varco ibop valves

Sa fe ty Va lveSa fe ty Va lve( I B O P )( I B O P )

Serv ice Manua lServ ice Manua l

DRILLING SYSTEMS

Feb. 2, 1994

Feb. 2, 1994

iFeb. 2, 1994

Contents

GENERAL DESCRIPTION.............................................................................. 1PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5

Introduction .................................................................................................. 5Principle Features ................................................................................... 5

Remote IBOP Actuator Improvements ........................................................ 7Internal Valve Mechanism Improvements.................................................... 8

INSTALLATION ............................................................................................ 9OPERATION.............................................................................................. 16

Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17LUBRICATION ........................................................................................... 18INSPECTION ............................................................................................ 21

Magnetic Particle Inspection...................................................................... 21Safety Valve Inspection Procedures .......................................................... 21

Visual Inspection ................................................................................... 22ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23MAINTENANCE ......................................................................................... 25

Seal Replacement ..................................................................................... 25Shop Assembly and Disassembly ............................................................. 27

Disassembly.......................................................................................... 28Assembly .............................................................................................. 32IBOP Valve Testing in the Shop ............................................................ 39

APPENDIX ................................................................................................ 40

ii

Feb. 2, 1994

1Feb. 2, 1994

Varco/BJSafety Valves

(IBOPs)

GENERAL DESCRIPTIONThe Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internalopenings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psiworking pressure.

If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lowerIBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and leftin 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 operatedat any height in the derrick from the drillers console. The upper IBOP can also be operatedmanually using a 7/8" hex wrench.

There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushingfor purging any debris that may get in the wave spring area.

2Feb. 2, 1994

LinkAdapter

RotatingHead (Ref.)

TorqueArrestor

LinkAdapterSupportPlate

Safety ValveActuator

Plain LowerSafety Valve

SaverSub

350 Ton108" Links(Ref.)

350 TonCenter-LatchDrill PipeElevator(Ref.)

SplinedUpperSafetyValve

LinkTilt

TorqueWrench

Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)

3Feb. 2, 1994

LinkAdapter

RotatingHead (Ref.)

TorqueArrestor

LinkAdapterSupportPlate

Safety ValveActuator

Plain LowerSafety Valve

SaverSub

350 Ton108" Links(Ref.)

350 TonCenter-LatchDrill PipeElevator(Ref.)

SplinedUpperSafetyValve

LinkTilt

TorqueWrench

Var co

Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)

4Feb. 2, 1994

CLSDOPE

N

Retaining Ring

Upper Seat

Back-up Rings

O-Ring

StabilizerRing

Ball

Back-upRings

O-Ring

Sleeve

Seal Ring

Crank

Seat

Grease/Mud Seal

Back-up Ring

O-Ring

WaveSpring

Body

ThreadProtector

Plug

ThreadProtector

Figure 3. Typical Upper Safety Valve (IBOP)

5Feb. 2, 1994

PH-60 IBOP/Actuator Upgrade Kit

Introduction

Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existingPH-60 pipe handler will dramatically improve the reliability of the remote-operated system, bothas a primary safety valve and as a mud saver while drilling ahead.

Maintenance and operating costs will be greatly reduced, allowing a minimum plannedmaintenance interval of six months for the upper IBOP.

PRINCIPLE FEATURES

o 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

o The new actuator shell is solid steel and bronze linedeliminating bolted-on external guides.

o The new cylinders operating the upper IBOP are 45% larger for positive closure and theyeliminate the need for periodic adjustment.

o The dual external crank assemblies share the operating loads. Each is reinforced, withimproved sealing and retention.

o The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, grease-packed, and completely isolated from mud caking and corrosion to ensure full bore opening.

6Feb. 2, 1994

ACTUATOR CYLINDERMOUNTING BRACKETREQUIRES NO ADJUSTMENT

LARGE BORE,LONG STROKE IBOPACTUATOR CYLINDERS (2)

REINFORCED DUALEXTERNAL CRANKS ANDHOUSINGS WITH IMPROVEDBALL ROTATION STOPS

SOLID, ONE-PIECE,JOURNAL-GUIDEDIBOP ACTUATOR SHELL

IMPROVED DESIGNDUAL-CRANKUPPER IBOP VALVE

Aug. 9, 1993. A.N.

Figure 4. PH-60 Upgrade Kit

7Feb. 2, 1994

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 positionadjustments, 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 currentmulti-piece actuator shell assembly, eliminating the separately attached (and vulnerable)guide roller assemblies. The bronze-lined internal diameter of the new actuator shell ridesdirectly 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. Thischange reduces the operating and environmental forces on the internal and external componentsby 50%. It also provides a balanced reaction force to the actuating levers. This force balanceallows elimination of the bolt-on guide roller assemblies.

Each of the two external crank housings is anchored to the IBOP body with 1/2" screwsinstead of the 3/8" screws used in the previous design. The crank housings are also securedto react the ball stop torque using a close-tolerance fit between the base of the housing andthe machined recess in the IBOP valve body. When required, jacking screws make removingthe housings easier.

8Feb. 2, 1994

Internal Valve Mechanism Improvements

1. Internal stress concentrations at the valves operating crank bores are eliminated. They arereplaced with a smooth bore through the ball and seat region. This significantly lowers themaximum stress in the valve body and effectively eliminates the possibility of leaks causedby 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 ballrotation stop in the previous design. The crank was easily replaced, but the body was notrepairable after stop shoulder wear. The wear-induced loss of ball stop accuracy overextended 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 internalcranks (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 externalcrank housing has two struts which contact the internal crank to stop the ball precisely at theopen or closed position. The torque required to stop the ball is then shared by four surfacesrather than the previous designs single surface.

The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricatedregions beneath the external cranks. This eliminates the presence of caked drilling fluidaround 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 andlocating components, decreasing wear and eliminating mechanical failure.

9Feb. 2, 1994

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.

CAUTIONThe same care should be taken with these valves as would be anyother threaded valve. Be sure to use a thread compound with 60%lead by weight or Kopper Kote. Varco does not recommend usinga zinc thread compound. If making up new threads for the firsttime, 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).

10

Feb. 2, 1994

Table 1. Make-Up Torque Values

Torque (ft-lb)Components I.D. Connection O.D. (min.) (max.)

Mainshaft to UpperIBOP Safety Valve*

3" 6-5/8 API Reg. 7-3/4 60,000 70,000

Upper IBOP SafetyValve to LowerIBOP Valve

3" 6-5/8 API Reg. 7-3/4 50,000 70,000

Lower IBOP Valveto Saver Sub

3" 6-5/8 API Reg. 7-3/8 46,000 64,000

Crossover Sub toLower IBOP SafetyValve

3" 6-5/8 API Reg. 7-3/8 46,000 60,000

Mainshaft to UpperIBOP SafetyValve**

3" 7-5/8 API Reg. 9 83,000 91,000

Upper IBOP SafetyValve to LowerIBOP

3" 7-5/8 API Reg. 9 75,000 91,000

Lower IBOP Valveto Saver Sub

3" 7-5/8 API Reg. 8-5/8 66,000 85,000

Crossover Sub toLower 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. Carefully grind off any raised tong marks on the O.D. of the safety valves.b. Open the valve exactly halfway (45 degree rotation of the actuator).c. Orient the levers on the crank assemblies horizontally as shown.d. Slide the shell up onto the valve with the actuator arm groove on the bottom.e. Hold the shell in position relative to the valve operating sockets.f. 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 screwsand 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.

11

Feb. 2, 1994

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 wirethe bolt heads, routing lock wire around the right side of the crank body through the safetywire 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 thirdroller 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.

NOTEWhen the actuator is in the lowest position, the valve should beopen.

7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manualfor 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.

12

Feb. 2, 1994

Safety WireGroove

7/8" Allen Crank

Cam Follower

CrankAssembly

Lock Tabs

Crank AssemblyRetaining ScrewAnd Lock Tabs

Slot

Crank Arm*

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

CrankAssembly

*Note Orientation

Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d

13

Feb. 2, 1994

Crank Arm

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

OpenPosition

ClosedPosition

Grease Port

Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions

14

Feb. 2, 1994

RollerAssembly (3)

RollerAssembly (3)

CrankAssembly

Safety WireGroove Shim

ActuatorArmGroove

Crank*

ActuatorShell

Slot

Crank AssemblyRetaining Screw

CrankAssembly

RollerAssembly(3)

SafetyValve

*Note Orientation

Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for thePH-60

15

Feb. 2, 1994

Crank Arm

Actuator ArmGroove

ActuatorShell

Upper IBOPValve

OpenPosition

ClosedPosition

Grease Port

Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions

16

Feb. 2, 1994

OPERATIONOperating the switch on the drillers 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. Thisupward 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.

17

Feb. 2, 1994

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 fullyclosed at least one time each shift change. The valves can partially open without being externallyactuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball andseats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommendsremoving 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

18

Feb. 2, 1994

LUBRICATIONLubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crankin 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 ofpressure. 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 anequivalent amount from an air powered grease injector. The grease pressure should notexceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude intothe 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.

CAUTIONThe plug must be replaced in the valve prior to use to maintainpressure integrity.

19

Feb. 2, 1994

SEAL RING STABILIZER

MUD/ GREASE SEAL

BALLFIXED SEAT

WAVE SPRING

PRESSURE

SPRING

VALVE

SEALS

CAVITY

BODY

FLOATINGSEAT

PRESSURE PLUG

GREASE PORT

CLLC

Figure 10. Lubricating a Typical Upper IBOP

20

Feb.

2, 1

994

BALLFIXED SEAT

WAVE SPRING

PRESSURE

SPRING

VALVE

SEALS

CAVITY

BODY

FLOATINGSEAT

PRESSURE PLUG

GREASE PORT

CLLC

Figu

re 1

1. L

ubric

atin

g a

Typi

cal L

ower

IBOP

21

Feb. 2, 1994

INSPECTION

Magnetic Particle InspectionAfter 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 crackindications (Figure 11). Any indications found are a potential cause for the replacement of thesuspect component.

Details on Magnetic Particle Inspection procedures are in the following publications:

I.A.D.C. Drilling Manual, 9th EditionASTM A-275 Std. Method for Magnetic Particle Inspection of Steel ForgingsASTM E-709 Std. Recommended Practice for Magnetic Particle

Safety Valve Inspection ProceduresUpper and lower safety valves, because of their internal grooves and shoulders, are particularlysusceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers forbending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crackmay begin at the root of the pit.

Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PHlevels below 9.0. Inspect safety valves operated under such exposures for internal, transversecracks every three to six months, depending on the severity of the exposure.

Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can behidden under corrosion products. Use the magnetic particle inspection procedure.

Concentrate attention on (Figure 12):o The area inside the operating crank windowo The fillet radii of internal grooves and shoulderso The last engaged threads of box connectionso The IBOP actuator shell

22

Feb. 2, 1994

RecommendedInspection Areas

Figure 12. IBOP Inspection Points

NOTERepairing valve body cracks is not practical because of the closetolerances of internal components and the metallurgy of the valvematerial. Remove from service and scrap any safety valve bodyshowing 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 otherabnormal conditions. Check shoulders for any marks, gouges or other damage.

2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on uppersafety valve for wear.

NOTERemove any surface imperfections on upper (splined) safetyvalves after the valve is made up into string to prevent remoteactuator malfunctions, causing the valve to wash out.

23

Feb. 2, 1994

ADJUSTING THE SAFETY VALVE ACTUATOR

Proper safety valve actuator installation and adjustment is essential to assure proper action of themechanism and to minimize mechanical component wear. The actuator shell installs over theupper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend thesafety 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 actuatorshell as follows:

1. After removing the crank assemblies, make sure the actuator shell easily moves up and downover the upper IBOP.

NOTEThere 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 checkfor signs of binding. Make sure the shell travels freely throughout its full range of travel. Ifbinding 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 cylindersshould 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 thecylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distanceis 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.

24

Feb. 2, 1994

Upper IBOP Valve Actuator Shell

Crank Assy(Shown with Valve OPEN. Note Crank Assy Position

Upper IBOP ValveActuator Air Cylinders (2)

Upper IBOP

ActuatorArm

Torque Tube

Lower IBOP

Saver Sub

DriveStem(Ref.)

Landing Collar

LinkAdapter

*1 Inch

RodEnd

CylinderGlandCylinder

in OPENPosition

OPEN

CLOSE

*IMPORTANT

Eye Bolts (2)

Cylinder Adjustment Bolts (4)

Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d &Single Crank PH-60

25

Feb. 2, 1994

MAINTENANCE

Seal Replacement

Replace seals at six month intervals under normal operating conditions (Figure 14). If there aresigns of wear, replace the ball and seat every six months. If the valve is used with oil-based orhigh salt content drilling fluids, shorter intervals may be necessary.

2 14517 6 1 10 18

13

12

12

9

3

4

208

7 16

19

15

2X

117/8" Hex

Note: Dual Crank Remote IBOP ShownSingle Crank Remote and Lower IBOPhave similar construction.

Figure 14. IBOP Safety Valve Illustrated Parts List

26

Feb. 2, 1994

BALL/SEAT SET

SEAL RING STABILIZER

1

17

16

20

19

18

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

PLUG

CRANK, LEFT HAND

NYLON PLUG

O'RING

BODY

WAVE SPRING

CRANK, RIGHT HAND

BACKING RING

O'RING

SLEEVE

CROWN SEAL

BACK-UP RING

POLYSEAL

UPPER SEAT (SET)LOWER SEAT (SET)BACK-UP RING

O'RING

RETAINING RING

BALL, DUAL CRANK (SET)

ITEM QYT. / KITDESCRIPTION

Parts List

1 -

1 1 -

1 1 1

1 1 1

1 1 -

1 1 -

1 1 1

2 2 2

1 2 2

1 2 -

1 2 2

2 4 4

1 1 -

1 1 -

- - -

1 1 1

2 2 2

- 1 -

1 1 -

1 1 1

REPAIR KIT - SINGLE CRANK

REPAIR KIT - DUAL CRANK

REPAIR KIT - SOFT SEAL ONLY

Refer to the Appendix for Part Numbers




(For either Single or Dual Crank)

1

1

1

2

PART NUMBERS

90939-5

89141-1

90441-9

90441-10

90939-5

90939-5

96439

89141-13

89141-8

90441-7 (93806-12 for Dual Crank)89141-11

89141-12

89141-7 (93806-10 for Dual Crank)89141-9

89141-3

93806-11

96438

Figure 14. IBOP Illustrated Parts List (Cont.)

27

Feb. 2, 1994

Shop Assembly and Disassembly

The following tools are required (Figure 15):Crank wrench Varco Part No. 77408Seat puller Varco Part No. 79489-14Nut wrench (for internal nut) Varco Part No. 89141-18Bushing installation toolOpen end or adjustable wrenchesTwo large flat screwdrivers or light pry bars1/4" and 3/4" allen wrenchesPipe vise or suitable holding device to hold valve secure

Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner ormild 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 thevalve:

1. Take proper precautions while working with the components of the valve to make sureprecision matched surfaces and seal contact surfaces are not damaged.

2. After removing each part, thoroughly clean the exposed area to prevent damage to other partsas they are removed.

7.5"

Load Bar

3"Maximum

22"

Seat Puller For All ModelsVarco Part No. 79489-14

Nut Wrench for DSV ModelsVarco Part No. 89141-18

7/8" Hex Wrench For All ModelsVarco Part No. 89141-18

15.25"

3"

Figure 15. IBOP Tools

28

Feb. 2, 1994

1. Place the valve in a vise orclamp to hold the valvesecurely (Figure 16).

Figure 16

2. Engage the seat puller inthe inside groove of thelower seat (Figure 17).

3. Using the load bar acrossthe face of the connection,tighten the nut against theload bar to compress thewave spring approximately0.030" (Figure 17).

Figure 17

DISASSEMBLY

Starting with the valve in the closed position, disassemble the IBOP as follows:

29

Feb. 2, 1994

4. At the other end of thevalve, insert the upper seatwrench, P/N 89141-18, intothe upper seat engaging thewrench lugs into the matingslots (Figure 18).

5. Using the crank wrench,P/N 77408, as a lever in thehole provided in the upperseat wrench, rotate theupper seat clockwise untilit stops (Figure 18).

Figure 18

6. Remove the wrench.

7. Remove the retainer ringfrom the groove in the valvebody by using a screwdriverto pry one end of the retainerring out of the groove. Thering can then be removedby hand (Figure 19).

8. Re-insert the upper seatwrench into the upper seat.

9. Rotate the upper seatcounterclockwise until itdisengages from the bodythreads.

10. Remove the wrench and theupper seat (Figure 20).

Figure 20

Figure 19

30

Feb. 2, 1994

11. Remove the ball valve(Figure 21).

Figure 21

12. From the outside of thevalve, push the crank intothe valve body and removethem (Figure 22).

Figure 22

13. Remove the pulling toolfrom the lower seat.

14. Insert the pulling tool fromthe opposite end of thevalve and engage thegroove on the I.D. of thelower seat (Figure 23).

Figure 23

31

Feb. 2, 1994

15. Using the load bar acrossthe face of the connection,tighten the nut against it toremove the lower seat andthe wave spring (Figures24 and 25).

16. Remove and discard theseals from all IBOPcomponents.

17. Thoroughly clean andinspect each item.

Figure 24

Figure 25

32

Feb. 2, 1994

ASSEMBLY

1. Inspect the lower seat.Look carefully for signs ofcorrosion, pitting andgaulling especially in thesealing areas (Figure 26).

2. Make sure the wave springis not broken or damaged(Figure 26).

3. Inspect the steel stabilizerring, making sure it is notworn, pitted or damaged(Figure 26).

4. Replace all O-rings, backuprings and seals (Figure 26).

Figure 26

5. Install the steel stabilizerand seal on the lower seat(floating seat), by placingthe steel stabilizer in thegroove of the U-cup sealand, starting on one side ofthe seat, work the stabilizerand seal around the seatusing a screw driver (Figure27).

NOTEThe steel stabilizer ringshould be inside the sealwhen properly installed.

Figure 27

33

Feb. 2, 1994

6. Install the wave spring onthe lower seat (Figure 28).

Figure 28

7. Inspect the ball valve forcorrosion, pitting andgaulling (Figure 29).

Figure 29

34

Feb. 2, 1994

8. Install new nylon plugs onthe upper stationary seat(Figure 30).

Figure 30

9. Make sure the snap ring isnot broken or damaged(Figure 31).

Figure 31

35

Feb. 2, 1994

10. Make sure the crankassembly notches are notworn and there is no pittingon the outside (Figure 32).Check for a sliding fit withthe slots in the ball.

11. Install the seals on the crankassembly.

12. Inspect the crank sleeve forwear and washouts.Replace as necessary.

Figure 32

13. Thoroughly lubricate thevalve bore with a thin filmof multipurpose grease ofNLGI Grade 2.

14. Insert the pulling tool intothe O-ring end of the lowerseat engaging the I.D.groove (Figure 33).

15. Apply a generous coat ofgrease to the O.D. of thelower seat.

16. Slide the wave spring downthe threaded rod of thepulling tool until it seats onthe spring surface of thelower seat (Figure 33).

17. Insert the threaded rod ofthe pulling tool first intothe box opposite the splinedend of the upper valve,pulling the lower seat intoplace in the valve body(Figure 33).

Figure 33

36

Feb. 2, 1994

18. Using the load bar againstthe face of the connection,tighten the nut to firmlyseat the lower seat in thevalve body (Figure 34).

Figure 34

19. Apply a generous coat ofgrease to the outside of thesleeve and crank.

20. From the inside of the valvebody, install the cranksleeve in the body. Insertthe crank into the sleeve(Figure 35).

Figure 35

21. Make sure the crank moves90 to the Open and Closedposition (the flat sides ofthe crank are parallel to thevalve body).

22. Position the crank in theClosed position.

23. Apply a generous coat ofgrease to the entire outsideof the ball, but make surethe holes are clear (Figure 36).

Figure 36

37

Feb. 2, 1994

24. Slide the ball onto the crankinside the valve body. Thekeyway must be in theClosed position, or parallelto the key of the crank.

25. Apply a generous coat ofgrease to the outside threadsand seal of the upper seat.

26. Insert the upper seat intothe valve body, engagingthe threads (Figure 37). Figure 37

Figure 38

30. Insert the upper seat wrenchinto the mating slots of theupper seat.

31. Rotate the upper seatcounterclockwise until theseat is firmly against theretainer ring.

32. Remove the puller and usean allen wrench to makesure the valve functionsproperly.

33. Leave the valve in the Openposition.

34. Remove the wrench.

27. Insert the upper seat wrenchinto the mating slots of theupper seat.

28. Rotate the wrenchclockwise until the upperseat sets firmly against theball.

29. Remove the upper seatwrench and install theretainer ring firmly into thegroove of the body (Figure38).

38

Feb. 2, 1994

35. Grease the valve throughthe pressure plug untilgrease extrudes from insidethe valve (Figure 39).

NOTEThe grease pressure should not exceed300 psi. Excess pressure can cause themud/grease seal to extrude.

Figure 39

36. Install the 1/4" N.P.T. pluginto the lubrication port ofthe body. Torque this plugto approximately 15 to 20ft.-lbs.Assembly is now complete. With the 7/8" hex wrench, open and close the valve several timesto assure smooth operation. Test the valve according to the procedure in the followingsection.

39

Feb. 2, 1994

IBOP VALVE TESTING IN THE SHOP

Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic testpump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use thefollowing 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 plugin the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valveto the plug in the opposite end.

3. Place the valve in the vertical position (splined end down for upper IBOP, box end down forlower 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 bodyespecially when thevalve is not in use for a prolonged period of time.

NOTEOpen and close the valve five times to release trapped air andoverflow through the bleed valve for approximately 30 seconds toassure complete filling of the valve cavity.

5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closedposition.

6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus1,000 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 hydrostatictest pump and the bleed valve. Reverse the orientation of the valve (splined end up for upperIBOP, 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 releasetrapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold workingpressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over theduration of the test.

10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve toinsure smooth operation.

11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. isacceptable.

12. Drain the valve cavity and remove the test plugs. Open and close the ball several times torelease trapped fluid. When testing with water, coat the valve internals with a preservativeto prevent oxidation and install thread protectors.

40

Feb. 2, 1994

APPENDIXIBOP Part Numbers

IBOPPART NO.

TYPE OFSERVICE DESCRIPTION

REPAIR KITPART NO.

SOFT SEALSPART NO.

BALL/SEAT PART NO.

94769-500 STD Upper Valve-PH60 90939-2 90939-1 90939-594769-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594769-501 NAM Load Collar Design 90939-2 90939-1 90939-5

94770-500 STD Upper Valve-PH60 90939-2 90939-1 90939-594770-502 H2S 7 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594770-501 NAM Load Collar Design 90939-2 90939-1 90939-5

94099-500 STD Upper Valve - PH60 90939-2 90939-1 90939-594099-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594099-501 NAM Landing Collar Design 90939-2 90939-1 90939-5

94100-500 STD Upper Valve - PH60 90939-2 90939-1 90939-594100-502 H2S 7 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594100-501 NAM Landing Collar Design 90939-2 90939-1 90939-5

90815 STD Upper Valve - PH85 93806 93806-1 90939-5- H2S 6 5/8 Box X 6 5/8 Box (Spl End) - - -- NAM Land Collar Design - - -

90814 STD Upper Valve - PH85 93806 93806-1 90939-5- H2S 6 5/8 Box X 7 5/8 Box (Spl End) - - -- NAM Load Collar Design - - -



94206-500 STD Upper Valve - PH85 93806 93806-1 90939-594206-501 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-1594206-502 NAM Landing Collar Design 93806 93806-1 90939-5



41

Feb. 2, 1994

IBOP Part Numbers (Cont.)IBOPPART NO.

TYPE OFSERVICE DESCRIPTION

REPAIR KITPART NO.

SOFT SEALSPART NO.

BALL/SEAT PART NO.


91138 STD Upper Valve - PH85 - Big Bore 95384 91137-SP 91137-1- H2S 7 5/8 Box X 7 5/8 Box (Spl End) - - -- NAM Load Collar Design - - -

89451-501 STD Lower Valve 90939-2 90939-1 90939-589491-503 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-1586434 NAM

89452-501 STD Lower Valve-Stepped 90939-2 90939-1 90939-589492-502 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-15- NAM 90939-2 90939-1 90939-5

90811 STD Lower Valve 93807 93807-1 90939-5- H2S 7 5/8 Pin X 7 5/8 Box - - -- NAM - - -

91138 STD Lower Valve - Big Bore 94385 91137-SP 91137-1- H2S 7 5/8 Pin X 7 5/8 Box - - -- NAM - - -

105629 STD Upper Valve - Type "E" - - 90939-5- H2S 6 5/8 Pin X 6 5/8 Box - - - -- NAM For Ids Only - - -

103220 STD Upper Valve - Type "E" 90939-2 90939-1 90939-5- H2S 6 5/8 Pin X 6 5/8 Box - - -- NAM For TDS and SDS - - -

98977-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 6517001498977-502 H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 9896698977-501 NAM Landing Collar Design 99468-2 99468-1 65170014

99461-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966NAM Landing Collar Design 99468-2 99468-1 65170014

42

Feb. 2, 1994

Identifying Varco Safety Valves

43

Feb. 2, 1994

44

Feb. 2, 1994

45

Feb. 2, 1994

46

Feb. 2, 1994

varco ibop valves

Documents

upper ibop

lower ibop valve

ibop valve testing

safety valve actuator

valve crank

splined upper valves

visual inspection

ball type valves