TECH MANUAL

TECH-5.12 10K ES SINGLE BOP

M60ES54-C549X

5.12” 10,000 PSI WP, 3,000 PSI HYDRAULICS ES

SERIES, PIPE/BLIND SINGLE BOP

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

ADDITIONAL CODE SDRL CODE TOTAL PGS

This document contains proprietary and confidential information TEXAS OIL TOOLS
which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is 3770 Pollock
REMARKS
loaned for limited purposes only and remains the property of NOV. Conroe, TX 77303
Reproduction, in whole or in part, or use of this design or Phone 936-777-6200
distribution of this information to others is not permitted without the
MAIN TAG NUMBER DISCIPLINE
express written consent of NOV. This document is to be returned to Fax 936-756-8102
NOV upon request and in any event upon completion of the use for
which it was loaned. This document and the information contained
CLIENT PO NUMBER and represented herein is the copyrighted property of NOV.
 National Oilwell Varco
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

Client Document Number M60ES54-C549X-MAN-001 01

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REVISION HISTORY

01 03/Nov/2015 Initial Release CP KM JD

Rev Date (dd.mm.yyyy) Reason for issue Prepared 13 Checked Approved

CHANGE DESCRIPTION

01 Initial Release

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CONTENTS

1.0 INTRODUCTION

2.0 FEATURES

3.0 CERTIFICATION

4.0 OPERATION

5.0 TESTING

6.0 SPECIFICATIONS

7.0 M60ES54-C549X
5.12 10K ES SINGLE
M60ES54-C549X-ART-001

8.0 ES56-ACT2L
PIPE/BLIND ACTUATOR W/ 6.00” PISTON
ES56-ACT2L-ART-001

9.0 EQ10-0001X
EQUALIZING VALVE 10K NACE
EQ10-0001X-ART-001

10.0 M60ES5R-*P**B
5.12” ES PIPE/BLIND RAM ASSEMBLY
M60ES5R-LP00-ART-001

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M60ES54-C549X
5.12 10K ES SINGLE PIPE/BLIND BOP
M60ES54-C549X-ART-001

1.0 INTRODUCTION
The 5.12" 10K ES Single BOP is designed for coiled tubing and snubbing operations. The ES is the
lightest in the industry, yet retains all the field-proven designs you have come to expect from Texas Oil
Tools.
The compact size allows easier handling along with easier maintenance. All actuators feature power
hydraulic ram change, low bonnet bolt torque requirement, and a pressure balance piston for shear.
Internally ported hydraulics (no external plumbing) eliminate the making and breaking of oil seals when
changing or servicing rams; thus removing the possibility of environmental pollution.

2.0 FEATURES

 Light and Compact

 Low Bonnet Bolt Torque
 Internal Equalizing Valves
 Well Pressure Isolated Seals
 Hydraulic Ram Change
 Internal Porting
 Independent Bonnet Testing
 No Welds - Solid Body
 Ram Position Indicator
 Manual Locks

3.0 CERTIFICATION - Testing - All BOPs are hydrostatic and function tested per API 6A.

H2S Service - Materials in contact with pressured well fluids conform to NACE Specification MR-01-75
for H2S Service.

North Sea Service - In addition to the NACE Specifications and API requirements additional Charpy
Impact and NDE are carried out. A Design Review and Certificate of Compliance by DNV, Lloyds, or
Bureau Veritas are furnished with the Data Book.

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4.0 OPERATION
Ram Open and Close - Before opening the rams be sure the lock screws are backed fully out (turn
counter clockwise). If lock screws do not turn out easily after a closed and locked wellbore pressure
test apply 1,500 to 2,200 psi hydraulic pressure to the "CLOSE" hydraulic port to relieve the load from
the end of the tail rod.
To open the rams apply 1,500 psi hydraulic pressure to the body port marked "OPEN". Close the
rams by applying 1,500 to 2,200 psi hydraulic pressure to the body port marked "CLOSE".

Bonnet Open and Close - Remove the bonnet bolts (16).

To open the bonnets apply 500 to 1,500 psi hydraulic pressure to the body port marked "CLOSE"
(ram close). To close the bonnets apply 1,500 psi operating pressure to the body port marked
"OPEN" (ram open). After closing the bonnets maintain the 1,500 psi hydraulic pressure to keep the
bonnet pulled tightly against the body as the bonnet bolts are reinstalled.

Ram Change - Vent all hydraulic pressure to zero.

Remove the bonnet bolts and open the bonnets as described above. Maintain hydraulic pressure
until the bonnets have fully retracted and the rams have fully extended making them accessible. Vent
all hydraulic pressure to zero to prevent personal injury in the event that the bonnet is closed
prematurely during the ram change procedure.

Remove the ram by lifting up and over the ram change rod. NOTE: Do not scratch ram change rods.

Front and rear seals may be replaced without fully removing the rams. Lift the ram up until it clears
the ram guide rod and rotate slightly to gain access to the front seal.
RECOMMENDED MAINTENANCE PROGRAM
After Each Job - Inspect Ram Rubber Seals
Normal wear will be a moderate amount of extrusion downstream of the pressured side.
Replace the ram seals when usage has resulted in any noticeable loss of rubber. Field testing only to
the maximum anticipated well pressure will extend the life of the seals.

Inspect Bonnet Seal - For scratches and deformation, inspect O-rings and O-ring grooves.

Always store and operate the BOP with the equalizing valve closed.
After 20 Jobs or 12 Months Maximum - Completely disassemble the equalizing valve, replace all
seals and worn parts.
Completely disassemble and inspect the bonnet assemblies. Replace all seals and worn parts.

Inspect all threads, connections, bushings and fittings. Replace and repair as required.

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5.0 TESTING

Function Test Bonnets - All actuators should be pressure tested to 3,000 psi working pressure in
both the ram open and ram close positions. A minimum hold time of 15 minutes is required without
leakage.
Check the manual lock system when in the ram closed position.
Blind Seal Tests - The blind rams seal should be closed using 1,500 psi hydraulic pressure and
pressure tested separately to 15,000 psi from below. The test medium should be water with a rust
inhibitor.
Function Test Slip Ram with Pipe Ram Seal Test - The pipe rams should be closed using 1,500 psi
hydraulic pressure and pressure tested to 15,000 psi from below. A minimum hold time of 15
minutes is required without leakage. The test medium should be water with a rust inhibitor.

6.0 SPECIFICATIONS
M60ES54-C549X
5.12 10K ES SINGLE PIPE/BLIND BOP
Maximum Working Pressure ............................................................................................................... 10,000 psi
Hydraulic Working Pressure ........................................................................................ 1,500 psi (3000 psi Max.)
Service .............................................................................................................................. H2S, NACE MR-01-75
Weight

Single ................................................................................................................................................ 2,300 lbs

Hydraulic Volumes

Pipe/Blind Actuator (ES56-ACT2L) (ES56-ACT2L)

Open (per set) ...................................................................................................................... 201.2 cu. in.
Close (per set) ...................................................................................................................... 201.2 cu. in.

Hydraulics/Wellbore Ratio

Pipe/Blind Actuator (ES56-ACT2L) .................................................................................................... 12.66:1

Tightening Torques

PIPE/BLIND ACTUATOR ES56-ACT2L

16 BONNET BOLT 4 500 FT LBS
17 SHCS 7/8-9UNC 4 160 FT LBS
18 SHCS 1 1/8-8UNC 6 335 FT LBS
19 GUIDE STUD 1 50 FT LBS
20 SHCS 7/8-9UNC 8 160 FT LBS
- END FLANGES - 401 FT LBS

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7.0 M60ES54-C549X
5.12 10K ES SINGLE BOP PIPE/BLIND BOP
Reference drawing M60ES54-C549X-ART-001

H2S & NORTH SEA

ITEM QTY DESCRIPTION
PART NO.
1 M601009429B 1 BODY 5.12 10K ES SINGLE
2 ES56-ACT2L 2 PIPE/BLIND ACTUATOR W/6'' PISTON
3 EQ10-0001X 1 EQUALIZING VALVE ASSY
4 7934-9094R 1 PLUG ASSY API PORT .562
5 2000-FP54 1 FLANGE PROTECTOR
6 EH34-CTAG 1 TAG KIT

M60ES54-C549X-ART-001

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8.0 ES56-ACT2L
5.12 15K ES56 PIPE & BLIND ACTUATOR
Reference Drawing ES56-ACT2L-ART-001

Disassembly - Open the bonnets. See bonnet open and close, section 4; vent all hydraulic
pressure to zero. Remove the rams and remove set screw (22), rod head (14) and guide (19).
Remove the bonnet seal (1-11). Remove nut (26) and handwheel (25) from the lock screw (24).
Remove socket head cap screws (17) and (18).

Remove end cap (5). Use caution not to drop indicator pod (15). Remove o-rings (1-2) and (1-4).
Remove retainer ring (1-9), polypak (1-8), and retainer (3). Remove socket head cap screws (20).
Remove lockscrew cap (10). Remove and inspect lock screw (24). Remove change cylinders (9)
and main cylinder (6) from bonnet (4). Remove seal retainer (21) and polypak (1-7). Remove
piston (12) and T-seal (1-5) from bonnet (4). NOTE: Do not remove piston from rod.
Support weight of bonnet (4) and remove ram change rod (7) and (8) from body with allen wrench.
NOTE: Do not scratch surfaces of ram change rods. Note specific location of change rods as they
have differing thread sizes. Remove o-rings (1-2) from body.
Remove T-seals (1-6) from ram change rods (7) and (8). Remove o-rings (1-2) and (1-4). Remove
retainer ring (1-9), polypak (1-8) and retainers (3) from bonnet (4). Remove bushings (2) and
polypak (1-8) from bonnet (4). Remove o-rings (1-1) from body. Clean and inspect all parts for
wear before reassembly.

Assembly - Typical reverse order of disassembly - pay careful attention to ram change rod surface
- do not scratch.

M60ES56-ACT2L
PIPE/SLIP/BLIND ACTUATOR 6” PISTON
M60ES56-ACT2L-ART-001

ITEM PART NUMBER QTY DESCRIPTION

1 ES56-SK02 1 SEAL KIT LT
2 7830-0239 2 BUSHING
3 7830-0240 3 RETAINER SEAL
4 2002-3758B 1 BONNET
5 2002-3759B 1 ENDCAP
6 2002-3768B 1 CYLINDER
7 2002-3745B 1 CHANGE ROD OPEN
8 2002-3746B 1 CHANGE ROD CLOSE
9 2002-3747B 2 CHANGE CYLINDER
10 2002-3769B 1 CAP LOCKSCREW
11 2002-3766B 1 PISTON ROD
12 2002-3767B 1 PISTON 6.00”

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13 2002-3752B 1 RAM GUIDE
14 2002-3753B 1 ROD HEAD
15 2002-3754B 1 INDICATOR ROD
16 2002-3755B 4 BONNET BOLT
17 2002-3756B 4 SHCS 7/8-9UNC X 13.12
18 2002-3757B 4 SHCS 1 1/8-8UNC X 12.31
19 2002-3770 1 GUIDE STUD
20 7935-1409G 8 SHCS 7/8-9UNC X 2.25
21 8007-3038 1 RETAINER
22 7941-0301 1 SSCR SKT #10
23 7934-0202 4 PLUG SKT #2
24 2002-3772B 1 LOCK SCREW
25 9905-2851 1 HAND WHEEL
26 7938-0510 1 NUT .625 18NF

ES56-SK02*
SEAL KIT F/ PIPE/SLIP/BLIND ACTUATOR 6” PISTON
M60ES56-ACT2L-ART-001

*SERVICE SPECIFIC PART NUMBER

ES56-SK02 ES56-SK02B
ITEM QTY DESCRIPTION
-25°F H2S & -50°F ARCTIC
NORTH SEA SERVICE
1-1 7813-3223 7813-A223 2 O-RING
1-2 7813-3229 7813-A229 4 O-RING
1-3 7813-3227 7813-A227 1 O-RING
1-4 7813-3358 7813-A358 2 O-RING
1-5 7951-3433 7951-A433 1 T-SEAL
1-6 7951-3326 7951-A326 2 T-SEAL
1-7 7820-0251 7820-0251B 1 SEAL DEEP B
1-8 7821-1622 7821-1622B 7 SEAL DEEP B
1-9 7826-2127 7826-2127 5 RETAINER RING INTERNAL
1-10 7978-1622 7978-1622B 1 PIP SEAL
1-11 9900-6221 9900-6221B 1 GASKET DUR-O-SEAL
1-12 7813-3258 7813-A258 2 O-RING
1-13 2005-0099 2005-0099 1 THREADLOCKER

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ES56-ACT2L-ART-001

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9.0 EQ10-0001X
EQUALIZING VALVE ASSEMBLY 10K
Reference Drawing EQ10-0001X-ART-001

DISASSEMBLY / ASSEMBLY
Disassembly

Remove the equalizing valve bonnet (1). NOTE: LEFT-HAND THREAD. Use a 1/4 “ Allen wrench
(4-4) & rotate right-hand to remove the equalizing valve stem (2), two seals (4-3), and spacer (4-1).
Remove and discard o-ring (4-2).
Remove the equalizing valve seat (3) using a short piece of heavy wire with a hook bent on the
end. Remove seals (4-3). Take care not to damage the sealing surface. NOTE: If the seat is
stuck, hold the hooked wire in place with the 1/4 “ Allen wrench while you pull on the wire.
Assembly

Install o-ring (4-2) on the equalizing valve bonnet (1). Install the stem (2) into the bonnet, rotating it
to the full open position. Install the spacer (4-1), NOTE: Beveled side in first. Install two seals (4-
3). Install two seals (4-3) into the body. When both seals are in place, install the seat (3).
Check to assure that the stem (2) is in the fully opened position, install the bonnet/stem assembly.
NOTE: left-hand thread.

CLOSE THE EQUALIZING VALVE!!

EQ10-0001X
EQUALIZING VALVE ASSEMBLY 10K
Reference Drawing EQ10-0001X-ART-001

PART NO. H2S &

ITEM
NORTH SEA -25°F
1 7808-1422B
2 7808-1426XB
3 7903-1122XB
4 EVA4-S000
QTY DESCRIPTION
1 BONNET F/ EQ VALVE 10K
1 STEM F/EQ VALVE 10K
1 SEAT F/EQ VALVE 10K
1 SEAL KIT H2S/NORTH SEA

EVA4-S000
SEAL KIT F/ STANDARD EQUALIZING VALVE
PART NO. H2S &
ITEM QTY DESCRIPTION
NORTH SEA -25°F
4-1 7808-1427 1 SPACER F/ EQUALIZING VALVE
4-2 7813-4911 1 O-RING 90 VITON
4-3 7817-0371 4 SEAL POLYMYTE SQ
4-4 7940-2501 1 ALLEN WRENCH – NOT SHOWN

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EQ10-0001X-ART-001

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10.0 M60ES5R-*P**B
5.12” ES PIPE/BLIND RAM ASSEMBLY
M60ES5R-LP00-ART-001

Disassembly

Remove the front seal (3) and retainer bar (2) by pushing the front seal to one side. Remove the
rear seal (4). Clean all parts and replace components as necessary.

Assembly

Install the rear seal (4) to fit flush with the surface of the ram body (1). While holding the retainer
bar (2) in position in the front seal (3), slide both into position in the ram body (1).

M60ES5R-*P**B
5.12” ES PIPE/BLIND RAM ASSEMBLY
M60ES5R-LP00-ART-001

Pipe & Blind Ram Assemblies

Assembly Type Blind Ram Pipe Ram
Assembly Number ES5R-VP21L ES5R-VP**L
Item Part Name QTY N/A
1 Ram Body 2 2002-3821B 2002-38**B
2 Retainer Bar 2 7805-3121 7805-3121
3 Front Seal 2 7805-3721 7805-37**
4 Rear Seal 2 7805-2437 7805-2437

M60ES5R-LP00-ART-001

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