Tech Manual 1222B

Booster Cylinder Assembly EH34-BC03

Texas Oil Tools

a Division of Tuboscope, Inc.
PO Box 2327
Conroe, TX 77305
(409)756-4800 or (409)441-0006
(409)756-8102 Fax; e-mail [email protected]
 Prepared by:
Approved by:

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SERVICE

3.0 OPERATION

4.0 SPECIFICATIONS

5.0 ASSEMBLY

6.0 PARTS LISTS & DRAWINGS

7.0 SHEAR TEST RESULTS

8.0 FIELD MODIFICATIONS

9.0 SHEAR RAMS

10.0 OTHER OPTIONS AVAILABLE

 UNIT 1222 Rev. B
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BOOSTER CYLINDER ASSEMBLY EH34-BC03

3.06" BOP 3,000psi Hydraulic Operating Pressure

1.0 INTRODUCTION

Since the introduction of the 2.50" and 3.06" coiled tubing BOPs in the early 1980s, the size and
wall thickness of coiled tubing has greatly increased. This required the design of the shear ram
blades to be modified to accommodate the larger sizes and increased wall thickness. Both changes
have contributed to higher forces being required to shear these new sizes of coiled tubing.

Booster cylinder assemblies are available for all 5,000 and 10,000 psi, 3.06" quad BOPs in either
the "EC" or "EH "models. The hydraulic circuitry does not change when connecting or using the
booster. The hydraulic pressure required for closing (shearing) is ported through the inside passage
of the booster piston rod to deliver the increased shearing force. The opening pressure area has
not changed therefore, there is no increase in opening force on the rams.

The EH34-BC03 Model Booster Cylinder Assembly increases the cutting force 2.91 times over the
standard operator. Installation of this model requires changing the Piston, piston guide and
piston rod with ram guide. This model is designed for 3,000 psi hydraulic operating pressure.

2.0 SERVICE

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 -50EF.

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.

3.0 OPERATION

Ram hydraulic closing pressure acts on the operator piston and additionally the hydraulic pressure
travels through the internal porting of the booster piston rod to act on the booster piston. This action
compounds the closing force.

Ram hydraulic opening pressure acts on the operator piston. There is no compounding of the
opening force as the operator piston moves the booster cylinder piston away from the BOP body.
The hydraulic fluid in the booster cylinder travels through the porting in the booster piston rod and
exits the closing port.
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4.0 SPECIFICATIONS

Piston Rod (1.00 dia.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7854 in2 area

Piston (3.00 dia.)
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.069 in2 area
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.283 in2 area
Booster Piston Rod (1.375 dia.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.485 in2 area
Booster Piston 4.375 dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.033 in2 area
Booster
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.548 in2 area
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 in2 area
Piston & Booster Area
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.617 in2 area
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.283 in2 area
Ratio
EH34-BC03/Standard Operator Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.91 / 1
Hydraulic Operating Pressure
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 psi max.
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 psi max.
Hydraulic Volume, One Pair Rams
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 cu. in.
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 cu. in.
Weight (Pair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 lbs.

Example Without Booster

Wellbore pressure of 3500 psi X .7854 = 2,749 # force on the piston rod.

2,749/7.069 = 389 psi hydraulic operating pressure required to balance the wellbore pressure.

Therefore; if we apply 2,000 psi hydraulic operating pressure to the BOP operator,
we have 2,000 - 389 = 1,611 psi net hydraulic operating pressure to cut the coiled tubing or

1,611 psi X 7.069 = 11,388 # force to cut the coiled tubing

Example With Booster EH34-BC03

Wellbore pressure 3,500 psi X .7854 = 2,749 # force on the piston rod

2,749/20.617 = 133 psi hydraulic operating pressure required to balance the wellbore pressure.

Therefore; if we apply the same 2,000 psi hydraulic operating pressure to the BOP operator and booster cylinder,
we have 2,000 - 133 = 1,867 psi net hydraulic operating pressure cut the coiled tubing or

1,867 psi X 20.617 = 38,492 # force to cut the coiled tubing

CAUTION ! ! ! The increased force with the booster piston acts on the BOP's piston, and piston rod.
The complete kit must be installed. The new BOP piston rod with guide is made of MP35N material with
approximately twice the strength as the rod that it replaces.
 UNIT 1222 Rev. B
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5.0 ASSEMBLY
Reference Drawing 9110-2093

Refer to the appropriate Tech Unit for parts and instructions for the BOP. Remove the hydraulic cap
sub-assembly, and set aside. Remove the rod with guide, piston guide, piston retainer, and piston.
These parts will not be re-used. This would be a good opportunity to replace all seals in the bonnet,
and hydraulic cap. Refer to the BOP Tech Unit for parts and instructions.

Install the rod with guide (1), install woodruff key (4), piston guide (2), and set screw (3). Install
piston (7), t-seal with back-ups (6), and set screw (5). Install BOP cylinder.

Install seal (9), (NOTE: The lip of the seal will face outward, toward the seal retainer), install seal
retainer (8), and o-ring (15) onto booster cylinder (12). Install o-ring (11) onto booster piston (10)
and install into booster cylinder. Install o-ring (13) onto booster bushing (14) and make up into
booster cylinder. Move the booster piston to the fully retracted (open) ram position, install the
hydraulic cap sub assembly, taking care to engage the indicator rod, per instructions in the BOP
tech unit. Install the booster assembly on the BOP.

Install the extended handwheel on the operators above the booster cylinder operators.

Apply rated hydraulic working pressure to the hydraulic operating system, observe for operation and
leaks. The assembly has been shell tested to the rated test pressure at the factory. That test
should not be repeated in the field.

Drawings Included: 9110-2093, 9201-2691, 9205-2692, and 9303-0191.

UNIT 1222 Rev. B
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6.0 PARTS LIST & DRAWINGS

EH34-BC03 BOOSTER CYLINDER ASSEMBLY

3.06 BOP, 3,000 psi Hydraulic Operating Pressure
Reference Drawing 9110-2093.

Item Part Name Qty. H2S DNV Arctic Wt.# Ea.

1 Rod with Guide 2 9110-2031 9110-2031L 9110-2031B 3.0
2 Piston Guide 2 9110-2024 9110-2024 9110-2024 .8
3
3 Set Screw /8" 2 7941-0602 7941-0602 7941-0602 .01
4 Woodruff Key 2 7970-0806 7970-0806 7970-0806 .01
5 Set Screw #10 2 7941-0302 7941-0302 7941-0302 .01
6 T-Seal, Wide Base 2 7951-3334 7951-3334 7951-3334 .02
7 Piston 2 9110-2023 9110-2023 9110-2023 3.3
8 Internal Retainer 2 7826-1757 7826-1757 7826-1757 .01
9 Seal 2 7820-1379 7820-1379 7821-1379B .02
10 Booster Piston 2 9110-2033 9110-2033G 9110-2033 6.9
11 O-Ring 2 7813-3345 7813-3345 7813-A345 .01
12 Booster Cylinder 2 9110-2036 9110-2036G 9110-2036 16.5
13 O-Ring 2 7813-3348 7813-3348 7813-A348 .01
14 Booster Bushing 2 9110-2037 9110-2037G 9110-2037 7.2
15 O-Ring 2 7813-3336 7813-3336 7813-A336 .01
16 Extended Handwheel 2 8007-3144 8007-3144 8007-3144 3.5
17 Grease Fitting 2 7912-2533 7912-2533 7912-2533 .01
18 Breather 2 7912-2551 7912-2551 7912-2551 .01

NOTE: The above kit contains only the parts and seals required for the booster assembly. Refer to the
Tech Unit for the BOP to order the seals for the operator and hydraulic cap. It is recommended that all
seals be replaced during installation of the booster assembly. If different operating pressures are required
for a 3.06" BOP, contact a Texas Oil Tools representative.

NOTE: Shaded parts without item numbers are parts re-used from the original BOP. The larger diameter
of the booster cylinder interferes with the standard handwheel for manual locks. New extended
handwheel for the operators, positioned above the booster cylinder, are included with the kit.
 UNIT 1222 Rev. B
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SEALS KIT

Assembly No. EH34-BCSK3 EH34-BCSK3B

Item Part Name Qty EF
H2S & North Sea -20E EF
Arctic -50E
6 T-Seal 2 7951-3334 7851-3334
8 Internal Retainer 2 7826-1757 7826-1757
9 Seal 2 7820-1379 7821-1379B
11 O-Ring 2 7813-3345 7813-A345
13 O-Ring 2 7813-3348 7813-A348
15 O-Ring 2 7813-3336 7813-A336
UNIT 1222 Rev. B
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7.0 SHEAR TEST RESULTS

Extensive testing on shearing coiled tubing was performed at the Conroe factory. The results have
been tabulated and are presented for your convenience. All tests were conducted at zero wellbore
pressure. Separate tests were conducted to confirm the additional pressure required to close the
rams under wellbore pressure. In each case, where multiple cuts were made, the highest observed
pressure is the one shown. Wireline was placed inside the coiled tubing for many of the cuts. Either
7
/32 or 15/32 line was used and in every case the wireline cut at a lower pressure than the coiled
tubing.

Column #3 records the type of material, 70, 80, or 100,000 yield. This column notes the published
yield strength of the tubing. Only a limited amount of higher strength tubing was available at the time
of the test. As additional samples of the higher strength material, and/or heavier wall thickness
becomes available, this tabulation will be amended.

Note that the test cut marked with a * was with 10,000# tension applied before making the cut. The
test marked with ** was with 20,000# tension applied before making the cut. Therefore, the tension
of hanging tubing weight, or applied pull, will always decrease the force required to cut the tubing.

Column # 4 records the part number of the Shear Blade used in the test.

Column #5 is the hydraulic operating pressure required to shear the coiled tubing and overcome
a wellbore pressure of 0 psi using the original 3.06" BOP hydraulic cylinders.

Column # 6 is the hydraulic operating pressure required to shear the coiled tubing and overcome
a wellbore pressure of 5,000 psi using the original 3.06" BOP hydraulic cylinders.

Column # 7 is the hydraulic operating pressure required to shear the coiled tubing and overcome
a wellbore pressure of 10,000 psi using the original 3.06" BOP hydraulic cylinders.

Column #9 is the hydraulic operating pressure required to shear the coiled tubing and overcome
a wellbore pressure of 10,000 psi using the Booster Cylinder, EH34-BC03.

Column # 11 is the net force delivered to the blade to shear the coiled tubing. This force remains
constant regardless of changing wellbore pressure. This information can be used to estimate the
force required to cut materials that are not listed.

Column # 12 is the nominal tubing shear (wall) area As, in2.

Column # 13 is the approximate shear stress, psi required to shear the coiled tubing.

This tabulation of actual hydraulic operating pressures required to cut coiled tubing should serve
only as a guide in determining when and if a booster is required.

The original type shear blades cut only one size of coiled tubing. The newer (Feb. 92) blades 8011-
5536 and 8011-5545 for the 3.06" BOP will cut wireline and make multiple cuts. More than 20 cuts
in the test lab were performed without blade damage. The new blades cut all sizes of coiled tubing
that fit into the ram body. Refer to drawing #9205-2691 & 9205-2692 for details.

Several cuts were made with the slips set to determine if this increased the force required. It did not.
 UNIT 1222 Rev. B
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1 2 3 4 5 6 7 9 11 12 13
O.D. Wall Material Shear Blade Hyd Opr Hyd Opr Hyd Opr EH34-BC03 Force Shear Area, Shear Stress,
Yield Part Number psi w/ psi w/ psi w/ psi w/ Required to in2 psi
0 psi 5000 psi 10000 psi 10000 psi Shear, lbs
wellbore wellbore wellbore wellbore
1.000 0.075 70 8011-3535 1,600 2,156 2,711 932 11,310 0.218 51,895
1.000 0.075 70 8011-5536 1,000 1,556 2,111 725 7,069 0.218 32,434
1.000 0.087 70 8011-3535 1,800 2,356 2,911 1,000 12,724 0.250 50,991
1.000 0.087 70 8011-5536 1,100 1,656 2,211 760 7,776 0.250 31,161
1.000 0.095 70 8011-3535 1,950 2,506 3,061 1,052 13,785 0.270 51,035
1.000 0.095 70 8011-5536 1,300 1,856 2,411 829 9,190 0.270 34,023
1.000 0.109 70 8011-3535 2,100 2,656 3,211 1,103 14,845 0.305 48,654
1.000 0.109 70 8011-5536 1,400 1,956 2,511 863 9,897 0.305 32,436
1.250 0.087 70 8011-3537 2,000 2,556 3,111 1,069 14,138 0.318 44,477
1.250 0.087 70 8011-5536 1,500 2,056 2,611 897 10,604 0.318 33,358
1.250 0.087 80 8011-5536 1,600 2,156 2,711 932 11,310 0.318 35,582
1.250 0.087 100 8011-5536 1,800 2,356 2,911 1,000 12,724 0.318 40,030
1.250 0.095 70 8011-3537 2,400 2,956 3,511 1,207 16,966 0.345 49,217
1.250 0.095 70 8011-5536 1,500 2,056 2,611 897 10,604 0.345 30,760
1.250 0.109 70 8011-5537 2,800 3,356 3,911 1,344 19,793 0.391 50,659
1.250 0.109 70 8011-5536 1,500 2,056 2,611 897 10,604 0.391 27,139
1.250 0.109 ** 70 8011-5536 900 1,456 2,011 691 6,362 0.391 16,283
1.250 0.109 * 70 8011-5536 1,400 1,956 2,511 863 9,897 0.391 25,329
1.250 0.109 100 8011-5536 2,100 2,656 3,211 1,103 14,845 0.391 37,994
1.250 0.134 70 8011-3537 3,150 3,706 4,261 1,464 22,267 0.470 47,397
1.250 0.134 70 8011-5536 2,400 2,956 3,511 1,207 16,966 0.470 36,112
1.250 0.156 70 8011-3537 3,600 4,156 4,711 1,619 25,448 0.536 47,464
1.250 0.175 70 8011-5536 3,000 3,556 4,111 1,413 21,207 0.591 35,882
1.250 0.175 70 8011-3537 3,950 4,506 5,061 1,739 27,923 0.591 47,245
1.500 0.095 70 8011-3541 2,700 3,256 3,811 1,310 19,086 0.419 45,517
1.500 0.095 70 8011-5536 1,700 2,256 2,811 966 12,017 0.419 28,659
1.500 0.109 70 8011-3541 2,900 3,456 4,011 1,378 20,500 0.476 43,038
1.500 0.109 70 8011-5536 1,900 2,456 3,011 1,035 13,431 0.476 28,197
1.500 0.125 70 8011-3541 3,500 4,056 4,611 1,585 24,742 0.540 45,821
1.500 0.125 70 8011-5536 2,100 2,656 3,211 1,103 14,845 0.540 27,492
1.500 0.134 70 8011-3541 3,800 4,356 4,911 1,688 26,862 0.575 46,713
1.500 0.134 70 8011-5536 2,750 3,306 3,861 1,327 19,440 0.575 33,805
1.500 0.134 110 8011-5555 2,916 3,472 4,027 1,381 20,617 0.575 35,855
1.500 0.156 70 8011-3541 4,250 4,806 5,361 1,842 30,043 0.659 45,611
1.500 0.156 70 8011-5536 3,200 3,756 4,311 1,481 22,621 0.659 34,343
1.750 0.109 70 8011-3544 3,200 3,756 4,311 1,481 22,621 0.562 40,255
1.750 0.109 70 8011-5545 2,450 3,006 3,561 1,224 17,319 0.562 30,820
1.750 0.134 70 8011-3544 3,950 4,506 5,061 1,739 27,923 0.680 41,045
1.750 0.134 70 8011-5545 3,000 3,556 4,111 1,413 21,207 0.680 31,173
1.750 0.156 70 8011-3544 4,600 5,156 5,711 1,963 32,517 0.781 41,625
1.750 0.156 70 8011-5545 3,550 4,106 4,661 1,602 25,095 0.781 32,123
1.750 0.175 100 8011-5555 4,374 4,390 5,486 1,881 30,925 0.866 35,714
1.750 0.190 80 8011-5555 5,249 5,805 6,360 2,181 37,110 0.931 39,853
2.00 0.203 80 8011-5555 5,833 6,389 6,944 2,381 41,234 1.150 35,980

NOTE: ** Cut with 20,000 # tension, * cut with 10,000 # tension.

UNIT 1222 Rev. B
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8.0 FIELD MODIFICATIONS FOR EH34-BC03 BOOSTER CYLINDER ASSEMBLY

As of August 1992, the EH34-BC03 Booster Cylinder Assembly has been modified to include two
1
/8" NPT ports in the booster cylinder (12). These ports were included to allow for the installation of
a grease fitting (17) and a breather (18) to permit periodic injection of grease or other lubricant on
the "open" side of the booster piston (10). Inclusion of this feature in the periodic maintenance
schedule will help prevent the formation of corrosion on the "open" side of the actuator.

Booster cylinder assemblies manufactured prior to August 1992 may be modified to the current
configuration as outlined in the following procedure and drawing #9303-0191.
1. Drill existing 1/4" port in the booster cylinder (12) with 11/32" drill to .62" deep. Tap hole with 1/8"-
27 NPT tap deep enough to install a 1/8" NPT plug flush with the face of the cylinder, or a
"flush-seal" type pipe plug may be used.
2. Rotate cylinder approximately 90E from plugged port and drill a 11/32" hole x .80" deep at a
2.33" bolt radius as shown in drawing 9303-0191. Tap hole to 1/8"-27 NPT to standard plug
depth.
3. Rotate cylinder 180E and repeat drilling and tapping procedure as outlined in Step 2.
4. Re-assemble booster cylinder assemblies onto the BOP and stroke the booster pistons (10)
to the full "open" position. Install the grease fitting (17) and relief valve (18) into the new 1/8"
NPT ports.
5. Attach a grease/lubricant hose to the grease fitting (17) and fill cylinder (12) to at lease half
full. Stroke pistons to the "closed" position to void excess lubricant through the breather (18).
As part of the periodic maintenance for the booster cylinders, the cylinders should be recharged with
grease/lubricant as described in Step 5 to prevent any build up of condensation and subsequent
corrosion in the "open" side of the booster piston.
 UNIT 1222 Rev. B
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9.0 SHEAR RAMS

The original shear ram bodies were designed for one size ram body to accept three different shear
blades for 1.00, 1.25 and 1.50 coiled tubing. A different shear blade was required for each size
coiled tubing and we did not anticipate 1.75 coiled tubing size.

Designing the shear rams for 1.75 coiled tubing required changing the location of the retaining bolt;
therefore, the blades for 1.00, 1.25 and 1.50 do not fit the ram body for 1.75. Ram bodies for 1.75
are part # 8011-3744 R.H. and 8011-3644 L.H.

This new shear blade 8011-5536 fits the original ram body Part # 8011-3742 R.H. & 8011-3642 L.H.,
and cuts the sizes of pipe 1.00, 1.25 or 1.50 with or without wireline. It should not be used to cut
1.75 coiled tubing.

The new shear blade 8011-5545 fits only the ram bodies part # 8011-3744 R.H. and 8011-3644 L.H.
for 1.75, however it is suitable for cutting all sizes of tubing 1.00, 1.25, 1.50 and 1.75 with or without
wireline.

Unless otherwise specifically ordered to the contrary, all 3.06 BOPs shipped after 1 May 92 will be
equipped with ram bodies 8011-3744 R.H. and 8011-3644 L.H. and shear blade 8011-5545.

When ordering shear blades REMEMBER:

Part #8011-5536 cuts 1.00, 1.25 and 1.50, and fits only ram bodies 8011-3742 and 8011-3642.

Part #8011-5545 cuts 1.00, 1.25, 1.50 and 1.75, and fits only ram bodies 8011-3744 and 8011-
3644.

In case the part numbers on the rams are not visible, the following dimensions will aid in the
identification process.

9205-2692

1.00 thru 1.50 1.00 thru 1.75

Shear Ram Bodies Shear Ram Bodies

8011-3642 L.H. 8011-3644 L.H.
8011-3742 R.H. 8011-3744 R.H.
UNIT 1222 Rev. B
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CAUTION !!! SHEAR BLADES CAN BE INSTALLED WRONG !!!

NOTE: As illustrated, the beveled side of the blade faces away from the head of the cap screw. The
sharper edge faces toward the head of the cap screw, and will be to the center of the ram body.

Both types of blades cut wireline equally well, and make multiple cuts. Only the blade changes, the
ram body does not change. The new blade 8011-5536 cuts all sizes of tubing from 1.00" dia.
through 1.50" dia. and replaces the old blades 8011-3535, 8011-3537 and 8011-3541. The new
blade 8011-5545 will cut 1.00" dia. through 1.75" dia. tubing, but requires using the 1.75" shear rams
8011-3644 and 8011-3744. This blade replaces the old 8011-3544 shear blade. The cut tubing is
a star shape, but the O.D. is even less oversized than the older blade cut, resulting in easier fishing.
The I.D. is not restricted, permitting circulation.

Part Nos. Part Nos.

8011-5536 8011-3535, 8011-3537

8011-5545 8011-3541, 8011-3544

Available Feb. 1992

 UNIT 1222 Rev. B
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10.0 OTHER OPTIONS AVAILABLE

OPTION 1

EH34-BC01 Booster Cylinder Model - This model increases the cutting force 2.34 times over the
standard operator; however, the hydraulic operating pressure is limited, as noted in the operating
instructions for that assembly. This is the only Booster Cylinder Assembly that does not require
any change in the other operator parts of the BOP. To install, remove the hydraulic cap sub-
assembly, install the EH34-BC01, re-install the hydraulic cap sub-assembly, and you are back in
business. This model is not certified for North Sea service.

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

OPTION 2

EH34-BC05 Booster Cylinder Model - This model increases cutting force 3.99 times over the
standard operator. Installation of this model requires changing out the Piston, piston guide
and piston rod with ram guide. This model is designed for a 1,500-2,000 psi hydraulic operating
pressure.

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 -50EF.

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.