Safety Valve (IBOP) Service Manual
®
™
DRILLING SYSTEMS Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
Contents
GENERAL DESCRIPTION.............................................................................. 1 PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5 Introduction .................................................................................................. 5 Principle Features ................................................................................... 5 Remote IBOP Actuator Improvements ........................................................ 7 Internal Valve Mechanism Improvements.................................................... 8 INSTALLATION ............................................................................................ 9 OPERATION .............................................................................................. 16 Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17 LUBRICATION ........................................................................................... 18 INSPECTION ............................................................................................ 21 Magnetic Particle Inspection ...................................................................... 21 Safety Valve Inspection Procedures .......................................................... 21 Visual Inspection ................................................................................... 22 ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23 MAINTENANCE ......................................................................................... 25 Seal Replacement ..................................................................................... 25 Shop Assembly and Disassembly ............................................................. 27 Disassembly.......................................................................................... 28 Assembly .............................................................................................. 32 IBOP Valve Testing in the Shop ............................................................ 39 APPENDIX ................................................................................................ 40
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Feb. 2, 1994
Varco/BJ Safety Valves (IBOPs) GENERAL DESCRIPTION The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi working pressure. If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left in the string if required. The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System (Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated at any height in the derrick from the driller’s console. The upper IBOP can also be operated manually using a 7/8" hex wrench. There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing for purging any debris that may get in the wave spring area.
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Feb. 2, 1994
Link Tilt
Rotating Head (Ref.)
Link Adapter
Torque Arrestor
Link Adapter Support Plate
Splined Upper Safety Valve
Safety Valve Actuator
350 Ton 108" Links (Ref.)
Torque Wrench
Plain Lower Safety Valve
Saver Sub
350 Ton Center-Latch Drill Pipe Elevator (Ref.)
Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)
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Feb. 2, 1994
Link Tilt
Rotating Head (Ref.)
Link Adapter
Torque Arrestor
Link Adapter Support Plate
Splined Upper Safety Valve
V a r c o
Safety Valve Actuator
350 Ton 108" Links (Ref.)
Torque Wrench
Plain Lower Safety Valve
Saver Sub
350 Ton Center-Latch Drill Pipe Elevator (Ref.)
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d) 3
Feb. 2, 1994
Thread Protector Body Retaining Ring
Upper Seat Plug Back-up Rings OPE
CL SD
Back-up Rings
N
O-Ring
O-Ring Ball Sleeve Seal Ring
Stabilizer Ring
Crank Grease/ Mud Seal Seat
Wave Spring Back-up Ring
O-Ring
Figure 3. Typical Upper Safety Valve (IBOP)
4
Thread Protector
Feb. 2, 1994
PH-60 IBOP/Actuator Upgrade Kit Introduction Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existing PH-60 pipe handler will dramatically improve the reliability of the remote-operated system, both as a primary safety valve and as a mud saver while drilling ahead. Maintenance and operating costs will be greatly reduced, allowing a minimum planned maintenance interval of six months for the upper IBOP.
PRINCIPLE FEATURES ❏ The upper IBOP valves (2 ea.) are equipped with: • PH-85 style dual-path operating systems • New low-stress inside body contours • Completely redesigned long-life internals ❏ The new actuator shell is solid steel and bronze lined—eliminating bolted-on external guides. ❏ The new cylinders operating the upper IBOP are 45% larger for positive closure and they eliminate the need for periodic adjustment. ❏ The dual external crank assemblies share the operating loads. Each is reinforced, with improved sealing and retention. ❏ The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, greasepacked, and completely isolated from mud caking and corrosion to ensure full bore opening.
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ACTUATOR CYLINDER MOUNTING BRACKET REQUIRES NO ADJUSTMENT LARGE BORE, LONG STROKE IBOP ACTUATOR CYLINDERS (2) SOLID, ONE-PIECE, JOURNAL-GUIDED IBOP ACTUATOR SHELL REINFORCED DUAL EXTERNAL CRANKS AND HOUSINGS WITH IMPROVED BALL ROTATION STOPS IMPROVED DESIGN DUAL-CRANK UPPER IBOP VALVE
Aug. 9, 1993. A.N.
Figure 4. PH-60 Upgrade Kit
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Remote IBOP Actuator Improvements (Refer to Drawing 99261 in the Appendix) 1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45% larger piston area ensures positive, complete ball rotation under the most arduous conditions. A 60% increase in available cylinder stroke eliminates the need for sensitive position adjustments, both at initial rig-up as well as over the life of the system. 2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the current multi-piece actuator shell assembly, eliminating the separately attached (and vulnerable) guide roller assemblies. The bronze-lined internal diameter of the new actuator shell rides directly on the IBOP outer diameter. The new design is very robust, requires no adjustments, and is able to withstand punishing environments without damage. 3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. This change reduces the operating and environmental forces on the internal and external components by 50%. It also provides a balanced reaction force to the actuating levers. This force balance allows elimination of the bolt-on guide roller assemblies. Each of the two external crank housings is anchored to the IBOP body with 1/2" screws instead of the 3/8" screws used in the previous design. The crank housings are also secured to react the ball stop torque using a close-tolerance fit between the base of the housing and the machined recess in the IBOP valve body. When required, jacking screws make removing the housings easier.
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Internal Valve Mechanism Improvements 1. Internal stress concentrations at the valve’s operating crank bores are eliminated. They are replaced with a smooth bore through the ball and seat region. This significantly lowers the maximum stress in the valve body and effectively eliminates the possibility of leaks caused by cracking at the crank bores under corrosive mud conditions. 2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ball rotation stop in the previous design. The crank was easily replaced, but the body was not repairable after stop shoulder wear. The wear-induced loss of ball stop accuracy over extended use could eventually allow the ball to over-travel, leading to washouts. In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internal cranks (2) and external crank housings (2) need replacement should they ever become worn. The external crank housings in the new design serve as the ball rotation stops. Each external crank housing has two struts which contact the internal crank to stop the ball precisely at the open or closed position. The torque required to stop the ball is then shared by four surfaces rather than the previous design’s single surface. The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricated regions beneath the external cranks. This eliminates the presence of caked drilling fluid around the stop mechanism and is more reliable. 3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler, the PH-85. This effectively cuts the operating forces in half on the critical ball actuating and locating components, decreasing wear and eliminating mechanical failure.
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INSTALLATION The following installation procedure assumes that all other rig components are already installed. 1. Use slips to install a joint of drill pipe into the rotary table. 2. Install the saver sub hand tight onto the drill pipe. 3. Install the lower IBOP hand tight onto the saver sub. 4. Install the upper IBOP hand tight onto the lower IBOP. 5. Screw the stem/main shaft and upper IBOP together.
CAUTION The same care should be taken with these valves as would be any other threaded valve. Be sure to use a thread compound with 60% lead by weight or Kopper Kote. Varco does not recommend using a zinc thread compound. If making up new threads for the first time, use the following procedure: a. Torque up to the recommended torque value (Table 1). b. Back off the connection and inspect the threads and face. c. Torque up to the recommended torque value (Table 1).
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Table 1. Make-Up Torque Values Components
I.D.
Connection
O.D.
Torque (ft-lb) (min.) (max.)
Mainshaft to Upper IBOP Safety Valve*
3"
6-5/8 API Reg.
7-3/4
60,000
70,000
Upper IBOP Safety Valve to Lower IBOP Valve
3"
6-5/8 API Reg.
7-3/4
50,000
70,000
Lower IBOP Valve to Saver Sub
3"
6-5/8 API Reg.
7-3/8
46,000
64,000
Crossover Sub to Lower IBOP Safety Valve
3"
6-5/8 API Reg.
7-3/8
46,000
60,000
Mainshaft to Upper IBOP Safety Valve**
3"
7-5/8 API Reg.
9
83,000
91,000
Upper IBOP Safety Valve to Lower IBOP
3"
7-5/8 API Reg.
9
75,000
91,000
Lower IBOP Valve to Saver Sub
3"
7-5/8 API Reg.
8-5/8
66,000
85,000
Crossover Sub to Lower IBOP Valve
3"
7-5/8 API Reg.
9
75,000
91,000
* 500 Ton ** 650 Ton 6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows (Figures 5 & 6): a. b. c. d. e. f.
Carefully grind off any raised tong marks on the O.D. of the safety valves. Open the valve exactly halfway (45 degree rotation of the actuator). Orient the levers on the crank assemblies horizontally as shown. Slide the shell up onto the valve with the actuator arm groove on the bottom. Hold the shell in position relative to the valve operating sockets. Using the bolts provided, install the two crank assemblies, sliding the safety tabs through and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws and locktite on the bolt threads to secure the assemblies. g. Manually operate the actuator to ensure free movement though a full 90° of crank travel.
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Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8): a. Carefully grind off any raised tong marks on O.D. of the safety valves. b. Open the valve exactly halfway (45 degree rotation of actuator). c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire groove on side of crank body is to the right and the safety tab is on the left). d. Slide the shell up onto the valve with the roller groove at the bottom. e. Hold the shell in position relative to the valve operating socket. f. Using the two bolts provided, install the crank assembly, sliding the safety tab through and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire the bolt heads, routing lock wire around the right side of the crank body through the safety wire groove. g. Install the two roller assemblies nearest the crank slot, and then using shims provided, install the third roller assembly, maintaining .005" to .010" clearance between the third roller assembly and the safety valve body with the shell vertically centered on the valve. h. Manually operate the actuator to ensure free movement through full 90° of crank travel.
NOTE When the actuator is in the lowest position, the valve should be open. 7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual for the installation and adjustment procedures). 8. Use the torque wrench to make up the saver sub to the lower IBOP. 9. Use the torque wrench to make up the lower IBOP to the upper IBOP.
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Crank Assembly Retaining Screw And Lock Tabs Crank Assembly Slot
Actuator Shell Crank Arm* Actuator Arm Groove
Lock Tabs Crank Assembly Safety Wire Groove
Upper IBOP Valve
7/8" Allen Crank
*Note Orientation
Cam Follower
Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d
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Open Position
Closed Position
Actuator Shell Crank Arm Grease Port Actuator Arm Groove
Upper IBOP Valve
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
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Roller Assembly (3)
Crank Assembly Retaining Screw
Crank Assembly
Slot Roller Assembly (3)
Actuator Shell Crank* Roller Assembly (3)
Actuator Arm Groove Safety Valve
Safety Wire Groove
Shim
Crank Assembly
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the PH-60
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Closed Position
Open Position
Actuator Shell Crank Arm Grease Port Actuator Arm Groove
Upper IBOP Valve
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
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OPERATION Operating the switch on the driller’s console to the IBOP Close position causes the two (2) actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This upward movement causes the crank assemblies to rotate 90°, closing the IBOP ball valve. Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.
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Erosion Prevention of the Ball and Seats in the Lower IBOP Valve To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully closed at least one time each shift change. The valves can partially open without being externally actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends removing the lip seal from the spring loaded (floating) seat to correct this problem. Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9): 1. Breakout and remove the lower IBOP. 2. Disassemble the valve and remove the lip seal from the floating (pin end) seat. 3. Replace the O-rings and back-up rings on the fixed and floating seats. 4. Re-assemble the valves. 5. Reinstall and torque the lower valve.
Figure 9. Lower IBOP Seal Removal
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LUBRICATION Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank in the recessed counter bore. There are three reasons for lubricating the valve: 1. To verify the integrity of the grease seal. 2. To lubricate the floating seat. 3. To flush mud and debris from the spring cavity. Use the following procedure to lubricate the IBOP valves (Figures 10 & 11): 1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of pressure. A release of pressure indicates the mud/grease seal is not functioning properly — the valve should be serviced. 2. Install a suitable grease fitting. 3. Open the valve. 4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an equivalent amount from an air powered grease injector. The grease pressure should not exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into the clearance between the floating seat and the valve body. 5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug, tightening securely.
CAUTION The plug must be replaced in the valve prior to use to maintain pressure integrity.
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WAVE SPRING MUD/ GREASE SEAL SEAL RING STABILIZER FIXED SEAT
19
Figure 10. Lubricating a Typical Upper IBOP
C L
BALL C L
FLOATING SEAT
PRESSURE SEALS SPRING CAVITY
VALVE BODY
GREASE PORT
Feb. 2, 1994
PRESSURE PLUG
WAVE SPRING
C L
FLOATING SEAT
PRESSURE SEALS SPRING CAVITY
Feb. 2, 1994
VALVE BODY PRESSURE PLUG GREASE PORT
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C L
BALL Figure 11. Lubricating a Typical Lower IBOP
FIXED SEAT
Feb. 2, 1994
INSPECTION Magnetic Particle Inspection After approximately three to six months (depending on the severity of operating conditions) Varco recommends performing a Magnetic Particle Inspection of all load bearing components – including IBOPs – over their entire surface and internal bores to reveal any fatigue or crack indications (Figure 11). Any indications found are a potential cause for the replacement of the suspect component. Details on Magnetic Particle Inspection procedures are in the following publications: I.A.D.C. ASTM A-275 ASTM E-709
Drilling Manual, 9th Edition Std. Method for Magnetic Particle Inspection of Steel Forgings Std. Recommended Practice for Magnetic Particle
Safety Valve Inspection Procedures Upper and lower safety valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crack may begin at the root of the pit. Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PH levels below 9.0. Inspect safety valves operated under such exposures for internal, transverse cracks every three to six months, depending on the severity of the exposure. Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can be hidden under corrosion products. Use the magnetic particle inspection procedure. Concentrate attention on (Figure 12): ❏ ❏ ❏ ❏
The area inside the operating crank window The fillet radii of internal grooves and shoulders The last engaged threads of box connections The IBOP actuator shell
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Feb. 2, 1994
Recommended Inspection Areas
Figure 12. IBOP Inspection Points
NOTE Repairing valve body cracks is not practical because of the close tolerances of internal components and the metallurgy of the valve material. Remove from service and scrap any safety valve body showing positive crack indications.
VISUAL INSPECTION Whenever connections are broken, clean and check them for the following: 1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other abnormal conditions. Check shoulders for any marks, gouges or other damage. 2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper safety valve for wear. NOTE Remove any surface imperfections on upper (splined) safety valves after the valve is made up into string to prevent remote actuator malfunctions, causing the valve to wash out.
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ADJUSTING THE SAFETY VALVE ACTUATOR Proper safety valve actuator installation and adjustment is essential to assure proper action of the mechanism and to minimize mechanical component wear. The actuator shell installs over the upper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend the safety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13) adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuator shell as follows: 1. After removing the crank assemblies, make sure the actuator shell easily moves up and down over the upper IBOP. NOTE There is only one crank on upper IBOPs for the PH-60 pipehandler. There are also three roller assemblies. 2. With the IBOP valve at mid-stroke, reinstall the crank assemblies. 3. Torque the 3/8" retaining bolts to 30-35 ft/lbs, lock tab. 4. Using a hex wrench, manually shift the IBOP valve through the crank assemblies and check for signs of binding. Make sure the shell travels freely throughout its full range of travel. If binding exists, troubleshoot to eliminate any problems before returning to service. 5. Actuate the control switch on the driller's console to the open the safety valve. The cylinders should retract and the actuator ring should be down. 6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between the cylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distance is not 1 inch, adjust the cylinder rod locknuts until it measures exactly 1 inch. 7. Actuate the valve to make sure it opens and closes fully.
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Feb. 2, 1994
DriveStem (Ref.) Link Adapter
Cylinder Adjustment Bolts (4)
Landing Collar Eye Bolts (2)
Upper IBOP Valve Actuator Shell
Upper IBOP Valve Actuator Air Cylinders (2)
Crank Assy(Shown with Valve OPEN. Note Crank Assy Position CLOSE OPEN
*1 Inch
Actuator Arm
Cylinder in OPEN Position
Rod End
Cylinder Gland
Upper IBOP Torque Tube
*IMPORTANT
Lower IBOP
Saver Sub
Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d & Single Crank PH-60
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MAINTENANCE Seal Replacement Replace seals at six month intervals under normal operating conditions (Figure 14). If there are signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or high salt content drilling fluids, shorter intervals may be necessary.
13
2
17
6
1
19
10
18
5
14
15 20
7
16 8
2X 4 3 9 12 11 12
7/8" Hex
Note: Dual Crank Remote IBOP Shown Single Crank Remote and Lower IBOP have similar construction.
Figure 14. IBOP Safety Valve Illustrated Parts List
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Parts List ITEM
QYT. / KIT
DESCRIPTION
PART NUMBERS
1
BALL, DUAL CRANK (SET)
90939-5
1
1
-
2
RETAINING RING
89141-1
1
1
-
3
O'RING
90441-9
1
1
1
4
BACK-UP RING
90441-10
1
1
1
5
LOWER SEAT (SET)
90939-5
1
1
-
1
6
UPPER SEAT (SET)
90939-5
1
1
-
1
7
POLYSEAL
96439
1
1
1
8
BACK-UP RING
89141-13
2
2
2
9
CROWN SEAL
89141-8
1
2
2
10
SLEEVE
90441-7 (93806-12 for Dual Crank)
1
2
-
11
O'RING
89141-11
1
2
2
12
BACKING RING
89141-12
2
4
4
13
CRANK, RIGHT HAND
89141-7 (93806-10 for Dual Crank)
1
1
-
14
WAVE SPRING
89141-9
1
1
-
15
BODY
-
-
-
16
O'RING
1
1
1
17
NYLON PLUG
2
2
2
18
CRANK, LEFT HAND
-
1
-
19
PLUG
1
1
-
20
SEAL RING STABILIZER
1
1
1
89141-3
93806-11
96438
REPAIR KIT - SINGLE CRANK Refer to the Appendix for Part Numbers REPAIR KIT - DUAL CRANK Refer to the Appendix for Part Numbers REPAIR KIT - SOFT SEAL ONLY (For either Single or Dual Crank) Refer to the Appendix for Part Numbers BALL/SEAT SET Refer to the Appendix for Part Numbers
Figure 14. IBOP Illustrated Parts List (Cont.) 26
1
2
Feb. 2, 1994
Shop Assembly and Disassembly The following tools are required (Figure 15): Crank wrench Varco Part No. 77408 Seat puller Varco Part No. 79489-14 Nut wrench (for internal nut) Varco Part No. 89141-18 Bushing installation tool Open end or adjustable wrenches Two large flat screwdrivers or light pry bars 1/4" and 3/4" allen wrenches Pipe vise or suitable holding device to hold valve secure Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner or mild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve, but also serves to loosen internal components. Follow these general rules while working on the valve: 1. Take proper precautions while working with the components of the valve to make sure precision matched surfaces and seal contact surfaces are not damaged. 2. After removing each part, thoroughly clean the exposed area to prevent damage to other parts as they are removed.
7.5"
3"
22" Load Bar
15.25"
3" Maximum Nut Wrench for DSV Models Varco Part No. 89141-18
Seat Puller For All Models Varco Part No. 79489-14
7/8" Hex Wrench For All Models Varco Part No. 89141-18
Figure 15. IBOP Tools
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Feb. 2, 1994
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows: 1. Place the valve in a vise or clamp to hold the valve securely (Figure 16).
Figure 16 2. Engage the seat puller in the inside groove of the lower seat (Figure 17). 3. Using the load bar across the face of the connection, tighten the nut against the load bar to compress the wave spring approximately 0.030" (Figure 17).
Figure 17
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Feb. 2, 1994
4. At the other end of the valve, insert the upper seat wrench, P/N 89141-18, into the upper seat engaging the wrench lugs into the mating slots (Figure 18). 5. Using the crank wrench, P/N 77408, as a lever in the hole provided in the upper seat wrench, rotate the upper seat clockwise until it stops (Figure 18).
Figure 18
6. Remove the wrench. 7. Remove the retainer ring from the groove in the valve body by using a screwdriver to pry one end of the retainer ring out of the groove. The ring can then be removed by hand (Figure 19).
Figure 19 8. Re-insert the upper seat wrench into the upper seat. 9. Rotate the upper seat counterclockwise until it disengages from the body threads. 10. Remove the wrench and the upper seat (Figure 20).
Figure 20 29
Feb. 2, 1994
11. Remove the ball valve (Figure 21).
Figure 21 12. From the outside of the valve, push the crank into the valve body and remove them (Figure 22).
Figure 22 13. Remove the pulling tool from the lower seat. 14. Insert the pulling tool from the opposite end of the valve and engage the groove on the I.D. of the lower seat (Figure 23).
Figure 23 30
Feb. 2, 1994
15. Using the load bar across the face of the connection, tighten the nut against it to remove the lower seat and the wave spring (Figures 24 and 25). 16. Remove and discard the seals from all IBOP components. 17. Thoroughly clean and inspect each item.
Figure 24
Figure 25
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Feb. 2, 1994
ASSEMBLY
1. Inspect the lower seat. Look carefully for signs of corrosion, pitting and gaulling – especially in the sealing areas (Figure 26). 2. Make sure the wave spring is not broken or damaged (Figure 26). 3. Inspect the steel stabilizer ring, making sure it is not worn, pitted or damaged (Figure 26).
Figure 26
4. Replace all O-rings, backup rings and seals (Figure 26). 5. Install the steel stabilizer and seal on the lower seat (floating seat), by placing the steel stabilizer in the groove of the U-cup seal and, starting on one side of the seat, work the stabilizer and seal around the seat using a screw driver (Figure 27). NOTE The steel stabilizer ring should be inside the seal when properly installed.
Figure 27
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Feb. 2, 1994
6. Install the wave spring on the lower seat (Figure 28).
Figure 28 7. Inspect the ball valve for corrosion, pitting and gaulling (Figure 29).
Figure 29
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Feb. 2, 1994
8. Install new nylon plugs on the upper stationary seat (Figure 30).
Figure 30 9. Make sure the snap ring is not broken or damaged (Figure 31).
Figure 31
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Feb. 2, 1994
10. Make sure the crank assembly notches are not worn and there is no pitting on the outside (Figure 32). Check for a sliding fit with the slots in the ball. 11. Install the seals on the crank assembly. 12. Inspect the crank sleeve for wear and washouts. Replace as necessary.
Figure 32 13. Thoroughly lubricate the valve bore with a thin film of multipurpose grease of NLGI Grade 2. 14. Insert the pulling tool into the O-ring end of the lower seat engaging the I.D. groove (Figure 33). 15. Apply a generous coat of grease to the O.D. of the lower seat. 16. Slide the wave spring down the threaded rod of the pulling tool until it seats on the spring surface of the lower seat (Figure 33).
Figure 33
17. Insert the threaded rod of the pulling tool first into the box opposite the splined end of the upper valve, pulling the lower seat into place in the valve body (Figure 33). 35
Feb. 2, 1994
18. Using the load bar against the face of the connection, tighten the nut to firmly seat the lower seat in the valve body (Figure 34).
Figure 34 19. Apply a generous coat of grease to the outside of the sleeve and crank. 20. From the inside of the valve body, install the crank sleeve in the body. Insert the crank into the sleeve (Figure 35).
Figure 35 21. Make sure the crank moves 90° to the Open and Closed position (the flat sides of the crank are parallel to the valve body). 22. Position the crank in the Closed position. 23. Apply a generous coat of grease to the entire outside of the ball, but make sure the holes are clear (Figure 36).
Figure 36
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Feb. 2, 1994
24. Slide the ball onto the crank inside the valve body. The keyway must be in the Closed position, or parallel to the key of the crank. 25. Apply a generous coat of grease to the outside threads and seal of the upper seat. 26. Insert the upper seat into the valve body, engaging the threads (Figure 37).
Figure 37
27. Insert the upper seat wrench into the mating slots of the upper seat. 28. Rotate the wrench clockwise until the upper seat sets firmly against the ball. 29. Remove the upper seat wrench and install the retainer ring firmly into the groove of the body (Figure 38).
Figure 38
30. Insert the upper seat wrench into the mating slots of the upper seat. 31. Rotate the upper seat counterclockwise until the seat is firmly against the retainer ring. 32. Remove the puller and use an allen wrench to make sure the valve functions properly. 33. Leave the valve in the Open position. 34. Remove the wrench.
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Feb. 2, 1994
35. Grease the valve through the pressure plug until grease extrudes from inside the valve (Figure 39). NOTE The grease pressure should not exceed 300 psi. Excess pressure can cause the mud/grease seal to extrude.
Figure 39 36. Install the 1/4" N.P.T. plug into the lubrication port of the body. Torque this plug to approximately 15 to 20 ft.-lbs. Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times to assure smooth operation. Test the valve according to the procedure in the following section.
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IBOP VALVE TESTING IN THE SHOP Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic test pump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use the following procedure to test IBOPs: 1. Rotate the valve crank to the Open position. 2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plug in the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valve to the plug in the opposite end. 3. Place the valve in the vertical position (splined end down for upper IBOP, box end down for lower IBOP) with the ball and the bleed valve in the Open position. 4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical, but using water increases the liklihood of corrosion in the valve body—especially when the valve is not in use for a prolonged period of time. NOTE Open and close the valve five times to release trapped air and overflow through the bleed valve for approximately 30 seconds to assure complete filling of the valve cavity. 5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closed position. 6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test. 7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatic test pump and the bleed valve. Reverse the orientation of the valve (splined end up for upper IBOP, box end up for lower IBOP). 8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP (pin end of the lower IBOP). 9. Fill the valve cavity with water while rotating the ball full open to closed five times to release trapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold working pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over the duration of the test. 10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve to insure smooth operation. 11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. is acceptable. 12. Drain the valve cavity and remove the test plugs. Open and close the ball several times to release trapped fluid. When testing with water, coat the valve internals with a preservative to prevent oxidation and install thread protectors. 39
Feb. 2, 1994
APPENDIX IBOP Part Numbers IBOP PART NO.
TYPE OF SERVICE
DESCRIPTION
REPAIR KIT PART NO.
SOFT SEALS BALL/SEAT PART NO. PART NO.
94769-500 94769-502 94769-501
STD H2S NAM
Upper Valve-PH60 6 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design
90939-2 89453-SP 90939-2
90939-1 90939-1
90939-5 89453-15 90939-5
94770-500 94770-502 94770-501
STD H2S NAM
Upper Valve-PH60 7 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design
90939-2 89453-SP 90939-2
90939-1 90939-1
90939-5 89453-15 90939-5
94099-500 94099-502 94099-501
STD H2S NAM
Upper Valve - PH60 6 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design
90939-2 89453-SP 90939-2
90939-1 90939-1
90939-5 89453-15 90939-5
94100-500 94100-502 94100-501
STD H2S NAM
Upper Valve - PH60 7 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design
90939-2 89453-SP 90939-2
90939-1 90939-1
90939-5 89453-15 90939-5
90815 -
STD H2S NAM
Upper Valve - PH85 6 5/8 Box X 6 5/8 Box (Spl End) Land Collar Design
93806 -
93806-1 -
90939-5 -
90814 -
STD H2S NAM
Upper Valve - PH85 6 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design
93806 -
93806-1 -
90939-5 -
90813 -
STD H2S NAM
Upper Valve - PH85 7 5/8 Box X 6 5/8 Box (Spl End) Load Collar Design
93806 -
93806-1 -
90939-5 -
90812 -
STD H2S NAM
Upper Valve - PH85 7 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design
93806 -
93806-1 -
90939-5 -
94206-500 94206-501 94206-502
STD H2S NAM
Upper Valve - PH85 6 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design
93806 89453-SP 93806
93806-1 93806-1
90939-5 89453-15 90939-5
94205-500 94205-501 94205-502
STD H2S NAM
Upper Valve - PH85 6 5/8 Box X 7 5/8 Box (Spl End) Landing Collar Design
93806 89453-SP 93806
93806-1 93806-1
90939-5 89453-15 90939-5
94204-500 94204-501 94204-502
STD H2S NAM
Upper Valve - PH85 7 5/8 Box X 6 5/8 Box (Spl End) Landing Collar Design
93806 89453-SP 93806
93806-1 93806-1
90939-5 89453-15 90939-5
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Feb. 2, 1994
IBOP Part Numbers (Cont.) IBOP PART NO.
TYPE OF SERVICE
DESCRIPTION
REPAIR KIT PART NO.
SOFT SEALS BALL/SEAT PART NO. PART NO.
94203-500 94203-501 94203-502
STD H2S NAM
Upper Valve - PH85 7 5/8 Box X 7 5/8 Box (Spl End) Landing Collar Design
93806 89453-SP 93806
93806-1 93806-1
90939-5 89453-15 90939-5
91138 -
STD H2S NAM
Upper Valve - PH85 - Big Bore 7 5/8 Box X 7 5/8 Box (Spl End) Load Collar Design
95384 -
91137-SP -
91137-1 -
89451-501 89491-503 86434
STD H2S NAM
Lower Valve 6 5/8 Pin X 6 5/8 Box
90939-2 89453-SP
90939-1 -
90939-5 89453-15
89452-501 89492-502 -
STD H2S NAM
Lower Valve-Stepped 6 5/8 Pin X 6 5/8 Box
90939-2 89453-SP 90939-2
90939-1 90939-1
90939-5 89453-15 90939-5
90811 -
STD H2S NAM
Lower Valve 7 5/8 Pin X 7 5/8 Box
93807 -
93807-1 -
90939-5 -
91138 -
STD H2S NAM
Lower Valve - Big Bore 7 5/8 Pin X 7 5/8 Box
94385 -
91137-SP -
91137-1 -
105629 -
STD H2S NAM
Upper Valve - Type "E" 6 5/8 Pin X 6 5/8 Box For Ids Only
-
-
90939-5 -
103220 -
STD H2S NAM
Upper Valve - Type "E" 6 5/8 Pin X 6 5/8 Box For TDS and SDS
90939-2 -
90939-1 -
90939-5 -
98977-500 98977-502 98977-501
STD H2S NAM
Upper Valve, PH60 Dual Crank 6 5/8 Box X 6 5/8 Pin Landing Collar Design
99468-2 99469-SP 99468-2
99468-1 99468-1
65170014 98966 65170014
99461-500
STD H2S NAM
Upper Valve, PH60 Dual Crank 6 5/8 Box X 6 5/8 Pin Landing Collar Design
99468-2 99469-SP 99468-2
99468-1 99468-1
65170014 98966 65170014
41
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Identifying Varco Safety Valves 42
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43
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46
