INDEX NO, ‘MODEL | WSPES Y. eo Weatherford ee Technical Unit For 4-1/2” X 3.813” WSPE-5 Optimax Tubing Retrievable Safety Valve TDA4500-00-01[Roexno MODEL | WSPE.S ASSY, “TDA4500-00.01 REV, 00. D, ‘TABLE OF CONTENTS 1.0 DESCRIPTION 2.0 OPERATIONAL DATA 3.0 DIMENSIONAL DATA 4.0 BILL OF MATERIALS 5.0 HYDRAULIC CONTROL LINE FLUID 6.0 ASSEMBLY/DISASSEMBLY TOOLING 7.0 DISASSEMBLY PROCEDURES 8.0 ASSEMBLY PROCEDURES 9.0 HANDLING & STORAGE 10.0 RUNNING/PULLING PROCEDURE 11.0 MAINTENANCE/SERVICE TESTING 12.0 TROUBLE SHOOTING 13.0 FIELD REPAIR 14.0 VALVE REDRESS: 45.0 FUNCTIONAL TEST DATA 2038Sd TNDEX NO, MODEL | WSPES Weatherford 8 12-May-2005 1.0 Description The Optimax™ WSP(E}5 Slim Line Tubing Retrievable Safety Valves are 5,000 psi rated working pressure, equalizing or non-equalizing tubing mounted safety valves with a premium redundant piston ‘seal stop feature. ‘These valves are designed to minimize the loss of reservoir resources, of production equipment resulting from catastrophic surface or subsurface events, by shutting in the well. This is achieved by design; the normally closed safety valves are controtied from the surface via a hydraulic control line that extends from the valve, through the wellhead to a surface controlled emergency closure system. Hydraulic pressure applied through the control line maintains the valve in the opened. Removal of control line pressure retums the valve to its normally closed position. Setting depth directly affects the ‘operational characteristics of the valve. Therefore, these valves are offered in various setting depth configurations to ensure that falleate operation is achieved. Optimax™ tubing retrievable safety valves are offered with a full compliment of remediation tools to either lock the valve opened or establish hydraulic communication. ‘The Optimax™ Lock Open Tool permanently locks the valve in the full opened position allowing the valve to be pulled from the weil or accept an Optimax™ Wireline Retrievable Safety Vatve, a separation sleeve, or any other equipment that may require the safety valve to be permanently locked open. The Optimax™ Communication Too! Is used to penetrate the tubing retrievable safety valves’ hydraulic piston bore, establishing control line pressure to the bore of the valve. This allows the existing hydraulic contro! system utilized for the tubing retrievable safety valve to be used to operate the Optimax™ Wireline Retrievable Safety Valve set within the tubing retrievable valve, providing continued failsafe operation. 30f 38 eee eeyy INDEX NO. MODEL | _WSPE-S. ee Weathertont ate DATE 12-May-2005 2.0 Operational Data Features Tubing Retrievable SCSSV 5,000 psi Working Pressure ‘© Ferrule Nut Hydraulic Fitting Premium Redundant Piston Seal Minimized Number of potential leak paths ‘Stops (optional) ‘= No complicated intemal vave components for lockopen or ‘+ SettEquatzing Option secondary communication ‘All Metal Body Joints + Optimax™ Lock Open Too! + NonElastomeric Seals = Optimax™ Communication Too! Operating Data Mode! wsPES Tubing Size (in) 412 Polished Bore Min 1D (in) 3813 API Service Class 382 Maximum Control Line Pressure (psi) 7,500, Rated Working Pressure (psi) 5,000 Test Pressure (psi) 71500, Piston Displacement (in?) in? Temperature Range 6) Hydraulic Fluid 20300, Temperature Range CF) Water Based Fluid 40-300 Operating Pressures 2.0008 Setting Depth Full Open Operating Pressure (psi) 2.250 (max.) Full Closed Operating Pressure (psi) 90 ¢min.y Maximum Setting Depth Maximum FSSD w/ Salt Water in CL (ft) Maximum FSSD w/ Hydraulic Oil in CL (R) Yield Pressure burst and cotapse (psi) 9,231 17,858 Collapse pressure @ max temperature (psi) 7,308 Tensile Rating @ max temperature (Ibs) 295,406) Tensile Rating @ ambient temperature (Ibs) 317,641 ‘Material Trim ser Fail Safe Setting Depth (FSS) Calculation (2000" spring force in the closed position) Total Piston Area (in?) A Sea water Gradient (psift) Gow Hydraulic Fluid Gradient (psift) Git Safety Factor Pressure due to Spring Force @ closed (psi) P=FS/A Max FSSD w/ Sak Water in Controt line (8) PAGew)1.20) Max. FSSD w/ Hyd. Fluid in Control fine (R} PAGHfX1.20)ROSS w aoe a Weatherford” a DATE Notes: * Piston Displacement is the nominal volumetric calculation of fd required to fully stroke the valve to the ‘opened position and does not consider the physical characteristics of either the control line fuid, seal stack deflections, and or temperature or pressure related deflections in the control line, the hydraulic chamber housing piston bore, or piston components. For best selection of water based control line fuids for the specific completion temperatures of the well, refer to the manufactures materials properties and specifications, not all water based contro! fine fluids are applicable to this terperature range. o" Maximum faiisafe setting depths have been cakulated considering seawater as the heaviest fluid gradient in the completion. Completions utiizing annulus fluids may offer fluid gradients greater than that of seawater, Failsafe closure is directy affected by and dependent on the level of hydrostatic pressure developed by these fluids and should be adjusted accordingly to accommodate heavier fluid gradients in ‘the annulus in the event that the control line should break. ‘sw Safety Valve tensile ratings do not consider end connections. Ifthe tensile rating of the valve and the tubing thread happen to differ, the lower of the two must be selected as the overall tensile rating. For questions related to thread selection please contact Weatherford Completions Systems or see the thread ‘manufactures specifications for information relating to tensile ratings for specific tubing threadsyw THDEKNO. MODEL WSPE.5 ameter Weatherford ee DATE, 12-May-2005 3.0 Dimensional Data Maximum 0.0. (in) esas Minimuen 1D. (in) 3813 ‘Overall Length (in) 7.00 Flow Tube TravelStroke in) 7454 Distance from landing profile no-go to equalizing dart (Rapper closed) (in) 47.651 Min. upper hone bore length (starts at no-go) (i) 77 Distance trom landing profie no-go to top of lower hone bore (in) 53.955 Distance from landing profie no-go to bottom of tower hone bore (in) 60.121 Special Kitting and Tools Redress Kit ‘TDA450000-01 Repair Kit TDAA500-00-01 Dit Ber See Next Page ‘Torque Shaft (spring compressor} 190646, 100068 Piston Assembly Installation Tool 00424 Premium Stop Torque Tool 100683 Remediation Tools ‘Optimax™ Lock Open Too! Tao Optimex™ Communication Tool TD ‘Optimax™ Wireline Retrlevable Safety Valve Teoyw INDEX NO. oer ware Weatherford’ See ses tran on rs Drift Bar Serial ‘Nominal Drift ie toate” | view [aes | cores | oe | ua vows [tas | tam | somone | ow | arcs sioswrs—[ rare [ts soon cens [ene [aa Sinz | “ae [oem | sa 000m [ ar en SVDB2310 2310 2.300 #0.000 / -0.005 002 36" +0250 Svommes [sash | —aas6 | ora | a Simmee [caret [ase | ora |g [aaa svorzre [gam [game [aero [ae [a en SVDB3313_ 3.313 3.303 +0.000 f -0.005 002 36" +/-0.250 SVDB3437 3.437 3.427 *0.000/-0.005 | 002_|__36" +/-0.250 SVDB3688 3.688 3678 +0.000/-0.005 | 002 36" +/.0.250 ‘SVDB3750 3.750 3.740 +0.000/-0.005 | 02 | 36" +/-0.250 Sang | og [sap] sassoroom [ae [se cts swets[ tie —[ ase | ese [oe | ore sve | a3 | aa | mor00m am [arc en ‘SVDB4562 A562 4552 +0.000 f 0.005 002 36" +/-0,250 svosues | “are [ss [suo [eee [ar arr SVDB4750_ A150 4.740 +0.000 /-0.005 002 36" +/-0.250 svoaeno [eno | ss | orrars |p ar svcserg “seo [sets | voworoom[aer [ ar svonsses | s.003 sasa__ | +0.0007-0005 [oo [oer +10804.0 Bill of Mater General Parts List (Sample BOM ONLY) DESCRIPTION TOP SUB HYDRAULIC CHAMBER HOUSING ISTON SEAL ASSEMBLY PREMIUM SEAL ASSY/BEARING FLOW TUBE PISTON UP-STOP PISTON GRIP "WAVE WASHER STACK [RETAINING RING PISTON RETAINER POWER SPRING “SPRING HOUSING ‘SPACER BEARING saleisee oa |a}=|-} |} 4) | |=} f-| 18) FLAPPER ASSEMBLY. BOTTOM SUB TNDEX NO. ‘MODEL | WSPES ASSY. TDA4500-00.01 REV. 00) (pate 12-May-2005 801 38wv INDEXNO, MODEL | WSPES Hees — Tronics Weatherford Ley. “Ps (Ste — Traswy INDEX NO. MODEL | WSPES SE neat Weatherford’ fev DATE May-2005 5.0 Hydraulic Control Line Fluid ‘The proper selection of a hydraulic control fine fuid is extical to the operation of a surface controled subsurface safety valve SCSSV. Factors relating to the well and the specific properties of the hydraulic control line uid chosen may have an Impact on valve performance, such as increased closure response time. Cleanliness - Hydraulic fuids must remain relatively clean and free from solids to minimize the potential for seal weat ‘and or damage. Hydraulic ids shoul! maintain a cleanliness consistent with NAS-1638 Class 7 or better. A firing system with a suction fiter of 40 microns or better may need to be installed into the hydraulic system to achieve the required hydraulic fluid cleantiness, Response Time ~ The duration of ime that elapses from the instant surface pressure is released to closure of the ‘SCSSV. Factors that directly influence response time are contro ine langth, control line size (determined by wal thickness), Nid viscosity, and wel temperatures, amid other considerations. (Lower viscosity fluis may need to be considered in unusually cola ‘environments, of for completions where excessively long control lines are utilized.) Temperature Effects ~ Primarily temperature effects alter the viscosity of the hydraulic Nuid, however, the fid ‘selected must also remain thermally stable if elevated temperatures are a factor At extreme temperatures, oll based hydraulic fuids may tend to break down, leaving deposits on wetted ‘components. “Therefore, ensure the fuid selected is stable beyond the operating temperature for which it will be exposed. Woeter-Based Hydraulic Fluid ~ Control line fuids that primarily consist of 50-75% water, 25-60% glycol, and between (0-10% corrosion additives. Water based fuids are widely used in sub sea applications for environmental consideration and for low viscosities, to control response time in longer sub sea control ines. However, metallic components exposed to water-based control line fuids may corrode, therefore, careful selection of ‘metallurgy exposed to the fluid in combination wth corrosion inhibitors added to the ‘uid will minimize correctional effec. ‘Special Considerations ‘Water-based control line fuids require special handling to prevent contamination either by debris or from ‘other hydraulic control fluids. Avoid cross contamination of water-based control line fuid with hydrocerbon-based fuids (oil, grease, diesel, etc.) if a new SCSSV is required to utiize a water-based hydraulic fuid, the safety valve manufacturer must be notifed in advance of the intent to use a water- based hydraulic fluid to ensure proper SCSSV preparation (See API 14ANSO 104321909 Annex F. Checklist of Suggested Ordering Information for SSSV Equipment). For redress of SCSSVs, only those lubricants spectied by the fluid manufacturer should be used in or around the hydraulic control fuid ‘chamber. Recommendations specific to control tine fluid applications can be obtained from Weathertords’ ‘Completions Engineering Department Page two of this document summarizes some typical hydraulic oils Used for SCSSV application and ther respective properties.yw TNDEXNO, MODEL | WEPES iar | Youraa Weatherford’ ef Lite — aera Recommended Control Line Fluids “The selection of a hydraulic ol for application as a control line fluid in a Weatherford SCSSV should at a minimum _meet the following properties: Oil-Based Hydraulic Fluids: Fluid Property _| Units 150 S.USS. at 100 Degrees F Viscosity 44 SUS. at 210 Degrees F Weight ow, Viscosity Index 100 Minirnam Pour Point 35 Degrees F ‘Open Cup Flash Point 400 Degrees F Properties include addfives fo minwmize foaming and oxidation ‘Hydraulic Oils that meet the above requirements: Manufacturer Trade Name. Faas Turbin OF 32 Industrial 32 ‘Aico Duro $180) ‘Chevron (OC Turbine 32 Exon "Teriesbe 32 Nuto 32 Turbo 32, Shel a Texaco Rando HD 32 ‘The tabulated fuid properties and fui types are satisfactory for SCSSV applications through temperature ranges from 20-300 Degrees Fahrenheit. For applications outside of this range, special fuids may be required Water-Based Hydraulic Fluids Fluid Property Units 2.1 eSt at 100 Degrees F Viscosity 5.0 oSt at 32 Degrees F Pour Pot — [ras Dogees F Open Cup Flash Pont [None Properties include addtives to minimize foaming, oxabon, and biological growth, Water-Based Hydraulic Fluids that meet the above requiremer Manufacturer ‘Trade Name Castrol “Transaqua [ Houghton Offshore ‘Agualink HTBGE MacDermic ‘Oceaniae6.0 Required Tools and Supplies for Valve Assembly and Disassembly Lubricants (general) Moly-Graphite Grease (Black Tube) Moly Coat (Spray Can) Thread Lubricants ‘CRC- Moly-Graphite Grease (Black Tube) Degreaser ‘CRC- Degreaser ‘Thread Seatants/Adhesive Loctite™ 222 (purple) is @ low strength formula suitable for smal! fasteners, long engagement lenath fasteners, and components requiring occasional adjustment. Best used with 14" and smaller screws, removable with ight hand tools, Approximately 45 in-b of breakout torque. Loctite™ 242 (blue) is a medium strength formula suitable for "and k with tight hand tools. Approximately 80 indb of breakout torque, er fasteners, itis removable Loctite™ 262 (red) is a high temperature/ high strength formula designed for extreme environmental ‘and chemical conditions. Particularly useful for heavy shock, vibration and stress levels, Removable with heat and heavy hand tools. Approximately 160 intb of breakout torque Loctite™ 272 (also red) isa high temperature and high strength formula for extreme duty applications. Good ‘or temperatures up to 450 degrees F. Removable with heat and heavy hand tools. Approxmately 160 into ‘of breakout torque. ‘Specialized Assembly Kits Seat Assembly Kit (TBD) Press ft plunger (Brass Hydraulic Press Flapper Mount Torque (TBO) ‘x torque pins, cap screws. ‘Spring Compressor Kit (TBD) OPTIONAL FOR HORIZONTAL ASSEMBLY ‘Aluminium Fly wheel, Aluminium Disc, 1-8 TPI all thread and back up hex nuts. ‘Specialized Tools Piston Assembly Installation Tool (TBD) Premium Stop Torque Tool (TBD)INDEX NO, MODEL | WSPES ASSY, “TDA4500-00-01 REV. 00. DATE 12-May-2005 Miscellaneous Tools and Equipment ‘Vacuum Plate Ficure System Soft jawed Vice Magnification lens light CraneMost Steady Rest / Pipe Stands ‘Two Small Chain/Strap Wrenches ‘Two Medium Chain/Strap Wrenches ‘Two Large Chain/Strap Wrenches Hydraulic Hand Pump Bubble Level Required Toots ITEM ‘Smait Hard rubber hammer ‘Small crescent wrench 11782" open-end wrench (Piston nuts) 414" open-end wrench Box end wrenches sizes Allen Wrenches Flat head sctew Drivers small fo large Needle Nose Phers 12° Pipe Wrench 16" Pipe Wrench 36" Pipe Wrench Torque Wrench 50-65 tb range Center Punch toot kit av Cnaaetnte 2TNDEX NO, MODEL [-WSPES io Aeon Weatherford Hata DATE 12-May-2005 7.0 Disassembly Procedures Pre-Disassembly Prior to disassembly verify the appropriate assembly drawing revision and exploded parts Ist are used to fd in the identifeation of components in the assembly (refer to Bill of Material Manual). Record the ‘assembly model number and serial numbers for each valve, if more than one valve is being disassembled care should be exercised not to mix parts between valves. Prior to disassembly ensure the appropriate tooling is used; refer to the assembly/disassembly tooling section for required disassembly tools end supplies Disassembly 1. Break all body joints with torque machine. If pup/joints or top subs are stil attached to the safely valve, break connections in each prior to breaking the valves’ body joint connections. Record each safety valve body joint breakout torque. 2. Remove pup-oints and top sub prior to disassembly (if applicable) Transfer the vahe to a vertical vice. Begin safety valve disassembly. 3. Clamp down on the lower Bottom Sub (ensure not to clamp through thin section if possible, avoid Using excessive force in vices on thin walled sections of parts) ‘Top Su and Chamber Housing Removal Using @ strap wrench remove the Chamber Housing and Top Sub from the valve. Using @ crane and @ liting eye attached to the Top Sub remove the Chamber Housing with the Top Sub connected and set, aside. Lif the Chamber Housing approximately eight to ten inches to access the Piston and Piston Grip. Use ‘a 10 mm open-end wrench to disassemble the Piston from the Piston Grip, Lift the Chamber Housing off of the end of the Flow Tube, Extract the Flow Tube and Power Spring from the Spring Housing, While supported by the crane remove the P-feature and extract the Piston assembly from the (Chamber Housing, Place a thread protector over the Chamber Housing pin thread and place the Top SubiChamber Housing sub-assembly on a pallet 7. Re-adust the strap to balance the load and lif the Top Sub/Chamber Housing into a horizontal vice. Clamping on the Chamber Housing 8. Using @ jack stand to support the Top Sub weight, remove the Top Sub from the Chamber Housing and place both rtems on a pallet. Shing Housing Boom Sub/Ftapper Mount Dssesemby Reposition the remaining valve (Spring Housing/Bottom Sub) ina horwontal viee, to prepare to remove the Bottom Sub, 2. Position a jack stand under the unsupported Bottom Sub to create a straight centerline and be as Square as possible (use of a Bubble level is recommended). Care should be exercised to prevent galling of the threads, 3, Remove the Bottom Sub to expose the Flapper Sub-Assembly. 4. Place the Flapper Assembly Tool Shim (TBD) over the end of the Flapper Mount aligning the slots with the pinholes, 5, Slide the RT Flapper Mount Assembly Tool over the end of the Flapper Mount and the Shim. Align the tapped notes to the pinholes in the Flapper Mount. 6 Insert the six Torque Screw Pins, apply between 2 to 3 ftibs of torque to the pins. eae eer tn tern stewv TNDEXNO, MODEL | _WSPES ke Pian Weatherford’ a8 DATE 12-May-2005 7. Transfer the Spring Housing to a calibrated torque machine and break the Flapper rrount from the ‘Spring Housing, 8 Set the Spring Housing on a pallet and see Flapper Module disassembly procedure. Piston Up-Stop and Flow Tube Disassembly 1. Apply torque to break the connection between the Piston Grip and the Piston Retainer using spanner ‘wrenches. This will alow disassembly and removal of the Retaining Ring, Piston Grip, Piston Retainer ‘and Wave Washer from the Flow Tube. Piston Disassembly 1. Disassemble the Piston sub-assembly by breaking the two lock nuts that retain the Piston Bearing at the end of the Piston, This will alow for the removal of the Piston Seal Stack, and the Premium Stop Seal Assembly, the Spit Ring Retainer and the Spit Rings. Flapper Module Disassembly 1. Use a 1/46 Allen Wrench to remove the Torsion Spring Pin Set-screws from the OD of the Flapper Mount 2. Pull the Torsion Spring Pins out of the Flapper Mount from above applying pressure to the Torsion ‘Spring leg in the Flapper Mount to prevent it from whipping around. 3. Use @ pair of phers and a small hammer to tap the Torsion Spring Pin out of the Flapper Pin, 4, Remove the remaining side using the same procedure, 5. Remove the Flapper from the Flapper Mount 6. If applicable, remove the equalizing dart and spring by placing the flapper in a vice with the spring and dart facing up. Use a 05 Allen Wrench to remove the Dart Spring set-screws. 7. Slide the Dart Springs our from under the recess and remove the equalzing dart from the flapper. Hard Seat Removal from the Flapper Mount 1. Place the Flapper Mount ito the Mount Holder Tool 2 Insert the Press Tools into the Flapper Mount and Hard Seat as shown in the Hard Seat Assembly Print (TBO). 3. Place the Flapper Mount and Tools into a hydraulic press with the Hard Seat facing downward. Use vee" notched plates to provide clearance for the Hard Seat and Tools to be extracted from the Flapper Mount. Center the Flapper Module and Tools to the centertine of the hydraulic ram. Press the Hard Seat out and allow it to fall into a bin with rags to prevent impact damage to the Hard Seat surfaces.y INDEX NO. ees Weatherford” fe Hite Seas 8.0 Assembly Procedures Pre-Ascembly Preparation Check List Aan emcee, 1 2 Collect the proper tooling, and test fixtures (Reference Assembty/Disassembly Tooling Module in this manual) ‘3. Ensure the tools are in good working condition. Use soft jaws to bold parts with critical surfaces, 10 void damaging them. Avoid using excessive force in vices on thin walled parts. Use calbrated torque wrenches where specific torque values are required. 4A. Collect the proper fluids; solvents thread sealantiadhesive and lubricants (Reference ‘AssemblyPDisassembly Tooling Module). For valves that use non-water based hydraulic fuids, apply slicone-based lubricants on dynamic seals land general use solvents to clean parts. For valves that use water based control line fuids, see work ‘order for special lubricants and solvents that are compatible with the specific water based fuld to be Prepare an exploded bil of materiais to document the exact parts that go into each specific safety valve assembly (part number, revision number, serial number, material specification and work order or heat batch number) and save all supporting documents and tags. NOTE: IF MULTIPLE VALVES ARE BEING ASSEMBLED, CARE SHOULD BE EXERCISED NOT TO MIX PARTS ‘BETWEEN VALVES. 10. Clean all components with a solvent and blow them dry prior io assembly. 11. Specific work order related or QA instructions should be highlighted to ensure they are followed. 12, Presnspect al critical dimensions, verify that all parts are im good condition, by visual Inspection in good Light and with magnification where required. 13. Check that all non-metal parts are dimensionally correct and are within usable shett ie 14, Ensure that all threads and edges are clean and free of burrs, surface defects and marks. Inspect ‘coatings for continuity. Inspect for physical damage or corrosion (especially for redresued valves). (D0 NOT USE WORN, PITTED OR DAMAGED PARTS. 45. Clean and examine all body joint connections (box and pin threads} Prepare the thresds for assembly by following Weatherford’s tread preparation procedures.vw INDEX NO. MODEL, se Weatherford” cS DAT! ‘TopiChamber Housing assembly Required Parts: Safety Valve Sub-Assembly, Top-Sub, Chamber Housing. Required Tools/Supplies: Jack-Stand, Moly-Grephite Lube, Bubble Level, Strap Wrench, 1. Remove the body joint thread protectors and inspect all body joint threads for unwanted marks Gee ‘Special Notes for Precautions), Refer to the body joint care section for thread repair or thread re-cut instructions, 2. Makeup the Top Sub to the Chamber Housing as shown in the assembly Gee Special Notes for Precautions). Use jack stands to adjust lit of the Top Sub to create a straight contertine i assembling horizontally and to ensure the assembly is as level as possible (Use of a bubbie level is recommended) 3. Extreme care should be taken not to gall the threads. Prep the threads according to the body joint thread care section and slowly hand thread the body joint, apply thin coat of Moly-Graphte lube to pin threads. Make-up the rest of the way with a strap wrench until ighty tight and stop. 4. Body Joint threads are to receive final makeup in a calibrated torque machine to the specific values ‘shown in the thread care section for this valve. Hydraulic Chamber Housing Required Parts: Chamber Housing. Required Tooling & Supplies’ Bore Scope, Air Gun, Denature Alcohol, Bore Swab Kil, 320 grit & 600 grit flex-tione, high speed dil (1200 RPM). 1. Place the Hydraulic Chamber Housing in @ soft jawed vice and remove the pinthread protector ‘a. Using a bore scope, check the finish of the hydraulic fing seal surface atthe contol ine port. b. Verify that the contol ine port communicates withthe piston bore ©. Clean all surfaces dry and ensure there are no buns remaining ftom manufacturing at the entrance tothe piston bore from the fiting hole 2. Blow shop air through the hydraulic chamber housing piston bore to remove any lage debris, continue to clean using denatured alcohol and a swab attached to a sof rod (akiminum or brass) to prepare the bore {or visual Inspection. Dry by reapplying air to the piston bore ad swabbing with dry swab. Repeat unl 2 fresh swab remains clean after removal from the bore. ‘3. Inspect the piston bore, using a bore scope w verify a 16 RMS finish, and ensure thatthe bore i fee from debris, manufacturing Muids, metalic shavings/burrs at the communication port to the bore, and or longitudinal scratches that refiect light when viewed with the skle looking Scope. A homogeneous crosshatch patiern should be present throughout the bore. ‘2. Lightlongitudinal scratches may be worked Out wth te use of aflexinone. Deeper scratches may require 2320 grit hexi-hone, folowed by 2600 grt exthone. ‘6 Once the bore has been honed, lean the bore and re-examine. W the scratches remain or there appears. to be deep piling the piston bore may be unusable. Call an engineering of manufacturing representative for further disposition. 4 Inspect the bore withthe bore scope starting with the forward looking scope: ‘a Inspect the PFeature threads, Seal Surfaces and leadsn chamfer into the piston bore. Ail should be clean and free from burs, cracks or any other imperfections that may affect the performance of the Premium Seal Assembly, or the Seal Stack during instalation Examine the ful length of the bore up to the communication hole. There should not be any ‘machining debris, ols or fis, or burs at the end of the hole where the communicaton and piston bore holes merge ©. Note depth of honing in the bore, ensure that tis to the depth speciied on the Hydraulic ‘Chamber Housing Print. 4. Look for longitudinal scratches, deep spirals, or tool marks in the bore. If any exist. use the side viewing scope to determine ther significance ¢. Seratches deep enough to interrupt the natural cross-hatch pattem of the hore are not acceptable and may damage the Seal Stack, consult WCS engineering, oF manufacturing for guidance, $7038 et rest ws err er eevy INDEX NO. MODEL | WSPES ean Weatherford’ ee DATE 12-May-2005 5. Once the bore has been inspected, prepare a swab dipped in conto! tine flux and cycle ft within the piston bore to prepare the bore to accept the piston assembly. Piston/Seal Sub-Assembly Prepare a clean work area equipped with a magnification lens/ ight. Required parts, Reter to Piston Assembly Drawing No. TED4500-A00': Piston, Seal Stack Assembly, Seal Stack Spit Ring, Spit Ring Retainer, Piston Seal Bearing Assembly, ‘#10 Washor , Two #10-32UNF Hex Nuts. Required Tools/Suppes: Red Lockite 262, 7/16" Open End Wrench (See Special Notes for Precautions). 1. Visually inspect the piston diameters to be sure there are no unwanted marks or sharp edges. 2. Using @ low powered microscope or a magnifying lens, visually inspect the seal stack ODs and IDs to be sure there are no unwanted marks or debris trapped within the energwzing springs. 3. Mask the threads on the end of te piston with Teflon tape to protect the seal stack ID as it passes over the OD of the threads. 4. Wet the entire piston seai surface OO with a small amount of appropriate contrat line fuid to provide Iubrcation. 6. Slide only the first haif of the seal stack carefully onto the piston one piece at a time. Refer to Seal ‘Stack Assembly Drawing No. 100156 for sequence of instalation (\e. Metal Energizing Sleeve (1), GTEnergized Seal (4), GT-Seal Ring! “White VARing’ (5), GT-Seal Ring “Black V-Ring” (6), GT-Back- Up Ring (7) in the direction shown in the assembly) Take precautions to avoid scratching the seal Internal diameters. 6. Place the Seal Stack Split Rings into the spit ingiretaining ring groove in the proper orientation as shown in the assembly drawing 100570, = 7. Carelully slide the Spit Ring Retainer over the Seal Stack Split Rings OD : {8 Install the remaining Seal Stack over the end of the piston this time in the opposite sequence, and {acing in the opposite direction as the first haf of the seal stack, one piece at a time. ‘9. Measure the OD of the Piston Bearing Assembly to ensure clearance win the piston bore (Bearing ‘OD should measure between .493 to .494 if the bearing is larger in diameter it must be reworked to the proper diameter, or @ replacement must be selected). 410. Remove the Teflon tape from the piston thread and slide the Piston Bearing Assembly into positon above the seat stack 111, Slide the #10 washer on over the Piston Bearing Assembly. 12, Secure the piston in a soft jawed vice along the flats. 18. Add a drop of Loctite™ 262 (red) on the thread nearest the Piston Bearing Assembly, make-up the frst of two #10-32UNF Hex Nuts onto the piston, When the nut frst becomes snug apply an additional % - tum to tighten the nut 14, Double check the Piston Bearing Assembly OO to ensure that it has not been compressed outward. 18. Add a second drop of Loctite™ 262 (red) to the end of the thread, makeup the second of two #10- 32UNF Hex Nuts onto the piston When the nut first becomes snug apply an addtional "ig - turn to tighten the nut. 16. Allow the thread lock to dry for 15 minutes prior to installation in the chamber housing. IF THE PISTON IS NOT TO BE INSTALLED AT THIS TIME, BAG OR SLIDE A PROTECTIVE ‘SLEEVE NET OVER THE ENTIRE ASSEMBLY AND PROPERLY TAG TO MATCH INSPECTION REPORTS AND ITS VALVE ASSEMBLY SERIAL NUMBER.INDEX NO, MODEL | WSPE:5 ‘ASSY. “TDAA500-00.0% REY, 00, DATE 12-May-2005 Piston Assembly Installation into Piston Bore Required part: Chamber Housing, Piston Assembly, Premium Seal Assmbly. 501. Required Tools/Supplies: Piston Assembly Installation Tool (Pt. No. TBD), Premium Stop Torque Too! (Pt No. TBD), Red Loctite 262, Hydraulic Control Line Fluid HT 443 (Water Based Application Only). 1. With the piston/seal stack assembly firmly secured in a soft jawed vice, and the lock tight cured, apply ‘small amount of appropriate control ine fuid to the Seal Stack Assembly and Bearing 2. Gently slide the Piston Assembly Installation Tool over the seal stack untl the lip of the upper MSE- Seal is fush with the edge of the Piston Assembly Installation Tool 2. Use swabs soaked wih the appropriate contol line fuid to wet the piston bore in the Chamber Housing, 4, Insert the Piston Assembly Installation Tool and Piston Assembly into the piston bore, make-up the Piston Assembly Installation Too! tight in the Chamber Housing 5. Using one continuous motion, slide the Piston/ Seal Stack Assembly into the Piston Bore, applying a constant axial force to the end of the piston. DO NOT PLACE SIDE LOADS ON PISTON DURING INSTALLATION. 6. Once the seals are in the bore, remove the piston installation tool and slide t off the end of the piston 7. Slide the piston out until the start of the flat toward the seal assembly side on the piston is fush with the entrance of the P-Feature hole. 8._Use shop ais to blow out the threads in the chamber housing for the Premium Seal Assembly. 8. With the thread end of the piston sticking out, slide the Premium Seal Assembly “P-Feature” over the end of the piston, threaded side first. Apply one drop of Red loctite 262 to the threads and make it up hand tight 10. Push the end of the piston up to within % inch of the end of the P-Feature, Be careful not to push the piston too far into the piston bore. Insert the Premum Stop Torque Tool and using @ Torque Wrench with a 14" dive and a “/d socket apply 60 indbs (5 ft1bs) of torque to seat the “P-Feature’ in the (Chamber Housing. 11, Remove the Torque Wrench, and prepare the flow tube and piston up-stop sub-assemblies for installation (refer to Flow Tube Assembly Procedure). Pull the piston out of the bore until about 7° of ‘the flat on the threaded end of the piston is protruding beyond the end of the pin thread of the chamber housing to prepare the piston to accept the flow tube/piston up-stop sub-assembly. Ifthe piston is, beyond reach, use hydraulic pressure to force the piston back out, Do Not fish around in the seal bore. 12 Refer to Final Assembly procedure for Piston sub-assembly to Flow Tube sub-assembly installaton procedure. Up-Stop Assy & Flow Tube Assembly Required parts: Spherical Insert, Piston Up-stop. Piston Grip, Wave Washer Stack, Retaining Ring, Piston Retainer, and Flow Tube, Required Tools/Supplies: Two Spanner Wrenches, Red Locktite 262, hydraulic press. UpsStop Assembly Inspect and clean all threads. 2. Inte the Speral Ie ho the Pit Up-Gtop to prepare to press the two components together (Refer to Piston Up-Stop Assembly print TBD). 3, Place the two components in a hydraulic press and apply 1000 Ibs of force to press the Spherical Insert into the Up-Stop. aaa aal ewe rates crm ov nityw INDEX NO. ope wares Sea toe Weatherford’ a fs 12M Flow Tube Assembly 4. Insert Flow Tube into Piston Retainer as oriented in the assembly drawing 2. Slide the Retaining Ring over the "Scraper" end of the Flow Tube and seat it inside the Piston Retainer. The flat side of the Retaining Ring should le fat on the Flow Tube shoulder as shown in the assembly drawing 3. Install the Wave Washer Stack over the Retaining Ring and inside the Piston Retainer. 4, Make-up the first few threads of the piston retainer and the piston gnp to hold the parts together in @ semi-assembled state. 5. Insert the Up-Stop Assembly into the Piston Grip groove as shown in the valve assembly print, place ‘mail amount of Red Locktite 262 to the Piston Grip threads and begin to make the Piston Grip and ‘the Piston Retainer up. 6. Using spanner wrenches tighten the Piston Retainer and the Piston Gip up and set the sub-assembly tothe side, FlapperiHard Seat Matching Required Parts: Flapper, Hard Seat and Soft Seat, Flapper Pin Required Tools & Supplies: Boron Carbon or Diamond Lapping Compound, Vacuum Piate Test Fixture, Hard Seat Press in Kit (Assy. # TBD), 1-1/8" socket with 14" drive, Graphite Grease. Hard Seat/Flapper Mount Assembly 1. Ensure there are no visible defects or scratches traversing the seat surfaces for either the Hard Seat or the Flapper. 2 Place a light source under the Hard Seat, set the Flapper on the Hard Seat and check for gaps. between the seat surfaces. A thin band of light may be visible (approximately 001 - .003 inches in width), rotating the flapper 180 degrees may minimze the visible light band. if excessive gaps are found, either the Hard Seat or the Flapper may be non-conforming and should be replaced. ‘3. Once the "Best orientation has been determined to minimize the light gap, mark the ID of the Hard Seat with a permanent marker locating the flapper hinge side to ensure that the Hard Seat is installed into the Flapper Mount in the proper orientation with respect to the Flapper. 4. Apply a thin coat of lubrication to the Flapper Mount threads and Screw the Flapper Mount into the Mount Holder. Place the Flapper Mount and Mount Holder on a flat surface to prepare to receive the Hard Seat, 5. Place the Plunger Tool on a flat surface with the Hard Seat end facing upward, place the Hard Seat over the Plunger Tool (Refer to RT Flapper Assembly Tool Drawing (TBD) érawing for onentation) 8 Slide the Hard Seat Press Tool over the Hard Seat Surface, insert the 24'-10 cap screw into the Hard Seat Press Tool and slightly tighten the components together. 7. Using the engine lube grease, apply a thin fim of lube to the Hard Seat OD and the Flapper Mount ID, ‘taking care not to spread lube on the bottom edge of the Hard Seat or on the shoulder surface in the Flapper Mount. 8 Insert the iting handle into the Hard Seat Press Tool and lit the Hard Seat and Tools into the Flapper Mount. NOTE: Care should be exercised to ensure the previously identified “Hinge Side” of the Hard Seat is otiented to the hinges of the Flapper Mount prior to installation, 9. Remove the iting handie, and place the assembly into the press. 10. Stroke the press downward inti tis just above the Hard Seat Press Tool, Use a scale to ensure the ress-in tool assembiy Is aligned to the center of the press ram. Adjust the speed of the hydraulic piston to within a rate of .16 to .20 infsec (1 inch in six to five Seconds). Stoke the hydraulic piston downward to make contact with the Pressin Toolyw INDEX NO, MODEL | WSPE-S Sea Weatherford” ae fs ia DAT ‘12-May-2005 42. Stroke the Hard Seat downward into the Flapper Mount until it bottoms out, Continue applying hydraulic pressure until 000 Ibs of force has been applied to the assembly. 13. Remove the Flapper Mount and Hard Seat assembly from the press and disassemble the took. 14, Transfer the Flapper Mount to the Vacuum Plate Test Faure. Flapper Lapping/Vacuum Testing ‘Test the Vacuum Plate Test Fiture using a blank test cap, to ensure the system will pull and hold 2- 30 inches of mercury 2 Degrease and clean the Flapper and Hard Seat to be vacuum tested. 3. Place ORing lube or Grease on the base of the Hard Seat and place it on the Vacuum Plate Test Fixture, 4. Place the dry Flapper on the Seat, insert the Flapper Pin into the hinges and begin to pull a vacuum ‘a. For Equalizing Flappers the vacuum test must be performed with a soft sealing dart plug (ie ‘oving bolt or hard rubber plug) installed into the dart hole to ensure the flapper seat line has been property isolated as the only source of potential leakage. ifthe Flapper and Seat combination pull a vacuum between 25 and 30 inches of mercury and bleeds less than or equal to 1 inch of Hg per seconds, the Flapper and Seat may be considered a matched set and you may proceed to Step six. Otherwise proceed to Stop five. ‘5. Lap the Flapper with a Flapper Pin inserted through the hinges to the Hard Seat to create a matched ‘set_The flapper may be of either an equalizing or not-equalizing design. For equalizing Nappers, DO NOT lap the dart to the fapper. ‘a Place the Flapper Mount and Hard Seat in the Shaker Plate on the vibrodapper. Begin with 240 grt Boron Carbide lapping compound, spread thinly on the Hard Seat surface ensuring that excess compound does not spill over into the space between the Hard Seat and the Flapper Mount. 'b._ Place bungee straps over the Flapper to prevert the Flapper from bouncing on the Hard Seat. ¢. Lapp aggressively in ten minute intervals replacing the compound each time with 250-grt unt an uninterrupted band is visible on the Flapper and the Hard Seat surfaces. 4. Once a continuous lapping band is visible, remove the Flapper Mount and clean the seat surfaces with degreaser. @. Place the Flapper Mount on the Vacuum Plate Test Foture, # @ vacuum less than 18 in-Hg is pulled repeat steps Sa to Se unti the required vacuum is achieved. Otherwise proceed to the next step. 1. Repeat steps Sa to Se with 400 grit Boron Carbide tapping compound, uni a vacuum of 25 in- Hg or greater is achieved 6 Once you have @ matched Hard SeatFlapper system, clean these parts with the appropriate degreasing soltion, and wrap the parts to prevent the lapped surtaces from impacting each other during handing, 7. Hdentify/mark oF tag the components as a matched set. 8, Proceed to Soft Seat installation procedure.yw INDEX NO. MODEL | WSPE-S. en 12-May-2005 Equalizing Flapper/Hard Seat Matching Required parts: Equalizing Papper, Equalizing Dart and Dart Spring, Dart Spring Set-screws. Required Tools & Supplies: Vacuum Plate Test Fixture, Degreaser/Denatured Alcohol, O-Ring Grease. 4. Follow Step 1 through Step 14 for Equalizing Flappers in the Flapper/Mard Seat Matching section. 1. Once an Equalizing Flapper and Seat have been matched, the dart must achieve the same or better vacuum as the flapper and seat 2 Select an Equalizing Dart and thoroughly clean the seat ine of the EQ Dart and EQ Flapper wth the appropriate degreasing soluton and visually inspect the dart seat line under magnifcaton for undesired marks. If there are any doubts, set the dart aside and seek a new dart 3. Following @ successful visual and dimensional inspection, prepare to inseft the Dart into the EQ- Flapper 4, Insen the EQ Datt into the dart hole in the EQ Flapper. '5. The dart must move freely within the EQ flapper, refer to the equalizing flapper and dart drawings for acceptable tolerances. 6. Place the Flapper and Dart on the Hard Seat and begin the vacuum test (grease may be applied to the Flapper and Hard Seat surfaces to isolate the Dart as the only source for leakage), puling the required 28.30 in-Hg and not bleeding in excess of 1 in+Hg per seconds. itan unacceptable bleed rate is observed a new dart may need to be selected, ‘Once you have matched a dart with a Hard SeatFlapper system, clean these parts with the ‘appropriate degreasing solution 9. Reassembie the EQ Dart into the Flapper and install the three Dart Springs (.009 thick or thicknesses ‘equivalent to .021 total) over the top of the Dart toward the set-screw holes in the Flapper. Refer to Eq. Flapper Assembly Drawing No. TFA4SO0-AG-01 10. Align the slots in the Dart Springs with the set-screw holes in the Flapper. 11, Apply Red Loctite 262 to the #4-40 set-screws and insert them into the Flapper set-screw noles, Ensure that the dog point penetrates through each Dart Spring. Once the springs and set-scraws have been installed, stroke the Dart upward to ensure that the springs are not binding and that the travel is smooth. 12, Wrap the matched parts to prevent the lapped surfaces from impacting each other during handling 18. Identifyrmark or tag the components as @ matched set exwv INDEX NO. MODEL | WSPES ee a Weatherford” oo oe eH DATE 12-May-2005 ‘Soft SeatHard Seat Assembly and installation into Flapper Mount Equalizing Flapper Assembly (Assy. # TFA4500-A0-01) Non-Equalizing Flapper Assembly (Assy. # TBD) : Required Parts: Matched Flapper/Hard Seat, Soft Seat, Flapper Mount, Flapper Pin, Torsion Springs, Torsion Spring Pins, #6-40 Set-scrows. Required Tools & Supplies: Hard Seat Assembly Press Too! (TBD), MolyGraphite Grease, 4. Select a Soft Seat, a good Soft Seat is determined by a visual inspection that yields no marks on the seat line. Always Use care when handing the Soft Seats, damage may occur from contact with heavier parts in the work area, from shipping, or improper storage. 2. Assemble Flapper Mount into Mount Holder. insert the Hard Seat Press Tool and the Plunger Tool and fox them to the hard seat with the 3%" -10, cap screw. 3. Place the assembly in the hydraulic press, with hard seat facing down. Align the assembly with the Press Ram, ensuring each is on centerline. Partially press the Hard Seat out unt the bottom edge of the Soft Seat groove on the Hard Seat is just above the Flapper Mount hinges. DO NOT PRESS ENTIRELY OUT. Remove the assembly from the press, disassemble the Plunger Tool and the Hard Seat Press Too! Slide the Soft Seat over the Hard Seat and snap it in place, reptace the Press Tools. Replace the assembly into the press with the Hard Seat facing upward Press the Hard Seat back into the Flapper Mount (More grease may need to be added prior to pressing). Disassemble the pressin tools from the Flapper Mount without removing the Flapper Mount from the ‘Mount Holder and install the Flapper and Flapper Pin. 40. Place the Contoured Flapper Press Tool over the flapper and center the assembly in the hydrauile press. 11. Apply 10,000 to 15,000 Ibs of setting force to the flapper assembly to seatfform the Sof Seat to the Flapper. Note: Pressing loads should not exceed 3000 tbs of force during each pressin and press-out ‘operation. if the load prematurely spikes above 3000 Ibs of force the Hard Seat may have galled ‘during assembly. Do Not Continue to press the Hard Seat in. The Hard Seat should then be pressed out for examination. 112. Install the Flapper Torsion Spring Rods, and Torsion Springs. Use a small hammer to snap the ends of the torsion spring rods into the ends of the flapper pin NOTE: DO NOT OVER STRESS THE FLAPPER TORSION SPRING ONCE INSTALLED. MAX ROTATION FROM HARD SEAT IS 90 DEGREES. 18. Use a center punch to ping the Flapper Mount hinge material toward the Flapper Pin to prevent it from sliding out. Ping the Flapper Pin toward the Torsion Spring Pins to prevent the Torsion Spring Pins ‘rom sliding out 14. Install the #6-40 set-screws into the Flapper Mount to secure the Torsion Spring Pins. Tighten the set- ‘screws while pulling the Torsion Spring Pins toward the centertine of the flapper assembly. 1. Retag the matched flapper mount, hard seat and flapper system fo ensure they are not mixed with any ‘other components.oe Se andl Weatherford’ He fae —| INDEXNO] MODEL | _WSPES ‘Spring Housing Flapper System Assembly 8 ‘Required Perts: Flapper Mount/Hard Seat sub-assembly, Spring Housing. Required Tools/Supplies: 51/2 RT Flapper Mount Assy. Too! (Pt. No. 101496), Jack-Stand, Red Locktite 282. Place the Spring Housing portion of the Spring Housing into a softjawed via Remove the body joint ‘thread protectors and inspect body joint threads for unwanted marks (Soe Special Notes for Precautions}. Refer to the body joint care section for thread repair or thread re-ut instructions. Inspect the intemal seal bevel surface, wivre the Flapper Mount will makeup to the Spring Housing, for ‘any unwanted marks. The ID should be bead blasted according to Weatherford Speciation WC-111 ‘Apply liberal amount: of Loctte™ 262 (red) to the frst two threads of the Flapper Mount thread 360 ‘segrees around the OD. Make-up the Flapper Mount sub-assembly into the spring housing hand tight Slide the Flapper Assembly Tool Shim over the end of the Flapper Mount, aligning the slots with the holes in the Mount. Slide the $-172" RT Flapper Mount Assembly Tool Pt. No(TED) over the Shim Pt_No, (TBD) and secure it to the Flapper Mount with six Assembly Tool Torque Screws. (Note: Do Nat excessively tighten the Torque Screws, torque should not exceed 3 tbs.) Using @ calibrated torque machine apply 1600 flbs to 2500 flbs of torque to the mount Remove the RRT Flapper Mount Assembly Toot Place the Spring Housing ito @ softjawed vice. Remove the body joint thread protectors and inspect all body joint tweads for unwanted marks Gee Special Notes for Precautions). Refer to the Dody Joint care Section for thread repair or thread re-cut instructions. Prep the Spring Housing and Chamber Housing threads according to the body joint thread care section (See Special Notes for Precautions) 10, Prep the Bottom Sub box thread (See Special Notes for Precautions). 11, Makeup the Bottom Sub to the Spring Housing/Flapper Sub-assembly.y TNDEX NO, MODEL | WSPE-5 sa | IDReSOo Weatherford ts = ‘DATE 42-May-2005 Power Spring/Spring Housing/Flow Tube Installation Require Parts: Bottom Sub/Spring Housing assy, Spacer Bearing, Power Spring, Chamber Housing/Top Sub Sub-assy, Flow Tube Sub-Assembly. Required Tools/Supplies: MolyGraphite Lube, Vertical Vice, Bubble Level, Strap Wrench, 1, Rotate the Spring Housing/Bottom Sub Sub-Assembly into a vertical positon and secure in a vertical Vice with the Spring Housing facing upward 2. Lube the Spring Spacer Bearing and insert it into the Spring Housing untl @ rests on the beck side of ‘the Flapper Mount. 3 Insert the Power Spring into the Spring Housing. (Note ensure the ends of the spring are smooth, and bevetled to allow the spring to spin freely asit ‘twists during assembly). 4, Insert the Flow Tube assembly into the Power Spring 5. Use a lifting eye to raise the Top Sub/Chamber Housing assembly to a vertical postion. 6. This is best performed on a pallet, to guide the end of the piston between the slats in the pallet during rotation. Un the Chamber Housing/Top Sub assembly above the vertical Spring Housing (Once the Chamber Housing and Spring Housings are aligned slowly lower the Chamber Housing over the end of the Flow Tube until the exposed end of the Piston in the Chamber Housing can be made-up 7 to the Piston Up-Stop. Apply Red Loctite to the Piston Thread and make-up with a 10 mm open-end wrench. 10. Once the Piston has been fully made-up to the Up-Stop continue to lower the Chamber Housing inte the box thread of the Spring Housing. Lower the crane and remeve tt from the iftng eye, 11. Extreme care should be exercised not to gail the threads, proceed slow. 12. Make-up the rest of the way with a strap wrench, unti lightly tight and stop, 13. Body Joint threads are to receive final make-up torque in a calibrated torque machine to the spectic values shown in the thread care section for this valve,INDEX NO. MODEL | WSPE.5 io Yeeeah Weatherford: 7 im DATE Installation of Thread Protectors Install Thread Protectors on both ends of the Safety Valve and store in a vertical position. Visually inspect the exterior of the valve for any unwanted wrench marks or burs and if any please remove Perform functional testing per APL14A and intemal quality assurance programs. Stamp the final assembly with required identifying marks as indicated on the assembly drawing Dein. Use Drift bar as specified in the Dimensional Data Module for this particular valves polished bore size. Orit the valve while in a vertical or horizontal position ‘Special Notes: Body Joint Threads ‘Body makeup. Ensure that pin threads have been coated per WC-406, and box threads bead blasted per weit Differ to Weatherford Engineering for recommended torque values and thread preparation procedures. ‘Apply @ thin coating of graphite/Moly grease to pin threads prior to makeup to prevent galing durng final torque Make sure that the file cuts 3 @120 degrees are on the torque shoulder face of the box body joint threads 25 called out on the thread details. Use roller stands for body joint make-up. Flapper Sub-assembly ‘Do not ever overextend the flapper torsion spring beyond 90 degrees. Most lappers operate between 85 and 87 degrees of rotation from the seat ine, resting on the back of the flow tube. Piston Sub-Assembly Extreme care must be used when handiing the piston assembly and dynamic seal stack Always practice ft parts and have everything ready to torque before applying Loctite to any threads. Avoid excessive application of Loctite especially on the piston assembly. Take necessary precautions to prevent Loctite from contacting the seals. Clean up any excess Lostite Cleaning solvents and lubricants used will depend on the Hydraulic fluid to be used as specified by the ‘customer refer to the Hydraulic Control Line Fluids Module, To dry parts compressed air can be used to ‘speed the process, Be sure to remove the any shipping protection devices Loctite™ Surfaces must be clean, degreased and dry. Free from oil, coatings and any other surtace contaminates. Loctite™ recommends Cleaning Solvent 755 or Loctite Primer 764. Apply the cleaner primer to the thread, filing the thread root of both box and pin threads and then dry the threads. Then, apply a thin fn of the adhesive to the first few threads filing the thread roct of the pin thread and immediately assemble the parts and allow the compound to cure. Avoid any contact between these adheshes and any non- thread surfaces. The Loctite™ cure times should be observed (see packaging) However, the Primer does help ‘speed things up when a cure time of less than 30 minutes is needed,wy INDEX NO. MODEL | WSPE-S Weatherford 38 DAI 12-May-2005 9.0 Handling & Storage Recommended Handling Guidelines. ‘Damage resulting from the mishandling of SCSSV equipment, rendering dents, gouges and or nicks can be detrimental to @ components ability to resist stress corrosion and cracking, regardless of the material type. Stainless and nickel-based materials are more susceptible to surface damage due to galing and cold working at metal-metal ‘and high-pressure contacts such as thread connections. Galing is aggravated by nicks and dings. File, grind or sand any and all such damaged areas completely to blend the damaged surface into the surrounding area Itthere are questions regarding the acceptabilty of a repair (Le. reduced wall thickness in the Bottom Sub, damage to critical contact surfaces on threads, etc), consult Weatherford's completions engineering group for guidance. Shipping Guidelines 1. Ensure Thread Protectors are installed at both ends of the safety valve prior to any movement, ‘shipping or handling of any kind 2 Ensure @ pipe plug fing is installed into the contro! line port of the hydraulic chamber housing to prevent any debris from contaminating the hydraulic cyinder, minimizing hydraulic seal damage 3. Prior to shipment insert and secure a wooden oF plastic dowel rod between the Flapper and the Flapper seat to prevent impact damage during shipment Storage Guidelines 4. Inspect all tools when received 2. Verity that a pipe plug has been installed into the control line port. The contro! line port must remain plugged when the valve is not being tested. Plugging the control ine port will prevent debris from ‘contaminating the hydraulic Piston bore. 3. Store all tools in a closed, dry, temperature-controed environment 4. Store tools verticaly, when possible, with an open-ended protector at the bottom to allow for moisture drainage, 5. Thoroughly dry tools tested with water and coat ID's and OD’s with corrasian inhibitor or oi, 6. File all gouges and burrs without reducing the original OD 7. Store spare elastomeric and rubber components in sealed bags away from direct sunlight, utraviolet light, or electric motors or generators. ANvays reseal the bags containing elastomeric componentswv INDEX NO, MODEL | WSPES seer Yeu Weatherford oe [pate 12-May-2005 Cross-Over Flow Coupling Torque Procedure ‘While making up Cross-Over Flow Couplings to the top and bottom end connections cf a tubing mounted safety valve, it is important to follow the procedure below. Gripping the safety valve OD in the wrong place could severely damage Parts of the safety valve that are required for pressure and operational integrity downhole. Failure to follow this procedure could be detrimental to the integrity of any of the WFT metal sealing connections or reduce the rated ‘working pressure of the safety valve. Grip Here Grip Here. (1475" ong) {82 long) ——>| Top sub Bottom Sub Top Tubing WET Wer wet Bottom Tubing Thread Thread Thread Thread Thread ross-Over x 4. _Use non-marking jaws or dies to grip on OD of Top Sub. Tooth marks or deep gouges in OD of Top Sub ‘could reduce safety valve's working pressure 2. As specified in diagram above, grip OD of Top Sub anywhere between top tubing thread and WET Thread, m sub 1. Use non-marking jaws or dies to grip on OD of Btom Sub, Tooth marks or deep gouges in OD of Bottom Sub could reduce safety vave's working pressure 2. As specified in diagram above, ip OD of Bottom Sub within 5.2 from botiom end of Bottom Sub wnere OO tapers down to OD at batom tubing thread. Do NOT grp Bator Sub near WFT thread. This could damage the WET thread and the safety valve would then not be able to hold intemal pressurey INDEX NO. MODEL | WSPES fae rou Weatherford’ see tS DATE 12-May-2005 10.0 Running and Pulling Procedures Running Procedure Preparation for runing tho avo, whe on he Sot vary he folowing Record Valve Type, Model, and Serial Number. 2 Venty seting Jopthcalulatons wih operasng pressures (Refer to Operatonal Data Manual Fail Safe Setting Depth (FSSD) Calculation 3. Visually inspect the Safety Valve prior to tnning in the well, to identity any potential damage resulting from shipment or handling on the rig floor. Any torque teeth indentations, wrench marks or scratches ‘on the OD of the valve must be filed down to provide a smooth surface reducing potential br stress ‘corrosion cracking 4. Prior to running the vaNe ensure all transportation devices (Thread protectors, dowel rods, etc) are removed 5. Temporanly install a control line fiting (See Control Line Fitting Installation below) and contol line to a hand pump and verify opening and closing pressures by cycling the valve one time. While in the open position hold hydraulics on the vale for ten minutes to verity Piston seal integrty. Record the ‘opening, hydraulic hold open, and closing pressures. 6. Replace the control fine fiting with a hydraulic plug f the valve is not to be run at this time. Runcing The Vaio (Zero OiierentintPresuere Across Valve} When the valve has been positioned for make up to the tubing sting, use a strap or chain wrench to make the valve up to the tubing string, (Do not use pipe wrenches on critical ODs if possibie) 2. Verify tubing thread connections recelve appropriate torque values for make-up, ‘3. Install contro line fiting and control line to the vate (Refer to control line fiting installation in this manual). 4. Apply full opening pressure to the hydraulics to maintain the valve opened while tripping tubing and control ine down hole 5. Band the control line to the tubing as required, maintaining the control Ine tight and close to the tubing Extreme care must be exercised to prevent control line damage while running. 6 Prior to setting the tubing hanger, bleed hydraulics to zero, Cut sufficient control line length to thread through the tubing hanger if applicable, or make up to the hanger using the appropriate tings, 7. Once the control line has been reattached to the rigs hydraulic control system, reapply hydraulic pressure to open the valve plus formation pressure and block the valve in to maintain the vatve in the opened position. 8 Monitor hydraulic pressure for ten minutes for any deviations from the blocked in pressure. Running The Valve (Differential Pressure Across Valve) Note: To open the valve with differential pressure, the differential must be equalized to less than 200 psi across the Flapper prior to opening. When the valve has been positioned for make up to the tubing sting, use a strap oF chain wrench to ‘make the valve up to the tubing string. (Do not use pipe wrenches on critical OO if possible) Verify tubing thread connectons receive appropriate torque values for make-up. Install control tine fiting and control line to the valve (Refer to contol line fiting preparation and Installation in this manual) Apply full opening pressure to the valve plus well bore pressure to the hydraulics to maintain the valve ‘opened while tipping tubing and control ine down hole. 8. Band the control line to the tubing as required, maintaining the control ine tight and close to the tubing Extreme care must be exercised to prevent control ine damage while running. 8. Phor to setting the tubing hanger, bleed hydraulics to zero. Cut sufficient control line length to thread make of 290f 98 ‘erry rote se arena a wees sae eeTNDEX NO. MODEL | WSPE.5 See Hens Weatherford ae DATE 12-May-2005 7. Once the control line has been reattached to the rigs hydraulic control system, reapply hydraulic pressure to stoke the valve into an equalzing position. Apply full opening pressure to hydraulics (Do Not Exceed Opening Pressure of Valve, Refer to the Operating Data Manual), monitor pressure gauge while equalizing. Once pressure bleeds the vaNe has been equalized to less than 200 psi differential. Reapply hydraulic pressure to establish full open pressure plus formation pressure and block the vale in to raintamn the vaive in the opened positon. 8. Montor hydraulic pressure for ten minutes for any deviatons from the blocked in pressure. Control Line Fitting Installation to the Safety Valve Use a tube cutter to cut the control line, verify the cutis square and free from burrs. Remove the pipe plug from the hydraulic chamber housing control ine port. Slide the Jam Nut over the control line, Slide the Back Ferrule over the control line; ensure that the smaller shouller is toward the cut end of ‘the contol line (see diagram). Slide the Front Ferrule over the contro! line, with the tapered end toward the cut end of the contro! fine Examine the control line and the Jam Nut components to ensure they are free from debris. Insert the end of the control line into the fydraulic chamber housing control line port, Make sure the control line has been inserted to its deepest point and hold in place Next slide the Front and Back Ferrules into the hydraulic chamber housing control line port 9 Move the Jam Nut into posttion to begin to make it up in the control line port. Tighten with a wrench Unt the Jam Nut bottoms out on the Ferrules, 10. Back the Jam Nut out to inspect the Ferrules, ensuring they have properly crimped the contol line. 11. Reinstall the Jam Nut tightening the Jam Nut using the 1-1/4 Tum Tightening Procedure as recommended by Swagelock to guarantee a reliable leak-Tee connection. Caution: Care should be ‘exercised not to over torque the Jam Nut during reinstallation. 12, Connect the otter end of the control line spool to a hand pump and apply full open pressure to the valve, Block in the pressure and monitor the fiting for ten minutes to verity Jam Nut seal integrty seoWw INDEX NO. MODEL | WSPE.S Weatherford” a DATE Jam Nut Diagram ‘Jam Nut 0.25" Control Line Back Fertule Front Ferrule Hydraulic Chamber Housing or Make- Up Block. Procedure 1. Apply maximum control tine pressure to the valve (Refer to Operating Data Module). Maintain the valve in the open position, Begin tipping out tubing, Remove control line straps as they become available and wrap the control ine on a spool while the ‘tubing is being pulled. 4, At the tubing hangar bleed hydraulies, and remove the control ine from the hanger. 5. Re-establish hyaraullc communication with the valve, maintain hold open pressure. 6. At the valve bieed hydraulics and disconnect the contro line fing, 7. Remove the valve from the tubing string. ifthe valve will nt open Reter to the Trouble Shooting Manual for guidance, 9. Ifthe vate remains inoperable, Refer to the Lock Out Procedure Manual 10. Once the valve has been locked-out, retract the valve as outlined in steps 2 through 7.y (NDEXNOT MODEL | WSPES. feo romasa Weatherford” se DATE 12-May-2005 11.0 Maintenance / Service Testing Maintenance To ensure proper valve operation after installation in a well, a maintenance program should be established. AP! RP 148, the most current edition, wil provide guidance with respect to maintenance/service testing frequency. Service ‘conditions may dictate that more frequent operation of the valve is necessary. NOTE: Only qualified personnel should Perform Service testing ‘As a routine function of the maintenance program, all accessible control ine connections should be checked for leakage. Additionally, the control ine fluid should be Kept clean and free from debris, which could cause seal damage. NAS CLASS 7 or better is recommended. Service Testing NOTE: Only qualified personnel should perform Service testing ‘Service testing an installed valve includes cycling the valve through one complete cycle, opening the valve and ‘closing the vave in the well. Periodic service testing will minimize the potential for welloorn deposits to accumulate in and around critical dynamic components in the valve. Record the opening and closing pressures in @ og for future reference. Use this recorded pressure as the basis of ‘comparison over the valves ife to monitor friction in the valve. Increased opening pressure and decreased closing pressure may indicate that scale, sand, or some other deposits are building up in the valve, ta valve falls to close, or malfunctions in any way, a failure report form must be filed out, and the valve pulled from the well to be either repaired or replaced API monogrammed (MMS qualified) safety valves in need of repair should be sent to an authorized service center for repair. ‘Once a valve has been pulled from the well proper handling procedures shoud be folowed to ensure further damage ‘to the valve does not occur. Reference the Handiing & Storage procedures manualyw INDEX NO- MODEL | WSPE-5 er oncasao Weatherford aye 12-May-20 12.0 Trouble Shooting Control Line Will Not Retain Pressure Ifa congole is boing used for vaWe operation, system check the consol to ensure itis operating property. Bypass the console by connecting @ hand pump direct to the welhead. Apply full working Pressure to the contol fe to open the vale (Refer to the Operational Data Module inthis manual for ‘maximum control ine pressures) 2 Check for wellhead leakage by pulling the test plug in the tee and inspect for the presence of hydraulic fd, Ifthe welhead leaks, contact the Company Man and or the manufacturer for remedial instructions. 3. Check the contol line from the welhead tothe fiting atthe safety valve down hole Bleed hydraulics on the contol tine . Pressurze the annulus to 1,000 pst. ©. Montor the control line gage for any increase in pressure 4 fa ise in conto line pressure is observed, the folowing areas may be fe |. Control ine connection below the surface hanger. i, Control ine fing at he safety vave. Ti, Ruptured control ne at some point between the hanger and the safety valve ing. Excessive Opening Pressures. 1. Refer to the Operational Data Module of this manual for required contol ine pressures to open the valve. This is proseure at the valve, nota the wolhead. Hyerastate prossutes must be coretdored when detarmning the opening Sina closing pressures atthe valve 2. Verify/Test the instrumentation measuring the opening and closing pressures to ensure its accuracy 3. Coafim the valve has been fuly equalzed. Ifa dfeertial pressure exists (/e. upstteam pressure trapped below the Flapper in excess of downstream pressure), the opening pressure of the vate vill increase. With the valve fully equalized, open and close the valve five (5) tres recording the ful open hydrautic pressure each time. ifthe average opening pressure &s unacceptable, contact the nearest WCS service center Flapper Falls to Open Pressure control line and check for Piston movement. (If Control Line fails to hold pressure, see paragraph one; Control Line Looses Pressure and or Will Not Retain Pressure) 1. Instantaneous control line pressure increase. ‘a if a console is being used for vaNe operation, system check the consol to ensure it is ‘operating property. Bypass the console by connecting a hand pump directiy to the wellhead Apply full working pressure to the contol line to open the valve (Refer to the Operational Data Module in this manual for maximum control line pressures) b. Check for blockage at the wellhead connection. Install a new wellhead fitting and try to re- pressurize. c._ Verify that the wellhead has been driled correctly and that the correct port is being used d._ Determine if the wellhead or control ine is blocked from debris, 1. Apply maximum control line pressure to the valve (Reference the Operational Data Module for maximum control line pressure), ji. Blood the control line pressure into @ reservoir other than that of the hand pumps, to measure returns, Repeat at least twenty times, taking care to measure retums accurately. If blockage is moving, returns will stat to increase in volume. 'v. Continue unti valve either starts to function or contol ine blockage ceases to move. When ether point is reached, continue to pressurize control line twenty more times,¥. If control ine blockage remains, discuss pulling the valve and replacing the contro! line with the company man 2. If the hydraulic control ine system pressures normally, yet the valve remains closed the Flapper may have difforontial prossure across it ft 6 not an equalizing vale ‘a To equalze the Flapper, apply tubing pressure from the wellhead until there are indications ‘hat the pressure has exceeded that below the Flapper (i. pumping through the Flapper) . Apply maximum control ine pressure to the system (Refer to the Operating Data Module). i Monitor pressure for Piston movement. Ji. If valve remains closed, continue to hold tubing pressure and pressurize the control line twenty times. ii, Ifthe valve stil remains closed, pull the valve and inspect an the nig floor 41. Attach a hand pump to the valve and actuate open and closed. 2 Ifthe vate fails to actuate, return the valve to the nearest WCS service center for repair 3. If the contro! line pressures normally and Piston moves normally, the completion may be a dual or tandem completion. Very that pressute is actuating the desired SCSSV. Welhheads can be ported backwards, Fallure to Close 1. Scale or other forms of debris may have accumulated in and around the moving parts of the valve. Flow the well to attempt to clean the tubing ofthis debris. 2 Pressurize the control line to determine if there is any Piston movement. ‘a. If there is no free Piston movernent i. Apply maximum control fine pressure to the system (Refer to the Operating Data Module), and bleed twenty times. li. Monitor the fluid retums for any increase in volume, which would indicate Piston ‘movernent. i, If ths falls, pull the valve and replace i with another SCSSV,vw Weatherford’ 13.0 Field Repair General Requirements 4. Replacement of items other than those specified in the redress procedure is considered a field repair Reference the Redress section ofthis manual 2. All replacement parts. shall be qualified parts. Qualifed parts are those parts that nave been manufactured in accordance with the WCS quality assurance program, and must meet or exceed the performance requiremonts of the orginal part Note: Repairs to API regulated safety vaives and related equipment are to be performed by qualified personnel, at an authorized WCS service center. Field Repair as defined by API RP 14B, is an activity involving disassembly, reassembly and functional testing of SSSV equipment with or without the replacement of qualified parts. Field repair ‘does not under any circumstances include machining, welding, heat treat or any other manufacturing process. Redressing a valve does not constitute a field repair (Refer to the redress section of this manual) ‘Qualified Personnel as defined by API RP 14B are those individuals with the characteristics or abilties gained through training or experience or both as measured against established requirements, such as performance standards or tests that enable the individual to perform a required function. Records of these standards and or tests are to be placed in the individual's training fle and maintained at the authorized service center. Field Repair Procedure Disassemble per disassembly instructions, (Refer to the Disassembly Procedure in this manual). 1 2 Thoroughly clean and inspect ail parts prior to reassembly 3. Replacement part must mest or exceed the performance requirements of te original part. 4. Replace any damaged metal part that cannot be salvaged, with a qualified part listed in the parts list ‘Al burs, rough spots, or other iregularties must be removed prior to reassembly. 5. Replace al item identified in the Repair Kit 6 Reassemble per assembly instructions. (Refer to the Assembly Procedure in this manual} Post Field Repair Testing Following Field Repa, the folowing tess must be permed ‘The valve must be bench tested in accordance with the Bench Testing Procedures outlined in the Functional Test Data module ofthis manual, to assure smooth operation during both the opening and closing cycle. If any obvious abnormality is observed, the valve should be disassembled and Inspected (Refer to Functional Test Data module) 2. Functional test ofthe valve must be accomplished in accordance with the current edition of API 14A and the approved WCS test procedure prior to instalaton (Refer to Functional Test Data module). Documentation 1. Valve size, model, working pressure, assembly number, and serial number. 2 Soft Bill, established for the work order rider, identifying the components replaced and cross telerenced to the original assembly traceabilty. (WCS Districts wil maintain the field repair/redross traceability sheets) Date of repair. Functional test data and results (recorded open and close pressures) Other relative test data or pertinent information, Al tepair steps taken documented on a work order rider by those “Qualified Personnel” involved. pane