Safety Valve

(IBOP)
Service Manual

DRILLING SYSTEMS
Feb. 2, 1994

Feb. 2, 1994

Feb. 2, 1994

Contents

GENERAL DESCRIPTION.............................................................................. 1
PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5
Introduction .................................................................................................. 5
Principle Features ................................................................................... 5
Remote IBOP Actuator Improvements ........................................................ 7
Internal Valve Mechanism Improvements.................................................... 8
INSTALLATION ............................................................................................ 9
OPERATION .............................................................................................. 16
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17
LUBRICATION ........................................................................................... 18
INSPECTION ............................................................................................ 21
Magnetic Particle Inspection ...................................................................... 21
Safety Valve Inspection Procedures .......................................................... 21
Visual Inspection ................................................................................... 22
ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23
MAINTENANCE ......................................................................................... 25
Seal Replacement ..................................................................................... 25
Shop Assembly and Disassembly ............................................................. 27
Disassembly.......................................................................................... 28
Assembly .............................................................................................. 32
IBOP Valve Testing in the Shop ............................................................ 39
APPENDIX ................................................................................................ 40

Feb. 2, 1994

ii

Feb. 2, 1994

Varco/BJ
Safety Valves
(IBOPs)
GENERAL DESCRIPTION
The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal
openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi
working pressure.
If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower
IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left
in the string if required.
The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System
(Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated
at any height in the derrick from the drillers console. The upper IBOP can also be operated
manually using a 7/8" hex wrench.
There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing
for purging any debris that may get in the wave spring area.

Feb. 2, 1994

Link
Tilt

Rotating
Head (Ref.)

Link
Adapter

Torque
Arrestor

Link
Adapter
Support
Plate

Splined
Upper
Safety
Valve

Safety Valve
Actuator

350 Ton
108" Links
(Ref.)

Torque
Wrench

Plain Lower
Safety Valve

Saver
Sub

350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)

Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)

Feb. 2, 1994

Link
Tilt

Rotating
Head (Ref.)

Link
Adapter

Torque
Arrestor

Link
Adapter
Support
Plate

Splined
Upper
Safety
Valve

V
a
r
c
o

Safety Valve
Actuator

350 Ton
108" Links
(Ref.)

Torque
Wrench

Plain Lower
Safety Valve

Saver
Sub

350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)

Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
3

Feb. 2, 1994

Thread
Protector
Body
Retaining Ring

Upper Seat
Plug
Back-up Rings
OPE

CL SD

Back-up
Rings

O-Ring

O-Ring
Ball
Sleeve
Seal Ring

Stabilizer
Ring

Crank
Grease/
Mud Seal
Seat

Wave
Spring
Back-up Ring

O-Ring

Figure 3. Typical Upper Safety Valve (IBOP)

Thread
Protector

Feb. 2, 1994

PH-60 IBOP/Actuator Upgrade Kit

Introduction
Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existing
PH-60 pipe handler will dramatically improve the reliability of the remote-operated system, both
as a primary safety valve and as a mud saver while drilling ahead.
Maintenance and operating costs will be greatly reduced, allowing a minimum planned
maintenance interval of six months for the upper IBOP.

PRINCIPLE FEATURES
The upper IBOP valves (2 ea.) are equipped with:
PH-85 style dual-path operating systems
New low-stress inside body contours
Completely redesigned long-life internals
The new actuator shell is solid steel and bronze linedeliminating bolted-on external guides.
The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, greasepacked, and completely isolated from mud caking and corrosion to ensure full bore opening.

Feb. 2, 1994

ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE

Aug. 9, 1993. A.N.

Figure 4. PH-60 Upgrade Kit

Feb. 2, 1994

Remote IBOP Actuator Improvements

(Refer to Drawing 99261 in the Appendix)
1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45%
larger piston area ensures positive, complete ball rotation under the most arduous conditions.
A 60% increase in available cylinder stroke eliminates the need for sensitive position
adjustments, both at initial rig-up as well as over the life of the system.
2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the current
multi-piece actuator shell assembly, eliminating the separately attached (and vulnerable)
guide roller assemblies. The bronze-lined internal diameter of the new actuator shell rides
directly on the IBOP outer diameter. The new design is very robust, requires no adjustments,
and is able to withstand punishing environments without damage.
3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. This
change reduces the operating and environmental forces on the internal and external components
by 50%. It also provides a balanced reaction force to the actuating levers. This force balance
allows elimination of the bolt-on guide roller assemblies.
Each of the two external crank housings is anchored to the IBOP body with 1/2" screws
instead of the 3/8" screws used in the previous design. The crank housings are also secured
to react the ball stop torque using a close-tolerance fit between the base of the housing and
the machined recess in the IBOP valve body. When required, jacking screws make removing
the housings easier.

Feb. 2, 1994

Internal Valve Mechanism Improvements

1. Internal stress concentrations at the valves operating crank bores are eliminated. They are
replaced with a smooth bore through the ball and seat region. This significantly lowers the
maximum stress in the valve body and effectively eliminates the possibility of leaks caused
by cracking at the crank bores under corrosive mud conditions.
2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ball
rotation stop in the previous design. The crank was easily replaced, but the body was not
repairable after stop shoulder wear. The wear-induced loss of ball stop accuracy over
extended use could eventually allow the ball to over-travel, leading to washouts.
In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internal
cranks (2) and external crank housings (2) need replacement should they ever become worn.
The external crank housings in the new design serve as the ball rotation stops. Each external
crank housing has two struts which contact the internal crank to stop the ball precisely at the
open or closed position. The torque required to stop the ball is then shared by four surfaces
rather than the previous designs single surface.
The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricated
regions beneath the external cranks. This eliminates the presence of caked drilling fluid
around the stop mechanism and is more reliable.
3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler,
the PH-85. This effectively cuts the operating forces in half on the critical ball actuating and
locating components, decreasing wear and eliminating mechanical failure.

Feb. 2, 1994

INSTALLATION
The following installation procedure assumes that all other rig components are already installed.
1. Use slips to install a joint of drill pipe into the rotary table.
2. Install the saver sub hand tight onto the drill pipe.
3. Install the lower IBOP hand tight onto the saver sub.
4. Install the upper IBOP hand tight onto the lower IBOP.
5. Screw the stem/main shaft and upper IBOP together.

CAUTION
The same care should be taken with these valves as would be any
other threaded valve. Be sure to use a thread compound with 60%
lead by weight or Kopper Kote. Varco does not recommend using
a zinc thread compound. If making up new threads for the first
time, use the following procedure:
a. Torque up to the recommended torque value (Table 1).
b. Back off the connection and inspect the threads and face.
c. Torque up to the recommended torque value (Table 1).

Feb. 2, 1994

Table 1. Make-Up Torque Values

Components

I.D.

Connection

O.D.

Torque (ft-lb)
(min.)
(max.)

Mainshaft to Upper
IBOP Safety Valve*

3"

6-5/8 API Reg.

7-3/4

60,000

70,000

Upper IBOP Safety

Valve to Lower
IBOP Valve

3"

6-5/8 API Reg.

7-3/4

50,000

70,000

Lower IBOP Valve

to Saver Sub

3"

6-5/8 API Reg.

7-3/8

46,000

64,000

Crossover Sub to
Lower IBOP Safety
Valve

3"

6-5/8 API Reg.

7-3/8

46,000

60,000

Mainshaft to Upper
IBOP Safety
Valve**

3"

7-5/8 API Reg.

83,000

91,000

Upper IBOP Safety

Valve to Lower
IBOP

3"

7-5/8 API Reg.

75,000

91,000

Lower IBOP Valve

to Saver Sub

3"

7-5/8 API Reg.

8-5/8

66,000

85,000

Crossover Sub to
Lower IBOP Valve

3"

7-5/8 API Reg.

75,000

91,000

* 500 Ton
** 650 Ton
6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows
(Figures 5 & 6):
a.
b.
c.
d.
e.
f.

Carefully grind off any raised tong marks on the O.D. of the safety valves.
Open the valve exactly halfway (45 degree rotation of the actuator).
Orient the levers on the crank assemblies horizontally as shown.
Slide the shell up onto the valve with the actuator arm groove on the bottom.
Hold the shell in position relative to the valve operating sockets.
Using the bolts provided, install the two crank assemblies, sliding the safety tabs through
and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws
and locktite on the bolt threads to secure the assemblies.
g. Manually operate the actuator to ensure free movement though a full 90 of crank travel.

10

Feb. 2, 1994

Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8):
a. Carefully grind off any raised tong marks on O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of actuator).
c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire
groove on side of crank body is to the right and the safety tab is on the left).
d. Slide the shell up onto the valve with the roller groove at the bottom.
e. Hold the shell in position relative to the valve operating socket.
f. Using the two bolts provided, install the crank assembly, sliding the safety tab through
and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire
the bolt heads, routing lock wire around the right side of the crank body through the safety
wire groove.
g. Install the two roller assemblies nearest the crank slot, and then using shims provided,
install the third roller assembly, maintaining .005" to .010" clearance between the third
roller assembly and the safety valve body with the shell vertically centered on the valve.
h. Manually operate the actuator to ensure free movement through full 90 of crank travel.

NOTE
When the actuator is in the lowest position, the valve should be
open.
7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual
for the installation and adjustment procedures).
8. Use the torque wrench to make up the saver sub to the lower IBOP.
9. Use the torque wrench to make up the lower IBOP to the upper IBOP.

11

Feb. 2, 1994

Crank Assembly
Retaining Screw
And Lock Tabs
Crank
Assembly
Slot

Actuator
Shell
Crank Arm*
Actuator Arm
Groove

Lock Tabs
Crank
Assembly
Safety Wire
Groove

Upper IBOP
Valve

7/8" Allen Crank

*Note Orientation

Cam Follower

Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d

12

Feb. 2, 1994

Open
Position

Closed
Position

Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove

Upper IBOP
Valve

Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions

13

Feb. 2, 1994

Roller
Assembly (3)

Crank Assembly
Retaining Screw

Crank
Assembly

Slot
Roller
Assembly
(3)

Actuator
Shell
Crank*
Roller
Assembly (3)

Actuator
Arm
Groove
Safety
Valve

Safety Wire
Groove

Shim

Crank
Assembly

*Note Orientation

Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60

14

Feb. 2, 1994

Closed
Position

Open
Position

Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove

Upper IBOP
Valve

Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions

15

Feb. 2, 1994

OPERATION
Operating the switch on the drillers console to the IBOP Close position causes the two (2)
actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This
upward movement causes the crank assemblies to rotate 90, closing the IBOP ball valve.
Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.

16

Feb. 2, 1994

Erosion Prevention of the Ball and Seats in the Lower IBOP Valve
To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully
closed at least one time each shift change. The valves can partially open without being externally
actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and
seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends
removing the lip seal from the spring loaded (floating) seat to correct this problem.
Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9):
1. Breakout and remove the lower IBOP.
2. Disassemble the valve and remove the lip seal from the floating (pin end) seat.
3. Replace the O-rings and back-up rings on the fixed and floating seats.
4. Re-assemble the valves.
5. Reinstall and torque the lower valve.

Figure 9. Lower IBOP Seal Removal

17

Feb. 2, 1994

LUBRICATION
Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank
in the recessed counter bore. There are three reasons for lubricating the valve:
1. To verify the integrity of the grease seal.
2. To lubricate the floating seat.
3. To flush mud and debris from the spring cavity.
Use the following procedure to lubricate the IBOP valves (Figures 10 & 11):
1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of
pressure. A release of pressure indicates the mud/grease seal is not functioning properly
the valve should be serviced.
2. Install a suitable grease fitting.
3. Open the valve.
4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an
equivalent amount from an air powered grease injector. The grease pressure should not
exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into
the clearance between the floating seat and the valve body.
5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug,
tightening securely.

CAUTION
The plug must be replaced in the valve prior to use to maintain
pressure integrity.

18

WAVE SPRING
MUD/ GREASE SEAL
SEAL RING STABILIZER
FIXED SEAT

19

Figure 10. Lubricating a Typical Upper IBOP

C
L

BALL
C
L

FLOATING
SEAT

PRESSURE
SEALS
SPRING
CAVITY

VALVE
BODY

GREASE PORT

Feb. 2, 1994

PRESSURE PLUG

WAVE SPRING

C
L

FLOATING
SEAT

PRESSURE
SEALS
SPRING
CAVITY

Feb. 2, 1994

VALVE
BODY
PRESSURE PLUG
GREASE PORT

20

C
L

BALL
Figure 11. Lubricating a Typical Lower IBOP

FIXED SEAT

Feb. 2, 1994

INSPECTION
Magnetic Particle Inspection
After approximately three to six months (depending on the severity of operating conditions)
Varco recommends performing a Magnetic Particle Inspection of all load bearing components
including IBOPs over their entire surface and internal bores to reveal any fatigue or crack
indications (Figure 11). Any indications found are a potential cause for the replacement of the
suspect component.
Details on Magnetic Particle Inspection procedures are in the following publications:
I.A.D.C.
ASTM A-275
ASTM E-709

Drilling Manual, 9th Edition

Std. Method for Magnetic Particle Inspection of Steel Forgings
Std. Recommended Practice for Magnetic Particle

Safety Valve Inspection Procedures

Upper and lower safety valves, because of their internal grooves and shoulders, are particularly
susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for
bending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crack
may begin at the root of the pit.
Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PH
levels below 9.0. Inspect safety valves operated under such exposures for internal, transverse
cracks every three to six months, depending on the severity of the exposure.
Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can be
hidden under corrosion products. Use the magnetic particle inspection procedure.
Concentrate attention on (Figure 12):

The area inside the operating crank window

The fillet radii of internal grooves and shoulders
The last engaged threads of box connections
The IBOP actuator shell

21

Feb. 2, 1994

Recommended
Inspection Areas

Figure 12. IBOP Inspection Points

NOTE
Repairing valve body cracks is not practical because of the close
tolerances of internal components and the metallurgy of the valve
material. Remove from service and scrap any safety valve body
showing positive crack indications.

VISUAL INSPECTION
Whenever connections are broken, clean and check them for the following:
1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other
abnormal conditions. Check shoulders for any marks, gouges or other damage.
2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper
safety valve for wear.
NOTE
Remove any surface imperfections on upper (splined) safety
valves after the valve is made up into string to prevent remote
actuator malfunctions, causing the valve to wash out.

22

Feb. 2, 1994

ADJUSTING THE SAFETY VALVE ACTUATOR

Proper safety valve actuator installation and adjustment is essential to assure proper action of the
mechanism and to minimize mechanical component wear. The actuator shell installs over the
upper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend the
safety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13)
adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuator
shell as follows:
1. After removing the crank assemblies, make sure the actuator shell easily moves up and down
over the upper IBOP.
NOTE
There is only one crank on upper IBOPs for the PH-60 pipehandler.
There are also three roller assemblies.
2. With the IBOP valve at mid-stroke, reinstall the crank assemblies.
3. Torque the 3/8" retaining bolts to 30-35 ft/lbs, lock tab.
4. Using a hex wrench, manually shift the IBOP valve through the crank assemblies and check
for signs of binding. Make sure the shell travels freely throughout its full range of travel. If
binding exists, troubleshoot to eliminate any problems before returning to service.
5. Actuate the control switch on the driller's console to the open the safety valve. The cylinders
should retract and the actuator ring should be down.
6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between the
cylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distance
is not 1 inch, adjust the cylinder rod locknuts until it measures exactly 1 inch.
7. Actuate the valve to make sure it opens and closes fully.

23

Feb. 2, 1994

DriveStem
(Ref.)
Link
Adapter

Cylinder
Adjustment
Bolts (4)

Landing Collar
Eye Bolts (2)

Upper IBOP Valve

Actuator Shell

Upper IBOP Valve

Actuator Air Cylinders (2)

Crank Assy(Shown with

Valve OPEN. Note Crank
Assy Position
CLOSE
OPEN

*1 Inch

Actuator
Arm

Cylinder
in OPEN
Position

Rod
End

Cylinder
Gland

Upper IBOP
Torque Tube

*IMPORTANT

Lower IBOP

Saver Sub

Figure 13. Adjusting the Safety Valve Actuator System for the PH-85, PH-60d &
Single Crank PH-60

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Feb. 2, 1994

MAINTENANCE
Seal Replacement
Replace seals at six month intervals under normal operating conditions (Figure 14). If there are
signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or
high salt content drilling fluids, shorter intervals may be necessary.

13

17

19

10

18

14

15
20

16
8

2X 4
3
9
12
11
12

7/8" Hex

Note: Dual Crank Remote IBOP Shown

Single Crank Remote and Lower IBOP
have similar construction.

Figure 14. IBOP Safety Valve Illustrated Parts List

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Feb. 2, 1994

Parts List
ITEM

QYT. / KIT

DESCRIPTION

PART NUMBERS

BALL, DUAL CRANK (SET)

90939-5

RETAINING RING

89141-1

O'RING

90441-9

BACK-UP RING

90441-10

LOWER SEAT (SET)

90939-5

UPPER SEAT (SET)

90939-5

POLYSEAL

96439

BACK-UP RING

89141-13

CROWN SEAL

89141-8

10

SLEEVE

90441-7 (93806-12 for Dual Crank)

11

O'RING

89141-11

12

BACKING RING

89141-12

13

CRANK, RIGHT HAND

89141-7 (93806-10 for Dual Crank)

14

WAVE SPRING

89141-9

15

BODY

16

O'RING

17

NYLON PLUG

18

CRANK, LEFT HAND

19

PLUG

20

SEAL RING STABILIZER

89141-3

93806-11

96438

REPAIR KIT - SINGLE CRANK

Refer to the Appendix for Part Numbers
REPAIR KIT - DUAL CRANK
Refer to the Appendix for Part Numbers
REPAIR KIT - SOFT SEAL ONLY
(For either Single or Dual Crank)
Refer to the Appendix for Part Numbers
BALL/SEAT SET
Refer to the Appendix for Part Numbers

Figure 14. IBOP Illustrated Parts List (Cont.)

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Feb. 2, 1994

Shop Assembly and Disassembly

The following tools are required (Figure 15):
Crank wrench
Varco Part No. 77408
Seat puller
Varco Part No. 79489-14
Nut wrench (for internal nut)
Varco Part No. 89141-18
Bushing installation tool
Open end or adjustable wrenches
Two large flat screwdrivers or light pry bars
1/4" and 3/4" allen wrenches
Pipe vise or suitable holding device to hold valve secure
Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner or
mild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve,
but also serves to loosen internal components. Follow these general rules while working on the
valve:
1. Take proper precautions while working with the components of the valve to make sure
precision matched surfaces and seal contact surfaces are not damaged.
2. After removing each part, thoroughly clean the exposed area to prevent damage to other parts
as they are removed.

7.5"

3"

22"
Load Bar

15.25"

3"
Maximum
Nut Wrench for DSV Models
Varco Part No. 89141-18

Seat Puller For All Models

Varco Part No. 79489-14

7/8" Hex Wrench For All Models

Varco Part No. 89141-18

Figure 15. IBOP Tools

27

Feb. 2, 1994

DISASSEMBLY

Starting with the valve in the closed position, disassemble the IBOP as follows:
1. Place the valve in a vise or
clamp to hold the valve
securely (Figure 16).

Figure 16
2. Engage the seat puller in
the inside groove of the
lower seat (Figure 17).
3. Using the load bar across
the face of the connection,
tighten the nut against the
load bar to compress the
wave spring approximately
0.030" (Figure 17).

Figure 17

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Feb. 2, 1994

4. At the other end of the

valve, insert the upper seat
wrench, P/N 89141-18, into
the upper seat engaging the
wrench lugs into the mating
slots (Figure 18).
5. Using the crank wrench,
P/N 77408, as a lever in the
hole provided in the upper
seat wrench, rotate the
upper seat clockwise until
it stops (Figure 18).

Figure 18

6. Remove the wrench.

7. Remove the retainer ring
from the groove in the valve
body by using a screwdriver
to pry one end of the retainer
ring out of the groove. The
ring can then be removed
by hand (Figure 19).

Figure 19
8. Re-insert the upper seat
wrench into the upper seat.
9. Rotate the upper seat
counterclockwise until it
disengages from the body
threads.
10. Remove the wrench and the
upper seat (Figure 20).

Figure 20
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Feb. 2, 1994

11. Remove the ball valve

(Figure 21).

Figure 21
12. From the outside of the
valve, push the crank into
the valve body and remove
them (Figure 22).

Figure 22
13. Remove the pulling tool
from the lower seat.
14. Insert the pulling tool from
the opposite end of the
valve and engage the
groove on the I.D. of the
lower seat (Figure 23).

Figure 23
30

Feb. 2, 1994

15. Using the load bar across

the face of the connection,
tighten the nut against it to
remove the lower seat and
the wave spring (Figures
24 and 25).
16. Remove and discard the
seals from all IBOP
components.
17. Thoroughly clean and
inspect each item.

Figure 24

Figure 25

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Feb. 2, 1994

ASSEMBLY

1. Inspect the lower seat.

Look carefully for signs of
corrosion, pitting and
gaulling especially in the
sealing areas (Figure 26).
2. Make sure the wave spring
is not broken or damaged
(Figure 26).
3. Inspect the steel stabilizer
ring, making sure it is not
worn, pitted or damaged
(Figure 26).

Figure 26

4. Replace all O-rings, backup

rings and seals (Figure 26).
5. Install the steel stabilizer
and seal on the lower seat
(floating seat), by placing
the steel stabilizer in the
groove of the U-cup seal
and, starting on one side of
the seat, work the stabilizer
and seal around the seat
using a screw driver (Figure
27).
NOTE
The steel stabilizer ring
should be inside the seal
when properly installed.

Figure 27

32

Feb. 2, 1994

6. Install the wave spring on

the lower seat (Figure 28).

Figure 28
7. Inspect the ball valve for
corrosion, pitting and
gaulling (Figure 29).

Figure 29

33

Feb. 2, 1994

8. Install new nylon plugs on

the upper stationary seat
(Figure 30).

Figure 30
9. Make sure the snap ring is
not broken or damaged
(Figure 31).

Figure 31

34

Feb. 2, 1994

10. Make sure the crank

assembly notches are not
worn and there is no pitting
on the outside (Figure 32).
Check for a sliding fit with
the slots in the ball.
11. Install the seals on the crank
assembly.
12. Inspect the crank sleeve for
wear and washouts.
Replace as necessary.

Figure 32
13. Thoroughly lubricate the
valve bore with a thin film
of multipurpose grease of
NLGI Grade 2.
14. Insert the pulling tool into
the O-ring end of the lower
seat engaging the I.D.
groove (Figure 33).
15. Apply a generous coat of
grease to the O.D. of the
lower seat.
16. Slide the wave spring down
the threaded rod of the
pulling tool until it seats on
the spring surface of the
lower seat (Figure 33).

Figure 33

17. Insert the threaded rod of

the pulling tool first into
the box opposite the splined
end of the upper valve,
pulling the lower seat into
place in the valve body
(Figure 33).
35

Feb. 2, 1994

18. Using the load bar against

the face of the connection,
tighten the nut to firmly
seat the lower seat in the
valve body (Figure 34).

Figure 34
19. Apply a generous coat of
grease to the outside of the
sleeve and crank.
20. From the inside of the valve
body, install the crank
sleeve in the body. Insert
the crank into the sleeve
(Figure 35).

Figure 35
21. Make sure the crank moves
90 to the Open and Closed
position (the flat sides of
the crank are parallel to the
valve body).
22. Position the crank in the
Closed position.
23. Apply a generous coat of
grease to the entire outside
of the ball, but make sure
the holes are clear (Figure 36).

Figure 36

36

Feb. 2, 1994

24. Slide the ball onto the crank

inside the valve body. The
keyway must be in the
Closed position, or parallel
to the key of the crank.
25. Apply a generous coat of
grease to the outside threads
and seal of the upper seat.
26. Insert the upper seat into
the valve body, engaging
the threads (Figure 37).

Figure 37

27. Insert the upper seat wrench

into the mating slots of the
upper seat.
28. Rotate the wrench
clockwise until the upper
seat sets firmly against the
ball.
29. Remove the upper seat
wrench and install the
retainer ring firmly into the
groove of the body (Figure
38).

Figure 38

30. Insert the upper seat wrench

into the mating slots of the
upper seat.
31. Rotate the upper seat
counterclockwise until the
seat is firmly against the
retainer ring.
32. Remove the puller and use
an allen wrench to make
sure the valve functions
properly.
33. Leave the valve in the Open
position.
34. Remove the wrench.

37

Feb. 2, 1994

35. Grease the valve through

the pressure plug until
grease extrudes from inside
the valve (Figure 39).
NOTE
The grease pressure should not exceed
300 psi. Excess pressure can cause the
mud/grease seal to extrude.

Figure 39
36. Install the 1/4" N.P.T. plug
into the lubrication port of
the body. Torque this plug
to approximately 15 to 20
ft.-lbs.
Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times
to assure smooth operation. Test the valve according to the procedure in the following
section.

38

Feb. 2, 1994

IBOP VALVE TESTING IN THE SHOP

Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic test
pump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use the
following procedure to test IBOPs:
1. Rotate the valve crank to the Open position.
2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plug
in the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valve
to the plug in the opposite end.
3. Place the valve in the vertical position (splined end down for upper IBOP, box end down for
lower IBOP) with the ball and the bleed valve in the Open position.
4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical,
but using water increases the liklihood of corrosion in the valve bodyespecially when the
valve is not in use for a prolonged period of time.
NOTE
Open and close the valve five times to release trapped air and
overflow through the bleed valve for approximately 30 seconds to
assure complete filling of the valve cavity.
5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closed
position.
6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus
1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test.
7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatic
test pump and the bleed valve. Reverse the orientation of the valve (splined end up for upper
IBOP, box end up for lower IBOP).
8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP
(pin end of the lower IBOP).
9. Fill the valve cavity with water while rotating the ball full open to closed five times to release
trapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold working
pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over the
duration of the test.
10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve to
insure smooth operation.
11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. is
acceptable.
12. Drain the valve cavity and remove the test plugs. Open and close the ball several times to
release trapped fluid. When testing with water, coat the valve internals with a preservative
to prevent oxidation and install thread protectors.
39

Feb. 2, 1994

APPENDIX
IBOP Part Numbers
IBOP
PART NO.

TYPE OF
SERVICE

DESCRIPTION

REPAIR KIT
PART NO.

SOFT SEALS BALL/SEAT

PART NO.
PART NO.

94769-500
94769-502
94769-501

STD
H2S
NAM

Upper Valve-PH60
6 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design

90939-2
89453-SP
90939-2

90939-1
90939-1

90939-5
89453-15
90939-5

94770-500
94770-502
94770-501

STD
H2S
NAM

Upper Valve-PH60
7 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design

90939-2
89453-SP
90939-2

90939-1
90939-1

90939-5
89453-15
90939-5

94099-500
94099-502
94099-501

STD
H2S
NAM

Upper Valve - PH60

6 5/8 Box X 6 5/8 Box (Spl End)
Landing Collar Design

90939-2
89453-SP
90939-2

90939-1
90939-1

90939-5
89453-15
90939-5

94100-500
94100-502
94100-501

STD
H2S
NAM

Upper Valve - PH60

7 5/8 Box X 6 5/8 Box (Spl End)
Landing Collar Design

90939-2
89453-SP
90939-2

90939-1
90939-1

90939-5
89453-15
90939-5

90815
-

STD
H2S
NAM

Upper Valve - PH85

6 5/8 Box X 6 5/8 Box (Spl End)
Land Collar Design

93806
-

93806-1
-

90939-5
-

90814
-

STD
H2S
NAM

Upper Valve - PH85

6 5/8 Box X 7 5/8 Box (Spl End)
Load Collar Design

93806
-

93806-1
-

90939-5
-

90813
-

STD
H2S
NAM

Upper Valve - PH85

7 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design

93806
-

93806-1
-

90939-5
-

90812
-

STD
H2S
NAM

Upper Valve - PH85

7 5/8 Box X 7 5/8 Box (Spl End)
Load Collar Design

93806
-

93806-1
-

90939-5
-

94206-500
94206-501
94206-502

STD
H2S
NAM

Upper Valve - PH85

6 5/8 Box X 6 5/8 Box (Spl End)
Landing Collar Design

93806
89453-SP
93806

93806-1
93806-1

90939-5
89453-15
90939-5

94205-500
94205-501
94205-502

STD
H2S
NAM

Upper Valve - PH85

6 5/8 Box X 7 5/8 Box (Spl End)
Landing Collar Design

93806
89453-SP
93806

93806-1
93806-1

90939-5
89453-15
90939-5

94204-500
94204-501
94204-502

STD
H2S
NAM

Upper Valve - PH85

7 5/8 Box X 6 5/8 Box (Spl End)
Landing Collar Design

93806
89453-SP
93806

93806-1
93806-1

90939-5
89453-15
90939-5

40

Feb. 2, 1994

IBOP Part Numbers (Cont.)

IBOP
PART NO.

TYPE OF
SERVICE

DESCRIPTION

REPAIR KIT
PART NO.

SOFT SEALS BALL/SEAT

PART NO.
PART NO.

94203-500
94203-501
94203-502

STD
H2S
NAM

Upper Valve - PH85

7 5/8 Box X 7 5/8 Box (Spl End)
Landing Collar Design

93806
89453-SP
93806

93806-1
93806-1

90939-5
89453-15
90939-5

91138
-

STD
H2S
NAM

Upper Valve - PH85 - Big Bore

7 5/8 Box X 7 5/8 Box (Spl End)
Load Collar Design

95384
-

91137-SP
-

91137-1
-

89451-501
89491-503
86434

STD
H2S
NAM

Lower Valve
6 5/8 Pin X 6 5/8 Box

90939-2
89453-SP

90939-1
-

90939-5
89453-15

89452-501
89492-502
-

STD
H2S
NAM

Lower Valve-Stepped
6 5/8 Pin X 6 5/8 Box

90939-2
89453-SP
90939-2

90939-1
90939-1

90939-5
89453-15
90939-5

90811
-

STD
H2S
NAM

Lower Valve
7 5/8 Pin X 7 5/8 Box

93807
-

93807-1
-

90939-5
-

91138
-

STD
H2S
NAM

Lower Valve - Big Bore

7 5/8 Pin X 7 5/8 Box

94385
-

91137-SP
-

91137-1
-

105629
-

STD
H2S
NAM

Upper Valve - Type "E"

6 5/8 Pin X 6 5/8 Box For Ids Only

90939-5
-

103220
-

STD
H2S
NAM

Upper Valve - Type "E"

6 5/8 Pin X 6 5/8 Box
For TDS and SDS

90939-2
-

90939-1
-

90939-5
-

98977-500
98977-502
98977-501

STD
H2S
NAM

Upper Valve, PH60 Dual Crank

6 5/8 Box X 6 5/8 Pin
Landing Collar Design

99468-2
99469-SP
99468-2

99468-1
99468-1

65170014
98966
65170014

99461-500

STD
H2S
NAM

Upper Valve, PH60 Dual Crank

6 5/8 Box X 6 5/8 Pin
Landing Collar Design

99468-2
99469-SP
99468-2

99468-1
99468-1

65170014
98966
65170014

41

Feb. 2, 1994

Identifying Varco Safety Valves

42

Feb. 2, 1994

43

Feb. 2, 1994

44

Feb. 2, 1994

45

Feb. 2, 1994

46