OPERATIONS AND MAINTENANCE MANUAL

ELMAR SINGLE MANUAL

MAN-1022220 NON RISING STEM WIRELINE
VALVE ASSEMBLY

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OPERATIONS AND MAINTENANCE MANUAL
ELMAR SINGLE MANUAL
MAN-1022220 NON RISING STEM WIRELINE
VALVE ASSEMBLY

This document is applicable to Manual Non rising Stem Wireline Valves that have a
working pressure of 5,000 psi or below.

This document is not Applicable to Arctic assemblies.

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Originally Prepared R. Joensen
Edited by S. Trevaskis
Approved by C. Wade
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Publication MAN-1022220
© Copyright National Oilwell Varco, Inc. 2009
The information is correct at the time of print
First Published in April 2009 by Elmar Engineering
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Approval and Issue

REV ECO PREPARED CHECKED APPROVED DATE COMMENTS

A R. Joensen C. Wade C. Wade 09/04/2009 1st Issue

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1 HEALTH AND SAFETY ................................................................................5
1.1 GENERAL .....................................................................................................6

1.2 SAFETY PRECAUTIONS AND WARNINGS.................................................6

1.3 COMPETENCY OF PERSONNEL ................................................................7

1.4 PERSONAL PROTECTIVE EQUIPMENT .....................................................9

1.5 PREPARATION OF THE WORKSITE...........................................................9

1.6 PRESSURE CONTROL SAFETY................................................................11

2 DESCRIPTION AND SPECIFICATIONS ....................................................14

2.1 GENERAL DESCRIPTION ..........................................................................15

3 EQUIPMENT DESCRIPTION ......................................................................17

3.1 BOP ASSEMBLY.........................................................................................18

3.2 BOP ADAPTER ASSEMBLY .......................................................................21

3.3 BOP RAM ASSEMBLY................................................................................21

4 SPECIFICATIONS AND FEATURES..........................................................24

4.1 SPECIFICATIONS.......................................................................................25

4.2 STANDARD FEATURES.............................................................................25

4.3 DESIGN STANDARDS AND REQUIREMENTS..........................................26

5 OPERATION ...............................................................................................28
5.1 FUNDAMENTAL RULES FOR PROPER OPERATION ..............................29

5.2 OPERATION ...............................................................................................29

5.3 SEALING ON SLICK LINE ..........................................................................31

5.4 BLEEDING DOWN LUBRICATORS............................................................32

5.5 EQUALISING PRESSURE PRIOR TO OPENING RAMS ...........................33

6 ASSEMBLY INSTRUCTIONS .....................................................................34

6.1 TOOL LIST ..................................................................................................35

6.2 ASSEMBLY INSTRUCTIONS .....................................................................36

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7 MAINTENANCE AND TESTING .................................................................46
7.1 ROUTINE MAINTENANCE .........................................................................47

7.2 MAJOR MAINTENANCE .............................................................................50

7.3 TESTING .....................................................................................................52

7.4 TROUBLESHOOTING.................................................................................55

7.5 MAINTENANCE RECORD SHEET .............................................................56

8 TRANSPORTATION, SPARES,ACCESSORIES AND DISPOSAL............57

8.1 TRANSPORTATION....................................................................................58

8.2 SPARES AND ACCESSORIES...................................................................58

8.3 DISPOSAL...................................................................................................59

9 DRAWINGS AND BILLS OF MATERIAL ...................................................60

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1 HEALTH AND SAFETY
1.1 GENERAL

1.2 SAFETY PRECAUTIONS AND WARNINGS

1.3 COMPETENCY OF PERSONNEL

1.4 PERSONAL PROTECTIVE EQUIPMENT

1.5 PREPARATION OF THE WORKSITE

1.6 PRESSURE CONTROL AND SAFETY

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1.1 GENERAL
This manual should be consulted as a minimum requirement by all persons involved
in work on Wellhead Pressure Control Equipment. All other documents such as
assembly drawings, bill of materials etc, should be made available at the worksite.
Failure to consult the manual could result in a lack of knowledge that could result in
accidents involving injury to personnel or lead to damage to property and equipment.

This manual documents Elmar's recommendations, but should not be assumed to

satisfy the requirements of legal regulations governing the region in which the
equipment is being used or additional company policy of the owner/user.

Additional measures must be put in place by owner/user to ensure that:

• The required competency of operators is defined, and that only

competent operators are permitted to operate the equipment;

• Suitable additional workplace measures are defined, and adhered to, to

further reduce the residual risks associated with the use of the
equipment;

• A suitable program for regular maintenance of the equipment is defined,

adhered to and recorded;

• A suitable program for periodic inspection, testing and examination of the

equipment is defined, adhered to and recorded.

1.2 SAFETY PRECAUTIONS AND WARNINGS

Operation and maintenance of wellhead pressure control equipment involves residual
risks which cannot be reduced by design lower than is reasonably practical. General
hazards and additional information to reduce these risks are provided in the form of
additional notes, cautions or warnings.

The following nomenclature is used throughout the manual. Its purpose is to make
the user aware of the potential hazards related to using pressure containing
equipment in general, and to allow the operator to minimise these risks by employing
safe working practices (refer also to 1.5, Preparation of the Worksite):

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 TIP !
An instruction preceded by this indicator is a tip to make a task easier to carry out.

NOTE !
An instruction preceded by this indicator is extra information that can prevent minor problems.

CAUTION !
An instruction FOLLOWED by this CAUTION highlights a hazard which could cause damage to
equipment or its components. Follow the instructions carefully.

WARNING !
An instruction FOLLOWED by this WARNING highlights a danger or injury to the OPERATOR
or other PERSONNEL, or danger of serious damage to the equipment or other objects. Follow
the instructions carefully.

DANGER !
An instruction preceded by this indicator highlights a danger to life for the operator or other
personnel. Follow the instructions carefully.

1.3 COMPETENCY OF PERSONNEL

All operation and maintenance of the Wellhead Pressure Control Equipment (WHE)
should be planned and supervised by a competent person. The competent person
will normally be the person in charge of the worksite who should consider the safety
aspects of the work and the competency of the persons carrying out the operations.

WARNING!
Any persons who feel sick, tired, or are under the influence of medicines, alcohol, or other
drugs should not be allowed to operate WHE.

The legal requirements and owner/user requirements for operator competency may
vary between regions and between owner/users. The definition of operator
competency should, therefore, be defined and controlled by the equipment
owner/user.

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Elmar recommend that the competent person must have, as a minimum:

• Sufficient practical and theoretical knowledge of wellhead pressure

control equipment at that particular location.

• Sufficient experience of the operation of wellhead pressure control

equipment in the environment in which it is used.

• The ability to detect deficiencies and to assess their criticality in relation

to strength and performance, and to recommend remedial action to
ensure that conditions are appropriate for safe use.

• Understand and comply with Emergency Procedures and Instructions.

• Be able to describe the nature of principal hazards that could occur at

the particular location including the appropriate worksite precautions, test
methods and means of safe handling.

• Be able to locate, identify, describe functionality and operate all fixed and
portable fire fighting and life support equipment at the location.

• Other personnel involved in the operations should have a sound

knowledge of their part of the operation and have received instructions
from the competent person.

Elmar recommend that personnel involved in wellhead pressure operations have

been formally trained. Elmar can provide formal training courses which should be
attended as part of the achievement of operator competency.

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1.4 PERSONAL PROTECTIVE EQUIPMENT
Appropriate PPE should be worn specific to the job. As a minimum standard the
following is recommended:

1) Safety Helmets.

2) Eye Protection.

3) Hearing Protection.

4) Respiratory Protection (where conditions deem necessary).

5) Body Protection.

6) Hand Protection i.e. wearing of gloves or use a barrier cream if

necessary.

7) Foot Protection.

1.5 PREPARATION OF THE WORKSITE

The competent person should not allow work to proceed until the thorough
examination and risk assessment of the work site and equipment has been carried
out, and that he is satisfied that it is safe to proceed. The risk assessment should be
carried out to identify hazards and assess their threat. This risk assessment should
be cascaded to all other persons involved in carrying out the work.

The examination should assess (as a minimum) the condition of the equipment
structure, the condition of all critical components, and ensure that the WHE shows no
signs of excessive damage or wear which may affect the safety of the equipment
during use. (Refer to Section 7 for inspection, examination and testing for WHE
details).

Hazards are identified and assessed through:

1) Experience/Judgement

- The knowledge of experienced staff provides a sound basis for

hazard identification and assessment.

2) Checklists

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 - These are a useful way of ensuring that known hazards have been
identified and assessed. They are normally drawn up from
operational experience and focus on areas where the potential for
mistakes is high or where problems have occurred in the past.

3) Hazards are assessed using any combination of:

- Engineering judgement, or

- Comparison with good practice in the field.

At the completion of the of the risk assessment it should be possible to document

that:

- All hazards have been identified;

- That controls to manage potential causes are in place;

- That prepared measures to mitigate potential consequences have been

taken.

Remember...

• Do use eye protection when using power tools.

• Do wear gloves or use barrier cream to protect your hands.

• Do wear protective footwear.

• Keep loose clothing and long hair well out of the way of moving
mechanical parts.

• Do remove rings, wristwatch etc, before working.

• Do change out of oil-soaked clothes and do not keep oily rags in your
pocket.

• Do ensure that any lifting or jacking equipment has a safe working load
rating Do get someone to check periodically that all is well if working
alone.

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1.6 PRESSURE CONTROL SAFETY

1.6.1 BASIC SAFETY

• Pressure control equipment is used to safely perform operations when

pressure is present or is likely to develop at the wellhead.

• A routine pressure job does not exist. Potential safety hazards always
exist during any operation performed under pressure.

• Well trained personnel and well maintained equipment are a

fundamental requirement for a safe pressure job.

• All personnel should wear adequate safety clothing, for example safety
glasses, gloves, boots, hard hats and overalls.

• Special precautions are necessary if H2S may be present at the well

site.

1.6.2 RESPONSIBILITY

• Safety is everyone’s responsibility. You are responsible for your own

safety and you have a duty of care to other personnel present on the rig
or well site.

1.6.3 BASIC SAFETY

• Never heat or weld any part of the pressure control equipment.

• Never tamper with equipment which is subjected to pressure.

• Never turn hose reels with pressure applied to hose.

• Never replace pressure fittings unless you are sure of the new parts
thread type, service type, and pressure rating.

• Never use any piece of equipment that does not have a Working
Pressure Rating.

1.6.4 PRE-DEPARTURE

• Detailed, advanced planning of a job is essential to ensure safe

operations.

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 • In order to gain details of possible hazards either visit the well site or call
the client. Points to discuss include:-

- Wellhead Pressure and Temperature;

- Production: gas, oil, H2S, CO2, chlorides, hydrates;

- Inhibitors, corrosive fluids, chemical injection;

- Rig: Height – BOP adapters flanges;

- Tubing, casing, restrictions, deviation;

- Wellhead crossover connection;

- Lifting equipment, cat lines, travelling blocks, cranes.

• Select proper equipment depending on pressure and type of service.

Equipment is usually chosen to have a Working Pressure Rating of 1.2
times the maximum expected well pressure. Check the rating and
compatibility of all connections.

• Perform a complete system check.

• The pressure rating of a complete control system is equal to the rating of

the lowest rated individual item – the weakest link in the chain. This
includes the pressure fittings, needle valves, gauges, etc.

• Ensure that enough lubricators are available to cover the tool and allow
3ft (1metre) clearance. This applies to fixed structures not semi-
submersible rigs drilling rigs.

• Check spare parts box.

1.6.5 ON LOCATION

• Review all operational steps, possible safety hazards, open and shut-in
well procedures.

• Be aware of rig emergency procedures, including shut-in, fire, H2S,

abandon ship etc.

• Never fill riser or pressure test with diesel oil. Air in the riser can be
compressed and mixed with diesel vapour to cause a diesel explosion.

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 • Drill floors are dangerous places. Be more alert and take care of
necessary precautions when working on a rig floor.

1.6.6 RIGGING UP

• Clear area of unnecessary personnel.

• Ensure drill floor is free of mud and dirt.

• Rig up wellhead adapter, BOP and tool trap first.

• Secure all flow lines.

• Ensure drain lines are coupled to closed drain system or environmental

secure area.

• Pressure test the complete set up to 1.2 times the expected wellhead
pressure. Hold pressure for 10 minutes and record. Use water or glycol
to test and NEVER diesel. Ensure that no air remains in the system
during a pressure test.

• Client representative controls the Christmas Tree master valves.

• Count the number of turns and tag the valve.

• Never tighten or loosen connections under pressure.

• Use a rope, NOT THE PRESSURE HOSES, to help align the grease
head and lubricator with the wellhead.

1.6.7 RIGGING DOWN

• Be aware that trapped pressure may exist in equipment even after it has
been rigged down and apparently bled down. A sure sign of trapped
pressure is an unusually tight union connection or a stiff hose.

1.6.8 AFTER JOB

• Perform maintenance. The time between the end of the job and
maintenance is when the equipment is most at risk from corrosion.

• Concentration is often low after the job is complete and this leads to
accidents. Please remember that the equipment is heavy and should
still be treated with care and attention.

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2 DESCRIPTION AND SPECIFICATIONS
2.1 GENERAL DESCRIPTION

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2.1 GENERAL DESCRIPTION
The Elmar Single Manual Non Rising Stem (NRS) Wireline Valves (Patent Pending)
or BOP’s, have been designed for use as part of a complete wireline/slickline
intervention string. The primary purpose is to provide a manageable safety barrier
during remedial work on a wireline. The valves are designed to control well pressure
by sealing around the wireline cable.

The Elmar Single Manual NRS Wireline Valves is designed for use on standard
wireline/slickline operations.

IMPORTANT!
For sealing on braided line two barriers and a grease injection system are recommended.

The Elmar NRS Wireline Valve is currently available with various through bores, up to
5,000 psi maximum working pressure H2S or STD service with a single set of
manually operated rams.

Various configurations can be supplied for the upper and lower connections including
quick unions and flanges.

The Elmar Single Manual NRS Wireline Valves are supplied with Elmar keyed rams
and the line size for which they are dressed has to be specified when ordering.

See relevant size generic assembly drawing.

The Elmar NRS Wireline Valves incorporate the following features as standard:-

• API 6A and NACE compliant (for H2S versions)

• Third Party Design Approval

• Compact, allowing easier handling

• Compact size, allowing shorter rig-up heights

• Non Rising Stem feature, allowing narrow rig ups.

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 • Threaded quick unions, allowing the use of any Elmar, Bowen or Otis
type quick union without changing the body. Body to quick union joint
has an elastomer seal as standard. Optional metal to metal seal is
available if required.

• Manifold blocks with integral equalisation valve and dump port.

• Keyed Q-GuideTM ram design providing positive wireline guiding

• Manual actuators

This manual is a generic manual for all Elmar Single Manual NRS Wireline Valves.

The following illustrations in this manual are provided for a 5.62" Single BOP and are
typical for all other sizes.

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3 EQUIPMENT DESCRIPTION
3.1 THE BOP ASSEMBLY

3.2 THE BOP ADAPTER ASSEMBLY

3.3 THE BOP RAM ASSEMBLY

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3.1 BOP ASSEMBLY
The following major assemblies/parts make up the BOP Assembly.

• BOP Body

• End Cap

• Block Manifold

Fig. 3.1 Bop Assembly

The Elmar Single NRS Wireline Valve Assembly (BOP) comprises of a single set of
rams, which are opened and closed using a 3/4" square drive ratchet. To close the
rams the stems are turned in the clockwise direction. To open, the pressure must be
equalised above and below the rams before attempting to turn the stems. To open,
turn stems in a counter-clockwise direction.

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3.1.1 THE BOP BODY
The BOP body is a single piece forging machined from alloy steel suitable for H2S or
STD service.

3.1.2 THE END CAP SUB ASSEMBLY

The NRS End Cap assembly ensures that the overall envelope of the BOP does not
change with opening and closing of the BOP rams. It includes a quick release end
cap for easy maintenance, thrust bearing for reduced friction and an indicator rod for
positive confirmation of the ram position.

All NRS BOPs are supplied fitted with retainer screws sized to ensure that the rams
are not over extended. the grease nipple is supplied to ensure the thrust bearing is
properly lubricated.

NOTE!
For maximum safety the rams must be fully opened (retracted) before attempting to remove the
end cap assembly from the BOP body

Fig. 3.2 End Cap assembly

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3.1.3 MANIFOLD ARRANGEMENT
To manage the seal around the wireline a block style equalisation manifold is
provided to allow the pressure from below and above a closed BOP ram to be
equalised. The manifold block (shown in the figure below) has an integral
equalisation (or cartridge) valve and NPT port for dumping pressure. The single piece
manifold block has integral ports which minimises the number of possible leak paths
and makes for a more robust construction.

Fig. 3.3 Block Manifold

Each cartridge valve consists of a stem, seat, gland and seals. The stem has a 3/8"
A/F female hex drive, which is operated by an Allen wrench. Rotating the stem
clockwise closes the valve, while anti-clockwise opens the valve. Care should be
taken not to over-tighten the stem, as too much torque will reduce the seat life. Only
enough torque should be applied to generate a seal.

NOTE!
A single configuration BOP has no grease or glycol injection points.
It is assumed that a Single BOP is purchased for Slickline Operations and the operator will have
the bleed off and pressure monitoring facility on one of the lubricator risers.

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 Fig. 3.4 Single Wireline Valve Manifold Configuration

3.2 BOP ADAPTER ASSEMBLY

The BOP Adapter assemblies are threaded quick unions allowing the use of any
Elmar, Bowen or Otis type quick union without changing the body. Body to quick
union joint has an elastomer seal as standard. Optional metal to metal seal is
available if required.

Plastic thread protectors are supplied with the Elmar Lightweight quick union and
steel protectors are supplied with most other connections.

3.3 BOP RAM ASSEMBLY

BOP rams are designed to seal the annular space around a wireline, shutting-off well
pressure to allow intervention in case of wireline damage or problems in maintaining
a seal at the grease head. The safety barrier is provided by the use of a pair of ram
elements which are brought together manually to close off the through bore and seal
around the wireline. When the BOP is closed and the pressure above the rams bled
down, the well pressure, acting behind the rams, assists in the actuation and helps to
maintain a positive seal. In the closing stroke, the rams guide the wireline into a
semi-circular groove in the ram body to allow a fluid tight seal without damaging the
line.

The number of ram assemblies required depends on the type of sealing function, the
desired working pressure of the wireline valve and the level of redundancy
acceptable. The acceptable minimum requirements are:

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 • if sealing around slickline a minimum of one ram assembly is required to
affect a seal
• if sealing around braided line a minimum of two ram assemblies are required
in conjunction with a grease injection facility. NRS BOPs are only available
with one set of rams and are not suitable for inverting, therefore they are not
suitable for high pressure braided line work.

Fig. 3.5 Inner Seals

The sealing elements are made up of a rubber element sandwiched between two
steel plates, called an inner seal. This is embedded in the face of the ram body to
provide the seal around the cable. In the conventional design, braided or electric line
rams have a groove through the ram body and the inner seal sized close to the line
diameter. Normally, a different ram body and inner seal is required for each line size,
refer section 3.3.1 for multi-line setups. Slickline rams have a rectangular slot in the
inner seal steel plates, and no groove in the rubber element. Around the upper part of
the ram body is an outer seal in the shape of a horseshoe. The outer seal prevents
well fluids from passing around the rams inside the main BOP body. The inner and
outer sealing elements join together on the side of the ram body.

A key is located under the ram which sits in a groove cut inside the ram bores of the
BOP body. The key prevents the ram body from turning. The Q-GUlDETM ram
provides a positive alignment for the wireline. V-shaped flat guides on either side of
the inner seal restrict the wireline so that the section of line contacting the inner seal
is always centred and parallel to the BOP axis. The Q-GUlDETM has been designed
to accommodate eccentric set-ups. There are scenarios with the standard and
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integral type rams where the wireline goes through the wireline BOP body at an
angle and can be trapped by the rams before falling in the cable groove.

3.3.1 MULTILINE INNER SEALS

Multiline Inner Seals are generally not recommended for NRS BOP's as they require
a larger force to create a seal. Ideally we would recommend a hydraulically actuated
BOP be used for multiline seals.

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4 SPECIFICATIONS AND FEATURES
4.1 SPECIFICATIONS

4.2 STANDARD FEATURES

4.3 DESIGN STANDARDS AND REQUIREMENTS

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4.1 SPECIFICATIONS
The exact specification of each Elmar Single NRS Manual Wireline Valve will vary
depending on the customer’s individual requirements.

Through Bore Currently available in through bores off:

5.62"

Working 5000psi
Pressures

Service Standard service/H2S Service

Ram Ram assemblies are provided line sized to suit the

Assemblies particular line size to be used. Multiline Seals are not
recommended for NRS BOP's.

Manifold Equalisation and dump port.

Upper and All industry standard connections are available including

Lower Elmar, Bowen, Otis and Flopetrol. Other connections can
Connections also be provided including API flanges. Metal to metal
sealing rings can be specified between each adapter and
the main body.

4.2 STANDARD FEATURES

Elmar Single NRS manual Wireline Valve assemblies have all the standard following
features:

• All components are rated for 5K working pressure.

• BOP body is always rated to 5K WP and H2S service.

• Interchangeable Upper and Lower Adapter assemblies allow a variety of

unions.

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 • Non Rising Stem feature to ensure that the envelope of the BOP does
not change with closing or opening of the rams. Compact overall size of
the BOP.

• Captive indicator rods provide positive confirmation of ram position.

• Thrust roller bearing on ram lead screw to reduce the torque required to
close rams.

• Manifold blocks with integral equalisation and dump port

4.3 DESIGN STANDARDS AND REQUIREMENTS

The Elmar NRS Wireline Valve assemblies have been designed in accordance with
the following standards and given third party approval by Bureau Veritas:

• API 6A (Latest Edition)

• NACE MR0175 (Latest Edition) for H2S assemblies only.

• Norwegian Petroleum Directorate, the Facilities Regulations, Sept 2001

• Schlumberger, Pressure Operations Manual

• SI 289, 1974

• SI 913, 1996

• SI 2306, 1998 - PUWER

Each Wireline Valve is designed to comply with the following requirements within API
6A:

• Pressure Rating 5,000 PSI WP 10,000 PSI TP

• Service Temperature Classes P, R, S, T, U & V (-29°C to 121°C)

• Manufacturing standards PSL 3 and PR1.

• Material Class CC-General Service or

EE-Sour Service depending on if it is

a STD or H2S assembly.

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All wireline valves are supplied as standard with Nitrile elastomers for all sealing
elements apart from the ram sealing elements which are Fluorocarbon (FKM). Other
grades are available in seal kit form on request.

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5 OPERATION
5.1 FUNDAMENTAL RULES FOR PROPER OPERATION

5.2 OPERATION

5.3 SEALING ON SLICKLINE

5.4 BLEEDING DOWN LUBRICATORS

5.5 EQUALISING PRESSURE PRIOR TO OPENING RAMS

CAUTION:
THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH THE
APPROPRIATE ASSEMBLY DRAWINGS BEFORE CARRYING OUT ANY OF THE
FOLLOWING ACTIONS

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5.1 FUNDAMENTAL RULES FOR PROPER OPERATION
The following fundamental rules apply to all operations with WHE Equipment.

• All equipment used for pressure control operations must be pressure

rated, to a defined Working Pressure, WP and a Test Pressure, TP. For
high temperature applications a Temperature Rating must also be
defined.

• Pressure control equipment shall never be used above its Working

Pressure (WP) rating, or outside its temperature rating.

• In a string of WHE equipment, the WP of the weakest component gives

the string overall pressure rating.

• All WHE components holding pressure must have valid certification.

• All WHE components holding pressure must have a quality file.

• All WHE equipment used on the well-site is qualified for its use by
passing annually a hydrostatic body test and an operation check at WP.

• A well-site pressure test must be carried out after set-up and before
opening the well on each job. The Maximum Allowable Working
Pressure during the job equals the well-site test pressure.

• All crews operating WHE equipment must be qualified to carry out

pressure operations.

5.2 OPERATION
Observe all safety considerations (Refer to Section 1 for general safety information)
and site rules.

Before operation of the wireline valves refer to Section 7, Maintenance and Testing to
ensure the equipment has been fully serviced and the necessary ‘Before Job Checks’
have been carried out. Do not assume that serviceable equipment on the last job will
be serviceable again.

During normal well site operation it is best practice to have all block manifold valves
closed. Each of the following procedures assumes this is the case.

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The equalisation valve consists of a stem, seat, gland and elastomer seals. The stem
has a female hex drive which is operated by the wrench provided with the BOP.
Rotating the stem CLOCKWISE closes the valve. ANTI-CLOCKWISE opens the
valve. Care should be taken not to over tighten the stem, as too much torque will
reduce the seat life and round the stem flats. Only enough torque should be applied
to generate a seal.

Connect a suitable dump hose to the dump port and lead off to an area well away
from personnel.

WARNING!
Ensure hose end is tied down and terminates in a”T”. Consider topography and weather
conditions such as wind direction etc.

We recommend a pressure gauge rated to the appropriate pressure should be

attached to the wellhead string for pressure monitoring (Refer to Section 8 for spares
and accessories).

Fig. 5.1 Block Manifold Configuration

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5.3 SEALING ON SLICK LINE
The ram face effectively seals around the outer surface of a wire line by
displacement of an elastomer which flows into gaps and irregularities on the surface.

STEP ACTION

1. Ensure equalizing valve on the manifold block is closed.

2. Connect a suitable dump hose with valve and gauge to the dump port on
upper BOP and lead off to an area well away from personnel. See figure
below for schematic. Valve is not supplied as standard with BOP.

WARNING!
Ensure hose end is tied down and terminates in a 'T'. Consider topography and weather
conditions such as wind direction etc.

CAUTION!
Manifold equalizing
Rotating the stem clockwise closes the valve, while anti-clockwise opens the valve. Care should
be taken not to over-tighten the stem, as too much torque will reduce the seat life and round the
stem flats. Only enough torque should be applied to generate a seal.

STEP ACTION

3. Close the rams by turning the stems clockwise and checking ram position
using the indicator rods, see illustration on following page for details.

Fig. 5.2 Indicator Rod illustration

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5.4 BLEEDING DOWN LUBRICATORS

STEP ACTION

1. Ensure equalisation valve is closed.

2. A suitable dump hose should already be connected to the dump port and
lead off to an area well away from personnel.

3. Open dump valve slowly.

WARNING!
Risk of high pressure and high velocity poisonous gasses and fluids.

CAUTION!
If there is high pressure gas, the valves should be closed slowly and the flow choked to avoid
freezing.

WARNING!
If freezing does occur and the gauge is reading ‘0’ there may still be pressure in the lubricators
due to the formation of hydrates.

STEP ACTION

4. Monitor lubricator pressure using the pressure gauge connected to the

string.

WARNING!
Before disconnecting any wellhead equipment quick unions ensure that all residual pressure,
which may be trapped inside the WHE string, is fully bled off. A sure sign of trapped pressure is
an unusually tight connection or a stiff hose.

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5.5 EQUALISING PRESSURE PRIOR TO OPENING RAMS

STEP ACTION

1. Ensure the valve on dump line on upper BOP is closed (valve not
supplied as standard with BOP).
2. Ensure fit for purpose equipment is attached above the BOP.

3. Ensure there is sufficient hydraulic pressure applied to the stuffing box to

contain the well pressure.
4. Slowly open equalisation valve and read well pressure on gauge
connected to dump port.
5. Monitor the well pressure rise on the gauge.

6. When well pressure is reached open the ram assemblies and confirm ram
position using the indicator rods.

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6 ASSEMBLY INSTRUCTIONS
6.1 TOOL LIST

6.2 ASSEMBLY INSTRUCTIONS

CAUTION:
THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH THE
APPROPRIATE ASSEMBLY DRAWINGS BEFORE CARRYING OUT ANY OF THE
FOLLOWING ACTIONS

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6.1 TOOL LIST
1) Clean Work Surface;

2) Airline;

3) O-ring pick;

4) Narrow grease brush (12" handle);

5) Plastic hammer;

6) Grease L-881720;

7) PTFE thread tape L-861900;

8) Clean rags;

9) 3M Scotchbrite;

10) Loctite 577 thread sealant L-862200;

11) Anti-seize protective compound;

12) 11mm socket (for grease nipple in end cap);

13) Vice;

14) Strap wrench L-840957 (for tightening adapters onto BOP body);

15) Tool – Ratchet 3/8” BOP Cartridge Valve (L-973132);

16) Tool - Swivel Allen Wrench BOP Cartridge Valve (L-890066);

17) Tool - Cartridge Valve Seat Tool (L-981053);

18) Tool - Cartridge Valve Seat Seal Setter (L-972776);

19) Small fanblade screwdriver (for cartridge valve panhead screw);

20) 5/16" Allen key (for manifold block screws);

21) 5/32" Allen Key (stem body retainer screws);

22) 3/8" Allen key (for ram body retainer screw);

23) 7/8" Spanner (for dump and gauge port) ;

24) Grease Nipple L-980108;

25) Diameter 0.50" punch (for tightening/removal of end cap collar;

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Page 35 of 60
 26) Ratchet with 3/4" square drive (reversible) ;

27) Breaker bar with 3/4" square drive;

6.2 ASSEMBLY INSTRUCTIONS

Remember...

• Do use eye protection when using power tools.

• Do wear gloves or use barrier cream to protect your hands.

• Do wear protective footwear.

• Keep loose clothing and long hair well out of the way of moving
mechanical parts.

• Do remove rings, wristwatch etc, before working.

• Do change out of oil-soaked clothes and do not keep oily rags in your
pocket.

• Do ensure that any lifting or jacking equipment has a safe working load
rating adequate for the job.

• Do get someone to check periodically that all is well when working alone.

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Page 36 of 60
6.2.1 CARTRIDGE VALVE ASSEMBLY
O-RING

VALVE SEAT

TEFLON SEAL
GLAND

BACK-UP

BACK-UP

VALVE STEM

TEFLON SEAL GLAND

VALVE SEAT
PH SCREW

BACK-UP

VALVE STEM

O-RING BACK-UP
PH SCREW

Fig. 6.1 Cartridge Valve Assembly

6.2.2 MANIFOLD BLOCK VALVE ASSEMBLY

NOTE!
Clean all parts thoroughly before beginning assembly

STEP ACTION

1. Place PTFE back-up rings in boiling water and leave to expand.

2. Screw valve seat onto the valve seat tool.

3. Place heated back-up rings (2 off) around the valve section and flatten out
on the valve seat.

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Page 37 of 60
 NOTE: O- Rings and Back-ups
(a) Check all components for cleanliness before installation
(b) Tape all threads over which O-rings will pass. O-rings should never be forced over
unprotected sharp edges.
(c) Use an O-ring lubricator.
(d) Double check O-ring to ensure correct size
(e) Don’t over stretch the O-ring.
(f) Prevent the O-ring from rolling or twisting during assembly
(g) Where only one back-up ring is used, it must be placed between the O-ring and the
pressure face.

BACK-UP RING O-RING

PRESSURE DIRECTION

PRESSURE FACE

Fig. 6.2 O-Ring Illustration

STEP ACTION

4. Apply grease between the back-ups and manually flatten out. Put on the
O-ring and apply grease.
5. Stab the seat into the seal setter tool and screw the valve seat tool out of
the seat.
6. Repeat 5, above, again so that 2 off seats are in the seal setter tool.
7. Remove 1st seat (screw valve seat tool in). Apply more grease and stab
into block.
8. Apply anti-seize compound to valve stem thread and screw into the gland
until the head is flush with the gland.
9. Slip on the PTFE valve seal over the stem.
10. Apply anti-seize compound to the gland threads and screw into the
manifold block.
11. Apply anti-seize compound to the cartridge valve panhead screw and
screw into the valve gland.

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Page 38 of 60
 Fig. 6.3 Block Manifold Assembly

NOTE!
Clean all parts thoroughly before beginning assembly.

STEP ACTION

12. Apply anti-seize compound to lock washer socket head screw and screw
the lock washer into the block.
13. Tape and Loctite the dump valve hex plug into the manifold block and
tighten.
14. Blow out manifold block ports and threaded fitting holes with an airline.
15. Blow out BOP body threaded fitting holes and run tap down the holes to
ensure that they are free of debris.
16. Grease and install o-rings on back of manifold block (2 x o-rings).
17. Grease the face of BOP & coat the manifold screws with anti-seize
compound.

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Page 39 of 60
18. Install manifold block (taking care not to damage o-rings).
19. Tighten manifold block cap screws to 35 lb.ft (47Nm) using torque
wrench.

6.2.3 BOP BODY AND END CAP ASSEMBLY

Fig. 6.4 Ram and End Cap Assembly

STEP ACTION

1. Clean all parts thoroughly before beginning assembly.

2. Apply grease to the O-ring grooves/seal surfaces and apply anti-seize
compound to all threads.
3. Fit all O-rings in the stem body. Refer to Figure 6.4 and the product
specific assembly drawing.

NOTE!
Check position of PTFE back up ring (if applicable). Place PTFE back up ring in boiling water to
expand before fitting.

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Page 40 of 60
STEP ACTION

4. Install the relevant ram assembly, complete with keys, into the BOP body
and ensure the keys locate in groove to maintain ram orientation.
5. Install the stem body onto the BOP body and screw on collar.

6. Apply anti-seize compound to the stem shaft threads.

7. Pack thrust bearing with grease.

8. Fit the bearing into the end cap and locate the stem shaft into the bearing.

9. Apply grease to stem shaft shoulder (non thrust-bearing face).

10. Fit ram body into stem body (Note, ram body fully assembled with seals
and key guide).
11. Screw end cap onto the stem body whilst ensuring that the stem shaft
engages with the ram body.
12. Locate the end cap grub screws.

13. Screw the retainer screw into the ram assembly using Loctite 270.

14. Fit the grease nipple onto the end cap and add 3 strokes of grease

15. Locate collar and secure stem body to BOP body.

16. Locate the retainer plate onto the stem body and fasten the screws.
(Leave one screw out for attaching indicator rod)
17. Fit the ram indicator rod onto the retainer plate and fit a crimp and wire
onto the Indicator, then fit a thimble, wire, button head screw and a
washer onto the retainer Plate.

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6.2.4 RAM ASSEMBLY

Fig. 6.5 Ram Assembly

STEP ACTION

1. Grease the ram body and install the outer seals. Ensure the seal is flush
with the ram body diameter. Tap into place using a plastic hammer to
ensure a perfect fit. Take great care not to damage the seal.

2. Grease the inner seals and install in position in the ram body.

Inner Seal (Slickline)

3. Apply anti-seize compound to the inner seal retaining screws and insert
into position. Tighten all four screws equally. Check that the inner seal is
still free to move.

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6.2.5 BOP ASSEMBLY

Fig. 6.6 BOP Assembly

STEP ACTION

1. Inspect the body internals, paying particular attention to seal surfaces.

Apply WD40 and lightly smooth using Scotchbrite to clean up surface, if
required.

NOTE!
Body internals are coated with corrosion inhibitor. Do not over-smooth.

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Page 43 of 60
STEP ACTION

2. Grease all O-ring grooves in the upper and lower BOP adapter threads.

3. Identify the BOP body orientation by checking the assembly drawing.

NOTE!
Reference should be made to the manifold block locating holes which will indicate the correct
orientation.

STEP ACTION

4. With the BOP lying horizontally, place the end cap assemblies on the flat
alongside the BOP in their respective positions.

NOTE!
Check the orientation of the end caps to ensure that the rams are in the correct orientation.

STEP ACTION

5. Grease the rams, seals and BOP body threads.

6. Assemble each ram/end cap assembly to the BOP body as per 6.2.3.

NOTE!
Ensure that seals are not damaged.

STEP ACTION

7. Identify the lower adapter and fit the appropriate seals and seal ring (if
applicable).
8. Grease the lower adapter external threads and relevant BOP body
threads.
9. Locate collar onto lower adapter.

10. Fit lower adapter to the BOP body and tighten using the non-marking
strap wrench (Connection does not require tonging).
11. Fit male thread protector to the lower adapter assembly.

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Page 44 of 60
12. Identify the upper adapter and fit the sealing ring (if applicable) and
appropriate seals.
13. Apply grease to the adapter external threads and BOP body threads.

14. Fit upper adapter to the BOP body and tighten using the non-marking
strap wrench (connection does not require tonging).
15. Fit the female thread protector.

16. Fit the Block Manifold assembly as per section 6.2.2 actions 14-19.

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Page 45 of 60
7 MAINTENANCE AND TESTING
7.1 ROUTINE MAINTENANCE

7.2 MAJOR MAINTENANCE

7.3 TESTING

7.4 TROUBLESHOOTING

7.5 MAINTENANCE RECORD SHEET

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7.1 ROUTINE MAINTENANCE

NOTE!
Refer to Section 1 for general safety information before carrying out any maintenance and
testing routines.

WARNING!
The Bop assembly is heavy; check that the lifting and handling equipment can support this load.
Never position yourself under the suspended equipment.

NOTE!
Refer to build specific assembly drawings for equipment details, e.g seal kit part numbers and
service details.

NOTE!
BOP’s need to be carefully maintained to perform properly.

7.1.1 BEFORE EVERY JOB

• Check the equipment maintenance record sheet to ensure the

equipment has been maintained by competent personnel.

• Check all threads, seals and sealing surfaces for damage that might
impair sealing. Repair or replace as necessary.

• Open and close the rams.

• Carry out test procedure to working pressure.

• Verify that well site test pressure does not exceed the working pressure
rating of that of the equipment.

• Pressure test the complete hook-up.

• Close the equalizing valve on the manifold block.

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7.1.2 AFTER EVERY JOB

NOTE!
Fully dismantling and cleaning all parts that have seen well fluids and debris will extend the life
of the product. The time between the end of the job and maintenance is when the equipment is
most at risk from corrosion.

NOTE!
Avoid steam cleaning any internal bores that have corrosion resistant coatings. Grease the
internal bores using a cloth/swab.
These coatings are sacrificial and may need re-applied periodically.

• Remove the end cap and ram assemblies from the BOP. Remove any
residual well deposits and clean the BOP thoroughly.

• Remove all well pressure seals from ram assemblies, lower adapter
union pin and end cap/BOP body connection pin.

• Check all threads

• Inspect all seals and sealing surfaces. Replace any damaged sealing
rings and back-ups.

NOTE!
Normal wear will be a moderate amount of extrusion downstream of the pressured side. When
useage has resulted in any noticeable loss of rubber or the bond between the metal and rubber
is separating – REPLACE THE SEALS.

• Before re-assembly spray end cap pockets, rams and ram bores with
corrosion inhibitor spray (L-883050)

• Test all functions at working pressure.

• Complete maintenance record sheet and affix dated chart.

• Open dump valve.

• Close equalization valve.

• Reassemble as per the assembly instruction in Section 6.

• Function test by opening and closing the rams.

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Page 48 of 60
 NOTE!
If the job contained any of the following then it is advisable to strip the end cap and manifold
assemblies replacing all seals that see well pressure.

• Extended exposure (>48 hours);

• High pressure gas.

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Page 49 of 60
7.2 MAJOR MAINTENANCE
All WHE shall be surveyed at regular intervals and at least once per year. An annual
survey usually consists of a visual inspection and dimensional checks for ovality of
tubulars and threads. For all jobs over 5,000 psi, the hydrostatic body test and
operational test shall not be older than 3 months. A verification procedure should also
be carried out after every job where the WHE has been subjected to extraordinary
conditions, such as rough handling, bending, accidental drops, corrosive fluids,
unexpected H2S or CO2 during standard service, or replacement of major parts.

All surveys and tests must be recorded in the equipment service record.

Renewal of certification requires a detailed survey and performance verification

carried out under the control of a certification agency. The need and frequency of
such certification renewal shall be determined by local regulations, but typically every
five years. All WHE pressure containing equipment should undergo a major re-
certification every five years based on the following general procedures:

• Visual inspection;

• Random thickness tests on risers, BOP, tool trap, ball check valve, tool
catcher and general bodies using direct measurements, ultrasonic or X-
ray.

TIP!
Refer to Elmar Technical Bulletin TB-735
Procedure for finding minimum acceptable wall thickness on pressure control equipment.

• Dye penetration or MPI examination on threads or any damaged area

determined at visual inspection.

• Hydrostatic body test to Test Pressure.

• Function tests at Working Pressure.

• Review of Quality Files.

All WHE having undergone three 5 year major re-certification should be retired
before the fourth re-certification is due.

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Page 50 of 60
7.2.1 TO BE CARRIED OUT ONCE A YEAR
1) Carry out Routine Maintenance procedure.

2) Replace all 'O' rings, inspecting all components and sealing surfaces for
corrosion or damage along the way. Pay particular attention to the
surfaces below the rams.

3) Rebuild BOP using seal kits and pressure test to Test Pressure.

4) Function test at Working Pressure

5) Complete maintenance record sheet and affix dated chart.

7.2.2 TO BE CARRIED OUT EVERY FIVE YEARS

1) Carry out complete disassembly of all components.

2) Remove all o-rings.

3) Inspect all components and sealing surfaces for corrosion and damage.

4) Magnetic Particle Inspection (MPI) of all parts.

5) Rebuild BOP using seal kits and any necessary new parts.

6) Pressure test to test pressure.

7) Function test @ Working Pressure

8) Third party certificate of final test and inspection, certificate of conformity

and lifting certification (BOP Cage).

9) Complete maintenance record sheet and affix dated chart.

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7.3 TESTING
The pressure rating of any item is expressed in pounds per square inch (psi) and it is
shown as a test pressure (TP) rating and a working pressure (WP) rating.

Every item of pressure control equipment has a particular pressure rating, and care
must be taken to ensure that no item is used in a situation that might cause its
working pressure to be exceeded. Although the test pressure rating is always higher
than the working pressure rating, the difference between the two must never be
considered as a safety margin. This is because the actual use of the equipment
under field conditions involves forces that result from both well pressure and
mechanical stress. For this reason, all pressure control equipment must be handled
and secured in such a way that the external stresses are kept to an absolute
minimum.

The overall WP rating of the assembled equipment shall be equal to the rating of the
weakest component. All components used shall have a valid dated test record;
including a hydrostatic body test to TP. Equipment lacking a current test record shall
not be used. The well site TP shall never exceed the equipment WP rating.

The wellsite TP shall be 1.2 times maximum potential wellhead pressure (MPWHP).
If no wellhead pressure is expected, the equipment shall be tested at 25% of its WP
rating. All wellsite pressure testing and the pressure test values obtained shall be
noted on the equipment service report. The use of a pressure recorder (chart or film)
is recommended during wellsite pressure testing.

All adapters, flanges etc., shall be tested. It is recommended to test as much of the
equipment assembled together as possible. Valves must be in the partially open
position during the body test. Test plugs with a pressure rating equal to or higher
than the equipment that is being tested shall be used to cap open ended
components.

Adequate warning signs shall be displayed and all unnecessary personnel cleared
from the pressure testing location during the pressure test.

WARNING!
Trapped air requires considerable time to compress and when it is compressed is highly
dangerous. It has enough stored energy to separate parts with considerable force.

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 WARNING!
Clear the area of unnecessary personnel and ensure procedures are in force to prevent
personnel from entering the test area. Pressure testing should only be performed by competent
personnel.

7.3.1 BODY PRESSURE TEST PROCEDURE

1) Locate the test plug and test cap on to their appropriate ends.

2) Bleed off all air within the assembly.

3) Ensure all external surfaces are dry.

4) Pressure test to test pressure for 3 minutes

5) Reduce pressure to zero and repeat test for 15 minutes minimum.

6) No leakage acceptable.

7.3.2 BOP MANIFOLD TEST PROCEDURE

Refer to relevant BOP assembly drawing for test procedure.

7.3.3 BOP RAM TEST PROCEDURE

If a test is conducted to the full test pressure, the rams should be open to prevent any
unnecessary damage to the ram seal. Testing with the rams closed should not be
conducted above the rated working pressure of the BOP.

If slickline inner seals are fitted, testing the BOP rams seals should be done 'blind'
with no test rod in place.

If line sized or multiline seals are fitted then a test rod must be used to prevent
damage to seals (Please contact Elmar for availability and selection of test rods).

WARNING!
Ensure personnel are familiar with the manifold configuration of the Single BOP before
operation.

• Close the manifold equalisation valve.

• Pressure test to WORKING PRESSURE through the test cap/stump for 3

minutes minimum below the ram assembly.

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Page 53 of 60
 • Bleed to Zero.

• No leakage acceptable.

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Page 54 of 60
7.4 TROUBLESHOOTING
Problem Possible Cause Corrective Action

Cartridge (a) Valve open (a) Turn clockwise to close

valve does
not seal
(b) Seals damaged/missing on (b) Inspect & replace as
cartridge seat necessary
(c) Metal surface
damaged/corroded on stem or
seat
(d) Stem seal leaking
Manifold leaks (a) O-ring between manifold
between BOP and body is damaged or
body & block missing
(b) Manifold block screws not
tight enough to energise seals
Cannot (a) Manifold Valve open
achieve seal
on rams
(b) Rams not dressed for
correct line size.
(c) Inner/outer seals in poor
condition
(d) Rams do not close
(e) Excessive corrosion of ram (e) Depending on severity
bores
(f) Damaged valve stem, worn
valve seat or damaged seals
Cannot (a) Valve closed
equalise
across BOP
(b) Manifold hydrated or
plugged
__________________________________________________________________
(c) Inspect & replace as
necessary
(d) Loosen gland locking
device & tighten gland nut
until leak stops. Retighten
locking device. Replace stem
seal if damaged
(a) Inspect and replace as
necessary.
(c) Tighten manifold block
screws to 35lb.ft (47Nm).
(a) Review & close required
valve
(b) Check
(c) Check & replace
(d) Rams obstructed. Seals in
end cap damaged or worn.
either remove corrosion and
spray corrosion inhibitor (L-
883050) or consider Inconel
625 inlay.
(f) Check and replace as
necessary.
(a) Review & correct as
necessary.
(b) Inject glycol/methanol
NOTE: do not exceed BOP
maximum working pressure.

Page 55 of 60
7.5 MAINTENANCE RECORD SHEET

Date Type of Performed Verified Comments

Peformed maintenance by by

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Page 56 of 60
8 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL
8.1 TRANSPORTATION

8.2 SPARES AND ACCESSORIES

8.3 DISPOSAL

Page 57 of 60
8.1 TRANSPORTATION

• The BOP assembly should always be stored with:

• The manifold equalisation valves closed;

• Top and bottom quick union threads protected;

• Protection from moisture ingress;

Whenever possible, the BOP should be enclosed in a protective cage during use and
stored in the transport frame when not in use.

8.2 SPARES AND ACCESSORIES

8.2.1 SPARES
Use only Elmar recommended spares.

For seal kit part numbers and spares parts, refer to the relevant Technical Illustration
supplied with the equipment.

All wireline valves are supplied as standard with Nitrile elastomers for all sealing
elements apart from the ram sealing elements which are Fluorocarbon (FKM). A
wide range of alternative compounds, for various service conditions, are available on
request. Contact the Elmar Sales Department for details.

Recommended spares:

• Seal Kit

• Ram Inner Seals

• Ram Outer Seals

8.2.2 ACCESSORIES
Elmar can supply a range of accessories for handling, testing and assembling the
Single Manual NRS Wireline Valve. The use of any other accessories is NOT
recommended as this could lead to damage that may result in failure of the
equipment.

Elmar can supply end adapters for various quick union sizes. Contact the Elmar
Sales Department for details.

Page 58 of 60
For accessories that do not have part numbers stated contact the Elmar Sales
Department for details. The part numbers for these accessories change depending
on the quick union being used.

Recommended Accessories

• Quick Union Test Plug

• Quick Union Test Stump/Cap

• Test Stump Mounting Table

• Quick Union Lift Bail

• Male thread protector (steel or plastic)

• Female Thread Protector (steel or plastic)

• Protection Cage

• Drift Gauge for 5.62”ID Pressure Control Equipment (Elmar Part No L-

975688)

• Non-Marking Strap Wrench (Elmar Part No L-840957)

• Grease (Elmar Part No L-881720)

• Anti-seize compound

• Manifold Gauge Kit 5K (Elmar Part No L-660492)

8.3 DISPOSAL
When the product approaches its twentieth service year it should be retired.

Ensure that the product is disposed of in a responsible manner and that any local
legislation is observed. Elmar can assist if required.

Page 59 of 60
9 DRAWINGS AND BILLS OF MATERIAL
For drawings specific to purchased equipment, refer to the drawing package supplied
with the equipment.

Page 60 of 60