Saf et y Val ve

Saf et y Val ve
( I BOP)
( I BOP)
Ser vi ce Manual
Ser vi ce Manual

DRILLING SYSTEMS
Feb. 2, 1994
Feb. 2, 1994
i
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
ADJ USTING 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
ii
Feb. 2, 1994
1
Feb. 2, 1994
Varco/ BJ
Safet y 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 drillers 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.
2
Feb. 2, 1994
Link
Adapter
Rotating
Head (Ref.)
Torque
Arrestor
Link
Adapter
Support
Plate
Safety Valve
Actuator
Plain Lower
Safety Valve
Saver
Sub
350 Ton
108" Links
(Ref.)
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Splined
Upper
Safety
Valve
Link
Tilt
Torque
Wrench
Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)
3
Feb. 2, 1994
Link
Adapter
Rotating
Head (Ref.)
Torque
Arrestor
Link
Adapter
Support
Plate
Safety Valve
Actuator
Plain Lower
Safety Valve
Saver
Sub
350 Ton
108" Links
(Ref.)
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Splined
Upper
Safety
Valve
Link
Tilt
Torque
Wrench
V
a
r

c
o
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
4
Feb. 2, 1994
C
L
S
D
O
P
E
N
Retaining Ring
Upper Seat
Back-up Rings
O-Ring
Stabilizer
Ring
Ball
Back-up
Rings
O-Ring
Sleeve
Seal Ring
Crank
Seat
Grease/
Mud Seal
Back-up Ring
O-Ring
Wave
Spring
Body
Thread
Protector
Plug
Thread
Protector
Figure 3. Typical Upper Safety Valve (IBOP)
5
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
J 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
J The new actuator shell is solid steel and bronze linedeliminating bolted-on external guides.
J The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
J The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
J 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.
6
Feb. 2, 1994
ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE
Aug. 9, 1993. A.N.
Figure 4. PH-60 Upgrade Kit
7
Feb. 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 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.
8
Feb. 2, 1994
Internal Valve Mechanism Improvements
1. Internal stress concentrations at the valves 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 designs 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.
9
Feb. 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.
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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Feb. 2, 1994
Table 1. Make-Up Torque Values
Torque (ft-lb)
Components I.D. Connection O.D. (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. 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 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.
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 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.
12
Feb. 2, 1994
Safety Wire
Groove
7/8" Allen Crank
Cam Follower
Crank
Assembly
Lock Tabs
Crank Assembly
Retaining Screw
And Lock Tabs
Slot
Crank Arm*
Actuator Arm
Groove
Actuator
Shell
Upper IBOP
Valve
Crank
Assembly
*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 Arm
Groove
Actuator
Shell
Upper IBOP
Valve
Open
Position
Closed
Position
Grease Port
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
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Feb. 2, 1994
Roller
Assembly (3)
Roller
Assembly (3)
Crank
Assembly
Safety Wire
Groove
Shim
Actuator
Arm
Groove
Crank*
Actuator
Shell
Slot
Crank Assembly
Retaining Screw
Crank
Assembly
Roller
Assembly
(3)
Safety
Valve
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60
15
Feb. 2, 1994
Crank Arm
Actuator Arm
Groove
Actuator
Shell
Upper IBOP
Valve
Open
Position
Closed
Position
Grease Port
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
16
Feb. 2, 1994
OPERATION
Operating 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. 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.
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 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
18
Feb. 2, 1994
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.
1
9
F
e
b
.

2
,

1
9
9
4
SEAL RING STABILIZER
MUD/ GREASE SEAL
BALL
FIXED SEAT
WAVE SPRING
PRESSURE
SPRING
VALVE
SEALS
CAVITY
BODY
FLOATING
SEAT
PRESSURE PLUG
GREASE PORT
C
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C
F
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B
O
P
2
0
F
e
b
.

2
,

1
9
9
4
BALL
FIXED SEAT
WAVE SPRING
PRESSURE
SPRING
VALVE
SEALS
CAVITY
BODY
FLOATING
SEAT
PRESSURE PLUG
GREASE PORT
C
L L
C
F
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1
1
.


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B
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21
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. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection of Steel Forgings
ASTM E-709 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):
J The area inside the operating crank window
J The fillet radii of internal grooves and shoulders
J The last engaged threads of box connections
J The IBOP actuator shell
22
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.
23
Feb. 2, 1994
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.
24
Feb. 2, 1994
Upper IBOP Valve
Actuator Shell
Crank Assy(Shown with
Valve OPEN. Note Crank
Assy Position
Upper IBOP Valve
Actuator Air Cylinders (2)
Upper IBOP
Actuator
Arm
Torque Tube
Lower IBOP
Saver Sub
DriveStem
(Ref.)
Landing Collar
Link
Adapter
*1 Inch
Rod
End
Cylinder
Gland
Cylinder
in OPEN
Position
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 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.
2 14 5 17 6 1 10 18
13
12
12
9
3
4
20
8
7
16
19
15
2X
11
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
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. / KIT DESCRIPTION
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
Refer to the Appendix for Part Numbers
Refer to the Appendix for Part Numbers
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. 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"
Load Bar
3"
Maximum
22"
Seat Puller For All Models
Varco Part No. 79489-14
Nut Wrench for DSV Models
Varco Part No. 89141-18
7/8" Hex Wrench For All Models
Varco Part No. 89141-18
15.25"
3"
Figure 15. IBOP Tools
28
Feb. 2, 1994
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
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows:
29
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).
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
Figure 19
30
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
31
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
32
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).
4. Replace all O-rings, backup
rings and seals (Figure 26).
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
33
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
34
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
35
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).
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).
Figure 33
36
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
37
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
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.
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).
38
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.
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 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 bodyespecially 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.
40
Feb. 2, 1994
APPENDIX
IBOP Part Numbers
IBOP
PART NO.
TYPE OF
SERVICE DESCRIPTION
REPAIR KIT
PART NO.
SOFT SEALS
PART NO.
BALL/SEAT
PART NO.
94769-500 STD Upper Valve-PH60 90939-2 90939-1 90939-5
94769-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94769-501 NAM Load Collar Design 90939-2 90939-1 90939-5
94770-500 STD Upper Valve-PH60 90939-2 90939-1 90939-5
94770-502 H2S 7 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94770-501 NAM Load Collar Design 90939-2 90939-1 90939-5
94099-500 STD Upper Valve - PH60 90939-2 90939-1 90939-5
94099-502 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94099-501 NAM Landing Collar Design 90939-2 90939-1 90939-5
94100-500 STD Upper Valve - PH60 90939-2 90939-1 90939-5
94100-502 H2S 7 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94100-501 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 - - -
90813 STD Upper Valve - PH85 93806 93806-1 90939-5
- H2S 7 5/8 Box X 6 5/8 Box (Spl End) - - -
- NAM Load Collar Design - - -
90812 STD Upper Valve - PH85 93806 93806-1 90939-5
- H2S 7 5/8 Box X 7 5/8 Box (Spl End) - - -
- NAM Load Collar Design - - -
94206-500 STD Upper Valve - PH85 93806 93806-1 90939-5
94206-501 H2S 6 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94206-502 NAM Landing Collar Design 93806 93806-1 90939-5
94205-500 STD Upper Valve - PH85 93806 93806-1 90939-5
94205-501 H2S 6 5/8 Box X 7 5/8 Box (Spl End) 89453-SP - 89453-15
94205-502 NAM Landing Collar Design 93806 93806-1 90939-5
94204-500 STD Upper Valve - PH85 93806 93806-1 90939-5
94204-501 H2S 7 5/8 Box X 6 5/8 Box (Spl End) 89453-SP - 89453-15
94204-502 NAM Landing Collar Design 93806 93806-1 90939-5
41
Feb. 2, 1994
IBOP Part Numbers (Cont.)
IBOP
PART NO.
TYPE OF
SERVICE DESCRIPTION
REPAIR KIT
PART NO.
SOFT SEALS
PART NO.
BALL/SEAT
PART NO.
94203-500 STD Upper Valve - PH85 93806 93806-1 90939-5
94203-501 H2S 7 5/8 Box X 7 5/8 Box (Spl End) 89453-SP - 89453-15
94203-502 NAM Landing Collar Design 93806 93806-1 90939-5
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 90939-5
89491-503 H2S 6 5/8 Pin X 6 5/8 Box 89453-SP - 89453-15
86434 NAM
89452-501 STD Lower Valve-Stepped 90939-2 90939-1 90939-5
89492-502 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 65170014
98977-502 H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
98977-501 NAM Landing Collar Design 99468-2 99468-1 65170014
99461-500 STD Upper Valve, PH60 Dual Crank 99468-2 99468-1 65170014
H2S 6 5/8 Box X 6 5/8 Pin 99469-SP - 98966
NAM 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