ES56 Dual Combi BOP
ES56 Dual Combi BOP
A
Issue Date: June 2006
Information in this manual is subject to change without notice. Please see our Website (www.tot.com) for the
latest version of our manuals.
TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 FEATURES
3.0 CERTIFICATION
4.0 OPERATION
1.0 INTRODUCTION
The 5.12" 15M ES Dual Combi 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.
FEATURES
2.0 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 -50EF.
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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3.0 SPECIFICATION
Maximum Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,000 psi
Hydraulic Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,500 psi (3000 psi Max.)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2S, NACE MR-01-75
Weight
Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,900 lbs
Triple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,000 lbs
Hydraulic Volumes
Shear / Seal (ES56-ACT6L)
Open (per set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447.1 cu. in.
Close (per set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.9 cu. in.
Pipe / Slip (ES56-ACT7L)
Open (per set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.7 cu. in.
Close (per set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.7 cu. in.
Hydraulics/Wellbore Ratio
Shear / Seal Actuator (ES56-ACT6L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Nearly Balanced) 208:1
Pipe / Slip Actuator (ES56-ACT7L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.55:1
Tightening Torques
Bonnet Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 ft. lbs.
End Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,280 ft. lbs.
Side Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 ft. lbs.
4.0 OPERATION
Ram Open and Close - Before opening the rams be sure the lock screws are backed fully out (turn counter
clockwise). If lock screws do not turn out easily after a closed and locked wellbore pressure test apply 1,500
to 2,200 psi hydraulic pressure to the "CLOSE" hydraulic port to relieve the load from the end of the tail rod.
To open the rams apply 1,500 psi hydraulic pressure to the body port marked "OPEN". Close the rams by
applying 1,500 to 2,200 psi hydraulic pressure to the body port marked "CLOSE".
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.
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.
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5.0 TESTING
Function Test Bonnets - All actuators should be pressure tested to 3,000 psi working pressure in both the
ram open and ram close positions. A minimum hold time of 15 minutes is required without leakage.
Check the manual lock system when in the ram closed position.
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.
6.0 ROUTINE MAINTENANCE
Disassembly - Open the bonnets. See bonnet open and close, section 4; vent all hydraulic pressure to zero.
Remove the rams and remove set screw (21), rod head (13) and guide (12). Remove the bonnet seal (33).
Remove nut (36) and handwheel (35) from the lock screw (34). Remove socket head cap screws (16) and
(17).
Remove end cap (4). Use caution not to drop indicator pod (14). Remove o-rings (24) and (26). Remove
retainer ring (31), seal (30), and retainer (2). Remove socket head cap screws (19). Remove lockscrew cap
(9). Remove and inspect lock screw (34). Remove change cylinders (8) and main cylinder (5) from bonnet
(3). Remove seal retainer (20) and seal (29). Remove piston (11) and T-seal (27) from bonnet (3). NOTE:
Do not remove piston from rod.
Support weight of bonnet (3) and remove ram change rod (6) and (7) 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 (23) from body.
Remove T-seals (28) from ram change rods (6) and (7). Remove o-rings (24) and (26). Remove retainer ring
(31), seals (30) and retainers (2) from bonnet (3). Remove bushings (1) and seals (30) from bonnet (3).
Remove o-rings (23) 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 (30) and retainer (2) and retainer ring (31), into end cap (4). Install seals (30), retainers (1),
retainer rings (31), and o-rings (24) and (26), into bonnet (3). Install seals (30) retainers (2) and retainer ring
(31), o-rings (24) and (26) into bonnet (3). Insert ram change rods (6) and (7) through bonnet (3). NOTE: Do
not scratch surfaces of ram change rods. Install o-rings (23) into body. Support weight of bonnet (3) and
thread ram change rod (6) and (7) into body with allen wrench. NOTE: Ram change rods have different
threads (6) = 1.250-8UNC, (7) = 1.125-8UNC.
Install T-seal (27) onto piston (11). Install piston (11) into bonnet (3); install guide (12), rod head (13) and
secure set screw (21). Install main cylinder (5) and change cylinders (8). Install seals (30) retainers (2) and
o-rings (24) and (26) into end cap (4). Thread lock screw (34) into cap (9) and attach with socket head cap
screw (19). Install end cap (4) onto main cylinder (5) and ram change cylinders (8); secure with socket head
cap screws (16) and (17). Install handwheel (35) and secure with nut (36). Install the bonnet seal (33) and
o-rings (37). Actuator can now be tested and functioned per 4.0 Operation.
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Install seal (30), bushing (1), retainer (31) into bonnet (3). Install seal (30), retainer (2) and retainer ring (31)
into bonnet (3). Install o-rings (24) and (26). Install T-seals (28) onto ram change rods (6) and (7). Install
o-rings (23) into body.
NOTE: Do note scratch surfaces of ram change rods. Note specific location of change rods as they have
differing thread sizes. (6) = 1.250-8unc, (7) = 1.125-8unc.
Insert ram change rods (6) and (7) thru bonnet (3). Support weight of bonnet (3) and thread ram change rods
(6) and (7) into body with allen wrench. Install T-seal (27) onto piston (11). Install piston rod assembly (10)
and (11) into bonnet (3). Install ram guide (12) and rod head (13) secure with set screw (21). Install main
cylinder (5) and change cylinder (8). Install seal (46), retainer (38) and retainer ring (47). Install o-rings (24)
and (26) into end cap (4). Install end cap (4) with socket head screws (16) and (17). Install seal (46), pip seal
(49) and bushing (39) into pressure balance chamber (9). Install pressure balance chamber (9) over piston
rod (10) and into end cap (4). Install seals (30) and retainer (2) over piston rod (10) and into end cap (4).
Install seals (30) and retainer (2) over piston rod (10) and into pressure balance chamber (9). Install slide lock
cap (48) and secure with socket head cap screws (19) tighten in an alternating diagonal pattern. Install leaf
spring (42) onto slide (40) with button head screw (41). Install lock screw (45) into slide (40) secure with
retainer (44). Install slide (40) into slidelock cap (48) secure with socket head cap screw (43). Install bonnet
seal (33) and o-rings (37).
Actuator can now be tested and functioned per section 4.0 operations.
Inspect Bonnet Seal - For scratches and deformation, inspect o-rings and o-ring grooves.
Check cutting edges of the shear or shear seal inserts. If the blade is chipped then the cutting action of the
insert may be impaired and therefore it should be discarded.
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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.
After 20 Jobs or 12 Months Maximum - Completely disassemble the equalizing valve, replace all seals and
worn parts.
Completely disassemble and inspect the bonnet assemblies. Replace all seals and worn parts.
Inspect all threads, connections, bushings and fittings. Replace and repair as required.
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Disassembly - Remove front seal (503) and retainer bar (505). Remove compression pin (507) and slip insert
(502) by pushing compression pin toward front of ram. Remove o-ring (506) and rear seal (504). Clean and
inspect all parts - replace as needed.
Remove set screws (510). Remove rocker (508). Clean and inspect all parts - replace as needed.
Assembly - Install rear seal (504) to fit flush with surface of ram body (501). While holding the retainer bar
(505) in position in the front seal (503), slide both into position in the ram body (501). Place o-ring (506) onto
compression pin (507). Slide compression pin into slot on rear of slip insert (502). Install compression and
slip insert assembly into body.
ES5R-T001
Unit 1449 Rev. A
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Disassembly - Remove socket head cap screw (704) and blade assembly (705 or 706) by pushing assembly
out the side of the ram body (701 or 702). Remove blade retainer (707) from blade assembly. Remove rear
seal (703). Clean and inspect all parts before replacement.
Assembly - Place blade retainer (707) into blade assembly (705 or 706) while holding blade retainer (707) in
position in the blade assembly (705 or 706). Slide both into position in the ram body (701 or 702). Secure
in place with socket head cap screw (704). Install rear seal (703) to fit flush with surface of ram body (701
or 702).
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Unit 1449 Rev. A
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Actuator Assemblies North Sea & H2S Arctic -50°F & H2S
Part Name Qty. Part No. Part No.
Shear / Seal Actuator 2 ES56-ACT6L ES56-ACT6B
Pipe / Seal Actuator 2 ES56-ACT7L ES56-ACT7B
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5.12", 15M, ES BOP
Shear / Seal Actuator
Reference Drawing ES56-ACT6L & ES56-ACT6B
(Quantity shown is for 1 actuator)
ES56-ACT6L ES56-ACT6B
Item North Sea & H2S Arctic -50°F & H2S Qty. Part Name
1 7830-0239 7830-0239 2 Bushing
2 7830-0240 7830-0240 3 Retainer
3 2003-0314B 2003-0314B 1 Bonnet Assy
4 2003-0313B 2003-0313B 1 Endcap
5 2003-0312B 2003-0312B 1 Cylinder
6 2002-3788B 2002-3788B 1 Change Rod Open
7 2002-3789B 2002-3789B 1 Change Rod Closed
8 2002-3787B 2002-3787B 2 Change Cylinder
9 2002-3782B 2002-3782B 1 Pressure Balance Chamber
10 2002-3784B 2002-3784B 1 Piston Rod
11 2003-0311B 2003-0311B 1 Piston
12 2002-3752B 2002-3752B 1 Ram Guide
13 2002-3753B 2002-3753B 1 Rod Head
15 2002-3755B 2002-3755B 4 Bolts, Bonnet
16 2002-3790B 2002-3790B 4 Socket Head Cap Screw
17 2002-3791B 2002-3791B 6 Socket Head Cap Screw
18 2002-3792 2002-3792 1 Guide Stud
19 7935-1428G 7935-1428G 8 Socket Head Cap Screw
21 7941-0301 7941-0301 1 Set Screw
22 7934-0202 7934-0202 4 Plug Skt
23 7813-3223 7813-A223 2 O-Ring
24 7813-3229 7813-A229 4 O-Ring
25 7813-3227 7813-A227 1 O-Ring
26 7813-3363 7813-A363 2 O-Ring
27 7951-3439 7951-A439 1 T-Seal
28 7951-1326 7951-A326 2 T-Seal
30 7821-1622 7821-1622B 7 Seal
31 7826-2127 7826-2127 4 Retainer Ring
33 9900-6211 9900-6211 1 Gasket
37 7813-4258 7813-A258 2 O-Ring
38 7830-0242 7830-0242 1 Retainer
39 7830-0241 7830-0241 1 Bushing
40 9905-0933B 9905-0933B 1 Slide, Shear / Seal
41 7943-0402 7943-0402 1 Screw Cap Buttonhead
42 9905-2935 9905-2935 1 Leaf Spring, Shear / Seal
43 9905-2938 9905-2938 1 Socket Head Cap Screw
44 7824-1257 7824-1257 1 Retainer Ring
45 9905-2934B 9905-2934B 1 Lock Screw
46 7821-2252 7821-2252B 2 Seal Polymyte
47 7826-2757X 7826-2757X 1 Retainer Ring
48 2002-3783B 2002-3783B 1 Slide Lock Cap
49 7978-2250 7978-2250B 1 Seal, Pip
Unit 1449 Rev. A
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Unit 1449 Rev. A
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ES56-ACT7L ES56-ACT7B
Item North Sea & H2S Arctic -50°F & H2S Qty. Part Name
1 7830-0239 7830-0239 2 Bushing
2 7830-0240 7830-0240 3 Retainer
3 2003-0315B 2003-0315B 1 Bonnet Assy
4 2003-0318B 2003-0318B 1 Endcap
5 2003-0316B 2003-0316B 1 Cylinder
6 2002-3745B 2002-3745B 1 Change Rod Open
7 2002-3746B 2002-3746B 1 Change Rod Closed
8 2002-3747B 2002-3747B 2 Change Cylinder
9 2002-3769B 2002-3769B 1 Lockscrew Cap
10 2002-3733B 2002-3733B 1 Piston Rod
11 2003-0317B 2003-0317B 1 Piston
12 2002-3752B 2002-3752B 1 Ram Guide
13 2002-3753B 2002-3753B 1 Rod Head
14 2002-3754B 2002-3754B 1 Indicator Rod
15 2002-3755B 2002-3755B 4 Bolts, Bonnet
16 2002-3756B 2002-3756B 4 Socket Head Cap Screw
17 2002-3757B 2002-3757B 6 Socket Head Cap Screw
18 2002-3770 2002-3770 1 Guide Stud
19 7935-1409G 7935-1409G 8 Socket Head Cap Screw
20 8007-3038 8007-3038 1 Retainer
21 7941-0301 7941-0301 1 Set Screw
22 7934-0202 7934-0202 4 Plug
23 7813-3223 7813-A223 2 O-Ring
24 7813-3229 7813-A229 4 O-Ring
25 7813-3227 7813-A227 1 O-Ring
26 7813-3363 7813-A363 2 O-Ring
27 7951-3439 7951-A439 1 T-Seal
28 7951-1326 7951-A326 2 T-Seal
29 7820-0251 7820-0251B 1 Seal
30 7821-1622 7821-1622B 6 Seal
31 7826-2127 7826-2127 5 Retainer Ring
33 9900-6211 9900-6211 1 Gasket
34 2002-3772B 2002-3772B 1 Lock Screw
35 9905-2851 9905-2851 1 Handwheel
36 7938-0510 7938-0510 1 Nut Hex
37 7813-4258 7813-A258 2 O-Ring
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Unit 1449 Rev. A
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Item No North Sea & H2S Arctic -50°F & H2S Qty Part Name
101 7909-2425B 7909-2425B 1 Bonnet
102 7913-4918 7913-A918 1 O-Ring
103 7909-2426XB 7909-2426XB 1 Stem
104 7808-1427 7808-1427 1 Spacer
105 7817-0371 7817-0371B 5 Seal Orange H2S
106 7909-2427XB 7909-2427XB 1 Seat
109 7940-2501 7940-2501 1 Allen Wrench (not shown)
9902-2498
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