Connector Systems, LLC

500 Tesconi Circle, Santa Rosa, CA 95401 U.S.A., Cage Code # 16326 Tel 707 / 523-2300 Fax 707 / 523-3567 E-mail address: tech_support@biwconsys.com

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INSTALLATION INSTRUCTIONS FOR TRIDENT 550 3-WAY PACKER FEEDTHRU SYSTEM

The information disclosed herein was originated by BIW Connector Systems, LLC, and except for uses expressly granted to the United States Government, BIW Connector Systems, LLC, reserves all patent, proprietary, design, use, sale, manufacture, and reproduction rights thereto.

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Installation Instructions for TRI 550 3-Way Packer F/T System

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This instruction procedure defines the installation of the BIW Trident 3-Way Packer Feedthru System, TW553XX-X, consisting of BIW P/Ns: TW551XX-XXX-XXX, Lower Cable Breakout Assembly TW551XX-XXX-XXX, Upper Cable Breakout Assembly. 2.0 2.0.1 2.0.2 2.0.3 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9 3.0 3.1 ADDITIONAL MATERIAL REQUIRED FOR INSTALLATION: Open-end wrench set up to one inch opening Adjustable crescent wrench up to two inch opening Nicropress Crimp Tool #53 XPJ (BIW P290-0018) Crimp tool is required if contact pins need to be replaced. SPARE PARTS KIT (not supplied): BIW P/N: P300-0133 - Contains the following: 3 EA A096-0044, Cable Splice Seal Tube 3 EA P140-0038, Contact Overmold Assembly 1 EA A215-0010, Translucent Sealant 6 EA A135-0150-07, Contact Crimp Pin 6 EA A125-0048, NPT Parker Fitting 3 EA A120-0067, Vespel Seal Ring 3 EA A125-0040, 3/8 NPT Seal Fitting 3 EA A125-0046, Seal Nut, JIC Adapter (.750-16UN-2B) PROCEDURE: Installation Of The Trident 550 3-Way Packer Feedthru System NOTE: The following are included in each shipment for installation: B.) C.) A.) Lower Cable Breakout Assembly (TW551XX-XXX-XXX) Upper Cable Breakout Assembly (TW551XX-XXX-XXX) Remainder of components packaged separately

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Installation Instructions for TRI 550 3-Way Packer F/T System

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UPPER 5KV CABLE BREAKOUT ASSEMBLY

Figure 1A

Installation Instructions for TRI 550 3-Way Packer F/T System

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LOWER 5KV CABLE BREAKOUT ASSEMBLY

Figure 1B

Installation Instructions for TRI 550 3-Way Packer F/T System

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Figure 1C REMAINING COMPONENTS FOR INSTALLATION

3.1.1

Installation of the Upper Cable Breakout Assembly:

3.1.1.1 Before installing the three tubes of the Upper Cable Breakout Assembly through the packer, protect the contact pins on the end of each cable with tape. 3.1.1.2 Slide a 3/8 NPT Seal Fitting, Vespel Seal Ring with long taper facing down, and Seal Nut onto each of the three tubes of the Upper Cable Breakout Assembly. Tape in place on the tubing until ready to install. Starting with the protected contacts carefully feed the three 3/8 inch diameter feedthru tubes through the packer until the 3/8 SST tubing of the center cable extends beyond the bottom of the packer as required. See Figure 2A. BIW Connector Systems, LLC Page 5 of 16

Installation Instructions for TRI 550 3-Way Packer F/T System

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3.1.1.3 With the longitudinal groove of the Upper Cable Breakout Assembly facing the production tubing secure the assembly to the production tubing with one (1) band in the center of the cable breakout housing and one (1) band three (3) feet above the housing over the cable pigtail. See Figure 2B. 3.1.1.4 Apply anti-seize (or equivalent) lubricant to the 3/8 NPT Seal Fitting threads. Install the three, 3/8 NPT, Seal Fittings into the three bores at the top of the packer hanger. Starting with the center seal fitting, tighten each fitting three turns past hand tight. See Figures 2A and 2C. 3.1.1.4 Slide the Vespel Seal Rings down the tubes and seat into each of the, 3/8 NPT, Seal Fitting bodies. Slide the Seal Nut (.7500-16UN-2B) onto each Seal Fitting Body over each Vespel Seal Ring and hand-tighten. Tighten up the Seal Nuts 1- turns past hand tight to lock the assembly in place. See Figures 2A and 2C.

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Installation Instructions for TRI 550 3-Way Packer F/T System

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Figure 2A Upper Cable Breakout Installation

Figure 2B Cable Banding

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Installation Instructions for TRI 550 3-Way Packer F/T System

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Figure 2C Vespel Seal Installation

3.1.2

Installation of Tubing Splice and Lower Cable Breakout Assembly:

3.1.2.1 NOTE: Center tube splice should be made first. 3.1.2.2 Remove the protective tape from the Pin Contacts on the Upper Cable Breakout Assembly and carefully Install one set of three, Nuts, Ferrules, and 1/2 NPT Parker Fittings onto each of the three Upper Cable Breakout Assembly tubes. Secure temporarily to the tubes with tape. See Figure 3A. On the Lower Cable Breakout Assembly tubes carefully install the remaining set of three Nuts, Ferrules, and 1/2 NPT Parker Fittings. Secure temporarily to the tubes with tape.

3.1.2.3

3.1.2.4 Apply the provided Translucent Sealant to each open end of the three Insulated Contact Sleeves. BIW Connector Systems, LLC Page 8 of 16

Installation Instructions for TRI 550 3-Way Packer F/T System 3.1.2.5

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Carefully install each of the Insulated Contact Sleeves onto the Lower Cable Breakout Assembly Pin Contacts. Make sure the sleeves are completely engaged on the Pin Contacts. See Figure 3A. Do not allow Pin Contacts or the 3/8 SST Tubing to twist while installing the Insulated Contact Sleeves.

NOTE:

3.1.2.6 For each splice connection, place the Seal Tube next to the Insulated Contact Sleeve centering it. Make a mark on the 3/8 SST Tubing at the end of the Seal Tube. This will ensure proper placement of the Seal Tube when installed over the Insulated Contact Sleeve. See Figure 3A.

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Installation Instructions for TRI 550 3-Way Packer F/T System

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Figure 3A Cable Splice

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Installation Instructions for TRI 550 3-Way Packer F/T System

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3.1.2.7 Slide each Seal Tube onto the 3/8 SST Tubing of the Upper Cable Breakout Assembly. Tape to tubing until ready to install over the Insulated Contact Sleeves. 3.1.2.8 With the longitudinal groove of the Lower Cable Breakout Assembly facing the production tubing, install the three Pin Contacts on the Lower Cable Breakout Assembly into the three Insulated Contact Sleeves. Make sure the sleeves are completely engaged on the Pin contacts. NOTE: Do not allow Pin Contacts or the 3/8 SST Tubing to twist while installing the Insulated Contact Sleeves. 3.1.2.9 With the longitudinal groove of the Lower Cable Breakout Assembly facing the production tubing, secure the assembly to the production tubing with one (1) band in the center of the cable breakout housing and one (1) band three (3) feet above the housing over the cable pigtail. See Figure 3B.

Figure 3B Cable Banding

3.1.2.10 Remove tape from the three BIW Connector Systems, LLC Page 11 of 16

Installation Instructions for TRI 550 3-Way Packer F/T System Seal Tubes and slide each one down over the Insulated Contact Sleeves until one end lines up with the alignment mark on the 3/8 SST Tubing. See Figure 3C.

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Figure 3C Cable Splice

hand-tight. See Figure 3D. 3.1.2.11 On each splice, install each 1/2 NPT Parker Fitting into each end of the Seal Tube BIW Connector Systems, LLC NOTE: To prevent movement of seal tube, mark tubing Page 12 of 16

Installation Instructions for TRI 550 3-Way Packer F/T System again at end of each fitting. See Figure 3D. 3.1.2.12 While holding one fitting at one end of the Seal Tube, tighten the fitting at the opposite end of the Seal Tube one-half turn using a wrench. Repeat for each fitting on each end of Seal Tube. Ends of each fitting should still be within new alignment markings. See Figure 3D.

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Figure 3D Cable Splice

3.1.2.13 Slide the Ferrule and Ferrule Seals into place and install the Nuts fingertight. Hold the NPT Fitting Body steady with a backup wrench and tighten the nut 1-1/4 turns. Repeat this step for each fitting. See Figure 3E.

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Installation Instructions for TRI 550 3-Way Packer F/T System

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Figure 3E Cable Splice

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Installation Instructions for TRI 550 3-Way Packer F/T System

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Figure 4 Trident 550 3-Way Packer Feedthru System Shown Installed

3.3 WORKOVER INSTRUCTIONS: 3.3.1 Used equipment is defined as any re-use of equipment after the first installation. The re-use of electrical power feedthru equipment shall be the responsibility of the Operating Company and is not covered by the BIW warranty. 3.3.2 Disassemble the system in the reverse order of the assembly instructions. 3.3.3 Unband the 3-Way Packer feedthru System. Cut the power cable allowing enough cable to do a field splice at each end. 3.3.4 Cut each splice tube at the tube end. Disassemble the re-useable fitting at the BIW Connector Systems, LLC Page 15 of 16

Installation Instructions for TRI 550 3-Way Packer F/T System top of the packer and remove. Clean and prepare system for re-use. 3.3.5 Reassemble per instruction in this manual as applicable.

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