 TEE 15,000 PSI
23 2 5415180 CONNECTOR COMPRESSION
24 2 5603650 VALVE CHECK
25 1 9611061 MANIFOLD
FIGURE 39. SINGLE MANIFOLD ASSY (9611156) PARTS LIST
66
FIGURE 40. SINGLE TANK ASSEMBLY (9611157)
67
1 6 1455530 SCREW PAN HEAD
3 1 2015016 NIPPLE KC
4 1 2033008 HOSE 200 PSI 36 IN
5 1 2033008 HOSE 200 PSI 6 IN
6 1 2033008 HOSE 200 PSI 8 IN
9 2 5030351 ELBOW 90 DEGREE 150 PSI
10 1 5030352 ELBOW 90 DEGREE 150 PSI
11 1 5055003 NIPPLE
12 2 5055025 NIPPLE
13 1 5055075 NIPPLE
14 2 5078038 TEE 150 PSI
15 1 5078040 TEE 150 PSI
16 1 5401010 TUBING VINYL
17 1 5806175 CAP BREATHER
18 1 9611029 TANK RESERVOIR
FIGURE 41. SINGLE TANK ASSEMBLY (9611157) PARTS LIST
68
FIGURE 42. SINGLE CONTROL CONSOLE PANEL SCHEMATIC
69
FIGURE 43. SINGLE CONTROL CONSOLE TUBING SCHEMATIC
70
FIGURE 44. DUAL CONSOLE SYSTEM (9611405) VIEW
71
1 8 1305210 NUT HEX
2 8 1345389 WASHER SPLIT LOCK
5 1 9611489 CONSOLE ASSEMBLY DUAL
6 OPTION 9611625 METERING SYSTEM 3 PUMP LIGHT SWITCH
6 OPTION 9611633 METERING SYSTEM 3 PUMP MAGNETIC SWITCH
7 4 ZNS10801 WASHER FLAT
FIGURE 45. DUAL CONSOLE SYSTEM (9611405) PARTS LIST
72
FIGURE 46. DUAL CONSOLE SYSTEM HDI (9612207) VIEW
73
1 8 1305210 NUT HEX
5 1 9612206 CONSOLE ASSEMBLY DUAL
7 4 ZNS10801 WASHER FLAT
FIGURE 47. DUAL CONSOLE SYSTEM HDI (9612207) PARTS LIST
74
FIGURE 48. DUAL CONSOLE FRONT/BACK (9611489) VIEWS
75
FIGURE 49. DUAL CONSOLE SIDE/HOSE (9611489) VIEWS
76
1 1 1305035 NUT HEX
2 10 1306167 NUT HEX
16 2 2010060 COUPLING SOCKET 10K PSI
18 4 2012021 CAP DUST
19 1 2012035 CAP DUST
24 2 3403052 PUMP HAND
26 4 5008518 BUSHING HEX
27 2 5030352 ELBOW 90 DEGREE 150 LB
28 2 5057193 NIPPLE
77
31 8 8087264 TIE CABLE (NOT SHOWN)
34 1 8650360 NAMEPLATE I.D.
35 1 9611406 SKID DUAL CONSOLE
36 1 9611410 MANIFOLD DUAL CONSOLE
37 1 9611412 TANK ASSEMBLY DUAL CONSOLE
38 1 9611413 PUMP ASSEMBLY DUAL
39 1 9611415 PANEL ASSEMBLY DUAL
40 2 9611643 PROTECTOR ASSEMBLY GAUGE
41 1 9650360 NAMEPLATE FUNCTION
103
FIGURE 50. DUAL CONSOLE (9611489) PARTS LIST
78
FIGURE 51. DUAL CONSOLE HDI FRONT/BACK (9612206) VIEWS
79
FIGURE 52. DUAL CHOKE CONSOLE SIDE (9612206) VIEW
80
FIGURE 53. HDI GAUGE FASTENER DETAIL (9612206)
81
1 1 1305035 NUT HEX
2 6 1305566 NUT HEX
3 10 1305167 NUT HEX
14 6 1441493 SCREW FLAT HEAD
21 4 2012021 CAP DUST
22 1 2012035 CAP DUST
26 2 2422961 10K PSI HDI GAUGE
27 2 3403052 PUMP HAND
82
29 4 5008518 BUSHING HEX
30 2 5030352 ELBOW 90 DEGREE 150 LB
31 2 5057193 NIPPLE
32 2 5088624 FEMALE SUB 10K PSI
35 6 5873554 STANDOFF
36 8 8087264 TIE CABLE (NOT SHOWN)
39 1 9650360 NAMEPLATE I.D.
40 1 9611406 SKID DUAL CONSOLE
41 1 9611410 MANIFOLD DUAL CONSOLE
42 1 9611412 TANK ASSEMBLY DUAL CONSOLE
43 1 9611413 PUMP ASSEMBLY DUAL
44 1 9612205 PANEL ASSEMBLY DUAL HDI
45 1 9650298 NAMEPLATE FUNCTION
103
FIGURE 54. DUAL CONSOLE HDI (9612206) PARTS LIST
83
FIGURE 55. DUAL PANEL ASSEMBLY CONSOLE (9611415)
84
1 4 1305236 NUT HEX

11 2 2422244 GAUGE 0-10000 PSI 0-70 KPA
13 2 5015232 COUPLING 150 LB.
14 3 5030352 ELBOW 90 DEGREE 150 LB.
15 2 5030449 ELBOW 90 DEGREE 3000 LB
16 2 5417526 CONNECTOR
17 8 5417567 ELBOW 37 DEGREE
18 1 5603038 VALVE 3 WAY
19 2 5603292 VALVE 4 WAY
21 1 5796693 NUT PANEL
24 1 9611408 BOX DUAL CONSOLE
25 1 9650295 NAMEPLATE DUAL CONSOLE
26 1 9650296 NAMEPLATE CASING DRILL PIPE PRESSURE
REF 2 9436145 HANDLE MANUAL CHOKE
REF 2 3491100 HANDLE HYDRAULIC HAND PUMP
FIGURE 56. DUAL PANEL ASSEMBLY (9611415) PARTS LIST
85
FIGURE 57. DUAL PANEL ASSEMBLY HDI (9612205)
86
1 4 1305236 NUT HEX
10 2 5015232 COUPLING 150 LB.
11 3 5030352 ELBOW 90 DEGREE 150 LB.
12 2 5030449 ELBOW 90 DEGREE 3000 LB
13 8 5417567 ELBOW 37 DEGREE
14 1 5603038 VALVE 3 WAY
15 2 5603292 VALVE 4 WAY
17 1 5796693 NUT PANEL
20 1 9611408 BOX DUAL CONSOLE
21 1 9650295 NAMEPLATE DUAL CONSOLE
22 1 9650296 NAMEPLATE CASING DRILL PIPE PRESSURE
REF 2 9436145 HANDLE MANUAL CHOKE
REF 2 3491100 HANDLE HYDRAULIC HAND PUMP
FIGURE 58. DUAL PANEL ASSEMBLY (9612205) PARTS LIST
87
FIGURE 59. DUAL MANIFOLD ASSY REAR (9611410)
88
FIGURE 60. DUAL MANIFOLD REAR (9611410) SECTION VIEW
89
1 1 1602226 FILTER AIR
2 4 2002051 ADAPTER TYPE M
3 2 2010040 COUPLING
6 2 2012021 CAP DUST
7 2 2012097 PLUG DUST
8 1 2012103 PLUG DUST
10 2 2033008 HOSE 200 PSI 12 INCH
11 1 2033008 HOSE 200 PSI 16 INCH
12 2 2033008 HOSE 200 PSI 36 INCH
15 4 5015232 COUPLING 150 PSI
16 1 5030198 ELBOW 90 DEGREE 150 PSI
17 1 5030352 ELBOW 90 DEGREE 150 PSI
19 4 5030393 ELBOW 90 DEGREE 5000 PSI
20 2 5031046 ELBOW 90 DEGREE 15K PSI
21 2 5050116 BULKHEAD FITTING 20K PSI
22 1 5055077 NIPPLE
23 2 5078344 TEE 15K PSI
25 2 5603650 VALVE CHECK
26 1 9611409 MANIFOLD DUAL
FIGURE 61. DUAL MANIFOLD ASSY REAR (9611410) PARTS LIST
90
FIGURE 62. DUAL PUMP ASSEMBLY (9611413) VIEW
91
FIGURE 63. DUAL PUMP ASSEMBLY SECTION A-A
92
FIGURE 64. DUAL PUMP ASSEMBLY SECTION B-B
93
2 2 2015016 NIPPLE
5 1 2033008 HOSE 200 PSI 12 INCH
6 7 2033008 HOSE 200 PSI 19 INCH
7 2 2033012 HOSE 200 PSI 12 INCH
8 2 2422227 GAUGE 0-200 PSI-13,500 KPA
9 2 2802100 LUBRICATOR
10 2 3403005 PUMP HYDRAULIC
11 1 3491500 MUFFLER
13 2 5005151 NIPPLE HEX
15 2 5008520 BUSHING HEX 3000 PSI
16 2 5030200 ELBOW 90 DEGREE 150 PSI
17 3 5030352 ELBOW 90 DEGREE 150 PSI
18 6 5030354 ELBOW 90 DEGREE 150 PSI
19 3 5055025 NIPPLE
20 4 5055073 NIPPLE
21 2 5055077 NIPPLE
22 2 5055123 NIPPLE
23 3 5078038 TEE 150 PSI
24 2 5078040 TEE 150 PSI
25 2 5201142 REGULATOR AIR
26 2 5603225 VALVE HYDRAULIC RELIEF
27 2 9611063 ADAPTER MANIFOLD
FIGURE 65. DUAL PUMP ASSEMBLY (9611413) PARTS LIST
94
FIGURE 66. DUAL CONTROL CONSOLE TUBING SCHEMATIC
95
FIGURE 67. DUAL CONTROL CONSOLE PANEL SCHEMATIC
96
FIGURE 68. GAUGE PROTECTOR ASSEMBLY
97
1 1 2010061 COUPLING QUICK DISCONNECT 10K PSI
2 1 3612200 RING RETAINER
3 3 3965224 O-RING VITON 90
5 1 5060075 PLUG HEX 10K PSI
6 1 5088623 SUB 15K PSI
7 1 5088643 NUT WING 15K PSI
8 1 9611338 PISTON
9 1 9611644 BODY
FIGURE 69. GAUGE PROTECTOR ASSEMBLY PARTS LIST
98
SECTION 8.1 STROKE/RATE METER CONFIGURATIONS
FIGURE 70. METER 2 PUMP WITH LIMIT (9611626)
99
1 1 6007124 BOX CONDUIT EP
2 3 6560049 CONNECTOR CABLE
3 5 8062680 NUT WIRE WING
4 2 9611049 SWITCH LIMIT ASSEMBLY PUMP STROKE
5 1 9611321 METER ASSEMBLY DIGITAL 2 PUMP
FIGURE 71. METER 2 PUMP W/LIMIT (9611626) PARTS LIST
100
FIGURE 72. METER 3 PUMP WITH LIMIT SWITCH (9611625)
101
4 3 9611049 SWITCH LIMIT ASSEMBLY PUMP STROKE
FIGURE 73. METER 3 PUMP W/LIMIT (9611625) PARTS LIST
102
FIGURE 74. METER 2 PUMP W/MAGNETIC SWITCH (9611641)
103
6 2 9611635 SWITCH ASSEMBLY PROXIMITY MAGNETIC
FIGURE 75. METER 2 PUMP W/MAG. (9611641) PARTS LIST
104
FIGURE 76. METER 3 PUMP W/MAG. SWITCH (9611633) VIEW
105
6 3 9611635 SWITCH ASSEMBLY PROXIMITY MAGNETIC
FIGURE 77. METER 3 PUMP W/MAG. (9611633) PARTS LIST
106
FIGURE 78. STROKE/RATE METER ASSY. 2 PUMP (9611321)
107
1 2 1305288 NUT HEX
2 1 1305986 NUT WING
10 2 1573800 RIVET POP
11 4 5873538 STANDOFF
13 1 8059397 MODULE LOGIC DIGITAL
14 1 8062650 NUT LOCK CONDUIT
15 1 9611325 SWITCH ASSEMBLY MODULE 2 PUMP
16 1 9611328 BATTERY PACK
17 1 9611331 COVER
18 1 9611385 HANDLE
19 1 9611624 CASE
20 1 9650270 DECAL DIGITAL 2 PUMP
FIGURE 79. STROKE/RATE METER 2 PUMP (9611321) PARTS

LIST
108
FIGURE 80. STROKE/RATE METER ASSY. 3 PUMP (9611612)
109
1 2 1305288 NUT HEX
2 1 1305986 NUT WING
10 2 1573800 RIVET POP
11 4 5873538 STANDOFF
13 1 8059397 MODULE LOGIC DIGITAL
14 1 8062650 NUT LOCK CONDUIT
15 1 9611328 BATTERY PACK
16 1 9611385 HANDLE
17 1 9611570 SWITCH ASSEMBLY 3 PUMP
18 1 9611571 COVER
19 1 9611624 CASE
20 1 9650393 DECAL DIGITAL 3 PUMP
FIGURE 81. RATE METER ASSY. 3 PUMP (9611612) PARTS LIST
110
FIGURE 82. PUMP STROKE W/LIMIT SWITCH (9611049)
111
1 4 1305212 NUT HEX
6 2 6592050 TERMINAL WIRE RING
7 1 6592095 TERMINAL WIRE RING
8 1 7569011 SWITCH LIMIT
9 125’ 7906111 CABLE
10 2 8087255 CABLE TIE
11 1 9389161 ROD ACTUATOR
12 1 9611055 PLATE MOUNT
13 1 9611123 BRACKET MOUNT
14 1 9611124 CLAMP
FIGURE 83. PUMP STROKE W/LIMIT SWITCH (9611049) PARTS

LIST
112
FIGURE 84. PUMP STROKE MAG. SWITCH (9611635)
113
1 4 1305212 NUT HEX
6 1 5015233 COUPLING 150 PSI
7 1 5055077 NIPPLE
9 1 7573251 SWITCH MAGNETIC
10 125’ 7906119 CABLE
11 1 9611123 BRACKET MOUNT
12 1 9611124 CLAMP
13 1 9611634 PLATE MOUNT
FIGURE 85. PUMP STROKE MAG. SWITCH (9611635) PARTS LIST
114
FIGURE 86. EQUIVALENT BEAN SIZE CHART
115
FIGURE 87. MULTIPLE CHOKE INSTALLATION DIAGRAM
116
APPENDIX A BARKSDALE VALVE
117
118
APPENDIX B HDI GAUGE
The HDI Gauge data has been deleted from the manual to reduce the
size of the file required for this document.
119
APPENDIX C SC HYDRAULIC PUMP
120
121
122
123
124
125
126
127
128
129
130
APPENDIX D PINE SIMPLEX PUMP
131
132
133
APPENDIX E FLO-TORK ACTUATOR
134
135
136
137
138
139
APPENDIX F TECHNICAL BULLETINS
The Technical Bulletins have been Deleted to reduce the size of the file
required for this document.
TB 003 Renold 275N Coupling P.N. 3105265
TB 019 10K Control Console Junction Box Assembly Changes
TB 023 10K Gauge Protector
TB 032 10K Choke Single and Dual Console Pressure Gauges
TB 053 10K Extended Wear Sleeve with O-Ring
TB 066 10K Non H2S Choke Bleeder Valve
TB 069 Gauge Protector Assembly
TB 087 Bonnet-end-Loading (BEL) Back Disc Assembly
TB 094 4-Way 3-Position Control Valves
TB 096 Inconel 625 vs. Austenitic Stainless Steel
TB 111 Gauge Protector Nipple Installation
TB 114 10K Choke Panel Digital Gauge Installation
TB 123 10K Super Choke Body Modification for Dowel Pin
TB 134 Super AutoChoke Console Air-Operated Hydraulic Pump Repair Kit
TB 142 Super Choke Shear Pin
TB 153 M-I SWACO Choke Panel Digital Gauge Installation
TB 163 Super Choke Repair Procedure
TB 171 Gauge Protector Caution
140

SWACO Operating & Service Manual Super Choke

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SWACO Operating & Service Manual Super Choke

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OPERATING & SERVICE

Global Sales/Technical Support

The remote operated M-I SWACO Super Choke is proven by experience to be a

This symbols draws attention to the safety measures to prevent

The symbols shown on the packing are as follows.

THIS EQUIPMENT OPERATES UNDER HIGH PRESSURE. NEVER

PROPER MAINTENANCE TOOLS SHOULD BE USED AND NO

USE ONLY AUTHORIZED REPLACEMENT PARTS.

WHILE PRESSURE TESTING, ASSURE THAT ALL AIR HAS BEEN

ALWAYS USE PROPER SAFETY PRECAUTIONS IF H2S GAS COULD

SECTION 2.1 CHOKE VALVE

FIGURE 1. CHOKE VALVE VIEW

• Stripping-in under pressure (controlled displacement)

SECTION 2.2 CONTROL CONSOLE

A needle valve, labeled HYDRAULIC REGULATOR, can be adjusted to control

SECTION 3.1 Choke Valve

SECTION 3.1.1 Installing the Choke Valve

FIGURE 5. SUPER CHOKE VIEW

SECTION 3.1.2 Repositioning the Actuator Assembly

SECTION 3.1.3 Control Lines

SECTION 3.1.4 Choke Disc Position Transmitter

SECTION 3.2.1 Installing the Control Console

FIGURE 6. M-I SWACO SINGLE CHOKE CONSOLE VIEW

SECTION 3.2.2 Air Supply

If there is any problem with these operations, refer to SECTION 7 of this

SECTION 3.2.3 Stroke/Rate Meter

Operate each pump stroke assembly by hand to determine Pump 1, 2, or 3.

SECTION 3.2.4 Gauge Protector

SECTION 3.3 Multiple Choke Installation

SECTION 3.3.1 Dual Control Console Assembly

FIGURE 7. DUAL CHOKE CONTROL CONSOLE VIEW

SECTION 3.3.3 Multiple Control Console Installation

SECTION 4.1 PROCEDURES

SECTION 4.1.1 Normal Operating Method (Fast)

• Fully close the Hydraulic Regulator.

FAILURE OF AIR SUPPLY OR AIR PUMP

RUPTURE IN HYDRAULIC LINE OR CONNECTION

SECTION 5.1 PROCEDURES

SECTION 5.1.1 Routine Inspection

FIGURE 9. SUPER CHOKE AND CONTROL CONSOLE

SECTION 5.1.2 DAILY VISUAL CHECKS

SECTION 5.1.4 REMOVING CHOKE VALVE FROM MANIFOLD

Before working on a Super Choke installed in a manifold verify that

Use appropriate safety precautions if H2S gas could be trapped in the

Before working on a Super Choke installed in a manifold verify that

Use appropriate safety precautions if H2S gas could be trapped in the

FIGURE 10. SUPER CHOKE DISC REMOVAL VIEW

SECTION 5.1.6 BONNET END DISASSEMBLY

Use appropriate safety precautions if H2S gas could be trapped in the

• Position the choke discs in the full OPEN position.

SECTION 5.1.7 GAUGE PROTECTOR

SECTION 5.1.8 GAUGE PROTECTOR DISASSEMBLY

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

FIGURE 13. CHECK VALVE

SECTION 5.1.10 POSITION INDICATOR SYSTEM

SECTION 5.1.11 CALIBRATION AND ADJUSTMENT

TO ZERO THE POSITION INDICATOR GAUGE

• Completely OPEN the choke.

SECTION 5.1.12 DIGITAL STROKE/RATE METER

The digital stroke/rate meter contains three interconnected modules; a display