TECH MANUAL

TECH-5.12 10K ES54 SINGLE P/S

M60ES54-U543XL

5.12”, 10,000 PSI WORKING PRESSURE,

ES54 SINGLE PIPE/SLIP, H2S NACE

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 77305
Reproduction, in whole or in part, or use of this design or Phone 936-777-6100
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-U543XL-MAN-001 01

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REVISION HISTORY

01 08/Mar/2013 Initial Release CP KM JD

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

CHANGE DESCRIPTION

01 Initial Release

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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 FEATURES

3.0 CERTIFICATION

4.0 OPERATION

5.0 RECOMMENDED MAINTENANCE

6.0 FIELD TESTING

7.0 SPECIFICATIONS

8.0 M60ES54-U543XL
5.12 10K ES SINGLE
M60ES54-U543XL-ART-001

9.0 M60ES56-ACT7
PIPE/SLIP ACTUATOR W/ 7” PISTON
M60ES56-ACT7-ART-001

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

11.0 ES5R-VT44L
PIPE/SLIP RAM
ES5R-VT00-ART-001

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M60ES54-U543XL
5.12 10K ES SINGLE PIPE/SLIP BOP
M60ES54-U543XL-ART-001

1.0 INTRODUCTION

The 5.12" 15K ES 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
operations (no booster required).

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

 Pressure Balance Piston
 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.

Arctic Service - In addition to the NACE Specifications above meets the API 6A with Charpy Impacts
at -50˚F.

North Sea Service - In addition to the NACE Specification s 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 3,000 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 3,000 psi hydraulic pressure to the body port marked "CLOSE".

Bonnet Open and Close - Remove the bonnet bolts (15).

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.

5.0 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.

Check the teeth of the slip inserts. If the slip teeth are blunt or dulled then the gripping action of the
ram may be impaired and therefore the slips should be discarded.

Always store and operate the BOP with the equalizing valve closed.

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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.

6.0 FIELD 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.

Function Tests Shear Seal Ram and Blind Seal Tests - The shear seal rams and 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 slip rams should be closed around a
suitable diameter test bar, using 1,500 psi hydraulic pressure. The pipe rams should then 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.

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7.0 SPECIFICATIONS

Maximum Working Pressure ............................................................................................. 10,000 psi

Maximum Hydraulic Working Pressure ............................................................................... 3,000 psi
Service ........................................................................................................... H2S, NACE MR-01-75

Weight

ES54 Single ........................................................................................................................ 2,300 lbs

Hydraulic Volume

Pipe/Slip Actuator (M60ES56-ACT7)

Open (per set) ................................................................................................................. 246 cu. in.
Close (per set) .................................................................................................................. 246 cu. in.

Hydraulics/Wellbore Ratio

Pipe/Slip Actuator (M60ES56-ACT7) .................................................................................... 18.55:1

Tightening Torques

Bonnet Bolts ..................................................................................................................... 500 ft. lbs.

End Flanges .................................................................................................................. 1,280 ft. lbs.
Side Outlet ........................................................................................................................ 310 ft. lbs.

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8.0 M60ES54-U543XL
5.12 10K ES SINGLE PIPE/SLIP BOP
M60ES54-U543XL-ART-001
Disassembly – Remove the Bonnet Bolts from all actuators. Open each Actuator & remove the
Ram assemblies. While supporting the actuator unscrew the Change Rods for the BOP body. Do
this for all actuators. Remove the Connector Guard assembly. Remove the Equalizer Valve
assemblies. Remove the Plug assemblies.
Assembly – Install Plugs , Equalizer Valves, & Connector Guards. Install the actuators by
supporting it and lining up the ram change rods, then screw the rods into the BOP body.

M60ES54-U543XL
5.12 10K ES SINGLE PIPE/SLIP
M60ES54-U543XL-ART-001

ITEM PART NO. QTY. DESCRIPTION

1 M601009800B 1 BODY; ES56 SINGLE PIPE/SLIP NACE
2 M60ES56-ACT7 2 PIPE/SLIP ACTUATOR W/ 7” PISTON
3 EQ10-0001X 1 10K EQUALIZING VALVE ASSY.
4 7934-9094R 1 PLUG ASSEMBLY API .562
5 2000-FP54 2 FLANGE PROTECTOR BX 169
6 ES54-SCG2 1 CONN GUARD ASSEMBLY
7 7933-4169 2 GASKET RING BX169
8 7949-1876B 24 STUD 1.125-8UN X 9.50
9 7937-0818B 48 NUT 1.125-8UN
10 ES5R-VT44L 1 PIPE/SLIP RAM ASSEMBLY
11 2003-0222 1 NAME PLATE HALLIBURTON

M60ES54-U543XL-ART-001

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9.0 M60ES56-ACT7
PIPE/SLIP ACTUATOR W/ 7” PISTON
M60ES56-ACT7-ART-001

Disassembly - Open the bonnets. See bonnet open and close, section 4.0; vent all hydraulic
pressure to zero. Remove the rams and remove set screw (21), rod head (13) and guide (12).
Remove the bonnet seal (1-11). Remove nut (26) and handwheel (25) from the lock screw (23).
Remove socket head cap screws (16) and (17).

Remove end cap (5). Use caution not to drop indicator rod (14). Remove O-rings (1-2) and (1-4).
Remove retainer ring (1-9),seal (1-8), and retainer (3). Remove socket head cap screws (19).
Remove lockscrew cap (24). Remove and inspect lock screw (23). Remove change cylinders (9)
and main cylinder (6) from bonnet (4). Remove seal retainer (20) and seal (1-7). Remove piston
(11) 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 (1-1) 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), seals (1-8) and retainers (3) from bonnet (4). Remove bushings (2) and seals
(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.
Install seals (1-8) and retainer (3) and retainer ring (1-9), into end cap (5). Install seals (1-8),
retainers (2), retainer rings (1-9), and O-rings (1-2) and (1-4), into bonnet (4). Insert ram change
rods (7) and (8) through bonnet (4). NOTE: Do not scratch surfaces of ram change rods. Install O-
rings (1-1) into body. Support weight of bonnet (4) and thread ram change rod (7) and (8) into body
with Allen wrench. NOTE: Ram change rods have different threads (7) = 1.250-8UNC, (8) = 1.125-
8UNC.
Install T-seal (1-5) onto piston (11). Install piston (11) into bonnet (4); install guide (12), rod head
(13) and secure set screw (21). Install main cylinder (6) and change cylinders (9). Install seals (1-
8) retainers (3) and O-rings (1-2) and (1-4) into end cap (5). Thread lock screw (23) into cap (24)
and attach with socket head cap screw (19). Install end cap (5) onto main cylinder (6) and ram
change cylinders (9); secure with socket head cap screws (16) and (17). Install handwheel (25) and
secure with nut (26). Install the bonnet seal (1-11) and O-rings (1-12). Actuator can now be tested
and functioned per 4.0 Operation.

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M60ES56-ACT7
5.12 10K ES SINGLE PIPE/SLIP ACTUATOR
Reference drawing M60ES56-ACT7-ART-001

ITEM -25°F H2S & NORTH SEA QTY DESCRIPTION

1 ES56-SK07* 1 SEAL KIT
2 7830-0239 2 BUSHING
3 7830-0240 3 RETAINER
4 2003-0315B 1 BONNET
5 2003-0318B 1 END CAP
6 2003-0316B 1 CYLINDER
7 2002-3745B 1 CHANGE ROD CLOSE
8 2002-3746B 1 CHANGE ROD OPEN
9 2002-3797B 2 CHANGE CYLINDER
10 2002-3733B 1 PISTON ROD
11 2003-0317B 1 PISTON
12 2002-3752B 1 RAM GUIDE
13 2002-3753B 1 ROD HEAD
14 2002-3754B 1 INDICATOR ROD
15 2002-3755B 4 BONNET BOLT
16 2002-3756B 4 SHCS
17 2002-3757B 6 SHCS
18 2002-3770 1 GUIDE STUD
19 7935-1409G 8 SHCS
20 8007-3038 1 RETAINER
21 7941-0301 1 SSCR
22 7934-0202 4 PLUG
23 2002-3772B 1 LOCK SCREW
24 2002-3769B 1 CAP LOCKSCREW
25 9905-2851 1 HANDWHEEL
26 7938-0510 1 NUT HEX

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ES56-SK07*
SEAL KIT F/ 5.12 10K ES SINGLE PIPE/SLIP ACTUATOR
Reference drawing M60ES56-ACT7-ART-001

*SERVICE SPECIFIC PART NUMBER

ITEM ES56-SK07 ES56-SK07B QTY DESCRIPTION
-25°F H2S & NORTH SEA -50°F ARCTIC
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 7813-3363 7813-A363 2 O-RING
1-5 7951-3439 7951-A439 1 T-SEAL
1-6 7951-1326 7951-A326 2 T-SEAL
1-7 7820-0251 7820-0251B 1 SEAL POLYPAK DEEP B
1-8 7821-1622 7821-1622B 6 SEAL POLYPAK DEEP B
1-9 7826-2127 7826-2127 5 RETAINER RING INTERNAL
1-10 9900-6211 9900-6211 1 GASKET
1-11 7813-4258 7813-A258 2 O-RING
1-12 2005-0099 2005-0099 1 LOCKTITE

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M60ES56-ACT7-ART-001

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

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 QTY DESCRIPTION
NORTH SEA -25°F
1 7808-1422B 1 BONNET F/ EQ VALVE 10K -50°F
2 7808-1426XB 1 STEM F/EQ VALVE 10K
3 7903-1122XB 1 SEAT F/EQ VALVE 10K
4 EVA4-S000 1 SEAL KIT H2S/NORTH SEA

EVA4-S000
SEAL KIT F/ STANDARD EQUALIZING VALVE
Reference Drawing EQ10-0001X-ART-001

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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12.0 ES5R-VT44L
PIPE/SLIP RAM ASSEMBLY
Reference Drawing M60ES5R-VT00-ART-001

Disassembly - Remove front seal (3) and retainer bar (5). Remove compression pin (7) and slip
insert (2) by pushing compression pin toward front of ram. Remove O-ring (6) and rear seal (4).
Clean and inspect all parts - replace as needed.
Remove set screws (9 & 10). Remove rocker (8). Clean and inspect all parts - replace as needed.
Assembly - Install rear seal (4) to fit flush with surface of ram body (1). While holding the retainer
bar (5) in position in the front seal (3), slide both into position in the ram body (1). Place O-ring (6)
onto compression pin (7). Slide compression pin into slot on rear of slip insert (2). Install
compression and slip insert assembly into body.

ES5R-VT**L
PIPE/SLIP RAM ASSEMBLY
Reference Drawing M60ES5R-VT00-ART-001

SERVICE SPECIFIC PART NUMBER

ITEM M60ES5R-VT**L M60ES5R-LT**B QTY DESCRIPTION
-25°F H2S & NORTH SEA -50°F ARCTIC
1 2002-47**B 2002-47**B 2 PIPE SLIP RAM BODY
2 9328-04** 9328-04** 2 SLIP INSERT
3 M602008-01** M602007-59** 2 FRONT SEAL
4 7805-2441 7805-2442 2 REAR SEAL
5 M601000518 M601000518 2 RETAINER BAR
6 7813-4214 7813-A214 2 O-RING
7 2002-3793XB 2002-3793XB 2 COMPRESSION PIN
8 9126-2642B 9126-2642B 2 ROCKER
9 9328-0510B 9328-0510B 4 SET SCREW
10 2002-3794 2002-3794 4 SET SCREW

SIZE VARIABLE CODE **

** SIZE
37 1.25”
41 1.50”
44 1.75”
51 2.00”
61 2.38”
73 2.88”
88 3.50”

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M60ES5R-VT00-ART-001

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