Unit No.

10401

Baker Oil Tools

Rev. New

GAS LIFT
TECHNICAL UNIT

Date: February 11, 2005

Page: 1 of 8

Tubing Retrievable Equipment

BCCO-1 Tubing Retrievable

Injection Pressure Operated Valve
Product Family No. H86101
Description
The BCCO-1 Tubing Retrievable Injection
Pressure Operated Gas Lift Valve is a 1 inch OD
valve primarily controlled by injection gas pressure. The valve is used to control gas pressure and
its flow from the casing annulus into the tubing during gas lift operations. The valve is installed on outside mount tubing retrievable mandrels.
The valve is designed with a sealed chamber,
including a bellows assembly, that contains a nitrogen charge over a dampening fluid which provides
the closing force of the valve. When injection gas
pressure exceeds the closing force, the bellows
compresses, thus lifting a valve stem off of a seat,
allowing gas to be injected through the valve and
into the tubing.
The BCCO-1 Injection Pressure Operated
valve consists of a tail plug, bellows assembly, bellows housing, stem with tungsten carbide ball and
seat housing with floating seat. The valve is available in either stainless steel or nickel alloys for corrosion resistance in wells with high concentrations
of H2S or CO2. Elastomeric materials for the valve
are available for standard service or special service to suit individual well conditions.

Drawing No. 399-917

This document is and contains unpublished, copyrighted and confidential information of Baker Hughes, and is revealed for limited purposes only. This document
is the property of Baker Hughes and is to be returned to Baker Hughes on request and may not be reproduced, used or disclosed to persons not having a need to
know consistent with the purpose of the document, without the written consent of Baker Hughes. This document is not rented, loaned or sold, either alone or in
conjunction with equipment or product. 2/11/05 Baker Hughes Incorporated.

Unit No. 10401

Rev. New

BCCO-1 Tubing Retrievable Injection

Pressure Operated Valve

2-11-05
Page 2 of 8

WARNING
Use of Baker equipment contrary to
manufacturers specification may result in
property damage, serious injury or fatality.

Features/Benefits
Stainless steel or premium materials
Three-ply Nickel-Copper Alloy 400 bellows
Mechanical stop prevents bellows overstroke
Viscous fluid shear dampening prevents

Tungsten Carbide ball

Replaceable floating Nickel-Copper Alloy 400
seat (Tungsten Carbide insert available)
Silver brazed bellows connections
Optional reverse flow check valve
Pressure rating up to 1,800 psi test rack open
maximum
Temperature rating to 250F (standard service)
Compatible with other manufacturers' industry
standard outside mount tubing retrievable
mandrels

bellows fatigue and stem-seat pounding

Specification Guide
Type

Nominal
OD (in.)

BCCO-1

1.000

Overall
Length (in.)
13.680

Connecting
Thread
1/2"-14 NPT

Reverse Flow
Check Valve
Required
BCCK-1
(H86122)

Available Ports And Specification Table

A b Effective
Bellows Area (in.2)

0.31

Port
Size (in.)
1/8
3/16
1/4
5/16
3/8

Ap Area
of Port (in.2)
0.013
0.029
0.051
0.079
0.113

Ap/Ab

1-(Ap/A b)

PPEF

0.042
0.094
0.165
0.255
0.365

0.958
0.906
0.835
0.745
0.635

0.044
0.104
0.198
0.342
0.575

PPEF = Production Pressure Effect Factor.

Operation
The dome of the valve is charged with nitrogen
to a predetermined test rack opening pressure. Before setting the test rack opening pressure, the
valve temperature or dome charge should be stabilized in a temperature controlled water bath (industry standard is 60F). A reverse flow check
valve assembly is installed on the valve and both
are then screwed into the lug of an outside mount
tubing retrievable mandrel.
In operation, high pressure gas that is injected
into the casing annulus enters through the ports in
the valves seat housing. When the gas pressure
overcomes the Nitrogen charge contained by the
bellows assembly, the bellows is compressed and
the valve stem ball is lifted off the valve seat thereby opening the valve. The high pressure gas then
flows through the seat, through the reverse flow

check assembly, through the lug of the outside

mount tubing retrievable mandrel and into the tubing. When the gas pressure in the casing annulus
drops below the nitrogen charge pressure contained in the bellows assembly, the bellows extends, causing the valve stem ball to engage the
seat and close the valve.
Reverse flow through the valve is prevented by
the auxiliary reverse flow check assembly. The
check dart in the reverse flow check assembly
seats against a fixed elastomeric primary seal with
a metal to metal secondary seal. The lower connection of the valve that makes up into the auxiliary
reverse flow check or conventional mandrel is a
1/2" NPT pin.
The stem ball, seat and bellows assembly of
the valve are protected from damage during valve
operation by the dampening effect of silicon fluid

BCCO-1 Tubing Retrievable Injection Pressure

Operated Valve
contained in the bellows. When the bellows compresses or extends, the silicon fluid has to fluid
shear past a rod installed in the bellows assembly.

Unit No. 10401

Rev. New

2-11-05
Page 3 of 8

The valve is available with stem and seat sizes

of 1/8 through 3/8 inch and is utilized both for continuous flow and intermittent gas lift.

Tubing Flow Application Drawing No. 399-918

Unit No. 10401

Rev. New

2-11-05
Page 4 of 8

Recommended Tools And Supplies

For Assembly, Setting, And
Disassembly
1. Hydraulic Sealant (Loctite #569)
2. Thread Lubricant (Anti-galling compound such
as API modified thread compound)
3. Seal Lubricant (Silicon O-ring lubricant)
4. #6 Mirror Image - Diamond Lapping Compound
5. G.E. Silicon Oil SF96-500
6. Hypodermic Syringe in Cubic Centimeters
7. #1 Parmalee Pipe Wrench (friction), 2 required
8. Small Bench Vise
9. High Pressure Nitrogen System (2,000 psi)
10.Hydro Test Tank
11.Hydro Test System (Pump - 6,000 psi)
12.Test Rack with High Pressure Air Source
13.Cooling Tank (60F)
14.Lapping Lathe
15.Valve Core Tapper
16.Valve Core Wrench
17.Charging Fixture
18.Buffing Wheel or Cloth
19.File (Bastard Mill)
20.Ice Pick
21.3/8" x 6" Wood Dowel
22.Internal Snap Ring Pliers
23.Adjustable Wrench 6"
24.7/8" Open End Wrench
25.1/2" Box End Wrench
26.7/16" Box End Wrench
27.8" Pipe Wrench
28.Small adjustable crescent wrench or (9 mm)
open end wrench
29.Wooden Mallet
30.Gas Flow Measurement Device (up to 35 Standard cu ft per Day Scale)

Disassembly Procedure
Refer to Drawing No. 399-917.
1. Insure valves are uniform and straight (not
bent).
2. Check valve in test rack to determine as received condition. Compare the test rack open

BCCO-1 Tubing Retrievable Injection

Pressure Operated Valve
to the opening pressure (Pvo) stamped on
valve. If depressured/abnormally pressured,
valve may have bad bellows or leaking tail plug
gasket/seal. Separate these valves for special
handling so rebuild technician will carefully
check for bellows leakage during hydrostatic
aging. At this point a preliminary check is made
on the stem and seat leakage by checking the
valve in the test rack before disassembly. Note
condition.
3. Place the valve into a mounted friction wrench
gripping onto the Dome (4) with the Tail Plug (1)
protruding to the right.
4. Remove the Tail Plug (1) from the Dome (4).
Look for looseness or damage to Tail Plug if
valve Pvo was abnormal.
Caution
If the Tail Plug (1) resists removal, there may
exist high pressure behind the Tail Plug and
caution must be exercised when removing.
5. Using the valve core tapper, depress the Valve
Core (5) In the Dome (4) and depressure bellows so that the nitrogen charge is vented to atmosphere. Leave Valve Core installed to
prevent loss of dampening fluid and/or entry of
cleaning solvent.
Danger!
If this step is not accomplished, there is a
possibility of injury to people in the work
area when the Dome (4) and Bellows
assembly is removed from the Bellows
Housing (10).
6. Place the valve into the mounted friction
wrench in such a way that the Bellows Housing
(10) is protruding to the right. Lock the second
friction wrench onto the Bellows Housing, loosen and remove.
Danger!
If the dome and bellows assembly resists
movement at this time, it is because step 5
has not been accomplished.
Caution
The Bellows (7) can be easily damaged
during this operation so special care must
be taken at this time to avoid any damage.
a. Discard Bellows (7) that are deformed,
smashed, snaked or otherwise damaged and
changed from their original permanent set.

BCCO-1 Tubing Retrievable Injection

Pressure Operated Valve
7. Place the Bellows Housing (10) into the mounted friction wrench so that only the Seat Housing
(16) is protruding to the right. Loosen and remove the Seat Housing with the 7/8" open end
wrench.
8. Remove the Retainer Ring (13) from the Seat
Housing (16) using the internal snap ring pliers.
9. Using the 3/8" diameter wooden dowel, remove
the Seat (15) from the Seat Housing (16). Insert
the dowel through the lower end of the Seat
Housing until it lands on the seat. Tap the Seat
out.
10.Place the Dome (4) in the mounted friction
wrench so that the Bellows (7) and Bellows
Adapter (9) protrude to the right. Using the
small adjustable crescent wrench or (9 mm)
open end wrench on the wrench flats of the Bellows Adapter as a backup, loosen and remove
the Ball Stem (11) with the 7/16" wrench. Do
not squeeze, twist or damage the Bellows in
any manner during the disassembly or assembly procedures. The application of a moderate
amount of heat (not to exceed 300F) may be
necessary to release the Ball Stem from the
Loctite which was applied during assembly.
NOTE: The Seat and the Ball Stem have been
lapped as a matched set. It is therefore essential to
keep the lapped pair separate from similar parts of
other valves which may have been dissembled at
the same time. If either the Ball Stem or the Seat is
damaged, both parts must be replaced with a new
matched pair.

11.Using an ice pick, remove all O-rings.

12.Wash all parts in solvent or other cleaning
agent and blow them dry with air. Visually inspect all parts for fluid cutting, thread damage,
cracks or abrasion. Reject any damaged parts.
13.Buff the Bellows (7) and Bellows assembly
clean.
Warning!
Use extreme care cleaning the bellows. The
bellows material is very thin and even a
small nick or dent from the file can render
the Bellows defective.
14.If the valve has been in service, discard seat
Retainer Ring (13), Tail Plug Gasket (3) and all
O-rings.

Unit No. 10401

Rev. New

2-11-05
Page 5 of 8

Assembly Procedures
Refer to Drawing No. 399-917.
1. Using lapping compound and lathe, lap the
Seat (15) and Ball Stem (11) as a matched set.
Lap them so that there is a completely mated
surface between the Seat and Stem Ball.
2. Insert the O-ring (14) into the Seats O-ring
groove (15). Be sure not to mix the matched
Seats and Ball Stems (11). Lubricate the Oring.
3. With the lapped surface of the Seat (15) facing
out of the Seat Housing (16), insert the Seat.
Use the 1/8" wooded dowel to push the Seat
into the Seat Housing so as not to scar the
lapped surface of the Seat. The Seat must be
seated at the flat bottom of the Seat Housing.
4. Using the internal snap ring pliers, insert the
Retainer Ring (13) into the Retainer Ring
groove just above the Seat (15) in the Seat
Housing (16). Be sure it is completely seated in
the groove.
5. Apply hydraulic sealant (Loctite #569) to the
Ball Stem (11) and thread it into the Dome (4)
and Bellows Adapter (9). Place the Dome in the
mounted friction wrench so that the Bellows (7)
and Bellows Adapter protrude to the left. Using
the small adjustable crescent wrench or (9 mm)
open end wrench on the wrench flats of the Bellows Adapter as a backup, tighten the Ball
Stem with the 7/16" wrench. Do not squeeze,
twist or damage the Bellows in any manner during the assembly procedures.
NOTE: It is important that the assemblies containing
the matched Seat and Ball Stems remain matched.

6. Lubricate and install the O-ring (6) into the

groove on the Dome (4).
7. Lubricate the threads and place the Dome (4)
and bellows assembly into a mounted friction
wrench with the Bellows (7) convolutions protruding to the left of the wrench. Install the Bellows Housing (10) onto the bellows assembly.
Lock the second friction wrench over the Bellows Housing and tighten the threads.
NOTE: Care must be taken not to dent or inflict any
damage to the Bellows (7) surface during this
application.

Unit No. 10401

Rev. New

2-11-05
Page 6 of 8

8. Lubricate threads and install Seat Housing (16)

with matching Seat (15) onto Bellows Housing
(10), tightening the threads with the 7/8" open
end wrench.
9. Remove the old Valve Core (5) using the Valve
Core wrench. If silicon fluid has leaked from the
valve or has been removed, the fluid must be
replaced. Drain off any remaining fluid from the
dome and bellows assembly. Hold the valve
vertically and inject 4 cubic centimeters of the
G.E. silicon oil (SF96-500) into the bore at the
upper end of the dome and Bellows assembly
using a large hypodermic syringe.
10.Lubricate and install the new Valve Core (5) in
the opening at the top of the Dome (4) and bellows assembly using the Valve Core wrench.
Screw the core in firmly, but do not over-tighten.
NOTE: New bellows assemblies already have the
G.E. silicon oil in them and more fluid should not be
added.

11.Screw the charging fixture completely into the

top of the Dome (4) and attach it securely to the
nitrogen high pressure system. Pressure up
Bellows (7) to 800 psig with nitrogen charge.
Apply charge slowly with valve in vertical position.
12.Check Ball Stem (11) and Seat (15) for leakage
in test rack by the following procedure: Ball
Stem and Seat leakage test can be done at ambient temperature.
a. Calculate valve closing pressure (Pvct)
where:
Pvc = Pvo x (1-Ap/Ab)
where:
Pvc = Closing pressure of the valve at a
valve temperature of 60F when
the injection gas pressure and production
pressure are equal at the instant the valve
closes.
Pvo = Valve opening pressure in the test
rack at valve temperature of 60F.
Ap = Effective pressure area of the valve
stem and seat contact, square inches.
Ab = Effective are of the bellows, square
inches.

BCCO-1 Tubing Retrievable Injection

Pressure Operated Valve
b. Ball Stem (11) and Seat (15) shall be dry during this test. No oil, grease or similar material
shall be allowed on the Ball (12) and Seat.
c. Install the valve in the tester, open the valve
with gas pressure and reduce the pressure to
Pvct.
d. Direct the downstream side of the valve to
the flow measurement device. If the flow rate
is greater the 35 standard cubic feet per day,
the Ball Stem (11) and seat shall be rejected.
(If a flow measurement device is not available, immerse the bottom of the valve in a
cup of water. A leakage rate of no more than
one bubble per second is acceptable.)
e. To correct a badly leaking valve seat, perform the following steps until the valves seat
does not leak in the test rack.
(1). Bleed the pressure from the test rack and
remove the valve. Tap lightly a few times
on the top of the valve with a wooden
mallet to settle the stem ball into the Seat
(15).
(2).Check valve in test rack. If valve continues to leak, disassemble valve and replace O-ring on Seat (15).
(3).Check valve in test rack. If valve continues to leak, disassemble valve and relap
Seat (15) and Ball Stem (11).
(4).Check valve in test rack. If valve continues to leak, disassemble valve and replace Seat (15) and Ball Stem (11) with a
new matched set.
13.Install the O-ring (2) and Tail Plug Gasket (3) on
the Tail Plug (1). Lubricate threads and install
tail Plug With properly stamped stem and seat
size. Tighten Tail Plug.
14.Place valve in pressure chamber or ager in a
vertical position. Fill chamber with water and
pressure up on the chamber to 5,000 psig and
hold for a minimum of 1 hour. Remove valve.
15.Check valve in test rack. If pressure has
changed significantly from original set pressure, record pressure and place in pressure
chamber for a minimum of 15 minutes and repeat process until valve stabilizes.

BCCO-1 Tubing Retrievable Injection

Pressure Operated Valve
Caution!
An opening pressure much lower than the
Pvo (50 psig) is an indication that the
Bellows (7) failed during the hydrostatic
pressure process. If the Bellows failed,
release the remaining Dome (4) charge
pressure completely. Remove and discard
the Dome and bellows assembly. Install a
new Dome and Bellows assembly and begin
the charging and setting procedure.
Caution
An opening pressure much higher than the
Pvo (50 psig) is an indication that the tail
plug leaked during the hydrostatic pressure
process allowing water to enter the Bellows
(7) and increase the Dome (4) pressure. If
the tail plug leaked, release the remaining
Nitrogen charge pressure completely.
Remove and discard the Dome and Bellows
assembly. Install a new Dome and Bellows
assembly and begin the charging and
setting procedure.

Valve Setting Procedure

Unit No. 10401

Rev. New

high pressure system. Charge the Bellows (7)

to a pressure 50 psig greater than the design
setting pressure required (Pvo).
4. Place valve in water bath set at 60F for 15 minutes.
5. Remove the valve from the water bath and insert in tester.
Caution
Do not hold the valve by the Dome (4) as that
will heat the dome and cause incorrect set
pressures.

6.

Refer to Drawing No. 399-917.

Valves should be stored on the shelf for a minimum of 5 days. The original set pressure of each
valve shall be checked before being set up per gas
lift design. If the original pressure the valve was set
at has changed more than 10 psig, that valve shall
be rejected.
1. Obtain the calculated test rack opening (Pvo)
pressure for the valves to be set.
2. Remove the Tail Plug (1).
Caution!
If the Tail Plug (1) resists removal, there may
exist high pressure behind the Tail Plug and
caution must be exercised when removing
the Tail Plug.
3. Screw the charging fixture completely into the
Dome (4) and attach it securely to the Nitrogen

2-11-05
Page 7 of 8

7.
8.

9.

Apply pressure in the tester to open the valve:

Using the valve core tapper, adjust the dome
pressure by tapping the Valve Core (5) releasing nitrogen pressure from the Bellows (7) until
the proper opening pressure (Pvo) is achieved.
If it takes longer than 30 seconds to obtain the
desired opening pressure, remove the valve
from the tester and return it to the water bath.
Lubricate thread and install Tail Plug (1) into
Dome (4) and tighten. Place valve in pressure
chamber or ager in a vertical position. Fill
chamber with water and pressure up on the
chamber to 5,000 psig and hold for a minimum
of 15 minutes. Release the pressure and cycle
the pressure at 5,000 psig a minimum of three
times without pausing between cycles.
Remove valve from chamber and place in water bath for a minimum of 15 minutes.
Remove a valve from the water bath and install
it in a tester and check the opening pressure. If
the opening pressure has changed 5 psig or
more, repeat steps 4 through 7 until the pressure does not change more than 5 psig.
The Pvo should be stenciled on side of Tail
Plug (1) to prevent mixing up of the valves at
the well installation.

Assembly Drawing No. 399-917

Unit No. 10401

Rev. New

BCCO-1 Tubing Retrievable Injection Pressure Operated Valve

2-11-05
Page 8 of 8

Refer to Drawing No. 399-917.

Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Description
Tail Plug
O-ring #013
Tail Plug Gasket
Dome
Valve Core
O-ring #017
Bellows
Cushion Rod
Bellows Adapter
Bellows Housing
Ball Stem
Ball
Retainer Ring
O-ring #111
Seat
Seat Housing

No.
Reqd.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Stainless Steel Service

Part No.
Material
104002
17-4 PH
0-013-70V
Viton
104003
BeCu
104001-02
316 SS
P-200-01
N/A
0-017-70V
Viton
P-201-01
Nickel-Copper Alloy
100110-02
316 SS
101002-02
316 SS
101003-02
316 SS
104004-02
316 SS
P-300
Tungsten Carbide
I-625
BeCu
0-111-70V
Viton
100105
Nickel-Copper Alloy
101006-02
316 SS

Nickel Alloy Corrosive Service

Part No.
Material
104002
17-4 PH
0-013-70V
Viton
104003
BeCu
104001-03
Nickel-Copper Alloy
P-200-01
N/A
0-017-70V
Viton
P-201-01
Nickel-Copper Alloy
100110-03
Nickel-Copper Alloy
101002-03
Nickel-Copper Alloy
101003-03
Nickel-Copper Alloy
104004-03
Nickel-Copper Alloy
P-300
Tungsten Carbide
I-625
BeCu
0-117-70V
Viton
100105
Nickel-Copper Alloy
101006-03
Nickel-Copper Alloy

BCCO-1 Tubing Retrievable Injection

Pressure Operated Valve

Parts List