Man-10000527 7447362 02
Man-10000527 7447362 02
Man-10000527 7447362 02
LIGHTWEIGHT BOP
UP TO 10,000 PSI WORKING PRESSURE
Published by:
Elmar
Tofthills Avenue,
Midmill Business Park,
Kintore, Aberdeen, AB51 0QP
Scotland, United Kingdom
No part of this document may be reproduced by any means without the written consent of
the publisher.
Whilst every care has been taken to ensure that the information in this document is
correct, no liability can be accepted by Elmar for loss, damage or injury caused by any
errors or omissions in this document.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
TABLE OF CONTENTS
1 Introduction.................................................................................................................. 5
2 Safety & EHSRs ............................................................................................................. 6
2.1 General Safety ......................................................................................................... 6
2.1.1 Employee responsibility ............................................................................ 6
2.1.2 Employer responsibility ............................................................................. 7
2.1.3 Warnings, cautions and requirements ...................................................... 7
2.2 Equipment specific safety ........................................................................................ 8
2.2.1 Heavy equipment ...................................................................................... 8
2.2.2 Pressure Control ........................................................................................ 8
3 Physical Description .................................................................................................... 10
Table of Contents
3.1 Unit Overview ........................................................................................................ 10
3.2 Guide to the use of Elmar Drawings ...................................................................... 11
3.2.1 Identification of unit part number .......................................................... 11
3.2.2 Identification of components within a unit ............................................. 11
4 Functional Description ................................................................................................ 12
4.1 Unit Overview ........................................................................................................ 12
4.2 BOP Sub-Assembly ................................................................................................. 13
4.2.1 BOP Body ................................................................................................. 14
4.2.2 Hydraulic Cylinder Assembly ................................................................... 14
4.2.3 Manifold Arrangement ............................................................................ 16
4.3 BOP Adapter Assembly .......................................................................................... 23
4.4 BOP Ram Assembly ................................................................................................ 23
4.4.1 Constrictor™ Multiline Inner Seals .......................................................... 25
5 Specifications & Features ............................................................................................ 26
5.1 Specifications ......................................................................................................... 26
5.2 Standard Features.................................................................................................. 26
5.3 Design Standards ................................................................................................... 27
5.4 Operating Requirements ....................................................................................... 27
6 Assembly Instructions ................................................................................................. 28
6.1 Recommended WPCE Tool List.............................................................................. 28
6.2 Assembly Instructions............................................................................................ 29
6.2.1 O-ring Installation .................................................................................... 29
6.2.2 BOP Adapters/Body ................................................................................. 30
6.2.3 Manifold Block Assembly ........................................................................ 31
6.2.4 BOP Hydraulic Cylinders .......................................................................... 33
6.2.5 Ram Assembly ......................................................................................... 38
6.2.6 3.00” BOP Assembly ................................................................................ 40
6.2.7 4.06” BOP Assembly ................................................................................ 42
6.2.8 Protection Cage ....................................................................................... 44
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7 Operation ................................................................................................................... 45
7.1 Fundamental Rules for WPCE Equipment ............................................................. 45
7.2 Normal Operation .................................................................................................. 46
7.3 Sealing on Braided Line ......................................................................................... 46
7.4 Injecting Grease ..................................................................................................... 47
7.5 Bleeding Down Lubricators.................................................................................... 48
7.6 Equalising Pressure Prior to Opening Rams .......................................................... 49
7.7 Injecting Glycol/Methanol ..................................................................................... 49
7.8 Ram Removal Procedure ....................................................................................... 50
7.8.1 Ram Redress with BOP Upright ............................................................... 50
7.8.2 Ram Redress with BOP Lying Flat (Non-Preferred) ................................. 51
8 Maintenance & Testing ............................................................................................... 52
Table of Contents
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
1 INTRODUCTION
This user manual is intended for operating, maintenance and supervisory personnel.
This manual (supplied in digital format) is part of the unit documentation set and must be read
before initial equipment installation and operation.
The validity of the manual can be compromised by post-delivery engineering modifications or
regulatory changes that affect equipment use, ratings and limits. All Elmar engineering
changes are documented in as-built drawings, even after product delivery. This means the
latest drawings always take precedence over manuals. If in doubt, contact Elmar.
1 Introduction
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
WARNING
Ignoring the instructions in this manual can result in serious injury or death. All personnel
that work with this equipment must read and understand this manual. Only qualified
personnel are permitted to assemble, operate, and maintain this equipment.
• Meet all applicable codes, laws and local field regulations (including environmental
and additional owner/user company policy). This manual contains recommendations
but should not be assumed to satisfy all requirements of legal regulations.
• Read and understand each item in this manual and follow all procedures,
precautions and advice - never take short cuts. Always consider your safety and that
of others.
• Only use the equipment within its design scope to avoid damage or dangerous
situations.
This manual (in its most current revision) is a minimum requirement for all persons working
with Elmar equipment. All other current and applicable documents such as certification,
drawings, bill of materials, vendor documentation, etc., should be readily available at the
worksite.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
• Do not use the equipment after an emergency without verifying that the cause of
the emergency has been removed or rectified.
• Immediately inform the employer and other workers of any situation that represents
a serious danger to safety and health, and of the shortcomings in protection
arrangements.
• Plan all operations including interdependencies with other equipment operations
• If equipment is tied down using rope/line/chains, attach a "flag" to signal their
location.
• During installation, maintenance and/or equipment inspection:
- where possible, make sure electrical/mechanical equipment is switched off
completely, and use a decal (or similar) to prevent unauthorized starting.
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LIGHTWEIGHT BOP
• CAUTION shows a relevant icon and the text CAUTION with a description of the
hazard and the best practise to avoid it. Ignoring a caution can result in damage to
equipment.
• REQUIREMENT shows an icon and a description of the required PPE to minimise
possible safety risks.
Warnings, cautions and/or requirements are listed in the manual as a preceding step to a
potentially dangerous action. Never proceed to following step(s) if you do not comply with or
fully understand a Warning/Caution/Requirement. See the following examples:
WARNING
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual.
2 Safety & EHSRs
Only qualified personnel are allowed to assemble, operate, and maintain this equipment.
CAUTION
EQUIPMENT DAMAGE
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual.
Only qualified personnel are allowed to rig up, rig down, operate, or maintain this
equipment.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
3 PHYSICAL DESCRIPTION
For sub-assembly and component level breakdown of a specific BOP always refer to the
drawing(s) relating to that assembly.
3 Physical Description
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
3 Physical Description
• Look at the drawing with the same number.
• The Bill of Material for this drawing will show the part numbers for individual
components. (In some cases, sub-assemblies reference further sub-assemblies
which then reference individual part numbers).
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4 FUNCTIONAL DESCRIPTION
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• Keyless Q-GUIDE™ ram design providing flexible ram configuration and positive
wireline guiding
• Maximum hydraulic working pressure 3,000 psi
• Ram position indicator rods
• Manually operated piston locks
This manual is a generic manual for all NOV Elmar Lightweight Wireline Valves with a
working pressure less than or equal to 10,000 psi.
Unless otherwise stated, the following information in this manual is provided for a Triple
and is typical for all other ram configurations.
4 Functional Description
The following major assemblies/parts make up the BOP Sub Assembly:
• BOP Body
• Hydraulic Cylinders
• Manifold Blocks
The Triple NOV Elmar Lightweight Wireline Valve Assembly (TLW BOP) comprises of three
sets of rams mounted one above the other. When the rams are closed, hydraulic fluid is
pumped into the outer chamber of the cylinder assemblies, pushing the pistons (which are
connected to the rams) inwards. Oil from the inner chamber then returns to a reservoir.
Piston locks are provided as a back-up system. When the rams have been closed
hydraulically, the Lock Sleeves are manually screwed in to provide a piston lock facility for
additional safety. With the piston locks backing up the piston the BOP cannot be opened
hydraulically. To open the BOP, the piston locks must first be unscrewed. The rams remain
closed. Hydraulic pressure applied to the inner chambers will open the cylinder pushing the
piston connected to the rams. Hydraulic fluid in the outer chamber will be returned to the
reservoir.
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MAN-10000527/F TFO-10006156/A3
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WARNING
For maximum safety, the rams must be fully opened before attempting to remove the
cylinders from the BOP body.
The cylinders have recessed pockets to prevent the ram assemblies from dropping
unexpectedly upon removal.
The quick connect hydraulic couplers on the cylinder assembly are male and female to
prevent cross coupling of supply lines.
4 Functional Description
Figure 3 Location of Vent holes in the Cylinder Assembly
The 3” cylinders are CNC timed allowing any cylinder to be positioned in any valve body
cavity giving full flexibility in ram orientation. Once located in the BOP body the cylinders
are aligned using the captive alignment pins located in the BOP body.
The 4 1/16” cylinders are assembled with the correct orientation using a support clamp
which slides on support arms. An external lock ring on the cylinder body is screwed into
the BOP body whilst the cylinder is held in position. Once fully assembled an alignment pin
on the BOP body enters a groove on the cylinder to prevent any rotation and the support
clamp can be removed.
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MAN-10000527/F TFO-10006156/A3
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Between the front and back manifolds the operator can carry out the following operations:
• read well bore pressures;
• bleed down lubricator risers;
• equalise across all ram assemblies;
• inject wireline grease between the rams;
• inject glycol between the rams.
The front manifold block assemblies have integral equalisation, grease and glycol injection
facilities. Each of the injection facilities are fitted with integral check valves. The rear upper
manifold assembly has pressure monitoring and lubricator bleed-off facilities. The rear
lower manifold assembly is a blank to plug off an existing port.
4 Functional Description
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 installed on one of the lubricator risers.
CAUTION
If using shear and seal rams in a Triple Lightweight Wireline Valve with the manifold
configured as standard these rams must be placed in the upper most ram bore so that
grease and glycol injection can be accomplished between the wireline rams.
If Shear and Seal rams are to be fitted to the lower cylinder bore the Manifold MUST be
reconfigured see Section 4.2.3.3.
The manifold assemblies on the front of the BOP must be arranged as described in the
following sections, depending on the location of the shear rams.
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MAN-10000527/F TFO-10006156/A3
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4 Functional Description
Figure 6: Front Manifold Assemblies for use with Upper Shear Rams
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The following diagrams show the connected pressure chambers between the closed rams
(black) when each of the valves A, B or C are opened individually.
• Yellow – Fluid from above the BOP.
• Blue – Fluid from manifold injection ports.
• Red – Fluid from below the BOP.
4 Functional Description
Figure 7: Fluid paths with the following valves open (from left to right): None, Valve A, Valve B, Valve C
MAN-10000527/F TFO-10006156/A3
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4 Functional Description
Figure 8: Front Manifold Assemblies for use with Lower Shear Rams
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The following diagrams show the connected pressure chambers between the closed rams
(black) when each of the valves A, B or C are opened individually.
• Yellow – Fluid from above the BOP.
• Blue – Fluid from manifold injection ports.
• Red – Fluid from below the BOP.
4 Functional Description
Figure 9: Fluid paths with the following valves open (from left to right): None, A, B, C
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
4 Functional Description
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. The Lock Sleeves can be used to lock the rams closed to prevent inadvertent
opening. 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:
• If sealing round slickline, a minimum of one ram assembly is required to affect a
seal.
• If sealing round braided line, a minimum of two ram assemblies are required in
conjunction with a grease injection facility.
Figure 10: Electric Line (left) and Slick Line (right) 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. A range
of rams and inner seals are available which are designed to be line size specific. 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
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
horseshoe. The outer seal prevents well fluids from passing around the rams inside the
main BOP body. The inner and outer sealing elements join on the side of the ram body.
Guide rods for the rams are located in the cylinders to prevent the ram body from turning
and to ensure correct alignment. The use of guide rods provide the user with orientation
flexibility.
There are three common designs of ram in service:
1. Rams with standard guide plates which are fitted with separate guides (one located
on each ram) fixed to the ram body with countersunk screws.
Rams with integral guides where the guides form part of the ram body.
NOTE: In both types the guides are only located on one side of the ram body and the cable is
guided by the shaped part of the rams as they are being closed.
4 Functional Description
The Q-GUIDE™ style of ram has been developed by NOV Elmar to replace the
standard and integral guide style rams. The Q- GUIDE ™ is available for all sizes of BOP
wireline valves. Inner and outer seals used in the Q- GUIDE ™ are the same as used in
the standard and integral type ram bodies. The Q- GUIDE ™ 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- GUIDE ™ has been designed to
accommodate eccentric set-ups. There are scenarios with the standard and 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.
NOTE: All Lightweight wireline valves will be supplied with Q-GUIDE™ style rams as standard.
See generic assembly drawing for relevant ram.
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4 Functional Description
Figure 12: Constrictor™ Multiline Inner Seal
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LIGHTWEIGHT BOP
5.1 Specifications
The exact specification of each Lightweight Wireline Valve will vary depending on the
customer’s individual requirements. The following table gives details of the basic options
available:
Through Bore 3.00”
4.06”
Working 5,000 psi
5 Specifications & Features
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
NOTE
The below volumes are sufficient to close a single ram BOP i.e. enough to operate 2
cylinders.
The quoted flow rate is that which is required to close a single ram BOP in 30 seconds.
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6 ASSEMBLY INSTRUCTIONS
WARNING
Please refer to Section 2 (Safety & EHSRs, p.6) for safety requirements. Ensure that all
personnel follow these requirements and wear appropriate PPE.
CAUTION
Only qualified personnel should be involved in assembly of the equipment.
6 Assembly Instructions
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
6 Assembly Instructions
personnel involved in the assembly before commencing work.
CAUTION
Ensure that all parts are thoroughly cleaned and free from damage or corrosion before
assembly.
• Check all components are clean and free from damage and corrosion.
• Tape all threads over which the O-ring will pass. O-rings should never be passed
over unprotected sharp edges.
• Use an O-ring lubricant
• Double check O-ring to ensure correct size
• Avoid over stretching the O-ring
• Avoid twisting or rolling the O-ring
• Where only one back-up ring is used, it must be placed between the O-ring and
pressure facing surface (Fig 13).
BACK-UP RING O-RING
PRESSURE DIRECTION
PRESSURE FACE
TFO-10006156/A3 MAN-10000527/F
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Figure 14: Bop Adapters fitted to the 3" TLW BOP Body
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
6 Assembly Instructions
Figure 15: Valve Seat shown in position
CAUTION
Once fitted in the factory the valve seat does not need removed. If for any reason the valve
seat gets damaged and requires replacing, it is suggested that the manifold be returned to
Elmar.
For reference only, the Valve Seat Removal Tool (Elmar Part No 981053).
NOTE: Check positions of the PTFE back-up rings (if applicable). Scarf cut at 45º the
PTFE back-up rings so that they can be assembled onto the valve stem.
Apply Nickelslip to the valve stem groove and fit the relevant O-ring and back-up ring.
Apply Nickelslip to the valve stem threads and screw into the manifold block using a
5/16” spanner.
Position the lock washer over the valve stem.
Apply Nickelslip to each PH screw and screw into the manifold using a small
screwdriver to secure the lock washer in place.
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6 Assembly Instructions
Figure 16: Equalisation valve shown fitted in manifold (Elastomers not shown)
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
6 Assembly Instructions
Hammer down with a plastic hammer until the piston passes through the elastomers
in the hydraulic cylinders and the threads that the ram nut attaches to are accessible
at the other end of the cylinder.
Apply Nickelslip to the piston external threads and the ram nut internal threads.
Screw the ram nut onto the piston and secure firmly.
NOTE: Both the piston and the ram nut have flats machined on them to
accommodate spanners.
Grip the ram nut and the end of the piston with a spanner and tighten. Dress up any
marks left by these tools.
Apply Nickelslip to the grub screw.
Position the locking insert into the ram nut, then locate and fasten the grub screw
behind it using a 1/8” allen key until it bottoms out.
NOTE: The locking insert is manufactured from PTFE and is required to grip into the
piston threads to act as a locking device. DO NOT OVER TIGHTEN THE GRUB SCREW
TFO-10006156/A3 MAN-10000527/F
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Using a plastic hammer, knock the ram nut so that the piston travels back to the fully
open position and the ram nut bottoms out on the cylinder.
Stand the cylinder on its end so that you can see into the cylinder and position the
piston so that the indicator groove is in the thread area.
Apply a coat of hydraulic oil or thin grease to the indicators.
Locate the three indicators into the groove on the piston.
Hammer down the piston with a plastic hammer so that the indicators are located in
the piston seal area.
TIP: Positioning the piston so that the indicator groove is in the thread area will allow
the indicators to be located into the groove. Once the indicators are located, slightly
tap the piston so that indicators are then in the seal relief diameter. Once in this
6 Assembly Instructions
position the cylinder should prevent the indicators from falling out of the groove
CAUTION
Do not move further in than necessary as this can lead to problems when assembling the end
cap to the cylinder
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Fit all O-rings and back-up rings in the end cap. Refer to the product specific assembly
drawing..
Ensure the internal cavity at the back of the end cap is full of grease before assembly.
CAUTION
The end cap is subjected to well fluids and pressure. The internal bore and piston seal
diameters have a corrosion resistant coating, but it is advised that this area is properly
maintained.
Apply grease to the cylinder internal thread and the mating end cap external thread
and the slots on the end cap.
NOTE: There are nine holes machined in the end cap. Only three holes are machined
6 Assembly Instructions
right through the end cap. Ensure these holes are the ones aligned with the indicators
Locate the end cap over the three indicators.
Using a plastic hammer, gently knock the end cap so that the piston passes the
elastomers in the end cap bore. Stop when the end cap threads touch the cylinder
threads.
Before screwing on the end cap, use a plastic hammer, and knock the ram nut so that
the piston is open again.
CAUTION
The piston has to be in the open position when screwing on the end cap to avoid excess
bending on the indicators.
TIP: For ease of assembly, position the cylinder into one of the cavities on the BOP
body
CAUTION
Do not grip the cylinder while screwing on the end cap as excessive deflection of the cylinder
may cause thread or seal bore damage.
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Locate the BOP Tool 974216 into the hole on the end cap and screw the end cap into
the cylinder.
TIP: Slightly tapping the end of the end cap with a plastic hammer while turning will
aid the thread start.
Apply a coat of grease onto the bearing washer and locate into the lock sleeve.
Locate the circlip into the lock sleeve to retain the bearing washer using a small
screwdriver.
Locate the O-ring onto the groove on the lock sleeve.
NOTE: The O-ring on the lock sleeve is for protection against dirt ingress and is used
as an anti-vibration lock during transportation. This O-ring is never subjected to
pressure.
6 Assembly Instructions
Apply a coat of grease onto the internal thread of the lock sleeve and the external
thread of the end cap.
Locate the lock sleeve onto the end cap so that the bearing washer contacts the
indicators.
Locate the BOP Tool 974216 through the two holes on the lock sleeve and screw in
the lock sleeve so that the piston is being moved manually. Continue until full stroke
has been achieved.
TIP: If fitted remove the complete cylinder assembly from the BOP body at this point.
NOTE: Before positioning the guide rod into the cylinder ensure you are familiar with
the ram orientation (inverted or non-inverted).
Apply Nickelslip onto the guide rod thread and screw into the relevant hole in the
cylinder body using a 7/16” spanner.
With the piston in the fully closed position fill the closed chamber with hydraulic oil.
Apply PTFE tape or Loctite 577 onto the female QC coupler threads. Insert and tighten
into the cylinder CLOSED port.
Apply PTFE tape or Loctite 577 onto the male QC nipple threads. Insert and tighten
into the cylinder OPEN port.
Page 36 of 77 Copyright National Oilwell Varco, ©2019
MAN-10000527/F TFO-10006156/A3
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Unthread the lock sleeve from the end cap and turn it around by 180º then thread it
back onto the end cap so that it is in the indicator protection position.
NOTE: The following steps apply to 4 1/16" Cylinders only:
Apply grease to inside of the lock ring and assemble over the cylinder body - ensure
the parallel grooves match up as shown in the assembly drawing. Secure in place
with retainer ring and button head screws. Check the lock ring is free to rotate
around the cylinder body.
Position the stainless-steel support clamp retainer and circlip as shown on the
assembly drawing.
Repeat steps 1 to 37 for each hydraulic cylinder.
6 Assembly Instructions
Figure 21: Lock Sleeve in the protection position
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
OUTER SEAL
GUIDE SCREW
GUIDE PLATE
RAM BODY LH
RAM BODY RH
6 Assembly Instructions
RAM BODY LH
RAM BODY LH
INNER SEAL
INNER SEAL
RAM BODY RH
RAM BODY RH
Figure 22: Standard (top), Q-GUIDE™ (left), and Integral (right) Ram Assemblies
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.
Nickelslip the inner seal retaining screws and insert into position. Tighten all four
screws equally. Check that the inner seal is still free to move.
Figure 23: Braided (left) and Slick Line (right) Inner Seal
MAN-10000527/F TFO-10006156/A3
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For standard rams with guide plates only: Nickelslip the ram guide screws. Fit top
ram guides (one to each ram) and screw into place. Fit bottom ram guides and screw
into place.
Ensure that the hydraulic cylinders are fully closed so the stem can be accessed for
mounting the ram.
For installation of non-inverted rams, ensure that outer seals are positioned to seal
towards the top of the ram bore.
For inverted rams, rotate the body of the ram on the cylinder stems to ensure the
outer seals are positioned to seal towards the bottom of the ram bore.
Pump the hydraulic cylinders open so that the rams locate in the cylinder pockets.
NOTE: This orientation is likely to apply to a triple bop being used for braided line work.
6 Assembly Instructions
Orientation of rams are job specific.
All ram assemblies should be non-inverted for slickline work. Lowest ram assembly
should be inverted for braided line work.
WARNING
As soon as an inverted ram body clears the cylinder pocket, it will fall off the stem.
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NOTE: The internals of the BOP body has a corrosion resistant coating. Do not remove
this coating with Scotchbrite.
1. Inspect body internals, paying particular attention to seal surfaces. Apply WD40 and
lightly smooth using Scotchbrite to clean up surface, if required.
NOTE: The alignment pin has to be located from the side shown
2. Grease the alignment pins and locate them into the bop body. (See Figure 25)
CAUTION
Do not grip the cylinder while screwing on the end cap as excessive deflection of the cylinder
may cause thread or seal bore damage.
NOTE: Check the orientation of the hydraulic cylinders to ensure that the rams are in
the correct position.
NOTE: Ensure that the cylinder is fully open and the ram is captive in the cylinder
pocket.
MAN-10000527/F TFO-10006156/A3
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6 Assembly Instructions
Figure 25: Alignment Pin location
3. Grease the rams, seals, cylinder thread, BOP body threads and cylinder bores.
4. Screw a ram /cylinder assembly to the BOP until it bottoms out.
5. Back off the cylinder until the groove lines up with the alignment pin. This does not
have to be exactly horizontal as the alignment pin will pull the cylinder in line when
locating.
6. Screw the alignment pin into the cylinder groove using the 3/8” allen key supplied
with the BOP tool 974216.
7. Repeat steps 1-6 for all of the cylinder assemblies.
NOTE: IMPORTANT MANIFOLD INSTRUCTIONS – Apply tightening torque 25-35 lbf-ft to
all SHC screws. Failure to do so may result in a leak at the manifold.
8. Blow out manifold block ports and threaded mounting holes with an airline to ensure
they are free of debris.
9. Apply grease to the BOP body and manifold block mating faces.
10. Nickelslip the SHC screws that are used to mount the manifold block.
11. Locate the manifold block into position and screw home the SHC screws to secure.
12. Repeat steps 8 to 11 to mount the other manifold assemblies to the BOP body.
13. The BOP can now be removed from the stump that was being used for assembly
purposes.
WARNING
When lifting the BOP ensure the appropriate lifting equipment is being used (See Section 8
for accessories).
14. Position the assembled BOP onto a wooden pallet taking care not to damage any of
the manifold blocks or threads when lying down the assembly.
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NOTE: The internals of the BOP body has a corrosion resistant coating. Do not to
remove this coating with Scotchbrite.
Inspect body internals, paying particular attention to seal surfaces. If required apply
WD 40 and lightly smooth using Scotchbrite to clean the surface.
Ensure Alignment Pin (Stainless Steel cap screw) is fixed in place. (See Figure 27)
NOTE: Check the orientation of the hydraulic cylinders to ensure that the rams are in
the correct position.
NOTE: Ensure that the cylinder is fully open and the ram is captive in the cylinder
pocket.
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6 Assembly Instructions
Figure 27: Alignment Pin location
3. Grease the rams, seals, lockring thread, BOP body threads and cylinder bores.
Attach the support bracket assembly onto cylinder and position on support arms.
Slide cylinder assembly in until the lockring thread contacts the BOP body.
Screw in lockring (using tool 974216) until it bottoms out.
Remove support bracket and repeat steps 1-6 for all of the cylinder assemblies.
NOTE: IMPORTANT MANIFOLD INSTRUCTIONS – Apply tightening torque 25-35 lbf-ft to
all SHC screws. Failure to do so may result in a leak at the manifold.
Blow out manifold block ports and threaded mounting holes with an airline to ensure
they are free of debris.
Apply grease to the BOP body and manifold block mating faces.
Nickelslip the SHC screws that are used to mount the manifold block.
Locate the manifold block into position and screw home the SHC screws to secure.
Repeat steps 8 to 11 to mount the other manifold assemblies to the BOP body.
The BOP can now be removed from the stump that was being used for assembly
purposes.
WARNING
When lifting the BOP ensure the appropriate lifting equipment is being used (See Section 8
for accessories).
Position the assembled BOP onto a wooden pallet taking care not to damage any of
the manifold blocks or threads when lying down the assembly.
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7 OPERATION
WARNING
Please refer to Section 2 (Safety & EHSRs) for safety requirements. Ensure that all personnel
follow the requirements and wear appropriate PPE.
CAUTION
Ensure all equipment has been fully serviced before commencing operation. Do not assume
serviceable equipment on the last job will be serviceable again. Refer to Section 8
(Maintenance & Testing) for more details.
7 Operation
WARNING
All instructions in this section assume no Shear rams are fitted and Rams and Manifolds
configured as per section 4.2.3.2. Refer to Figures 5 and 6 for Valve identification.
If BOP is fitted with shear rams consult Section 4.2.3 and adjust the following steps
accordingly.
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Connect a suitable dump hose to the dump port and lead off to an area well away from
personnel.
WARNING
Ensure hose the end is tied down and terminates in a ”T”. Consider topography and weather
conditions such as wind direction etc
A pressure gauge manifold rated to the appropriate pressure should be attached to the
rear manifold block for pressure monitoring (Refer to Section 8 for spares and accessories).
CAUTION
Unseasoned or new cable is particularly difficult to obtain a reliable grease seal with and
every care should be taken to avoid using the equipment to seal on new or clean cable.
MAN-10000527/F TFO-10006156/A3
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CAUTION
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.
Close the lower most set of rams (inverted) from the module control panel. Leave
the hydraulic pump on the Hydraulic Control Module stalled against the BOP close
function.
Begin to inject grease at approximately 1.2 times the well pressure above the lower
7 Operation
set of rams through the grease injection connection on the manifold.
Whilst continuing to inject grease, close the upper most set of rams from the control
panel. Leave the hydraulic pump on the Hydraulic Control Module stalled against the
BOP close function.
Screw in lock sleeves to provide safety back-up on both sets of rams.
A suitable hose should already be connected to the dump port and lead off to an area
well away from personnel.
WARNING
Ensure the hose end is tied down and terminates in a”T”. Consider topography and weather
conditions such as wind direction etc
When the grease injection rate has stabilised/stopped then the lubricators can be
bled down.
CAUTION
If using shear and seal rams on a Triple Wireline Valve, the operator MUST be aware of the
orientation and position of each set of rams and ensure the correct manifold configuration
is in place. Ref Section 4.2.3
NOTE: In a Triple Wireline Valve the middle set of rams are only used in case of failure
to the upper most set of rams. In normal operations, the upper most and lower most
rams are closed and grease injected between the two. In case of failure of the upper
most rams to hold a seal, the middle ones can be closed, and the upper most set
serviced after ensuring that a seal has been achieved with the middle set.
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WARNING
The following steps assume no Shear rams are fitted and Rams and Manifolds configured
as per section 4.2.3.2. Refer to Figures 5 and 6 for Valve identification.
If BOP is fitted with shear rams consult Section 4.2.3 and adjust the following steps
accordingly.
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.
Monitor lubricator pressure using the pressure gauge manifold connected to the rear
manifold.
WARNING
Before disconnecting any wellhead equipment quick unions ensure that all residual
pressure, which may be trapped inside the WPCE string, is fully bled off. A sure sign of
trapped pressure is an unusually tight connection or a stiff hose.
MAN-10000527/F TFO-10006156/A3
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WARNING
The following steps assume no Shear rams are fitted and Rams and Manifolds configured
as per section 4.2.3.2. Refer to Figures 5 and 6 for Valve identification.
If BOP is fitted with shear rams consult Section 4.2.3 and adjust accordingly.
7 Operation
Slowly open valve C to allow pressure to equalise across the middle set of rams,
monitoring the well pressure rise on the pressure gauge manifold.
When well pressure is reached open all ram assemblies.
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CAUTION
The Circlip to the outside of the lock ring should not be removed.
TIP
Due to a combination of the tight fit of the rams in the BOP bores and the weight of these
cylinder assemblies, these do take reasonable effort to back off due to high friction
7 Operation
between threads as they attempt to pull the rams through the bore. There are two ways of
assisting the removal of these cylinders:
1. Use a longer/extended punch to apply greater force when unscrewing the lock rings.
2. If when applying method 1 it is found that excessive effort is required, functioning the
rams a minimal amount in the close direction will relieve the pressure between the
two mating threads allowing them to spin off with relative ease.
Once the lock ring is completely disengaged from the BOP body, it is essential that
you return the rams to the fully open position.
Ensure all hydraulic pressure has been dumped and disconnect the hydraulic hoses
at the QC Couplings.
The cylinder assembly can now be pulled back fully on the support arms.
NOTE
This will not apply to 3” BOPs as these are not fitted with support arms.
NOTE
For larger BOPs, lifting equipment should be used for this operation.
MAN-10000527/F TFO-10006156/A3
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WARNING
As soon as an inverted ram body clears the cylinder pocket, may fall clear from the stem.
7 Operation
The rams can now slide off the stems.
NOTE
The rams will now need to tip sideways once clear of the stem before being lifted clear.
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WARNING
Refer to Section 2 (Safety & EHSRs) for safety information before carrying out any
maintenance and testing routines.
WARNING
The BOP assembly is heavy; check that the lifting equipment can support this load. Never
position yourself under the suspended load.
8 Maintenance & Testing
CAUTION
Refer to build specific assembly drawings for equipment details, e.g. seal kit part numbers
and service details.
CAUTION
Equipment needs to be maintained properly to perform as designed.
8.1 Introduction
Only qualified and trained personnel should perform maintenance on Elmar units. The
maintenance procedures described here include:
• Scheduled periodic (preventive); (e.g. cleaning, inspecting and testing
components, filling fluid levels and lubricating moving parts)
• Corrective (troubleshooting and repairing any malfunctions, plus
calibrating/adjusting)
• Exchanging parts (according to operational requirements)
The assembly can experience extreme forces and rugged conditions, so scheduled
maintenance is regularly required to prevent equipment damage and potential hazards.
Inspections and tests should be carried out daily before working with the assembly, but
regular maintenance must be performed. See Section 8.4 for full details of routine
maintenance.
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CAUTION
Fully dismantling and cleaning all parts that have been exposed to 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.
CAUTION
Avoid steam cleaning any internal bores that have corrosion resistant coatings. Grease the
internal bores using a cloth/swab.
8 Maintenance & Testing
• Remove the cylinder assemblies from the BOP and clean the BOP thoroughly to
remove any residual well deposits.
CAUTION
If the job contained any of the following then it is advisable to strip the cylinder and
manifold assemblies, replacing all seals which are exposed to well pressure;
• Extended Exposure to well fluids (>48 hours)
• H2S
• High pressure gas
• Function each cylinder assembly until it is fully extended and remove the ram
assemblies. Thoroughly clean the cylinder ram pocket.
• Remove all well pressure seals from the ram assemblies, upper & lower BOP
connections (if fitted with Quick Union Connections) and cylinder/BOP body
connection pin.
• Inspect all threads for damage and wear.
• Inspect all seals and sealing surfaces, replacing any damaged seals and back-ups.
CAUTION
Normal wear on inner seals will be a moderate amount of extrusion downstream of the
pressurised side. When usage has resulted in any noticeable loss of rubber or the bond
between the metal and rubber is separating – REPLACE THE SEALS
• Apply corrosion inhibitor to the cylinder ram pockets. Ensure that the piston is
retracted fully into the hydraulic cylinder before application.
MAN-10000527/F TFO-10006156/A3
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• Ensure all manifold valves are in the fully open position. Pump grease into the
manifold blocks until clean grease can be seen exiting through the hole in the
main through bore.
• Reassemble the BOP as per the assembly procedure in Section 6, being careful
not to damage any of the seals and ensuring that all sealing areas are free from
contaminants and have been suitably greased.
CAUTION
Check that the rams and seals are suitable for the intended wireline.
• Insert the grease nipple supplied with the BOP assembly into the port on the
cylinder assembly shown in the image overleaf. Inject grease until clean grease is
seen exiting around the stem.
• Check the operation of the piston locks
CAUTION
The piston locks must be fully backed off to permit the rams to fully open.
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CAUTION
All WPCE having undergone three 5-year major re-certifications should be retired before
the fourth re-certification is due.
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8.6 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 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 should not be used.
The well site TP should 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 should 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., should be tested. It is recommended to test as much of the
equipment as possible whilst assembled together. 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 should be displayed, and all unnecessary personnel cleared from
the pressure testing location during the pressure test.
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WARNING
Trapped air requires considerable time to compress and when it is compressed is highly
dangerous. It has enough energy to separate parts with considerable force.
Always ensure air is completely bled from the system prior to pressure testing.
WARNING
Clear the area of all unnecessary personnel and ensure procedures are in place to prevent
access to all unauthorised personnel during testing. Pressure testing should only be
performed by competent personnel.
8 Maintenance & Testing
CAUTION
No leakage is acceptable in any of the following test procedures unless stated otherwise. In
the event of a leak, appropriate maintenance action should be taken. See Section 9
(TROUBLESHOOTING) for more information.
CAUTION
No leakage acceptable.
MAN-10000527/F TFO-10006156/A3
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rubber is reversible and the rams will lose the ability to seal on a different section of the
line. In any case, new cables will often leak due to fluid passing between the inner and outer
armour strands and give the impression that the rams are not sealing properly.
Elmar designed test rods should be ordered to match the maximum line size for which the
ram seals are dressed. The table below shows the relevant part numbers.
TEST ROD ASSEMBLY
PART NUMBER LINE SIZE (ROD DIAMETER) TEST LOAD (KG)
974956 3/16” 500
973440 7/32” 500
WARNING
Only Elmar designed test rods are suitable for testing. BOP Test Rods should not be made
locally.
Test rods should be inspected regularly and re-tested to test load annually.
CAUTION
The ram seals are limited by API specification to working pressure only.
When testing the shear and seal rams, DO NOT use a test rod as these can damage the
shear blades and reduce effectiveness and lifespan.
TFO-10006156/A3 MAN-10000527/F
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zero.
5. Open shear/seal rams and disconnect hydraulic supply to ensure that the ram is
omitted from further testing.
No leakage acceptable
NOTE
For correct method of fitting shear blades and carrying out shear tests refer to TB-
10006406
WARNING
If the welded tab on the base of the test rod is not positioned closely against the underside
of the lowest closed ram, the rod may slip during testing (see Figure 30, p.61).
At worst, this can cause the entire rod to be rapidly and violently ejected from the top of
the BOP, potentially causing damage to seals, facilities and personnel.
MAN-10000527/F TFO-10006156/A3
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WARNING
If pressure testing through any of the grease or glycol injection lines, bleed off pressure
using the equalisation valves. The check valves in the injection line will prevent pressure
from bleeding off within the BOP when pressure is dumped through the control module.
If bleeding off using the equalisation valves, it is recommended that pressure be directed
into fluid filled cavities – i.e. below the rams and through the test stump.
WARNING
Use of shear rams and standard ram orientation is entirely at the discretion of the end user.
For configurations not shown, testing shall be carried out to ensure that all rams have been
tested against Working Pressure as described in Section 8.6 whilst maintaining
communication to the gauge.
WARNING
When testing shear rams do not insert a test rod
In the following diagrams a shear ram can be considered in the same way as a non-inverted
ram.
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Upper
1 & Manifold Injection Port
Lower (inverted)
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Figure 33: Valve and injection port labels for TLW manifold assemblies
Middle
2 & Manifold Injection Port
Lower (inverted)
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WARNING
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
8 Maintenance & Testing
MAN-10000527/F TFO-10006156/A3
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9 TROUBLESHOOTING
9 Troubleshooting
PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY
Leakage at the (a) Damage to the O-Rings (a) Replace faulty parts.
connections: and/or seal surfaces
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10.2 Transportation
Before transporting any BOP assembly, Routine Maintenance should be carried out as per
Section 8.5.2.
The BOP assembly should always be transported with:
• All fluids drained.
• All bores coated with a light oil/corrosion inhibitor.
• The manifold equalisation valves closed.
• The lock sleeve in position to protect the indicators.
• Top and bottom quick union threads and seal surfaces 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. Care should be taken to ensure that the injection
couplings are left unobstructed and not subjected to any loads or impacts.
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10.3 Spares
Use only NOV Elmar recommended spares.
For seal kit part numbers and spares parts, refer to the relevant Technical Illustration
supplied with the equipment.
Recommended spares:
• Seal Kit
10 Transportation, Spares, Accessories & Disposal
10.4 Accessories
NOV Elmar can supply a range of accessories for handling, testing and assembling the
Lightweight 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.
NOV Elmar can supply adapters for various quick union sizes. Contact the NOV Elmar Sales
Department for details.
For accessories that do not have part numbers stated contact the NOV Elmar Sales
Department for details. The part numbers for these accessories may 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
• Test Rod (see Section 8.6.3)
• Drift Gauge (contact local NOV Elmar sales team for appropriate part)
• ‘C’ Spanner
• Non-Marking Strap Wrench (part number 840957)
• Grease (part number 881720)
MAN-10000527/F TFO-10006156/A3
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10.5 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. NOV Elmar can assist if required.
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APPENDICES
This section contains the following appendices:
Appendix 1: Maintenance Record Sheet
Appendix 2: Contact Us
Appendices
MAN-10000527/F TFO-10006156/A3
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DATE TYPE OF
PERFORMED BY VERIFIED BY COMMENTS
PERFORMED MAINTENANCE
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Appendix 2: Contact Us
MAN-10000527/F TFO-10006156/A3
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CUSTOMER NOTES
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Published by:
Elmar
Tofthills Avenue,
Midmill Business Park,
Kintore, Aberdeen, AB51 0QP
Scotland, United Kingdom
No part of this document may be reproduced by any means without the written consent of
the publisher.
Whilst every care has been taken to ensure that the information in this document is
correct, no liability can be accepted by Elmar for loss, damage or injury caused by any
errors or omissions in this document.
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