GNRC Na Mpm100524

Multiplex (MUX) Pod
Care and Maintenance

Course
Basic Training Manual
copyright 2010 Hydril USA Distribution LLC

Houston, Texas
GNRC-NA-MPM100524
Published by GE Oil & Gas

Multiplex (MUX) Pod Care and Maintenance Course
Basic Training Manual
GNRC-NA-MPM100524
GE Oil & Gas makes no warranties of any kind, expressed or implied, including any warranty of
mechanical fitness for any particular purpose that the work performed pursuant to this manual
will be free from defects in workmanship or material. GE Oil & Gas retains for itself all propriety
rights in and to all designs, engineering details, data, and procedures set forth herein. This manual is intended for the sole use of GE Oil & Gas customers, and they shall strictly control copying
and distribution of same, as this manual and all paper and electronic copies thereof may be
recalled by GE Oil & Gas at any time.
This manual makes recommendations only. The customer is at all times responsible for actual
disassembly, inspection, reassembly, and testing of the equipment. The customer also is solely
responsible for providing competent and qualified persons; equipment and facilities to perform
such operations; and for workmanship and safety. If at any time the customer is unable to
understand recommendations made in this manual or is unable to follow those recommendations, they should consult the nearest GE Oil & Gas location. GE Oil & Gas reserves the right to
make additions, changes or deletions on the equipment described, at any time, without obligation.
No portion of this work may be reproduced by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from GE Oil & Gas.
Copyright 2010 Hydril USA Distribution LLC
All rights reserved. Printed in the United States of America.
To contact GE Oil & Gas:
Pressure Control Systems
ATTN: Customer Service and Training
3300 North Sam Houston Parkway East
Houston, TX 77032-3411 USA
Phone
(281) 449-2000 (USA)
(800) 231-0023 (USA and Canada)
Fax
(281) 985-2828 (USA)
Web
www.geoilandgas.com/hydril
Introduction
Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1
Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1
Ancillary Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2
Chapter 1
Pod Lifting Techniques
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Using the Pod Lift Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chapter 2
Pod Section Assembly and Disassembly
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Separating the EH and LVCU Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Joining the EH and LVCU Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Chapter 3
SEM Housing Dome and Chassis
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Required Tools and Accessories for Dome . . . . . . . . . . . . . . . . . . . . . . . 3-1
Required Tools and Accessories for SEM Chassis . . . . . . . . . . . . . . . . . 3-2
Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removing the Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removing the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Dome Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Chapter 4
Removal and Installation of the Pod Transformer
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
MUX Pod Care and Maintenance Course

i-1
TABLE OF CONTENTS
Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removing the Transformer Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removing the Heat Shields and Transformer . . . . . . . . . . . . . . . . . . . . 4-3
Transformer Housing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Reassembling the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Chapter 5
Pod Wedge Packer Seals
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lowering the Pod Wedge by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Removing the Packer Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Chapter 6
Solenoid Housing Pressure Compensator
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Solenoid Housing Cover/Compensator Removal . . . . . . . . . . . . . . . . . 6-2
Preparing the Solenoid Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Placing a New Bladder in Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Reattach Cover to Solenoid Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Chapter 7
Shear Seal Valves
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Removing the Solenoid Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Removing the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Disassembling the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Inspecting the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Reassembling the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Installing the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Installing the Solenoid/Shear Seal Housing Cover . . . . . . . . . . . . . . . 7-15
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GNRC-NA-MPM100524
TABLE OF CONTENTS
Chapter 8
Solenoids
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Draining the Solenoid Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Removing the Solenoid/Shear Seal Housing Cover . . . . . . . . . . . . . . . 8-2
Removing the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Removing the Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Solenoid Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Installing the Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Chapter 9
Filling the Solenoid Housing
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Preparation for Solenoid Housing Fill Procedure . . . . . . . . . . . . . . . . . 9-2
Solenoid Housing Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
An Alternativeto the Above Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Preparation for Solenoid Housing Fill Procedure . . . . . . . . . . . . . . . . . . . . . 9-7
Solenoid Housing Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Chapter 10
Solenoid/Shear Seal Valve Assembly Testing
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Solenoid Test Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Solenoid Pull-in/Drop-out Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Preparation of EH Function Solenoid Testing . . . . . . . . . . . . . . . . . . . 10-4
EH Function Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Auto Shear Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Solenoid Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Solenoid Fire Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Solenoid Resistance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

i-3
TABLE OF CONTENTS
Chapter 11
Pressure Transducer
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Transducer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Installation of Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Chapter 12
Pressure Transducer Calibration
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Calibrating Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Chapter 13
One Atmosphere Housing Hydrostatic Test
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Test Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Test Procedure for Test Port O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Test Procedure For External Cable Connector Ports . . . . . . . . . . . . . 13-4
Test Procedure For The MUX Cable VCC29 Connector . . . . . . . . . . . . 13-4
Test Completion and Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Chapter 14
Subsea Regulator
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Regulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Regulator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Reinstall the Subsea Regulator on the Pod . . . . . . . . . . . . . . . . . . . . . 14-9
Chapter 15
SPM Valve
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
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GNRC-NA-MPM100524
TABLE OF CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Chapter 16
2.5 Liter Regulator Accumulators
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Removing the Regulator Accumulators . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Installing the Regulator Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Chapter 17
Regulator Accumulators Precharge
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Test Equipment, Supplies, Facility Requirements . . . . . . . . . . . . . . . . 17-1
Preparation for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Accumulator Precharge Circuit Pressure Test . . . . . . . . . . . . . . . . . . . 17-2
Accumulator Precharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
Chapter 18
Flowmeter Removal and Installation
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Flowmeter Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5
Chapter 19
Flowmeter Calibration
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Preparation For Determination of Pod K-Factor . . . . . . . . . . . . . . . . . 19-1
Function Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
K-Factor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-3

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TABLE OF CONTENTS
i-6

GNRC-NA-MPM100524
Introduction
Course Description
The Hydril Multiplex (MUX) Pod Care and Maintenance course is for subsea technicians and supervisors,
hydraulic engineers and technicians, and anyone interested in understanding the maintenance
procedures for the MUX control pod. The Basic MUX Control System course is a recommended
prerequisite for this course.
Each course model is intended to give a student 1) an understanding of what equipment makes up a
MUX control pod, 2) how each piece of equipment operates and interrelates with the pod, 3) how to
install and remove each component, and 4) basic maintenance and troubleshooting of the equipment.
Course Objectives
This course is designed with several objectives in mind. As the student reads this manual and
participates in the classroom these goals should be achieved.
An understanding of the purpose and function of the MUX control pod.
The ability to identify the major components that make up the pod.
An introduction to these components and their operation and interaction.
The ability to remove and to install the components on the MUX control pod.
The ability to maintain and troubleshoot the customer-serviceable parts of the pod.
This manual is developed to act as a guide during the classroom and serve as a reference guide to the
system. As always, for exact system information, students should refer to the Hydril Operations &
Maintenance Manual Set for the MUX control system installed on their rig.

ii - 1
INTRODUCTION
Introduction
Ancillary Materials
Ancillary Materials
There are no ancillary materials for this class.
How to Use This Manual

Scope
The scope description provides a quick overview of the chapter contents, and allows you to
quickly familiarize yourself with the subject matter.
Conventions
This manual uses the following conventions.
Note...
Notes provides additional useful information.
Caution...
Cautions indicates procedures which can potentially damage
equipment if not performed properly.
Warning...
Warnings indicate potentially hazardous situations or procedures or
which can potentially injure or kill personnel if not performed
properly.
Things to Remember...
Things to Remember contains important facts about individual
components in the MUX system, bullet points, special instructions, or
installation tips.
ii - 2

GNRC-NA-MPM100524
Chapter 1
Notes
Scope
The purpose of this procedure is to demonstrate the proper technique
for using the pod lift frame to lift the MUX pods.
Figure 1-1 Subsea Pod
Required Tools and Accessories

Pod lift frame
5/16"
11/16"
open ended wrench

open ended wrench
(2) Lifting straps rated to lift 26,420 lbs.

(2) 11/2" - 21 ton shackles (entire assembly)
(2) 11/4" - 9.5 ton shackles (EH section)
Overhead crane/hoist

1-1
CHAPTER 1
Notes
Using the Pod Lift Frame

Remember...
Before using the overhead crane and the
pod lift frame to move any part of the pod,
survey the path of travel to ensure that it is
and will be clear.
Remove all trip hazards, and identify any
overhead obstacles which may present a
problem throughout the operation.
Be Careful...
The entire pod assembly weighs 22,700 lbs. The
EH section weighs 10,100 lbs. empty, and the
LVCU section weighs 12,600 lbs. empty. To
prevent damage to equipment and/or bodily
injury, ensure the shackles and lifting straps are
appropriately rated for this lifting procedure.
1. Attach a shackle to each of the lifting eyes on top of the pod lift
frame.
Figure 1-2 Pod Lift Frame
2. Insert a lifting strap through each shackle.

3. Center the crane hoist over the lift frame, and lower the hoist to
a height suitable for attaching the straps.
4. Install both loops of the lifting straps onto the hoist hook.
5. Ensure that the hoist safety latch closes to prevent the loops
from coming off the hook.
6. Raise the hoist until the straps are tight. Ensure the weight of
the pod lift frame is evenly distributed.
1-2

GNRC-NA-MPM100524
CHAPTER 1
Notes
Dont Forget...
If the lift frame does not appear level, lower the
hoist until the straps slacken.
7. Adjust the straps until the weight is evenly distributed.

8. Locate the four bolts (one bolt per corner) installed in the upper
four corners of the pod assembly.
9. Using the 11/16" and the 5/16" wrenches, loosen the nuts from the
bolts, and remove both the nuts and the bolts from the pod
assembly.
Figure 1-3 Removing the Bolts and Nuts
10. Continue raising the hoist until the bottom end of the lift frame
legs are higher than the assembly to be lifted.
Be Careful...
To prevent damage to the pod electronics,
ensure the legs of the frame do not come in
contact with the electronics dome or the
transformer housing when centering the frame
over the EH section.
11. Center the lift frame over the assembly.
12. Align the frame legs with the holes at each corner of the
assembly.
13. Lower the lift frame into the holes.
14. Install a retaining bolt in each of the four holes.
15. Install a nut on each of the bolts.
16. Tighten each retaining bolt assembly.
17. Raise the hoist until the straps are tight.

1-3
CHAPTER 1
Notes
Remember...
If the lift frame does not appear level, lower
the hoist until the straps slacken.
Adjust the straps until the weight is evenly
distributed.
18. Continue raising the assembly.
Make Sure...
When lift the entire pod or the LVCU, ensure that
the assembly is clear of the pod test stand or
other supporting framework before moving.
Figure 1-4 Lifting the Pod EH Assembly
Watch Out...
To prevent bodily injury, keep a safe distance
from the pod assembly when it is suspended.
Watch the path of travel to ensure no one
walks in front of or under the pod assembly
while it is in motion.
19. Move the assembly to the desired location.
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GNRC-NA-MPM100524
CHAPTER 1
Notes
Remember...
When separating the EH section from the
LVCU, ensure the EH section legs clear the
LVCU before moving.
When lifting the EH section from its stand,
ensure the legs clear the stand before
moving.
20. Lower the assembly into its destination location until the straps
are slack.
21. Loosen the nuts from the retaining bolts.
22. Remove the nuts and bolts.
23. Use the hoist to raise the pod lift frame until the bottom of the
legs are above the EH section electronics dome.
24. Move the pod lift frame to a safe location.
25. Lower the hoist until the straps are slack.
26. Remove the straps from the hoist hook.
27. Install the four retaining bolts in the four corners of the EH
section. Install the nuts on the bolts and hand tighten.
This student ____________________________________________ has

successfully completed the procedures described in this chapter.
Instructor
Signature ________________________________ Date ___________

1-5
CHAPTER 1
1-6

GNRC-NA-MPM100524
Chapter 2
Pod Section Assembly
and Disassembly
Notes
Scope
This purpose of this procedure is to show how to separate and to join
the electro-hydraulic (EH) and the lower valve control unit (LVCU)
sections of the MUX control pod.
Figure 2-1 Subsea Pod

Pod lift frame
Ratchet
Extension
5/16"
15/16"
open ended wrench
11/16"
open ended wrench
Allen socket

2-1
CHAPTER 2
Notes
(2) Lifting straps rated to lift 26,420 lbs.

(2) 21 ton shackles (entire assembly)
(2) 9.5 ton shackles (EH section)
A-frame ladder
Nickel-plated Never Seez
Separating the EH and LVCU Sections

Be Careful...
The entire pod assembly weighs 22,700 lbs. The
EH section weighs 10,100 lbs., and the LVCU
section weighs 12,600 lbs. To prevent damage
to equipment and/or bodily injury, ensure the
shackles and lifting straps are appropriately
rated for the lifting procedure.
Remember...
Before using the overhead crane and the
pod lift frame to move any part of the pod,
survey the path of travel to ensure that it is
and will be clear.
Remove all trip hazards, and identify any
overhead obstacles which may present a
problem throughout the operation.
1. Remove all of the cap screws that hold the solenoind/shear seal
housing covers.
2. Remove the covers from both sides of the E/H section and set
them aside.
3. Using the 15/16" wrench, loosen the retaining bolts that are
located on the junction plates. (They will not totally remove
from the EH junction plate)
Check to See...
Ensure the LVCU is fastened securely to a stable
platform or a pod test stand.
4. Locate the four bolts installed in the upper four corners of the
pod assembly.
2-2

GNRC-NA-MPM100524
CHAPTER 2
Notes
5. Using the 11/16" and the 15/16" wrenches, loosen the nut and bolt
assembly.
6. Attach a shackle to each of the lifting eyes on top of the pod lift
frame.
Figure 2-3 Pod Lift Frame
7. Insert the lifting strap through each shackle on the pod lift frame.
8. Center the crane hoist over the lift frame, and lower the hoist to
install the straps.
9. Hook both sides of the strap to the hoist.
Remember...
distributed.
10. Raise the hoist until the straps are tight. Ensure the weight of
the pod lift frame is evenly distributed.

2-3
CHAPTER 2
Notes
Be Careful...
When centering the frame over the EH section,
transformer housing.
11. Center the lift frame over the EH section.
12. Align the frame legs with the holes at each corner of the EH
housing.
13. Lower the lift frame until the retaining bolt holes in the EH
section line up with the holes in the frame legs.
14. Install a retaining bolt in each of the four holes. Tighten each
retaining bolt.
15. Locate the retaining bolts installed in the upper four corners of
the LVCU.
16. Using the 15/16" wrench, loosen the nuts from the bolts. Remove
the nuts and bolts from the LVCU.
Remember...
distributed.
Be Careful...
Separating the EH section from the LVCU
involves the hydraulic junction plates at both
ends of the pod. To prevent damage to the
junction plate O-rings and seal subs, ensure the
crane is centered over the pod prior to lifting.
18. Continue raising the pod lift frame until the bottom ends of the
EH section legs are above the LVCU.
19. Carefully move the EH section to its stand.
20. Align the EH section legs with the stand.
21. Lower the EH section onto the stand until the straps are slack.
22. Using the 15/16" and the 11/16" wrenches, loosen the nuts from
the retaining bolts.
2-4

GNRC-NA-MPM100524
CHAPTER 2
Notes
Figure 2-4 Lifting the Pod EH Assembly
24. Use the hoist to raise the pod lift frame until the bottom of the
legs are above the EH section electronics dome.
27. Remove the straps from the hoist.
28. Install the retaining bolts in the four corners of the EH section.
29. Install the nuts on the bolts hand tight.
30. Install the retaining bolts in the four corners of the LVCU.
31. Install the nuts on the bolts hand tight.
Joining the EH and LVCU Sections

1. Use the 5/16" Allen socket to remove the cap screws that hold
the Solenoid/shear seal housing cover in place.
2. Set the screws in a cup or bag so that they will not be
misplaced.
3. Set the covers off to the side so that they will not become an
obstacle or safety hazard.
4. Locate the four bolts (one bolt per corner) installed in the upper
four corners of the EH section.
5. Loosen the nuts from the bolts. Remove the nuts and bolts from
the EH section.
2-5
CHAPTER 2
Notes
6. Attach an appropriately rated shackle to each of the lifting eyes

on top of the pod lift frame.
7. Insert a 26,420 lb. rated lifting strap through each shackle.
8. Center the crane hoist over the lift frame, and lower it to a
height suitable for installing the straps.
9. Install both loops of the lifting straps onto the hoist hook and
ensure that the hoist safety latch closes.
Verify...
Ensure that the weight of the pod liftlift frame is
evenly distributed.
11. Adjust the straps until the weight is evenly distributed.

12. Continue raising the hoist until the bottom end of the lift frame
legs are above the EH section dome.
Be Careful...
When centering the frame over the EH section,
13. Center the lift frame over the EH section.
14. Align the frame legs with the holes at each corner of the EH
housing.
15. Lower the lift frame until the retaining bolt holes in the pod line
up with the holes in the frame legs.
16. Install a retaining bolt in each of the four holes. Install a nut on
each of the bolts.
2-6

GNRC-NA-MPM100524
CHAPTER 2
17. Tighten each retaining bolt assembly using the 15/16" wrench in
conjunction with the 11/16" wrench.
Notes
18. Locate the retaining bolts installed in the upper four corners of
the LVCU.
19. Loosen the nuts from the bolts.
20. Remove the nuts and bolts from the LVCU.
21. Raise the hoist until the straps are tight. (Ensure that the weight
of the pod lift frame is evenly distributed)
Remember...
distributed.
22. Continue raising the EH section until the legs are above the
LVCU.
23. Move the EH section until it is centered over the LVCU.
24. To ensure the EH section is oriented properly with the LVCU,
locate the pod select valve on the LVCU.
25. Orient the EH section over the LVCU so the electronics dome is
on the same side of the assembly as the pod select valve.
Be Careful...
Joining the EH section with the LVCU involves
the hydraulic junction plates at both ends of the
pod. To prevent damage to the junction plate Orings and seal subs, employ the assistance of a
co-worker to guide the EH section into position
as it is lowered.
26. Slowly lower the EH section until the junction plates mate.
27. Before contact, verify that both junction plates are properly
aligned.
Figure 2-6 Aligning the Junction Plates

2-7
CHAPTER 2
Notes
Be Careful...
Proceed slowly when lowering the EH section to
prevent cutting the O-rings.
28. Slowly lower the EH section onto the LVCU.

29. Install the retaining bolts in the four corners of the LVCU.
30. Install a nut on each bolt and tighten hand tight.
31. Place an A-frame ladder next to the pod assembly.
32. Locate the retainer bolts that are on the junction plates.
33. There are four bolts per side; tighten each bolt down until it
bottoms out.
34. Move the ladder to the side of the pod where the HPHT and
Flowmeter connections are located.
35. Remove the cover plate located on the side of the LVCU.
36. Take the cable that is coming from the top of the pod wedge
and attach to the J5 connection point..
37. Take the cable that is coming from the inner body of the LVCU
and connect to the J6 connection.
.
Figure 2-7 Junctions for the HPHT and the Flowmeter
38. Replace the panel.

39. Standing on the ladder, loosen the nuts attaching the pod lift
frame to the EH section.
41. Raise the pod lift frame until the bottom of the legs are above
the EH section electronics dome.
44. Remove the straps from the hoist hook.
45. Install the retaining bolts in the four corners of the EH section.
Install the nuts on the bolts and hand tighten.
2-8

GNRC-NA-MPM100524
CHAPTER 2
This student ____________________________________________ has
Instructor
Signature ____________________________ Date ___________

2-9
CHAPTER 2
2 - 10

GNRC-NA-MPM100524
Chapter 3
Notes
Scope
The purpose of this procedure is to describe the removal and
installation of the MUX control pods SEM chassis and housing dome.
Figure 3-1 SEM Housing Dome
Required Tools and Accessories for Dome
5/8"
Allen socket
Ratchet
(2) 1/4" shackles
Clevis/lift frame (GE Oil & Gas # AC534)
1" shackle
Full circle lifting strap, 4 feet in length
Petroleum jelly

3-1
CHAPTER 3
Notes
Required Tools and Accessories for SEM Chassis

Phillips head screwdriver
3/8"
Allen socket
Ratchet
(2) lifting straps, 10 feet in length
Small flat head screwdriver
Remove Pod Power

Watch Out...
The pod is powered by 720 VAC and 120 VAC
signals. To prevent electric shock, ensure that
all power sources are locked out before
proceeding.
1. Turn the subsea power breaker located at the PDP to the OFF
position and place a lockout tag on the PDP.
2. Place the CCU logic drawer subsea SEM power switch to the AON/B-ON position.
3. Remove the Pyle National connector at the umbilical J-box, or
remove the VCC-29 connector at the pod.
Removing the Dome

Before removing the dome, ensure a level area for it to be placed.
1. Attach the clevis frame to the dome.
2. Attach a 1" shackle to the clevis.
3. Run the strap through the shackle and hook the ends of the
strap on to the hoist.
4. Remove all of the cap screws attaching the SEM housing dome
to the one atmosphere housing.
5. Set the cap screws aside in a secure and clean location.
6. Remove Test Port 4 (TP4).
7. Lift the hoist until the strap becomes taut.
Watch Out...
The SEM dome weighs 1,100 pounds. To
prevent bodily injury, DO NOT walk under the
dome when it is suspended.
3-2

GNRC-NA-MPM100524
CHAPTER 3
Notes
Remember...
Ensure the path of travel for the dome is free of
trip hazards and overhead obstacles.
8. Slowly lift the dome off the one atmosphere housing.

9. Once the housing clears the chassis, move it to a safe location.
10. Lower the hoist and remove the strap.
Removing the Chassis

Before removing the chassis, designate a work area where the chassis
will be placed once it is removed. Ensure that the area is clean and
level.
1. Take the lifting strap and connect the two 1/4" shackles to eyebolts.
2. Attach the strap to the hook on the hoist.
3. Raise the hoist until the straps are hanging loosely above the
chassis.
Remember...
Be sure that all cables and connectors are
labeled before disconnecting.
4. Remove both cowlings from the chassis.

5. Remove the two top mounting screws for the navigation
computer.
6. Pull out the navigation computer and place it in a clean area.
7. Disconnect the transducer connector (hypertronic connector
A/BP1).
8. Desconnect Solenoid Connector #1 (hypertronic connector
A/BP3).
9. Disconnect Solenoid Connector #2 (hypertronic connector
A/BP4).
10. Disconnect the 90 VAC & 48 VAC input connector (hypertronic
connector JPWR1).
11. Disconnect the X/Y riser angle connector (DB9 JSENS).
12. Disconnect the solenoid #15 (hyper 4-pin connector).
13. Disconnect the SEM communication connector (4-pin, MLModem).
14. Disconnect the navigation communication connector (4-pin,
ML-RS485).
3-3
CHAPTER 3
Notes
15. Disconnect the ROV.NAV. connector (Hyper, 4-pin).

16. Disconnect the flowmeter connector (DB9, JF1).
17. Disconnect the gyro connector (DB15).
18. Place all of the cables in the one atmosphere housing before
removing the chassis from the housing.
19. Using the small screwdriver, remove all of the screws that hold
the chassis to the housing.
20. Set the screws aside in a place that will be secure.
21. Slowly lift the hoist and remove the chassis.
22. Set the chassis in the designated area and remove the strap.
Dome Maintenance
1. Remove the O-rings and backup rings from the base of the
dome.
2. Check the O-ring grooves and sealing surfaces for cuts and
abrasions.
3. Replace the O-rings. Lightly lubricate the new O-rings with
petroleum jelly.
4. Install the new O-rings on the base of the dome.
Installing the Chassis

1. Connect the two 1/4" shackles to the eye bolts.
2. Lift the chassis and set in on the one atmosphere housing.
3. Route the cables located in the one atmosphere housing up
through the center of the chassis.
4. Rotate the chassis until it is oriented with the PC boards facing
out.
5. Connect the JPWR1 connector to the PPWR1 connector of the
chassis.
6. Connect the JSENSF 9-pin female connector of the pod to the
JSENSM 9-pin male connector of the chassis.
7. Connect the chassis, 4-pin MIL-M connector of the surface
communication harness to the 4-pin MIL-F connector of the
pod surface communication harness.
8. Connect the DB15 connector of the gyro harness of the chassis
to the DB15 connector.
9. Connect the DB9 connector of the flowmeter harness of the
SEM2003 to the DB9 connector PF1 of the hypertronic plug
A/BP1 in the pod.
10. Secure the chassis to the one atmosphere housing, using the
base mounting screws.
3-4

GNRC-NA-MPM100524
CHAPTER 3
(If converting from SEM 1999 to SEM 2003, add the steps below to the
steps that are shown above)
Notes
1. Change the pin out of the 4-pin female connector of the pod
which was originally for NAV communication as follows:
2. Move the wire from Pin 3 to Pin 2.
Move the wire from Pin 4 to Pin 1.
3. Connect the modified 4-pin female connector of the pod to the
4-pin male connector of the NAV communication harness of the
chassis.
4. Modify the pin out of the hypertronic plug A/BP1 in the pod as
follows:
Remove FLM1 from Pin E18.
5. Perform the three steps below:
Remove the 4-pin HYPER-M connector (w/cable) from the
original SEM.
Connect Pin 1 to Pin J3 of the hypertronic plug A/BP3 in the
pod.
Connect Pin 3 to Pin K3 of the hypertronic plug A/BP3 in the
pod.
Remove FLM2 from Pin F18 to Pin E18.
Installing the Dome

1. Attach the clevis frame to the top of the dome.
2. Attach the shackle to the eye bolt and lifting device.
3. Lower the hoist above the dome.
4. Run the strap through the shackle and hook the ends of the
strap on to the hoist.
5. Lift the hoist until the strap becomes taut.
Be Careful...
Two people should perform the next step. Clear
communication is vital to prevent damage to
the chassis.
6. Slowly lift the dome off the ground.
7. Center the dome over the chassis.
8. Slowly lower the dome over the chassis.
9. Align the bolt holes with the holes in the dome.
10. Lower the dome onto the one atmosphere housing.
11. Lubricate the dome cap screws with nickel-plated Never Seez
and install them in the bolt holes.
3-5
CHAPTER 3
Notes
12. Tighten the cap screws in a star pattern.

13. Torque the bolts to 80 ft-lbs (108 Nm).
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________
3-6

GNRC-NA-MPM100524
Chapter 4
Removal and Installation of the
Pod Transformer
Notes
Scope
This purpose of this procedure is to demonstrate the process for
removing the transformer housing that is located on the MUX pod,
and removing the transformer that is located under the housing. This
chapter will also cover the installation of the transformer and housing.
Figure 4-1 Pod Transformer

Lifting eye
Clevis frame lift (GE Oil & Gas # AC534)
1" shackle
(2) 1/4" shackle
4-1
CHAPTER 4
Notes
3/8"
drive ratchet
3/8"
drive extension, 4 feet in length
1/2"
socket with a 3/8" drive
11/16"
9/16"
3/8"
Allen socket with a 3/8" drive
1/8"
Allen wrench
open ended wrench
open ended wrench
Open ended wrench
Full circle lifting strap, 4 feet in length
Nylon strap, 6 feet in length
Transformer housing shackle
O-ring pick
Petroleum jelly
Heat sink compound
Clean cloths
Remove Pod Power

1. To lock out the 720 VAC, turn the subsea power breaker located
at the PDP to the OFF position and place a lockout tag on the
PDP.
2. To lock out the 120 VAC, place the CCU logic drawer subsea
SEM power switch to the A-ON/B-ON position.
3. To ensure that the pod is completely de-energized, remove the
Pyle National connector at the umbilical J-box, or remove the
VCC-29 connector at the pod when possible.
Removing the Transformer Housing

Watch Out...
proceeding.
Before removing the transformer housing, indentify the location that
the housing will be placed once it has been removed. Ensure the area
is clean and level.
1. Locate the cap screws that mount the transformer housing to
the pod (see Figure 4-2).
4-2

GNRC-NA-MPM100524
CHAPTER 4
2. Use the ratchet, the four-foot extension, and the 5/8" Allen
socket to remove the cap screws.
Notes
Figure 4-2 Transformer Housing Cap Screws
3. Attach the eye bolt to the top of the transformer housing.
Figure 4-3 Clevis Lift Frame and Eye Bolt
4. Thread the lifting strap through the eye bolt and attach both
ends of the strap to the hoist.
5. Slowly raise the hoist.
Dont Forget...
Stabilize the housing as it rises so it does not
bump into the transformer and damage it.
6. Set the housing in a safe location.
Removing the Heat Shields and Transformer

1. Remove the heat shields from the transformer with the 1/8"
Allen wrench. Place the screws in a cup or a container.

4-3
CHAPTER 4
Notes
Figure 4-4 Transformer Heat Shields
2. Set the heat shields in a safe location.

3. Using the 9/16" open ended wrench, remove the two bolts
holding the transformer to the one atmosphere housing.
4. Place the bolts in a cup or a container.
5. Using the 11/16" open ended wrench, remove the cap located on
the top of the transformer.
6. Using the 1/2" socket, remove the cable connections. Cut all of
the zip ties that hold the wires to the transformer body.
7. Place the wires on top of the one atmosphere housing.
8. Using the 11/16" open ended wrench, reinstall the cap to the top
of the transformer.
9. Grasp the handle on top of the transformer (see Figure 4-5) and
carefully lift it off the one atmosphere housing.
10. Place the transformer on a work bench.
Figure 4-5 Transformer Handle
4-4

GNRC-NA-MPM100524
CHAPTER 4
Transformer Housing Maintenance
Notes
1. Remove the two O-rings and three backup rings from the
2. Inspect the O-ring grooves for galling, cuts, and abrasions.
3. Using a clean, wet cloth, wipe out the O-ring grooves on the
transformer. Remove any grit and residue.
4. Using a clean, wet cloth, wipe the one atmosphere housing
clean.
Figure 4-6 Housing O-Rings
5. Lubricate two new O-rings with petroleum jelly. Install the new
O-rings on the transformer housing (see Figure 4-6).
6. Install the backup rings.
Remember...
The transformer housing upper O-ring has a
backup ring on both sides.
The lower O-ring has a backup ring above
the O-ring.
Reassembling the Transformer

1. Lift the transformer by the handle and carry it to the one
atmosphere housing.
2. Install it on the housing.
3. Route the wires up the side of the transformer and zip tie them
in place.
4. Reattach the connections to their appropriate location:
Each wire is identified by a tag. The number on the tag that
is preceded by a dash is the position identifier.
Match the wire number to its appropriate location on the
top of the transformer (see Figure 4-7).

4-5
CHAPTER 4
Notes
Center each wire lug over its designated connection, and

using the 1/2" socket, fasten in place with a lock nut.
Figure 4-7 Top of the MUX Transformer
5. Lubricate the two transformer cap screws with nickel-plated

Never Seez and install them in the one atmosphere housing.
6. Brush heat sink compound on the transformer frame work.
7. Install the heat shields on the transformer.
8. Brush heat sink compound on the heat shields.
9. Route the lifting strap through the shackle on top of the
10. Using the hoist, lift the housing and center it over the
transformer.
Remember...
Have an assistant guide the housing over the
transformer to reduce the risk of damage to the
transformers.
11. Align the holes in the transformer housing with the bolt holes in
the one atmosphere housing.
12. Slowly seat the housing on the one atmosphere housing.
13. Brush nickel-plated Never Seez on the cap screws.
14. Using the cap screws, tighten in a star pattern till the housing
the rest of the way down until it seats properly.
15. Install the cap screws into the housing and torque to 24 ft-lbs
(33 Nm).
16. Remove the lifting strap and shackle from the top of the
4-6

GNRC-NA-MPM100524
CHAPTER 4
This student _______________________________________ has
Instructor
Signature ____________________________ Date ___________

4-7
CHAPTER 4
4-8

GNRC-NA-MPM100524
Chapter 5
Notes
Scope
This purpose of this procedure is to demonstrate the removal and
installation of the MUX pod rubber packer seals and packer seal
retainers.
Figure 5-1 Pod Wedge Packer Seals

2" open ended wrench
1/2"
packer seal tool (GE Oil & Gas # 3135320)
1" packer seal tool (GE Oil & Gas # 3135321)

11/2" packer seal tool (GE Oil & Gas # 3135322)
WD-40
Petroleum jelly
Clean cloths
Disassembly
To remove the packer seals, the pod wedge must first be exposed.
Follow the steps below to expose the wedge from the body of the
LVCU by using a stand.
Lowering the Pod Wedge by Hand

1. Using the principles described in Chapter 1, Pod Lifting
Techniques, raise the pod.

5-1
CHAPTER 5
Notes
2. As shown in Figure 5-2, place a stand or similar stable

object under the pods wedge.
Figure 5-2 Stand for Pod Wedge
3. Lower the pod unit until the wedge rests on the stand.
4. Continue lowering the pod until the weight is off the
shoulder bolt.
Figure 5-3 Stand Penetrating Body of LVCU to Support Pod Wedge
5. Remove the shoulder bolt that is located in the side of

the wedge.
Figure 5-4 Remove Shoulder Bolt
5-2

GNRC-NA-MPM100524
CHAPTER 5
6. Lift the pod. The wedge will fully extend (See Figure 5-5).
Notes
Figure 5-5 Pod Wedge Fully Extended
7. Support the pod on a stand or blocks. Figure 5-6 shows a

stand that GE Oil & Gas built specifically for this process.
Figure 5-6 LVCU Stand for Replacing Packer Seals
Removing the Packer Seals

1. Place the appropriate size tool in the packer seal and
loosen the packer seal.
Figure 5-7 Packer Seal Tools

5-3
CHAPTER 5
Notes
Figure 5-8 Remove Packer Retainer with Packer Seal Tool
2. Pull the packer seal retainer from the cavity and set it
aside.
Figure 5-9 Packer Retainer
3. Remove the packer seal from the pod wedge and set
aside or discard.
4. Set the wave spring(s) aside.
Did You Know...

Only the 1/2" packer has two wave springs. The
two larger packer seals only have one wave
spring.
Figure 5-10 Packer Seal and Wave Spring
5-4

GNRC-NA-MPM100524
CHAPTER 5
Inspection
Notes
1. Inspect the seal ports for thread damage, galling, cuts,

abrasions or other signs of wear.
Reassembly
1. Clean the wedge using WD-40 spray and a clean cloth. Remove
all dirt and foreign particles, paying attention to the seal port
threads and the port passages in the wedge.
Figure 5-11 Parts for Reassembly
2. Lubricate the wave spring(s) with a liberal amount of petroleum

jelly.
3. Install the wave spring into the seal port cavity. The petroleum
jelly should hold the wave spring in place.
Remember...
The wave springs are not a complete circle.
They have breaks in them.
Rotate the springs so that the breaks are on
opposite sides of each other.
4. Lubricate the the packer seal with petroleum jelly and install it
in the wedge.
5. Lubricate the packer seal retainer threads with nickel-plated
Never Seez.
6. Install the packer seal retainer into the cavity.
7. Select the appropriate sized packer seal tool and open ended
wrench.
8. Tighten the packer seal till it bottoms out.

5-5
CHAPTER 5
Notes
Be Aware...
There is not a torque value for the packer seals.
9. Continue this process for all of the seals that need to be

replaced.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________
5-6

GNRC-NA-MPM100524
Chapter 6
Solenoid Housing Pressure
Compensator
Notes
Scope
The purpose of this procedure is to demonstrate the process to
remove the solenoid cover and extract the bladder that is located
inside the cover. The process also demonstrates replacing the cover
with a new bladder and reinstalling the cover on the solenoid housing.
Figure 6-1 Solenoid Housing Pressure Compensator

(2) 1/4" shackles
Ratchet
Extension
5/16"
Allen socket
Overhead hoist
O-ring pick
Petroleum jelly
Clean cloths

6-1
CHAPTER 6
Notes
Solenoid Housing Cover/Compensator Removal

For this process, you will need the hoist, the strap, the two shackles,
and the ratchet set.
1. Maneuver the hoist over the solenoid housing.
2. Attach the two shackles to the strap.
3. Attach the two shackles to the picking eyes located on either
end of the housing cover.
4. Using the ratchet, the extension, and the 5/16" Allen socket,
remove the cap screws that hold the solenoid cover to the
housing.
5. Remove the screws and place them in a cup or a container.
6. Attach the strap to the hoist.
7. Begin lifting the hoist until the strap is tight.
8. Slowly lift the cover off of the housing.
Be Careful...
When lifting the cover off of the housing, there
will probably be dielectric fluid coming from out
of the cover and housing. Be careful to not slip
on this overflow.
9. Remove the cover from the housing and place it on a worktable.
10. Remove the four cap screws holding the protector cap down
and place them in a container.
Figure 6-2 Cover Plate
11. Remove the next set of four cap screws. Place them in a safe
place so they will become lost.
6-2

GNRC-NA-MPM100524
CHAPTER 6
Notes
Figure 6-3 Cap Screws
12. As shown in Figure 6-4, flip the cover over and remove the cap
screws that are holding the stainless steel plate to the bottom
of the cover.
Figure 6-4 Removing Stainless Steel Plate
13. Remove the old bladder from the cover.

14. Unscrew the stainless steel compensation port from the top of
the bladder and set it aside. See Figure 6-5.
Figure 6-5 Compensation Port

6-3
CHAPTER 6
Notes
Preparing the Solenoid Housing Cover

1. Remove the old O-rings and set aside.
2. Take a clean cloth and wipe off any buildup and debris on the
top of the housing.
3. Take a clean wet cloth, finish cleaning the top section of the
solenoid housing.
4. Inspect the O-rings; if they are damaged, replace them with
new ones.
5. Coat the O-rings with petroleum jelly and place them in the Oring slots on top section of the housing.
6. Lay the cover over with the bottom facing up.
7. Take a couple of clean cloths, get them wet and begin cleaning
the covers edge. Clean inside the insert area where the
pressure compensator fits. The bladders O-rings will sit in this
area so it is very important that all grit and grime is removed
from this area.
8. Take a dry clean cloth and wipe down the cover.
Figure 6-6 Wipe Down Cover With Wet Cloth
9. Take the stainless steel compensation port and wipe it down

with a clean, wet cloth until all of the mud and grit have been
removed.
Figure 6-7 Remove all Grit
6-4

GNRC-NA-MPM100524
CHAPTER 6
Placing a New Bladder in Cover
Notes
1. Coat the threads of all of the cap screws with Never Seez.
2. Take the new bladder and set it on a work bench.
3. Screw the cleaned compensation port into the top of the
bladder.
4. Set the cover with the back side facing up next to the bladder.
5. Place the bladder inside the cover.
Figure 6-8 Inserting New Bladder
6. Press the compensation bladder in to the solenoid housing

cover and screw in cap screws.
Figure 6-9 Securing Bladder to Cover
7. Torque the cap screws to 120 in-lbs.

8. Turn the cover with the bottom up and place the stainless steel
plate over the bottom of the cover.
9. Insert the cap screws and begin tightening them down.

6-5
CHAPTER 6
Notes
Figure 6-10 Reassembling Stainless Steel Plate
10. Torque these cap screws to 70 in-lbs.

11. Attach the vacuum port to the compensation port and collapse
the bladder.
Figure 6-11 Collapsing the Compensation Bladder
12. Remove the vacuum pump.

13. Place the round plate over these cap screws and insert the next
set of cap screws.
14. Torque these cap screws to 120 in-lbs also.
Reattach Cover to Solenoid Housing

1. Re-attach 1/4" shackles to the top of the cover.
2. Take the lifting strap and run it through the two shackles.
3. Attach the strap to the hoist and lift the cover.
4. Set the cover on the housing paying attention to not cause
misalignment with the O-rings.
5. Lower the hoist and remove the strap and 1/4" shackles.
6. Take the cap screws and begin tightening the bolts to torque
value of 190 in-lbs.
6-6

GNRC-NA-MPM100524
CHAPTER 6
This student _______________________________________ has
Instructor
Signature ____________________________ Date ___________

6-7
CHAPTER 6
6-8

GNRC-NA-MPM100524
Chapter 7
Shear Seal Valves
Notes
Scope
The purpose of this procedure is to describe the proper methods to
remove, disassemble, maintain, assemble, and install the sheal seal valve.
Figure 7-1 Shear Seal Valve

(2) 1/4" shackles
3/8"
drive ratchet
3/8"
drive extension
5/16"
Allen wrench
3/16"
Allen wrench
1/4"
Allen wrench

7-1
CHAPTER 7
Shear Seal Valves
Notes
O-ring pick
Needle nose pliers
Small flat-head screwdriver
Armature gauge tool
Wire brush
Paint pen
Petrolem jelly
WD-40 residual cleaner
Clean cloths
Removing the Solenoid Housing Cover

1. Attach a 1/4" shackle to each of the two lifting ears on the
solenoid housing cover.
2. Thread the lifting strap through each shackle and attach the
ends of the strap to the hoist.
3. Using the 5/16" Allen wrench, remove all of the cap screws from
the solenoid housing cover. Place the screws in a clean container.
4. Slowly raise the hoist, and lift the cover off the solenoid housing.
5. Place the housing cover in a safe location.
Removing the Shear Seal Valve

1. Using the 3/8" drive ratchet, the 3/8" drive extension, and the 3/16"
Allen wrench, remove the two cap screws that hold the shear
seal valve to the solenoid housing.
2. Place the cap screws in a clean cup or container.
3. Pull the shear seal valve from the solenoid housing, and place it
on a clean work table.
4. Using the paint pen, mark the shear seal valve with its pod
position number (the number is stamped on the housing just
above each shear seal valve).
Did You Know...

The solenoid bore and the armature are
manufactured from nearly pure iron and are
very susceptible to corrosion, thus both are
specially coated.
5. Inspect the armature and the solenoid bore for corrosion. If
there is little or no corrosion, clean the armature and the
solenoid bore with a cloth rag (or similar) and dry the parts.
7-2

GNRC-NA-MPM100524
CHAPTER 7
Shear Seal Valves
Notes
Figure 7-2 Moderate (Left) and Minor (Right) Corrosion
6. If there is some corrosion, but it is not extensive, it may be

cleaned with emery cloth. Use care not to remove any
remaining coating. Clean the armature and the solenoid bore
and dry the parts.
7. If there is extensive corrosion, replace the parts. If it is not
possible to replace the parts that have corrosion, then clean
the parts with emery cloth to remove the corrosion. Use care so
as not to remove any remaining coating.
Disassembling the Shear Seal Valve

1. Remove the two seal subs from the shear seal valve.
2. Remove the two O-rings from each seal sub.
Remember...
The solenoid armature position is critical to
the proper functioning of the solenoid shear
seal valve assembly.
If the position is off by as little as 0.015", the
solenoid may not function as intended.
Excessive pressure on the armature will
bend the spool rod and effect the armature
position.
3. Support the plunger on a padded wooden block or other firm
surface that is the same height as the shear seal valve when it
is laid on its side. Be sure to keep the plunger and the valve level
during the cotter pin removal.
7-3
CHAPTER 7
Shear Seal Valves
Notes
4. Straighten the armature cotter pin, taking care not to apply

excessive pressure to the armature.
Figure 7-3 Straightening the Cotter Pin
5. Remove the cotter pin from the armature.
Figure 7-4 Removing the Cotter Pin
6. Unscrew the armature from the spool rod using a

counterclockwise motion.
Figure 7-5 Removing the Armature
7. Using a 1/4" Allen wrench, remove the four, 1/4"-20UNC x 21/4"

cap screws holding the outlet plate to the assembly.
7-4

GNRC-NA-MPM100524
CHAPTER 7
Shear Seal Valves
Notes
Figure 7-6 Removing the Cap Screws
8. Remove the four 1/4" lock washers.

9. Set the screws and lock washers aside.
10. Remove the inlet plate from the valve body.
11. Remove the O-ring from the inlet plate.
12. Remove the outlet plate from the valve body.
13. Remove the O-ring from the outlet plate.
Figure 7-7 Outlet and Inlet Plates Removed
14. Remove the inlet and outlet shear seal plates.
Figure 7-8 Inlet and Outlet Shear Seal Plates
15. Remove the O-rings from the inlet and outlet shear seal plates.
7-5
CHAPTER 7
Shear Seal Valves
Notes
16. Remove the shear seal cage and seals from the seal carrier
spool.
Figure 7-9 Removing the Shear Seal Cage
17. Remove one of the shear seals from the cage.

18. Remove the spring from the cage.
19. Remove the other shear seal from the cage.
20. Remove the O-rings from the inside diameter of the cage.
21. Use either a 1" open ended wrench or 1" deep socket to remove
the seal bushing.
22. Remove the filter element from the seal bushing.
23. Remove the O-ring from the seal bushing.
24. Remove the rod seal from the seal bushing.
25. Remove the shear seal rod spool and carrier assembly from the
body.
Figure 7-10 Removing the Rod Spool and Carrier Assembly
26. Remove the dowel pin from the seal carrier spool.
27. Separate the rod spool from the seal carrier.
28. Use either a 1" open ended wrench or 1" socket to remove the
check valve from the shear seal body.
29. Remove the O-rings from the check valve.
30. Remove the O-rings from the shear seal valve body.
7-6

GNRC-NA-MPM100524
CHAPTER 7
Shear Seal Valves
Inspecting the Shear Seal Valve
Notes
Figure 7-11 Shear Seal Valve Components
1. Inspect all seal surfaces for damage.

2. Inspect all parts for cleanliness. Clean and dry if necessary.
3. Inspect all O-rings for damage and replace if necessary. If the
valve is to be rebuilt, always replace elastomer seals; these are
contained in the seal kit.
4. Ensure that all valve interior and mating surfaces are free from
damage, dirt, metal shavings, burrs, or any other foreign
material.
5. If a shear seal valve is to be re-assembled with a new seal kit,
perform the following steps:
Inspect the shear seals for any indications of wear or
surface imperfections. The shear seals must NOT have
anything unusual on the shear seal surface. If there are any
indications of wear, replace the shear seal. Do not attempt
to polish or buff out any imperfections on the shear seal
surfaces; such a procedure would not meet the flatness
requirements to operate properly.
Clean the shear seal plates with non-residual cleaner. Inspect
the shear seal surface for scoring, galling, or distortion. The
shear seal surface is very flat, and should have a mirror-like
finish. If there are any indications of wear, replace the shear
seal plates. Do not attempt to polish or buff out any
imperfections on the shear seal surface; such a procedure
would not meet the flatness requirement to operate properly.
Remember...
If the shear seals indicate any wear, replace
the shear seals and the shear plates.
If the shear seal plate indicates any wear,
replace the shear seals and the shear seal
plates. (If one of the parts is worn, the other
is also worn).

7-7
CHAPTER 7
Shear Seal Valves
Notes
Remember...
Replacing only the shear seals or only the
shear seal plate will lead to premature wear
and reduced service life.
The repair kit includes both the shear seals
and the shear seal plates.
Reassembling the Shear Seal Valve

1. Lubricate all the seals with petroleum jelly.
2. Lubricate all threads prior to assembly, including the collar
contact area.
3. Install the O-rings onto the check valve assembly.
4. Install the check valve into the valve body until it is snug. Do not
overtighten this part.
Figure 7-12 Installing the Check Valve
5. Attach the spool rod to the spool seal carrier using the dowel
pin.
Figure 7-13 Assembling the Spool Seal Carrier
6. Insert the spool carrier into the valve body until it is stopped by
the check valve.
7-8

GNRC-NA-MPM100524
CHAPTER 7
Shear Seal Valves
Notes
Figure 7-14 Installing the Spool Seal Carrier
7. Install the filter element onto the seal bushing .
Figure 7-15 Installing the Filter Element
8. Install O-ring onto the seal bushing.

9. Install the rod wiper seal into the seal bushing.
10. Install the spring into the seal bushing.
11. Install the seal bushing with spring into the valve body by
threading the rod spool through the seal bushing and spring.
Figure 7-16 Installing the Seal Bushing and Spring
12. Tighten to 40 ft-lbs (54 Nm) to ensure that the seal bushing is
bottomed into the seal body.
13. The filter is designed to be retained once the seal bushing is
tightened. If the filter is not secure, verify that the seal bushing
is properly tightened. If the filter is still loose, replace the filter.
14. Install two O-rings into the seal cage.

7-9
CHAPTER 7
Shear Seal Valves
Notes
Be Careful...
When assembling the seal cage, DO NOT push
the shear seals through the cage, as they will
damage the O-rings inside the cage.
15. Taking care not to damage the seals, install one shear seal , the
spring , and the other shear seal into the center of the seal
cage.
Figure 7-17 Seal Cage Assembly
16. Install this assembly into the spool seal carrier through the
opening for the inlet seal plate.
17. Install O-ring into the valve body at the seal plate outlet.
18. Install the outlet seal plate and the orientation pin into the
valve body.
Figure 7-18 Outlet Seal Plate Installation
19. Install O-ring into the valve body at the seal plate inlet.
20. Install the inlet seal plate into the valve body.
7 - 10

GNRC-NA-MPM100524
CHAPTER 7
Shear Seal Valves
Notes
Figure 7-19 Inlet Seal Plate Installation
21. Install face seal O-ring into the outlet plate .

22. Install face seal O-ring into the inlet plate.
23. Reposition the valve body assembly and carefully align the inlet
plate and the outlet plate with the body.
24. Verify that the inlet plate and outlet plate port orientations are
correct.
Figure 7-20 Inlet (Left) and Outlet (Right) Plates
25. Apply nickel-plated Never Seez thread lubricant to the four,

1/4"-20UNC x 21/4" cap screws.
26. Install the four lock washers and four cap screws.
Figure 7-21 Installing the Cap Screws

7 - 11
CHAPTER 7
Shear Seal Valves
Notes
27. Using a 1/4" Allen wrench, install the four, 1/4"-20UNC x 21/4" cap
screws.
28. Using a torque wrench and a 1/4" Allen wrench socket, torque
the cap screws to 40 in-lbs (5 Nm).
29. Thread the solenoid armature onto the rod spool.
Figure 7-22 Installing the Armature
30. Use the armature gauge tool and screw on the armature so
that the gauge is touching, with no play. Do not over tighten.
Figure 7-23 Armature Gauge Tool
31. Remove the gauge tool. There should be no movement

between the armature and the valve when the gauge tool was
removed. If there was, or if not sure, re-gap the armature using
the gauge tool.
32. Install cotter pin. If the cotter pin does not line up with the hole
in the valve stem, rotate the armature CLOCKWISE (toward the
valve) until the cotter pin can be inserted. This will take less
than of one turn. If the armature is rotated more than turn,
re-gap the armature using the gauge tool to ensure that the
proper armature position is obtained.
7 - 12

GNRC-NA-MPM100524
CHAPTER 7
Shear Seal Valves
Notes
Figure 7-24 Installing the Cotter Pin
33. Center the cotter pin in the armature. It is only necessary to

bend one ear of the cotter pin, bending both just makes it more
difficult to remove.
34. Verify that the cotter pin does not extend past the armature; if it
does it will remove the coating from the solenoid bore and
cause corrosion and valve sticking.
35. Install two O-rings onto each seal sub. Install the seal subs into
their respective ports.
Did You Know...

The subsea valve has two seal subs, the surface
valve has one seal sub.
Figure 7-25 Installing the Seal Subs
36. Install O-ring onto the valve body.

37. Perform a quick check that the valve is assembled properly by
pulling on the armature. Actuation force is typically less than 35
lbs.
7 - 13
CHAPTER 7
Shear Seal Valves
Notes
Installing the Shear Seal Valve

Check to See...
For subsea control systems, ensure that the
manifolds are centered on the solenoid housing
openings. If the manifolds are not correctly
centered, it may not be possible to install the
armature or the armature may not function
properly. If the manifold has been removed
from the solenoid housing, the armatures are
not moving freely, or if the armatures are
sticking, use the following procedures to ensure
that the manifolds are centered. Manifold
alignment procedures do not apply to surface
control pods.
1. If the manifold and solenoids have been removed from the
solenoid housing, use an alignment tool provided by Hydril.
Place one alignment tool at one end of the manifold and
another at the other end, and mount the manifold to the
solenoid housing. Proceed to Step 4.
2. If the manifold and solenoids are still mounted on the solenoid
housing, perform the following:
Remove the shear seal valves.
Ensure that the manifold is loose. If re-installing the
manifold, only use 4 cap screws, and tighten hand tight
(only 2 cap screws are needed for a small manifold). Each
manifold has 8 to 40 cap screws to mount the manifold to
the solenoid housing. If adjusting a manifold, loosen all of
the cap crews, and remove the corner cap screws.
Using two alignment tools, place one alignment tool at one
end of the manifold and another at the other end, and
tighten some cap screws.
3. If it is absolutely necessary to align the manifolds without an
alignment tool:
Remove the shear seal valves.
Ensure that the manifold is loose. If re-installing the
manifold, only use 4 cap screws, and tighten hand tight
(only 2 cap screws are needed for a small manifold). Each
manifold has 8 to 40 cap screws to mount the manifold to
the solenoid housing. If adjusting a manifold, loosen all of
the cap crews, and remove the corner cap screws.
Visually line up the bolt holes in the manifold with the
tapped holes in the solenoid housing. Perform this
alignment for all corner bolt holes as a minimum. For a
large manifold, also remove some of the cap screws from
the center of the manifold to ensure proper alignment.
7 - 14

GNRC-NA-MPM100524
CHAPTER 7
Shear Seal Valves
Once the manifold is aligned, tighten the cap screws to
around 100 in-lbs (11 Nm). Verify that alignment is still
correct and install the remaining cap screws. Torque all cap
screws to 150 to 160 in-lbs (17 to 18 Nm), starting from the
center of the manifold and moving out.
Notes
4. Coat the solenoid bore and the solenoid armature (which is

attached to the shear seal valve) with LPS 3 Heavy Duty Rust
Inhibitor or similar product.
5. Lubricate the cap screws with Moly-lube TS70 or equivalent.
6. Install the shear seal valve into the solenoid using the cap
screws and lock washers . The armature should have a snug fit,
but should slide freely and not bind.
Figure 7-26 Installing the Shear Seal Valve
7. If the armature does not fit correctly, inspect the parts and
verify the manifold is correctly aligned. Correct any deficiencies.
Note that the shear seal valve cap screws pass through the
manifold and thread into the solenoid.
8. Tighten these cap screws evenly (to prevent binding) to 140 inlbs (16 Nm).
Installing the Solenoid/Shear Seal Housing Cover

1. Lift cover and set in place.
2. Brush the threads of the housing cover cap screws with nickelplarted Never Seez.
3. Using the 5/16" Allen wrench, install the cap screws.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________

7 - 15
CHAPTER 7
Shear Seal Valves
Notes
7 - 16

GNRC-NA-MPM100524
Chapter 8
Solenoids
Notes
Scope
The purpose of this procedure is to demonstrate the proper methods
used to remove, maintain, and install the solenoid.
Figure 8-1 Solenoid

(2) shackles
(2) lifting straps
3/8"
drive ratchet
3/8"
drive extension
5/16"
Allen socket head
3/16"
Allen socket head
1/4"
Allen socket head
O-ring pick
Needle nose pliers
(2) medium flat-head screwdrivers
Syringe plunger

8-1
CHAPTER 8
Solenoids
Notes
Repair kit
Torque wrench
Ohmmeter
DC200 dielectric fluid
Paint pen
Clean cloths
Petroleum jelly
WD-40 residual cleaner
Draining the Solenoid Housing

1. Vent the solenoid housing.
2. Locate the needle valve on the bottom of the solenoid housing.
3. Place an appropriately-sized drain pan under the needle valve.
4. Remove the nut from the end of the needle valve, and open the
valve.
5. Once the dielectric fluid has fully drained from the solenoid
housing, close the needle valve.
Removing the Solenoid/Shear Seal Housing Cover

1. Attach a shackle to each of the two lifting ears on the solenoid
housing cover.
2. Thread a lifting strap through each shackle and attach the ends
of the straps to the hoist.
3. Using the 5/16" Allen wrench, remove all of the cap screws from
the solenoid housing cover. Place the screws in a clean cup or
container.
4. Slowly raise the hoist, and lift the housing cover off the solenoid
housing.
5. Place the housing cover in a safe location.
Removing the Shear Seal Valve

1. Using the 3/16" Allen wrench, remove the two cap screws that
hold the shear seal valve to the solenoid housing.
2. Place the cap screws in a clean cup or container.
3. Pull the shear seal valve from the solenoid housing, and place it
on a clean work table.
4. Using the paint pen, mark the shear seal valve with its pod
position number (the number is stamped on the housing just
above each shear seal valve).
8-2

GNRC-NA-MPM100524
CHAPTER 8
Solenoids
Removing the Solenoid
Notes
1. Remove the solenoid maintenance covers located on the sides

of the housing.
2. Reach through the opening on one side and disconnect the
electrical leads attached to the solenoid.
3. Remove the two 1/4" cap screws that hold the solenoid to the
housing.
4. Carefully pull the solenoid from the inside of the solenoid
housing. If the solenoid is stuck, insert a broom handle through
the shear seal opening and tap the solenoid loose.
Solenoid Maintenance
1. Place the solenoid on a clean work table.
2. Remove the solenoid O-rings and discard them.
3. Measure the electrical resistance of the solenoid coil with the
ohmmeter.
4. If the measured resistance ranges from 129 to 139 ohm,
proceed to Step 5. If the measured resistance does not range
from 129 to 139 ohms, return the solenoid to Hydril for
refurbishing.
5. Visually inspect the indicator piston to determine the solenoid
fluid level. If 1/2" of the piston is not visible, the solenoid requires
fluid.
Figure 8-2 Fluid Level Indicator
6. Stand the solenoid up on a stable work bench or flat surface

with the pressure balance cap facing up.
7. Using a flat head screwdriver, remove the two pan head screws
from the pressure balance cap.
8. Remove the pressure balance cap from the pressure balance
holder.
9. Remove the indicator piston and the compression spring from
the pressure balance holder.

8-3
CHAPTER 8
Solenoids
Notes
10. Locate the self-sealing screw on the side of the solenoid base.
Remove the screw using a flat head screwdriver.
11. Lay the solenoid on its side with the fill port facing up.
12. Fill the syringe with DC-200 dielectric fluid.
13. Screw the syringe onto the solenoid oil fill port. Ensure the
connection is sealed to prevent the fluid from leaking as the
syringe is compressed.
14. Using your finger, press on the top of the diaphragm seal to
compress it.
Figure 8-3 Manually Compressing the Diaphragm
15. Pull gently on the syringe plunger to apply a vacuum to the

solenoid. As fluid is pulled from the solenoid, watch for air
bubbles coming into the syringe.
16. Press gently on the syringe plunger to inject fluid into the
syringe.
Figure 8-4 Adding Fluid to the Solenoid
17. Repeat Steps 10 through 12 until no more air bubbles appear.

18. Unscrew the syringe from the solenoid.
19. Check the O-ring on the self sealing screw for nicks, cuts or
wear. Replace the O-ring if necessary.
20. Using a flat-head screwdriver, install the self-sealing screw on
the solenoid base. Hand tighten the screw.
21. Install the indicator piston in the pressure balance holder.
22. Install the compression spring in the pressure balance holder.
8-4

GNRC-NA-MPM100524
CHAPTER 8
Solenoids
23. Install the pressure balance cap on the solenoid.
Notes
24. Install the two pan head screws on the pressure balance cap.
Hand tighten the screws.
25. Verify that 1/2" of the indicator piston is visible. If the solenoid
requires additional fluid, repeat Steps 3 through 20 until the
indicator piston is in the appropriate position.
Installing the Solenoid

1. Lubricate two new solenoid O-rings with petroleum jelly.
2. Install the O-rings on the solenoid.
3. Brush the cap screw threads with nickel-plated Never Seez.
4. Place the solenoid inside the housing, and thread the two 1/4"
cap screws through the solenoid housing and into the solenoid.
5. Attach the electrical leads to the end of the solenoid. The
electrical leads are marked with a positive or a negative sign. It
is important that each lead is attached to its designated post
on the solenoid.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________

8-5
CHAPTER 8
Solenoids
8-6

GNRC-NA-MPM100524
Chapter 9
Notes
Scope
The purpose of this procedure is to demonstrate the proper method
used to fill the solenoid electronics housing with dielectric fluid.
Figure 9-1 Solenoid Housing
Assumptions
This procedure assumes that the following steps have been
performed. If they have not, do so before moving forward.
1. Contaminants, debris, and foreign matter have been flushed
from MUX pod hydraulic circuits and from fluid lines that supply
the MUX pod.
2. All MUX control pod solenoids have been successfully tested in
accordance with Hydril publication X-1009370.
3. All MUX control pod transducers have been calibrated, tested,
and installed.
9-1
CHAPTER 9
Notes
4. The interior of the solenoid electronics housing is free of debris

and has been inspected for damage and correct component
installations.
5. Except for the cover of the solenoid electronics housing, all
control pod components are installed and are ready for
operational service.
6. The solenoid electronics housing is uncovered.

The following equipment and materials are required to perform the
necessary steps in this procedure.
Two vacuum pumps.
Dielectric fluid, Dow Corning DC-200 or equivalent
Torque wrench, 300 in./lbs. capability
Violet dye, GE Oil and Gas # 3144693-02
Red dye, GE Oil and Gas # 3144693-01
Funnel
Bostik Never Seez Pure Nickel Special (NSN-165) or
equivalent fastener lubricant
Petroleum jelly
New O-rings for the solenoid electronics housing cover and
orifice plugs
SAE feed-through fittings 1920406-0408 for 1/2"-1/4" SAE
receptacle; 1/4" fitting 1920406-0404 for seal test port
receptacle; and the appropriate fitting for the compensator
plug receptacle
Filtering Flask, Erlenmeyer form with heavy wall detachable
side arm secured by neoprene grommet; Kimax brand or
equivalent
Air filter with moisture trap
Lint-free cloths
Preparation for Solenoid Housing Fill Procedure

1. Verify that the cleanout ports are bolted securely to the sides of
the solenoid pressure compensator housings.
2. On E/H section, remove cover from one solenoid housing. Start
with either solenoid housing cover.
3. On solenoid housing surface uncovered in previous step,
inspect seals and seal grooves and:
Remove dirt and other foreign matter from sealing grooves.
9-2

GNRC-NA-MPM100524
CHAPTER 9
Notes
Figure 9-2 Cleaning the Solenoid Housing O-Ring Grooves
Replace seals showing damage or evidence of excessive

wear.
Figure 9-3 Installing the Solenoid Housing Seals
Coat seals with petroleum jelly.

Remove scratches or blemishes from sealing surface of
cover and grooves with fine emery cloth.
Be Aware...
If scratches and blemishes can not be removed
with an emery cloth, replace the cover.
Figure 9-4 Torquing the Solenoid Housing Cover Bolts

9-3
CHAPTER 9
Notes
Solenoid Housing Filling Procedure

1. At solenoid housing cover, remove plugs from Vacuum and
Compensator Ports. Store the plug for the bladder access port.
The plug is only used to protect the port and bladder during
transport and storage.
2. At bottom of solenoid housing perform the following:
Remove the tube cap from the end of the ball valve.
Close the ball valve.
Did You Know...

The ball valve is closed when the handle is
rotated fully perpendicular to the flow path
through the valve.
3. As shown in Figure 9-5, attach a hose from the dielectric fluid
source to the ball valve.
Figure 9-5 Attaching the Dielectric Fluid Source Hose
4. Attach a fitting for the vacuum pump into the Compensator

and Vacuum Ports. The Compensator Port threads are 9/1618UNF-2B. The Vacuum Port threads are SAE 1/2- 16UNJF-3A.
Figure 9-6 Compensator Port Valve (Typical)
9-4

GNRC-NA-MPM100524
CHAPTER 9
5. As shown in Figure 9-7, connect a vacuum pump with shutoff
valve to the feed through fitting on the Compensator Port. The
tube must be able to hold a vacuum without collapsing.
Notes
Figure 9-7 Vacuum Pump (Typical)
6. For the compensator port, operate the vacuum pump to draw

the bladder flat against the underside of the solenoid housing
cover. Verify at the vacuum pump that no air is being drawn
from the bladder when bladder has flattened against solenoid
housing cover:
Close shutoff valve between pump and compensator port.
Allow the bladder to sit 30 minutes to verify no leaks in the
seals.
Terminate pump operation.
7. For vacuum port, operate vacuum pump until the gauge reads
20-25 bars.
8. Close the shut-off valve between pump and vacuum port.
9. Let the housing sit for 30 minutes to verify there are no leaks in
the housing, solenoids, or shear seal valves.
Figure 9-8 Vacuum Port Gauge

9-5
CHAPTER 9
Notes
10. Open ball valve to admit dielectric fluid into solenoid housing.
Dielectric fluid enters solenoid housing.
Figure 9-9 Flow of Dielectric Fluid
11. Continue pumping until fluid appears in filtering flask.

12. Stop pumping and close off the ball valve.
13. Remove the vacuum on the Vacuum Port.
Did You Know...

If needed, drain out some of the fluid to give
room for the addition of the dye.
14. Place a funnel in the Vacuum Port and pour in the dye.
15. Reattach the vacuum pump to the the Vacuum Port. Attach
another hose to the otherside of the pump.
16. Attach the end of the hose to the ball valve located at the
bottom of the housing.
17. Open the ball valve and turn on the pump.
18. Circulate the dye for 30 minutes.
19. Remove pump hose from the backside of the pump and from
the ball valve.
20. Reattach the hose leading into the 55 gallon drum to the ball
valve.
21. Open the ball valve and turn the vacuum on.
22. When fluid appears in the flask, perform the following tasks in
the sequence below:
Close ball valve at bottom of solenoid housing.
Turn off vacuum pump. Dielectric fluid flow in transparent
tube terminates.
23. Remove tube and feed through fitting from Vacuum Port.
24. As necessary, add dielectric fluid until fluid overflows from lip of
port.
9-6

GNRC-NA-MPM100524
CHAPTER 9
Notes
Be Sure to...
Coat stainless steel fastener threads with Never
Seez or equivalent lubricant to minimize
possibility of galling.
25. Replace plug in Vacuum Port and tighten to torque in
procedure AH240. The plug is 316SS, 9/16- 18UNF-2B.
26. Repeat steps 1 through 20 for other solenoid housing.
An Alternativeto the Above Process

As an alternative to the steps shown above, the process explained
below may also be used.

The following equipment and materials are required to perform
the necessary steps in this procedure.
Two vacuum pumps.
Dielectric fluid, Dow Corning DC-200 or equivalent.
Torque wrench, 300 in./lbs. capability.
Violet dye, GE Oil and Gas # 3144693-02
Red dye, GE Oil and Gas # 3144693-01
Funnel
Bostik Never Seez Pure Nickel Special
Petroleum jelly (Vaseline or equivalent).
New O-rings for the solenoid electronics housing
cover and orifice plugs.
SAE feed through fittings 1920406-0408 for 1/2"-1/4"
SAE receptacle; 1/4" fitting 1920406-0404 for seal test
port receptacle; and the appropriate fitting for the
compensator plug receptacle.
Filtering Flask, Erlenmeyer form with heavy wall
detachable side arm secured by neoprene grommet;
Kimax brand or equivalent.
Air filter with moisture trap.
Lint free rags.
Preparation for Solenoid Housing Fill Procedure

Follow the same steps for the Preparation for Solenoid Housing
Fill Procedure shown in the first example.

9-7
CHAPTER 9
Notes
Solenoid Housing Fill Procedure

1. Attach a fitting for the vacuum pump into the
Compensator and Vacuum Ports. The Compensator Port
threads are 9/16-18UNF-2B. The Vacuum Port threads are
SAE 1/2 -16UNJF-3A. See Figure 1-5 for reference.
Figure 9-10 Compensator Port Valve (Typical)
2. As shown in Figure 9-11, connect a vacuum pump with

shutoff valve to the feed through fitting on the
Compensator Port. The tube must be able to hold a
vacuum without collapsing.
Figure 9-11 Vacuum Pump (Typical)
3. For the Compensator Port, operate the vacuum pump to

draw the bladder flat against the underside of the
solenoid housing cover. Verify at the vacuum pump that
no air is being drawn from the bladder. When bladder
has flattened against solenoid housing cover:
Close shutoff valve
COMPENSATOR port.
between
pump
and
Allow the bladder to sit 30 minutes to verify no leaks

in the seals.
Terminate pump operation.
9-8

GNRC-NA-MPM100524
CHAPTER 9
4. For vacuum port, operate vacuum pump until the gauge
reads 20-25 bars.
Notes
5. Close the shut-off valve between pump and Vacuum

Port.
6. Let the housing sit for 30 minutes to verify there are no
leaks in the housing, solenoids, or shear seal valves.
Figure 9-12 Vacuum Port Gauge
Before Proceeding...
Once it is confirmed that the bladder does not
leak, proceed with the process of filling the
housing.
7. Open the first 55 gallon drum and add the dye.
8. Attach a pneumatic pump to the top of the 55 gallon
drum of DC200.
9. Close the ball valve
10. Remove the tube cap located on the ball valve.
11. Attach a hose to the ball valve tube and to the
pheumatic pump.
12. Remove the vacuum plug to the Vacuum Port.
13. Remove the Compensation Port cover and plug.
14. Begin pumping in DC-200.
15. Pump one drum of DC-200 into the housing. Before
adding the remainder amount, close the ball valve on the
bottom attach a pump with the vacuum side hooked to
the Vacuum Port and the other end attached to the ball
valve. Circulate the fluid dye mix for 30 to 45 minutes.
16. Remove the pump and hoses that were used for the
circulation and reattach the hose to the ball valve.
17. Continue adding DC-200 to the housing.

9-9
CHAPTER 9
Notes
18. Stop the pump when the fluid surfaces the top of the
Vacuum Port.
19. Replace the Vacuum Port plug.
20. Turn the pump back on until the Check valve vents.
21. close ball valve and remove hose.
22. Replace ball valve cap.
23. Replace Compensation Port cover.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________
9 - 10

GNRC-NA-MPM100524
CHAPTER 9
Notes

9 - 11
CHAPTER 9
Notes
9 - 12

GNRC-NA-MPM100524
Chapter 10
Solenoid/Shear Seal Valve
Assembly Testing
Notes
Scope
The purpose of this procedure is to describe the correct method for
testing the MUX control pod solenoid and shear seal valve assembly.
Figure 10-1 Solenoid Test Set

Solenoid test set w/stethoscope (GE Oil and Gas # 3136197)
Solenoid gauge tool (GE Oil and Gas # 3136192)
Flat head screw driver
Needle nose pliers
Watch Out...
Before beginning, disable the 720 VAC and
bleed off all hydraulic pressure. To not do so,
could potentially cause severe injury or loss of
life.

10 - 1
CHAPTER 10
Notes
Remove Pod Power

1. To lock out the 720 VAC, turn the subsea power breaker located at
the PDP to the OFF position and place a lockout tag on the PDP.
Solenoid Test Preparation

1. Remove all hydraulic pressure and release any residual
pressure before proceeding.
2. Remove the housing dome exposing the SEM chassis.
3. Locate and remove the hypertronics connector from the SEM
that is being tested.
Figure 10-2 Hypertronics Connector on the Test Set
4. Attach the hypertronics connector to the test set. See

Figure 10-2 for reference.
5. Connect test set DC power supply to the VOLTAGE IN
FROM POWER SUPPLY jacks using Cable 1.
Figure 10-3 Cable 1 connected on the Test Set
6. Connect Cable 2 to the VOLTAGE OUT TO SOLENOIDS jacks to

the first solenoid in test jacks on the back panel, with proper
polarity. Now testing can begin.
10 - 2

GNRC-NA-MPM100524
CHAPTER 10
Notes
Figure 10-4 Cable 2 connected on the Test Set
Test Procedure
1. Turn the voltage level controls counter clockwise until it cannot
be turned any further.
2. Begin turning the course voltage control clockwise until the
display reads 60 VDC.
Be Aware...
The current meter should show energizing
current around 450mA.
3. At this point, turn the course voltage control back down to zero.
4. Repeat the above process twice before recording the pullin/drop-out of voltage and current.
Dont Forget...
When testing the EH functions and shear
seal/solenoid functions, refer to the figures for
wire connection reference.
Solenoid Pull-in/Drop-out Test

1. Switch the Fire Mode and the Diode Check to the OFF
position.

10 - 3
CHAPTER 10
Notes
2. Begin applying voltage to the solenoid being tested. record the

point at which the solenoid energizes. This is considered the
pull-in and it is required that it meet certain standards. these
set standards specify that the pull-in shall be 38.5 volts or less.
3. Begin to slowly decrease the voltage and record where the
solenoid de-energizes. The de-energizing part is considered the
drop-out and likewise it too has to meet certain standards in
order to be considered acceptable. The drop-out current should
be 30mA or greater.
Did You Know...

Steps 1 and 2 of this section are the ideal times
to use the stethoscope. Place the end of the
stethoscope against the shear seal valve and
have your partner work the voltage dial.
4. If the drop-out and pull-in do not meet the required standards,
pull the shear seal valve out of the housing and adjust the
armature. This is accomplished by removing the cotter pin and
turning the armature either clockwise or counter clockwise.
If the pull-in is higher then the requirements, rotate the
armature counter clockwise 1/4 turn. Replace the cotter pin
and retest the pull-in. Continue this process until the
specifications are meet.
If the drop-out is to low, rotate the armature clockwise 1/4
turn. Replace the cotter pin and retest the drop-out.
Continue this process until the specifications are meet.
5. Record the armature position on the calibration test form. Find
this area in the far right column.
Preparation of EH Function Solenoid Testing

On some control systems, there are 4 EH solenoids which are
controlled directly from an EH controls box on the surface. Typically
these are solenoid numbers 1, 2, 49, and 50. These solenoids are
accessed through the VCC29 Mux cable connector. In order to check
these solenoids, follow the steps below:
1. Remove the MUX cable from the system.
2. Verify proper connector pin-outs using the Hydril controls
system manuals that came with the equipment.
3. Connect Cable 2 from the VOLTAGE OUT TO SOLENOIDS jacks to
the EH function solenoid jacks on the back panel, with proper
polarity.
10 - 4

GNRC-NA-MPM100524
CHAPTER 10
Notes
Figure 10-5 Mechanics Stethoscope
Figure 10-6 Monitoring Solenoids Using a Mechanics Stethoscope
4. As shown in Figure 10-7, connect one end of Cable 4 to the EH

function solenoid in test jacks in the lower section of the back
panel with proper polarity.
Figure 10-7 Connections for Cable 2 & 4

10 - 5
CHAPTER 10
Notes
5. As shown in Figure 10-8, connect the other end of Cable 4 to

the appropriate pins on the VCC-29 connector.
Figure 10-8 Cable 4 Connection on VCC-29
EH Function Solenoid Testing

1. With voltage level controls turned fully counter clockwise, turn
the power supply on. Slowly turn the course voltage control
clockwise until you get to 60 VDC. The current meter should
show an energizing current. This should be right about 450mA.
2. Turn the voltage back down to zero.
3. Repeat twice before recording the readings of the pull-in and
drop-out voltage and current.
4. Record the readings for pull-in and drop-out for each E/N
function solenoid.
Auto Shear Valve Solenoid Testing

The auto shear valve is functioned by either solenoid 15 or 16. This will
depend on the customers requirement. Remember that with your
test kit will come a Hydril manual that will also walk you step by step
through this process.
Make sure that the shear seal valve 4-pin connector in the lower
electronics housing must be disconnected for access to the shear seal
valve solenoid.
1. Connect cable 2 to the VOLTAGE OUT TO SOLENOIDS jacks to
the shear seal valve solenoid test jacks 15 or 16 on the back
panel (with proper polarity).
2. Connect one end of cable 4 to the shear seal valve solenoid test
jacks in the lower section of the back panel assuring that it has
proper polarity. See Figure 10-9 for visual.
10 - 6

GNRC-NA-MPM100524
CHAPTER 10
Notes
Figure 10-9 Auto Shear Valve/Cable 4 Connections
3. Connect the female end of Cable 4 to Cable 5 while assuring

polarity.
4. Connect the 4-pin connector of Cable 5 to the mating 4-pin
female connector from the shear seal valve in the lower
electronics section.
Figure 10-10 Cable 5 Connections for Auto Shear Valve Test

10 - 7
CHAPTER 10
Notes
Solenoid Diode Testing

The EH function solenoids have a diode that has been embedded in
the end of the coil. The diode is used for solenoid current kickback
protection.
1. Wire in the solenoid that will be tested.
2. Click the DIODE CHECK switch to the ON position.
3. Increase the voltage to 30 VDC.
Dont Forget...
Remember to document the current value.
4. Turn the power going to the solenoid OFF.

5. Reverse the polarity on cable 2 to the solenoid.
6. Increase the voltage back up to 30 VDC.
7. The current reading should be approximately twice the current
since the diode is now forward based in the solenoid and the
coil is being bypassed.
8. Make sure to record all variations.
Solenoid Fire Testing

1. Reassure that the solenoid in test is wired in.
2. Switch the FIRE/PROFILE MODE switch to the fire position.
3. At this point, increase the voltage to the solenoid to 38.5 VDC.
4. Switch the FIRE/PROFILE MODE switch to the Idle position. This
would be in the forward position or (up).
10 - 8

GNRC-NA-MPM100524
CHAPTER 10
5. Now record on the form whether the drop-out operation was a
pass or fail.
Notes
Solenoid Resistance Testing

The coil that is within the solenoid housing should be tested for proper
DC resistance.
1. Connect the appropriate hypertronic into the test set.
2. Attach cable 2 from the RESISTANCE METER jacks on the test set
to the solenoid jacks on the back panel and read ohms directly
from the ohmmeter.
3. At this point, record the actual resistance values on the test
form.
Dont Forget...
If the resistance reading is less than 129 Ohms
or greater than 139 Ohms, further investigation
and troubleshooting will be required to
determine if there is a wiring problem or if the
solenoid winding needs replacement.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________

10 - 9
CHAPTER 10
10 - 10

GNRC-NA-MPM100524
Chapter 11
Pressure Transducer
Notes
Scope
removing and installing the MUX control pod pressure transducers.
Figure 11-1 Pressure Transducer
3/8"
drive socket
3/8"
drive extension
3/8"
allen socket
Torque wrench reading in-lbs

Paint pen
Petroleum jelly
O-ring pick
WD-40
Clean cloths
Watch Out...
proceeding.

11 - 1
CHAPTER 11
Pressure Transducer
Notes
Remove Pod Power

1. To lock out the 720 VAC, turn the subsea power breaker located
at the PDP to the OFF position and place a lockout tag on the
PDP.
Transducer Removal
1. Remove the dielectric fluid in the solenoid housing.
2. Inside of the solenoid housing, disconnect and remove the
electrical connectors from the transducer.
3. Outside of the housing, use the 3/8" ratchet, extension, and 3/8"
allen socket to remove the two cap screws from the pressure
transducer.
4. Pull the transducer from the housing. Be careful not to damage
the transducer, the housing, or the tubing that is located
around the area.
5. Take the paint pen and write the number on the side of the
transducer. The number of that particular slot can be found just
above the hole that the transducer was pulled from.
6. Take the transducer back to the work bench and using the Oring pick, remove the two O-rings and backup ring.
7. Use WD-40 or a non-residual cleaner and spray down the
transducer. Wipe it down with a clean cloth.
8. If there is rust or corrosive on the transducer, take a scotchbrite
pad and rub down the transducer till its totally clean.
Installation of Transducer
1. Rub petroleum jelly on the O-rings.
2. Install the new O-rings and backup ring on the transducer.
3. From the outside of the housing, begin pressing the transducer
in to the appropriate slot.
Dont Forget...
The transducer bracket has a pin on it. Make
sure to position the bracket with the pin side
facing down.
4. As the transducer is being pressed in, make sure to be aware of
the alignment so that once in, the cap screws will line up.
11 - 2

GNRC-NA-MPM100524
CHAPTER 11
Pressure Transducer
5. With a brush, put Never Seez on the cap screws threads.
Notes
6. Screw the cap screws in to the holes.

7. Torque the cap screws to 150 in-lbs.
8. From the inside of the housing reattach the electrical
conductors to their correct terminals.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________

11 - 3
CHAPTER 11
Pressure Transducer
11 - 4

GNRC-NA-MPM100524
Chapter 12
Notes
Scope
This purpose of this procedure is to verify the pressure transducers
are calibrated with the MUX software. Follow the procedure as given.
Figure 12-1 Pressure Transducer

Calibrated hydraulic hand pump, capable of pressurizing to
10,000 PSI
3/8"
NPTF hose, 6 feet in length
10,000 PSI gauge

20,000 PSI gauge
9/16"
3/8"
x 3/8" NPT nipple
3/8"
x 3/8" coupling
3/8"
NPTF needle valve
open ended wrench
Gauge adapter
Test laptop
Test jumper cable
Ethernet cable
Calibrating Transducers
1. Ensure the coupling and hose is connected to the transducer.
2. Attach test laptop to J-box by way of ethernet cable.
12 - 1
CHAPTER 12
Notes
3. Connect J-box to MUX pod by way of the test jumper cable.

4. On the pod tester program Menu Bar, select CONFIGURE and
then CALIBRATE TRANSDUCERS.
5. On the Calibrate Transducers window, select either SEM as the
Active SEM and wait for said SEM to re-establish
communications as evidenced by the menu bar indicator or the
main screen.
6. Record the tested pod and SEM on the 6.0 sign-off sheet.
7. From the left side Transducer menu, select one of the
transducers for calibration by clicking on the appropriate box.
8. In the upper right EU scale pre-defined options, select the 0 PSI
box.
9. Using the hydraulic hand pump, adjust the pressure to closely
approximate 0 psi and enter the hand pump gauge reading in
the window immediately below Choose EU Scale.
10. Confirm the same approximate pressure is displayed in the
right side Pressure column and the transducer reported raw
count value is displayed in the adjacent New Equivalent Raw
Count Value column.
11. Click the Test Calibration Data button.
12. Verify presentation of a New EU Scale Calibration Value that is
proportionate to the New Equivalent Raw Count Value and
approximates the Pressure reading.
13. Click the Apply Changes, Create Calibration Data .txt & .bin
Files button to write the new calibration information to the local
records.bin and also to pod-SEM specific Binary and Text files
under the default/Pod_Test/directory. (e.g. Pod1-SEMA_calibrate.bin, Pod1-SEM-A_claibrate.txt) The 8 individual PodSEM specific binary files (if selected individually) need to be
MANUALLY transferred to the system controller node//1/mmi
directory.
For example: When you calibrate Pod 1 and SEM A and
there is one system controller node (i.e. Node 1) and after
Pod1-SEM-A_calibrate.bin
has
been
generated
automatically, you would be viewing and Information
Advisory window with the following information as
described below:
Pod1-SEM-A_calibrate.bin needs
transformed to //1/mmi directory.
to
be
MANUALLY
ONLY when the system is in MAINTENANCE MODE, run the

//1/hydril/phUpd_Calib_DataUTILITY to update disk
storage media on all detectable Control System nodes.
14. Repeat Steps 7 through 12 three additional times noting the
following differences:
In Step 7, with each successive repetition, select the 2500,
5,000, 7,500, and 10,000 PSI box for the EU Scale option.
12 - 2

GNRC-NA-MPM100524
CHAPTER 12
In step 8, increase the hand pump pressure to closely
approximate the Step 7 EU Scale pressure selection.
Notes
15. Repeat Steps 6 through 13 noting the following differences:

In Step 6, from the upper center Choose Transducers to
Calibrate options, select the box associated with the 10
transducers that includes the previously calibrated
transducer, and when said 10 individual Transducer Menu
boxes are illuminated Red, de-select the previously
calibrated transducer.
16. Repeat Steps 6 through 13 noting the following differences:
In Step 6, deselect the Choose Transducers to Calibrate
group of 10, and when said 10 individual Transducer Menu
boxes are extinguished, select the alternate group of 10
transducers.
17. Click the EXIT button to terminate the calibration feature and
return to the pod Tester screen.
18. Via a shell window, type less/Pod_Test/Pod1-SEMA_calibrate.txt<Enter> to view the calibration value changes
made for Pod 1 and SEM A (for instance) during performance of
this test. Type the letter q to quit the less utility.
19. In order to verify the calibration value changes made during the
test have been updated in the Node 6 database records.bin file,
exit the pod Tester application by clicking EXIT from the File
Menu Bar and then let the program start back up. Once the pod
Tester main screen appears, select CONFIGURE followed by
CALIBRATE TRANSDUCERS, and then compare the calibration
data values displayed in the Current Section of this window
with the pod-SEM specific text files (see step 17), for example,
/Pod_Test/Pod1-SEM-A_calibrate.txt.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________

12 - 3
CHAPTER 12
12 - 4

GNRC-NA-MPM100524
Chapter 13
One Atmosphere Housing
Hydrostatic Test
Notes
Scope
This chapter defines the single unit test (SUT) procedures for the
penetrators, external cable connections, and internal seals used on
the EH section of the MUX control pod. The purpose of this test is to
verify the pressure integrity of the penetrator O-rings and the cable
connector O-rings.
The one atmosphere housing provides a protected environment for
the MUX control pod subsea electronics modules (SEMs), the
transformer, and the VCC-29 connector. The one atmosphere housing
is designed as an external pressure vessel capable of 12,500 foot
water depths, which correlates to about 5,600 PSI external pressure.
The pass-through penetrators (45 pin and 60 pin) are used to provide
electrical connections between the MUX control pod one atmosphere
housing base and the solenoid housings. The solenoid housing is used
to mount the solenoids and to protect electrical components from the
subsea environment. There are two solenoid housings used on each
MUX pod. The interior on the solenoid housings are filled with pressure
compensated dielectric fluid to offset the exterior pressure.
The penetrators are subjected to subsea pressure differential
(hydrostatic) head pressure. Other components, in addition to the 45
and 60 pin penetrators, that are subjected to this pressure differential
are the MUX cable connector (VCC-29 or similar) and the external
cable connectors going to the RTU, flowmeter, etc.
The MUX pod electrical connector is a two part assembly. One part,
the flange connector receptacle (FCR), bolts to the top of the EH
section and contains connector pins. The other part, the cable
connector plug (CCP), attaches to the end of the multiplex cable and
has receptacles for the FCR pins.
Figure 13-1 One Atmosphere Housing

13 - 1
CHAPTER 13
Notes

A calibrated pressure gauge suitable for measuring 7,500 PSI
A calibrated pressure gauge suitable for measuring 400 PSI
A hydraulic power supply capable of 6,000 PSI
Test tubing, test connections, cover plates, and valves as
required. The test equipment must be designed for safe
operation at the test pressures designated in this document
A chart recorder to document time intervals
1/8"
Allen wrench
Pressure test fitting (JIC 37 flare, 7/16-20UNF-2B threads)

Petroleum jelly
New O-rings and seals
New backup rings for O-ring seals
Dielectric fluid, Dow Corning DC200 or equivalent
Thread lubricant for stainless steel fasteners (Bostik Never
Seez Pure Nickel Special or equivalent)
FCR test cap (Hydril P/N 3142647)
Lint-free absorbent wipes
Test Preparation
1. Record the solenoid housing part number and serial numbers in
the TDDR.
2. REcord the one atmosphere base housing part number and
serial number in the TDDR.
3. Collect the necessary test equipment. Record the range, serial
number, calibration number and date of the pressure gauges/
transducers in the TDDR.
4. Physically inspect the system for manufacturing flaws or in
service damage and record on the TDDR.
Be Aware...
Any stainless steel fasteners removed during
this procedure must be reinstalled and
tightened in accordance with procedure X1009932. Failure to comply can result in
damaged fasteners and fastener receptacles,
and loss of pressure sealing integrity.
5. All of the EH section test ports are labeled, except for the test
port in the cap of the transformer housing. List the results for
this unlabeled port in the At Cap row in the TDDR. The test port
labels and their corresponding locations are as follows:
13 - 2

GNRC-NA-MPM100524
CHAPTER 13
TP1, TP2, TP3, TP5, TP6, and TP7 are test ports for the 45
and 60 pin penetrators.
Notes
TP4 is the test port for the electronics dome.

TP11 is the test port for the VCC29 connector.
TP9 is the test port for the transformer housing.
TP8 and TP10 are test ports for the seal sub to the housing
for the external cable connectors.
ECC1-X through ECC6-X are test ports for the external cable
connectors.
Test Procedure for Test Port O-Rings

1. Remove the plug from the test port.
2. Connect test circuit to test port.
Dont Forget...
Remember to lubricate the O-ring seal on the
test fitting. Tighten the test fittings just enough
to ensure a leak proof seal.
Did You Know...

Multiple test ports can be tested. However, if the
multiple ports test indicates leakage, then each
part must then be individually tested.
3. With the use of dielectric test fluid and the test pump,
pressurize the test circuit to 250 PSIG.
4. Close the isolation valve to begin the pressure test.
5. Record the test pressure in the TDDR.
6. Hold the test pressure for 5 minutes.
7. After 5 minutes, record the test pressure and the test timing the
TDDR.
8. Inspect all accessible areas around the tested seals for any
visible leakage.
Check to See...
If there is visible leakage, or the indicated
pressure decreases, inspect sealing surfaces
and seals. Repair/replace as required and
repeat the test from the beginning.

13 - 3
CHAPTER 13
Notes
9. Repeat Steps 1 through 8 with a test pressure of 5,600 PSI.

Record results in the TDDR.
10. If the tests were successful, remove the test circuit from the test
port(s).
11. Inspect test port plug. Repair or replace if thread damage is
observed.
12. Replace O-ring if damage or excessive wear is evident.
13. Lubricate O-ring with petroleum jelly and re-install and tighten
plugs in test ports.
Test Procedure For External Cable Connector Ports

1. Remove the external cable from the connector, or removing the
blanking cover from the external cable connector.
2. Install the test cap to the external cable connector.
3. Pressurize the test circuit to 5,600 PSIG.
4. Close the isolation valve to begin the pressure test.
5. Record the test pressure in the TDDR.
7. At the end of the test period, record the test pressure and the
test time Hold Period in the TDDR.
visible leakage. If there is visible leakage, or the indicated
pressure decreases, inspect sealing surfaces and seals.
Repair/replace as required and repeat the test from the
beginning.
9. If the test was successful, remove the test circuit from the
external connector.
10. Repeat the test for all external cable connectors.
Test Procedure For The MUX Cable VCC29 Connector

Be Sure to...
Complete all penetrator and external cable
connector tests prior to performing the MUX
cable connector pressure test.
1. (If installed), remove the MUX cable connector from the flange
connection receptacle (FCR) connector.
2. Install the FCR test cap.
3. Remove the plugs from the test ports.
4. Connect the test circuit to the port labeled A on the FCR.
5. Pressurize to 5,600 PSIG.
13 - 4

GNRC-NA-MPM100524
CHAPTER 13
6. Close the isolation valve to begin the pressure test. Record the
test pressure in the TDDR under FCR-A.
Notes

8. At the end of the test period, record the test pressure and the
test time in the TDDR.
visible leakage.
Check to See...
If there is visible leakage, or the indicated
pressure decreases, inspect sealing surfaces
and seals. Repair/replace as required and
repeat the test from the beginning.
10. If the test was successful, remove the test circuit from FCR-A.
11. Repeat the procedure for Port B and Test Cap port.
12. Inspect the test port plugs. Repair or replace if thread damage
is observed.
13. Replace the O-ring if damage or excessive wear is evident.
14. Lubricate the O-ring with petroleum jelly and re-install and
tighten the plugs in the test ports.
Test Completion and Documentation

1. Remove all test equipment.
2. Re-torque all bolted connections in accordance with Hydril
document X-1009932.
3. Prepare units for shipment as designated on the BOM.
All sheets in the FAT/TDDR shall be reviewed for completeness. They
shall have been filled out, signed, and dated by the Hydril test
technicians who performed the tests, and the Hydril Quality
Assurance personnel who witnessed and documented the test. A
customer Representative (when requested by the customer) shall sign
the TDDR.
Documentation from vendors shall be included in the TDDR, and
remain as part or the FAT/TDDR record. Include certificates of
conformance (COCs). Copies are acceptable.
Tests that were not completed must be approved by the customer
representative as waived (signature required) or a written explanation
added to the TDDR.
All test charts and printed data shall be identified with the assembly
tested and tests performed. They shall be signed and dated by the
test technician and a customer representative (when requested by the
customer).

13 - 5
CHAPTER 13
Notes
Copies of these tests shall be retained in Hydrils documentation

system for a period of five years after shipment of the unit.
Copies of these tests shall be sent to the customer with individual
units, if applicable.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________
13 - 6

GNRC-NA-MPM100524
Chapter 14
Subsea Regulator
Notes
Scope
removing, disassembling, maintaining, assembling, and installing the
MUX control pod subsea regulator.
Figure 14-1 Subsea Regulator

Shelf (Hydril part number AE703)
3/8"
drive ratchet
1/2"
drive ratchet
3/8"
drive extension
1/2"
drive extension
5/16"
3/8"
Allen socket head
Allen socket
Emery cloth
O-ring pick
Rubber mallet
Large flat-head screwdriver
Repair kit
Torque wrench measuring in-lbs.
Petroleum jelly
14 - 1
CHAPTER 14
Subsea Regulator
Notes
Nickel-plated Never Seez w/brush

LP3 rust inhibitor
WD-40 or other non-residual cleaner
Clean cloths
Watch Out...
The Subsea Regulator may be under EXTREME
hydraulic pressure! Even though power is
shut-off, pressure may still be behind the
regulator. When back off the bolts, if the bolts
remain tight, STOP! DO NOT CONTINUE! Stop
and bleed off pressure. To disregard this
warning may cause serious injury or loss of
life.
Arrange all of the necessary tools and accessories on a table in a safe
and clean work area. The table must be large enough to allow space
for the disassembly, maintenance, and reassembly of the regulator. It
must also be large enough for all of the tools to be laid out in an
orderly fashion.
Regulator Removal
Watch Out...
When loosening the cap screws, pay strict
attention to the existing tension on the cap
screws. If the screws are not getting easier to
loosen, there may be existing hydraulic
pressure that has not been bled off. STOP and
bleed off remaining pressure before
continuing.
1. Hang the shelf from the manifold behind the regulator.
2. Take the 3/8" allen socket and make two turns to loosen the ten
bolts that are holding the regulator to the pod. Verify that the
bolts are loose.
Be Aware...
The regulator weighs approximately 110 lbs. Be
prepared to support this weight when removing
the ten bolts that hold it to the LVCU manifold.
3. Remove the ten screws and place them to the side.
4. Grasp the two handles and pull the regulator straight out.
14 - 2

GNRC-NA-MPM100524
CHAPTER 14
Subsea Regulator
Notes
Pay Attention...
The seal subs may come out with the regulator,
or they may pull away from the regulator and
stay in the manifold.
5. Set the regulator on the table.
6. Remove all of the seal subs from the manifold and/or from the
base plate of the regulator as shown in Figure 14-2.
Figure 14-2 Regulator Seal Subs
7. Place the ten bolts on the table so all parts and accessories will
be together.
8. Remove and discard all O-rings from the seal subs.
Regulator Disassembly
1. Clean the seal subs with WD-40 and set them aside.
2. Set the regulator with the handles up and begin removing the
six screws holding the top plate to the body.
Figure 14-3 Removing the Top Plate Screws

14 - 3
CHAPTER 14
Subsea Regulator
Notes
Did You Know...
All of the exterior cap screws on the regulator
are the same size and diameter. They can be
placed together without concerns of mixing
them.
3. Take the six screws and set them aside.
4. Remove the top plate (see Figure 14-4).
Figure 14-4 Removing the Top Plate
5. Remove the compression springs.

6. Using the O-ring pick, remove the O-rings that are holding the
shear seal housings in place. Discard the O-rings.
7. Remove the inlet and outlet shear seals.
Figure 14-5 Seal Housing and Inlet Shear Seal
8. Remove the O-rings and backup rings from the shear seals.
Discard the o-rings and backup rings.
9. Flip the regulator body over.
10. Remove the ten screws from the base plate (see Figure 14-6).
14 - 4

GNRC-NA-MPM100524
CHAPTER 14
Subsea Regulator
Notes
Figure 14-6 Removing the Base Plate Screws
11. Remove the compression springs.

12. Pick the O-rings out and remove the inlet and outlet shear
seals.
13. Take the eight cap screws out of the discharge cap.
14. Using the rubber mallet and flat head screwdriver, place the flat
head in the bolt hole of the discharge cap and tap it at an angle
to cause the cap to rotate. Now you will notice that a corner
edge of the discharge cap is above the top level of the regulator
body. Place the flat head tip against the inner side of that
corner edge and tap the discharge cap out.
Dont Forget...
Make sure that the body is not too close to the
edge of the work bench. If it is, when the cap
pops out, the cap may fall to the floor incurring
possible damage.
15. Take the eight cap screws out of the piston cap.
16. Repeat Step 14 to remove the piston cap.
Figure 14-7 Piston Cap

14 - 5
CHAPTER 14
Subsea Regulator
Notes
17. Stick the handle of the rubber mallet in the end of the slide.
Using the tip of the handle, tap the slide forward to push the
piston out the end of the regulator body. Pull on the piston as it
comes out the other side. HINT: take one of the cap screws and
screw it into the end of the piston; use this cap screw as a
handle to pull on as the mallets handle taps against the
opposing side (see Figure 14-8).
Figure 14-8 Removing the Piston
18. Pull the locking pin from the piston and slide (see Figure 14-9).
Figure 14-9 Disassembling the Piston
19. Using the O-ring pick, remove the T-seal and two backup rings
from the inner side of the regulator body, and discard them.
14 - 6

GNRC-NA-MPM100524
CHAPTER 14
Subsea Regulator
Notes
Figure 14-10 Regulator Component Parts
Maintenance
1. Take a clean cloth and WD-40, and clean all of the parts.
2. Inspect each part. Look for visible damage such as deep
scratches, pitting, and wear.
3. Check the regulator slide for scoring, scratches, pitting, galling
of any sort. The slide has a very flat surface and any deviation
from this will cause the regulator to not perform to its needed
capacity. An important note to remember is that the slide is
made of a carbon steel material and can not be buffed. If the
slide becomes damaged, it must be replaced.
4. Inspect the inside of the regulator body. Again, check for wear,
galling, scoring of any kind. If the damage is not too bad, 600
grade emery cloth can be used to try and buff the damaged
area.
Reassembly
1. Using a small brush, brush Never-Seez on the threads of each
screw. Set these screws facing up so that they will not collect
debris.
2. Take the new T-seal and put a coat of petroleum jelly on it.
3. Place the T-seal in the inner piston side of the regulator body.
4. Place a backup ring on both sides of the T-seal. Make sure that
the beveled edges of the backup rings overlap correctly.
5. Assemble the piston on the slide. Lock them together with the
locking pin.
Did You Know...

Placing a layer of petroleum jelly on the locking
pin before inserting it will help it to stay in place.
6. Rub a thin coat of petroleum jelly on the sides of the slide and
around the piston (see Figure 14-11).
14 - 7
CHAPTER 14
Subsea Regulator
Notes
Figure 14-11 Lubricating the Piston
7. Align the piston assembly and slide it in the end that has the Tseal on the inner side. Be careful when passing through the Tseal and backup rings. The petroleum jelly will help in the
passing. Once the assembly is completely in, you will notice
that the piston is the part that is passing back and forth over
the T-seal.
Figure 14-12 Inserting the Piston
8. Take the end caps and replace the O-rings. There is one O-ring
on each end cap. Rub petroleum jelly on the O-rings before
placing them on the caps.
9. Slide the caps on to the ends of the regulator body.
10. Place two cap screws in the cap and begin tightening in an
alternating pattern. Tighten evenly so that the cap will slowly
work on to the body. By doing this, the O-rings will go into the
body without being cut.
14 - 8

GNRC-NA-MPM100524
CHAPTER 14
Subsea Regulator
11. Take the appropriate number of cap screws, brush Never Seez
on the threads, and screw them through the cap and into the
body. Tighten the screws to 54 ft-lbs torque (73 Nm).
Notes
12. Rub petroleum jelly on the shear seals and the shear seal
housings (see Figure 14-13).
Figure 14-13 Lubricating Shear Seals
13. Press them into the appropriate slots.

14. Rub petroleum jelly on the O-rings and place them along with
the backup rings on to the shear seals.
15. Press them into the appropriate housing.
16. Rub petroleum jelly on the housing O-rings. Inserting these Orings will also secure the housing in place.
17. Set the compression springs on each shear seal housing.
18. Take the cover plate and orient according to the bolt hole
alignment.
19. Take the appropriate number of cap screws, brush never seez
on them, and insert them in to the plate.
20. Start from the outer screws and begin to ratchet them down
alternating from one side to the other. Working back and forth,
work towards the center section. Be careful to not tighten one
side down quicker then the other. Following this process will
help to prevent binding.
21. Torque the cap screws to 54 ft-lbs torque (73 Nm).
22. Flip the regulator over and repeat Steps 11 through 21.
Reinstall the Subsea Regulator on the Pod

1. Take the seal subs and clean them with a non-residual cleaner.
2. Take the O-rings and rub petroleum jelly on them.
3. Place O-rings on the seal subs.
4. Insert the seal subs into the ports located on the pod.
5. Take the shelf (GE Oil and Gas # AE703), hang it from the
manifold.
14 - 9
CHAPTER 14
Subsea Regulator
Notes
6. Slide the subsea regulator on to the shelf.

7. Slide the regulator on to the seal subs. Be careful not cut or
cause the O-rings to roll.
8. Put Never Seez on all the bolts threads.
9. Place the bolts through the regulator, using the 3/8" socket allen,
ratchet, and extension, begin bolting up the regulator starting
from opposite sides. Tighten each side of the regulator evenly
being careful not to place the regulator in to a bind.
10. Torque these cap screws to 54 ft-lbs torque (73 Nm).
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________
14 - 10

GNRC-NA-MPM100524
Chapter 15
SPM Valve
Notes
Scope
removal, disassembly, maintenance, and reinstallation of the MUX
pod SPM valve.
Figure 15-1 SPM Valve

Cage and seat removal kit (Hydril part number 3135439)
3/8"
drive ratchet
3/8"
drive extension
5/16"
Allen socket head
3/16"
Allen socket head
1/4"
Allen socket head
Medium-sized flat head screwdriver

15 - 1
CHAPTER 15
SPM Valve
Notes
O-ring pick
Needle nose pliers
Repair kit
Torque wrench measuring in-lbs.
Hand-operated press
Emery cloth
LP3 Rust inhibitor
Petroleum jelly
Nickel-plated Never Seez w/brush
WD-40 or other non-residual cleaner
Clean cloths
Disassembly
1. Depressurize the hydraulic system.
2. If the valve is accessible, the valve can be rebuilt while
connected to a manifold or piping. If it is not accessible, remove
the valve from the connected manifold or piping.
Be Careful...
If mounting the SPM in a vise, protect the body
against damage.
3. Use the valve cap tool from the tool kit to unscrew and remove
the piston housing. Remove the housing carefully to avoid
damaging housing threads.
Figure 15-2 Remove Piston Housing
15 - 2

GNRC-NA-MPM100524
CHAPTER 15
SPM Valve
4. Place the tip of the screwdriver between the spring coils and
push down against the SPM body. Gently apply pressure on the
spring/spool assembly to force it out of the body. Care must be
taken not to damage the spool face seal surface.
Notes
Figure 15-3 Spring/Spool Assembly
5. Use the cage removal tool from the tool kit to remove the cage
from the valve body.
6. Use the seat removal tool from the tool kit to remove the lower
valve seat from valve body.
Figure 15-4 Removing the Lower Valve Seat
7. Place the spring/spool assembly in the spring compression

base tool from the tool kit.
8. Place the spring compression cap tool from the tool kit on the
end of the spool.
9. Place the assembly in a press.

15 - 3
CHAPTER 15
SPM Valve
Notes
Figure 15-5 Spring/Spool Assembly in Press
Watch Out...
Valve springs are highly compressed. Use
press with extreme caution to avoid injury
when removing split collet halves.
10. Apply pressure to compress the valve springs until the split
collet halves are accessible.
11. Carefully remove the split collet halves from the spring retainer.
Figure 15-6 Removing the Collets
12. Slowly decompress the springs.

13. Remove the assembly from the press and disassemble it.
15 - 4

GNRC-NA-MPM100524
CHAPTER 15
SPM Valve
Notes
Figure 15-7 Disassembling the Spring/Spool Assembly
14. Hold the valve stem at its flats and remove the lock nut.
15. Remove the piston from the piston housing.
Figure 15-8 Piston, Piston Housing, and Lock Nut
16. Remove all elastomers and backup rings from the components.
Maintenance
1. Clean all of the parts with a non-residual cleaner.
2. Inspect each component for deformation and mechanical
damage. Specifically examine the sealing surfaces on both
ends of the spool, spool to cage interface and piston rod.
Figure 15-9 SPM Valve Component Parts

15 - 5
CHAPTER 15
SPM Valve
Notes
3. Replace any components showing excessive wear or damage.

Replace all of the seals and backup rings. Inspect the upper and
lower seats for surface scratches and cracking. A minor
impression from the spool is common in the seats but if
cracking is evident, replace the seats. If only surface scratches
are evident, the seats can be rotated once before replacement.
Remove minor surface damage on non-critical components
with an emery cloth.
Assembly
1. Hold the valve stem at its flats and install new lock nut on the
stem.
2. Tighten the lock nut until it bottoms out on the stem shoulder.
Tighten the nut in accordance with Table 15-1.
Table 15-1 Lock Nut Torque Values

Valve Size
In/Lbs
Nm
" Valve
35
4.0
1" Valve
115
13.0
1 " Valve
265
30.0
3. Verify the spool rotates freely after the nut is tightened.
Figure 15-10 Installing the Lock Nut on the Stem
4. Lubricate and install the T-seal in the ID groove on the new

upper seat.
15 - 6

GNRC-NA-MPM100524
CHAPTER 15
SPM Valve
Notes
Make Sure...
Use only petroleum jelly to lubricate SPM valve
components. DO NOT use PTFE or other sealingtype lubricants on stainless steel components
exposed to saltwater. PTFE and sealing type
lubricants cause oxygen deprivation that
accelerates the corrosive affects of saltwater.
5. Orient and install the backup rings above and below the T-seal.
6. Lubricate and install a new O-ring in the OD groove of the new
upper seat.
7. Install the upper seat on the valve stem.
Figure 15-11 Installing the Upper Seat
8. Install the backup plate on the valve stem.
Figure 15-12 Installing the Backup Plate
9. Install the inner spring on the valve stem.

15 - 7
CHAPTER 15
SPM Valve
Notes
Figure 15-13 Installing the Inner Spring
10. Install the outer spring on the valve stem.
Figure 15-14 Installing the Outer Spring
11. Install the spring retainer on the valve stem.
Figure 15-15 Installing the Spring Retainer
15 - 8

GNRC-NA-MPM100524
CHAPTER 15
SPM Valve
12. Place the spring/spool assembly in
compression base tool from the tool kit.
the
spring
Notes
13. Place the spring compression cap tool from the tool kit
on end of the spool.
14. Place the assembly in a press.
Figure 15-16 Spring/Spool Assembly in Press
15. Apply pressure to compress the inner and outer valve

springs. Ensure the spring retainer does not hang in the
collet groove on the valve stem as the spring
compresses.
Figure 15-17 Compressing the Spring
16. Install split collet halves in spring retainer. When

correctly installed collets are flush (to within 1/32") with
spring retainer.

15 - 9
CHAPTER 15
SPM Valve
Notes
Figure 15-18 Installed Collets
17. Lubricate and install new T-seal in ID groove on cage.

18. Orient and install back up rings with T-seal.
19. Lubricate and install new O-ring on OD groove of cage.
20. Place installation tool in valve spool.
Figure 15-19 Installation Tool
21. Lightly lubricate valve spool.

22. Lightly lubricate installation tool. The installation tool is
specified in the SPM valve repair kit.
Figure 15-20 Lubricating the Installation Tool
15 - 10

GNRC-NA-MPM100524
CHAPTER 15
SPM Valve
23. With valve spool facing up and large diameter of cage
facing down, hand press cage onto spool.
Notes
Figure 15-21 Hand Pressing Cage onto Spool
24. Remove installation tool from valve spool.

25. Inspect bore of SPM body for damage and debris.
26. Lightly lubricate bore of SPM body.
27. Install new lower seat.
28. Press spring/spool assembly into SPM body ensuring
that cage OD O-rings pass undamaged through supply
and vent ports of body.
Figure 15-22 Hand Pressing Spring/Spool Assembly
29. Lubricate and install new T-seal in OD groove on piston.

30. Orient and install back up rings with T-seal.
31. Install piston on valve stem.
15 - 11
CHAPTER 15
SPM Valve
Notes
Figure 15-23 Lubricating Piston Seal Grooves
32. Screw piston housing into SPM body and tighten in

accordance with Table 15-2.
Figure 15-24 Installing Piston Housing
15 - 12

GNRC-NA-MPM100524
CHAPTER 15
SPM Valve
Table 15-2 Piston Housing Torque Values
Valve Size
Working
Pressure
(PSI)
Torque
(Ft/Lbs)
Torque (Nm)
"
3,000
40
55
5,000
40
55
3,000
50
68
5,000
80
110
3,000
100
140
5,000
40
55
1"
1 "
Notes
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________

15 - 13
CHAPTER 15
SPM Valve
15 - 14

GNRC-NA-MPM100524
Chapter 16
Notes
Scope
The purpose of this procedure is to describe the proper methods used
to remove and install the 2.5 liter regulator accumulators.
Figure 16-1 2.5 Liter Regulator Accumulator

Nylon lifting strap
9/16"
3/4"
open ended wrench
open ended wrench
Operating crane/hoist
Removing the Regulator Accumulators

Watch Out...
Remove alll hydraulic pressure from the MUX
system must be removed. Make sure that this
step has been performed before proceeding.

16 - 1
CHAPTER 16
Notes
1. Before moving any part of the pod assembly using an overhead

crane and the pod lifting frame, survey the path of travel to
ensure it is clear. Remove all trip hazards, and identify any
overhead obstacles which may present a problem.
2. Remove the bolt and nut from each end of the LVCU frame
crossbar, and remove the crossbar.
3. Remove the cap screws from the upper left-hand corner brace
on the LVCU frame, and remove the brace.
Figure 16-2 Brace Attached to LVCU Frame
4. Disconnect the hydraulic lines from the bottom of both the 2.5
liter and the one-quart accomulator bottles (see Figure 16-3).
Figure 16-3 Hydraulic Connections
5. Remove the two 1/2-13NCX1.50 stainless steel hex head screws

that secure the accumulator bracket to the LVCU frame (see
Figure 16-4).
Figure 16-4 Remove the Two Screws
6. Swing the accumulator assembly forward. Ensure the

accumulators are clear of the LVCU frame.
16 - 2

GNRC-NA-MPM100524
CHAPTER 16
Notes
Figure 16-5 Regulator Accumulators
7. Wrap the nylon strap through and around the accumulators,

creating a sling (see Figure 16-6).
Figure 16-6 Strapping the Accumulators
8. Attach one end of the strap to the hoist.
Remember...
To prevent the accumulator bottles from
swinging freely, employ the assistance of a coworker to aid in lifting the accumulator bottles.

16 - 3
CHAPTER 16
Notes
9. Slowly lift the hoist until the accumulator bottles clear the
hinges.
10. Guide the hoist away from the LVCU. Place the bottles in a clean
and secure area.
Installing the Regulator Accumulators

1. Wrap the nylon strap through and around the bottles, creating
a sling.
2. Attach one end of the strap to the hoist.
Be Sure To...
Employ the assistance of a co-worker to aid in
guiding the accumulator bottles into place.
3. Slowly lift the accumulator bottles with the hoist.

4. Guide the hoist towards the LVCU. Maneuver the bottles onto
the accumulator swing bracket.
Figure 16-7 Reattachment of Assembly
5. Remove the nylon strap from the accumulator bottles.

16 - 4

GNRC-NA-MPM100524
CHAPTER 16
6. Swing the accumulator bottle bracket inside the LVCU frame
and install the two hex head screws. Torque the two screws to
24 ft-lbs.
Notes
7. Install the corner brace on the LVCU frame with the cap screws,
and torque the cap screws to 24 ft-lbs.
8. Connect the hydraulic lines to the bottoms of the accumulator
bottles. Tighten hand tight.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________

16 - 5
CHAPTER 16
16 - 6

GNRC-NA-MPM100524
Chapter 17
Notes
Scope
This purpose of this procedure is to describe the proper methods used
to precharge the regulator accumulators.
Figure 17-1 Regulator Accumulators
Test Equipment, Supplies, Facility Requirements

Hydraulic power supply (intensifier) unit capable of
pressurizing to 5,200 PSI
Air supply unit capable of pressurizing to 7,600 PSI
15,000 to 20,000 PSI gauge
5,000 PSI gauge
3/8"
NPTF hose, 6 feet in length
3/8"
x 3/8" NPT nipple
3/8"
x 3/8" coupling
3/8"
NPTF needle valve
11/4" open ended wrench

17 - 1
CHAPTER 17
Notes
5/16"
Allen wrench
(2) 3/4" open ended wrench

Nitrogen (compressed nitrogen bottles to precharge the
accumulators)
Bubble type leak detector and spray bottle (Red Devil,
Snoop, etc)
Blind flanges, test flanges, test piping, hose connections,
test connections, and valves as required. The test
equipment must be designed and built for safe operation at
the test pressures designated in this document
Preparation for Testing

1. Collect the necessary test equipment.
Did You Know...

In accordance with API, the test pressure
readings shall be in the range of 25% to 75% of
the full scale of the pressure gauges and chart
recorders.
2. Record the MUX pod assembly part number and serial number.
3. Record the part numbers and serial numbers for the EH section
assembly.
4. Record the part numbers and serial numbers for the lower
hydraulic control section and the hydraulic regulators.
Accumulator Precharge Circuit Pressure Test

1. Attach the nitrogen fitting to the hydraulic pump.
2. Attach an air supply to the pump.
3. Detach the circuit line from the top of the 2.5 and 1 liter bottles.
Figure 17-2 Circuit Connections
17 - 2

GNRC-NA-MPM100524
CHAPTER 17
Notes
Remember...
Remember, the circuit pressure test is just
testing the circuit lines between the
accumulator bottles located above the pod
wedge to the schrader valve.
4. Attach hose fitting that is coming from the pump.
5. Ensure that proper personnel barriers are in place and all
unnecessary personnel are out of the area.
6. Verify that the isolation valve is closed.
7. Open the nitrogen bottle.
Figure 17-3 Nitrogen Rack
8. Open the isolation valve and allow the pressure to level off.
9. Slowly open the air supply until the PSI reaches between 7,400
and 7,600 PSI.
10. Close off the isolation valve.
11. Allow the pressure to stabilize for 15 minutes. Use a stopwatch
to monitor this process.

17 - 3
CHAPTER 17
Notes
Remember...
If the accumulators became hot during
pressurization, allow time for the accumulators
to cool to near room temperature. If necessary,
it is permissible to apply additional pressure
during the stabilization process to maintain
pressure between 7,400 to 7,600 PSI. Pressure
shall be considered stabilized when there is no
noticeable change in the pressure reading.
Pay Attention...
The pressure can not drop below 7,400 PSI and
there shall be no noticeable change in pressure
observed. If the pressure does drop below 7,400
PSI, stop the test, shut down the pumping system
and check the fitting. Once checked, resume test.
Make Sure...
If there is a change in pressure, verify the leak
by spraying a leak detection fluid on the joints.
12. Record the pressure at the end of the hold period and the
length of the hold period.
13. Shut off air supply to the pump.
14. Close the isolation valve.
15. Using the two 3/4" open ended wrenches, open the schrader
valve and decrease the circuit pressure to 0 PSI.
16. Move on to the next circuit line.
Accumulator Precharge Procedure

Follow the steps below to precharge the 2.5 and 1 liter accumulator
bottles.
Watch Out...
Maintain a minimum compression ratio of 4:1
for nitrogen precharge pressure. For example,
if working pressure is 3,000 PSI, then minimum
precharge pressure is 750 PSI. If working
pressure 2,000 PSI. then minimum precharge
pressure is 500 PSI.
17 - 4

GNRC-NA-MPM100524
CHAPTER 17
1. Verify that the nitrogen bottle is closed.
Notes
2. Verify that the isolation valve is closed.

3. Use a 11/4" open ended wrench or a 5/16" Allen wrench to
remove the schrader valve cover.
Figure 17-4 Schrader Valves
4. Attach the nitrogen hose fitting to the schrader valve.

5. Using two 3/4" open ended wrenches, use one to hold the valve
in place and the other to open the valve.
6. Open the nitrogen bottle.
7. Open the isolation valve and precharge all bladder type
accumulators to the minimum precharge pressure (750 PSI for
a 3,000 PSI system). Allow the pressure to stabilize.
Dont Forget...
to cool to near room temperature, and then
recheck the precharge pressure. Add more
nitrogen as needed.
8. Using the 3/4" open ended wrenches, close the schrader valve.
9. Close the precharge isolation valve.
10. Remove the connection from the schrader valve.
11. Replace the schrader valve cover.
12. Bleed the built up pressure located between the nitrogen bottle
and the isolation valve to 0 PSI.
13. Repeat the above precharge procedure until all bladder type
accumulators have been precharged.
14. Connect the nitrogen source, with an isolation valve to a 1 liter,
piston type accumulator.
15. Open the isolation valve and precharge all 1 liter piston type
accumulators to 500 PSI. Allow the pressure to stabilize.

17 - 5
CHAPTER 17
Notes
Dont Forget...
to cool to near room temperature, and then
recheck the precharge pressure. Add more
nitrogen as needed.
16. Using the two 3/4" open ended wrenches, close the schrader
valve.
17. Close the precharge isolation valve.
18. Bleed the built up pressure located between the nitrogen bottle
and the isolation valve to 0 PSI then disconnect equipment.
19. Repeat the above precharge procedure for all piston type
accumulators.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________
17 - 6

GNRC-NA-MPM100524
Chapter 18
Notes
Scope
This purpose of this procedure is to demonstrate the proper methods
for removing and installing the flowmeter.
Figure 18-1 Pod Flowmeter

Pry bar
Ratchet
Extension
3/8"
Allen socket
Allen wrench
9/16"
open ended wrench
O-ring pick
Petroleum jelly
Repair kit
Clean cloths
Disassembly
Follow the steps below to disassemble the areas surrounding the
flowmeter so that the flowmeter can be removed properly without
damaging the assembly or the sealsubs that are located within.
1. Remove the stainless steel plates that encase the inner
components of the LVCU.
18 - 1
CHAPTER 18
Notes
Dont Forget...
Because the 1/4" hydraulic line crosses over the
front of the flowmeter, in Step 2 the electronic
housing will need to be removed from the front
of the turbine housing.
2. As shown in Figure 18-2, remove the cap screws from the
electronics housing and pull the housing free.
Figure 18-2 Electronic Housing Removal
3. Once the O-ring section of the electronic housing is free, take

one hand and prepare to support the wiring that is within the
housing. See Figure 18-3.
Figure 18-3 Flowmeter Preamplifier Board
4. Set the electronics housing off to the side and remove the
magnetic pickup. See Figure 18-4 .
18 - 2

GNRC-NA-MPM100524
CHAPTER 18
Notes
Figure 18-4 Magnetic Pickup
5. Set the magnetic pickup off the side so as to not damage the
flowmeter preamplifier board.
6. Moving back over to the side of the LVCU, remove the lower cap
screws that are holding the plate for the jumper manifold elbow
(see Figure 18-5).
Figure 18-5 Jumper Manifold Plate Removal
7. Loosen the cap screws on the upper section of the jumper

manifold elbow, but do not remove them.
8. Move to the other side of the LVCU and begin remove the cap
screws holding the jumper manifold to the flowmeter. By
loosening the joints, the lower section of the jumper manifold
elbow (shown in Figure 18-6) can be manuevered out. If the
joints are not first loosened, the manifold elbow will bind up
during its removal.

18 - 3
CHAPTER 18
Notes
Figure 18-6 Loosening Cap Screws on Jumper Manifold
9. Loosen the cap screws located at the opposite end of the photo
shown in Figure 18-6. The other section is connected to an
elbow.
10. Move back around to the side of the LVCU that has the jumper
manifold elbow.
11. Take a pry bar and pry the jumper manifold elbow out of the
lower assembly. See Figure 18-7.
Figure 18-7 Jumper Manifold Elbow
12. Once the jumper manifold elbow is free, pull it out through the
cut away that is recessed above it.
13. Pull the assembly out and set it on an adequate work area.
14. Remove the old O-rings and clean the parts until they are free
of grit and or anything else that may compromise the integrity
of a good seal.
18 - 4

GNRC-NA-MPM100524
CHAPTER 18
Flowmeter Reassembly
Notes
1. After the parts have been thoroughly cleaned, take the new kit
of O-rings and begin to reassemble the O-rings on to the parts.
Make sure to rub plenty of petroleum jelly on the O-rings before
placing them on the parts.
Figure 18-8 Reassembly of O-rings and Petroleum Jelly
2. In order to place the flowmeter back into original position, you

may have a person help start the cap screws coming in from
the jumper manifold located on the other side of the flowmeter.
3. As shown in Figure 18-9, have a helper use a pry bar to press up
on the bottom of the flowmeter as you push the jumper
manifold elbow in to place. Once the elbow is attached to the
flowmeter, allow the seal sub of the elbow to fall into place.
Figure 18-9 Prybar Pushing Up On Flowmeter

18 - 5
CHAPTER 18
Notes
4. Bolt up the base of the elbow and upper section of the elbow.
5. Tighten the cap screws through out the assembly.
6. Torque the cap screws to their appropriate weight.
7. Replace the outer panels and torque to appropriate value.
This process is now complete.
This student _______________________________________ has

Instructor
Signature ____________________________ Date ___________
18 - 6

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Multiplex (MUX) Pod

Care and Maintenance

copyright 2010 Hydril USA Distribution LLC

Published by GE Oil & Gas

MUX Pod Care and Maintenance Course

Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

How to Use This Manual

MUX Pod Care and Maintenance Course

Figure 1-1 Subsea Pod

Required Tools and Accessories

open ended wrench

(2) Lifting straps rated to lift 26,420 lbs.

MUX Pod Care and Maintenance Course

Using the Pod Lift Frame

Figure 1-2 Pod Lift Frame

2. Insert a lifting strap through each shackle.

MUX Pod Care and Maintenance Course

7. Adjust the straps until the weight is evenly distributed.

Figure 1-3 Removing the Bolts and Nuts

MUX Pod Care and Maintenance Course

Figure 1-4 Lifting the Pod EH Assembly

MUX Pod Care and Maintenance Course

This student ____________________________________________ has

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

Figure 2-1 Subsea Pod

Required Tools and Accessories

open ended wrench

open ended wrench

MUX Pod Care and Maintenance Course

(2) Lifting straps rated to lift 26,420 lbs.

Separating the EH and LVCU Sections

MUX Pod Care and Maintenance Course

Figure 2-2 Removing the Bolts and Nuts

Figure 2-3 Pod Lift Frame

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

Figure 2-4 Lifting the Pod EH Assembly

Joining the EH and LVCU Sections

Figure 2-5 Removing the Bolts and Nuts

6. Attach an appropriately rated shackle to each of the lifting eyes

11. Adjust the straps until the weight is evenly distributed.

MUX Pod Care and Maintenance Course

Figure 2-6 Aligning the Junction Plates

MUX Pod Care and Maintenance Course

28. Slowly lower the EH section onto the LVCU.

38. Replace the panel.

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

MUX Pod Care and Maintenance Course

Figure 3-1 SEM Housing Dome

Required Tools and Accessories for Dome