TECH MANUAL

TECH-5.12 10K ES SINGLE W/BSTR

M60ES54-SA19X

5.12” 10,000 PSI WP, 3,000 PSI HYDRAULICS ES

SERIES, SHEAR/SEAL ACTUATOR 7” PISTON
W/BOOSTER SINGLE BOP

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

ADDITIONAL CODE SDRL CODE TOTAL PGS

This document contains proprietary and confidential information TEXAS OIL TOOLS
which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is 3770 Pollock
REMARKS
loaned for limited purposes only and remains the property of NOV. Conroe, TX 77305
Reproduction, in whole or in part, or use of this design or Phone 936-777-6200
distribution of this information to others is not permitted without the
MAIN TAG NUMBER DISCIPLINE Fax 936-756-8102
express written consent of NOV. This document is to be returned to
NOV upon request and in any event upon completion of the use for
which it was loaned. This document and the information contained
CLIENT PO NUMBER and represented herein is the copyrighted property of NOV.
 National Oilwell Varco
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

Client Document Number M60ES54-SA19X-MAN-001 03

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REVISION HISTORY

03 29-July-15 Revision rs MD KM
02 20/Nov/2012 Revision CP KM MW
01 05/Oct/2012 Initial Release CP KM MW
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

01 Initial Release
02 Correct 15K references per upper level BOP number
03 6.0 change Hydraulic Volumes and Hydraulic/Wellbore Ratio

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CONTENTS

1.0 INTRODUCTION

2.0 FEATURES

3.0 CERTIFICATION

4.0 OPERATION

5.0 TESTING

6.0 SPECIFICATIONS

7.0 M60ES54-SA19X
5.12 10K ES SINGLE W/ BOOSTER
M60ES54-SA19X-GAD-001

8.0 M60ES56-ACT9
SHEAR/SEAL ACTUATOR W/BOOSTER
M60ES56-ACT9-ART-001

9.0 EQ15-0001X
EQUALIZING VALVE 15K NACE
EQ15-0001X-ASM-002

10.0 ES5R-VS**L
SHEAR/SEAL RAM
M60ES5R-VS00AL-ASM-002

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M60ES54-SA19X
5.12 10K ES SINGLE BOP W/ BOOSTERS
M60ES54-SA19X-GAD-001

1.0 INTRODUCTION
The 5.12" 10K ES Single BOP is designed for coiled tubing and snubbing operations. The ES is the
lightest in the industry, yet retains all the field-proven designs you have come to expect from Texas Oil
Tools.
The compact size allows easier handling along with easier maintenance. All actuators feature power
hydraulic ram change, low bonnet bolt torque requirement, and a pressure balance piston for shear
operations (no booster required).
Internally ported hydraulics (no external plumbing) eliminate the making and breaking of oil seals when
changing or servicing rams; thus removing the possibility of environmental pollution.

2.0 FEATURES

 Light and Compact

 Pressure Balance Piston
 Low Bonnet Bolt Torque
 Internal Equalizing Valves
 Well Pressure Isolated Seals
 Hydraulic Ram Change
 Internal Porting
 Independent Bonnet Testing
 No Welds - Solid Body
 Ram Position Indicator
 Manual Locks

3.0 CERTIFICATION - Testing - All BOPs are hydrostatic and function tested per API 6A.

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

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.

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4.0 OPERATION
Ram Open and Close - Before opening the rams be sure the lock screws are backed fully out (turn
counter clockwise). If lock screws do not turn out easily after a closed and locked wellbore pressure
test apply 1,500 to 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".

Bonnet Open and Close - Remove the bonnet bolts (24).

To open the bonnets apply 500 to 1,500 psi hydraulic pressure to the body port marked "CLOSE"
(ram close). To close the bonnets apply 1,500 psi operating pressure to the body port marked
"OPEN" (ram open). After closing the bonnets maintain the 1,500 psi hydraulic pressure to keep the
bonnet pulled tightly against the body as the bonnet bolts are reinstalled.

Ram Change - Vent all hydraulic pressure to zero.

Remove the bonnet bolts and open the bonnets as described above. Maintain hydraulic pressure
until the bonnets have fully retracted and the rams have fully extended making them accessible. Vent
all hydraulic pressure to zero to prevent personal injury in the event that the bonnet is closed
prematurely during the ram change procedure.

Remove the ram by lifting up and over the ram change rod. NOTE: Do not scratch ram change rods.

Front and rear seals may be replaced without fully removing the rams. Lift the ram up until it clears
the ram guide rod and rotate slightly to gain access to the front seal.
RECOMMENDED MAINTENANCE PROGRAM
After Each Job - Inspect Ram Rubber Seals
Normal wear will be a moderate amount of extrusion downstream of the pressured side.
Replace the ram seals when usage has resulted in any noticeable loss of rubber. Field testing only to
the maximum anticipated well pressure will extend the life of the seals.

Inspect Bonnet Seal - For scratches and deformation, inspect O-rings and O-ring grooves.

Check 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.
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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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 SPECIFICATIONS
M60ES54-SA19X
5.12 10K ES SINGLE BOP W/ BOOSTERS
Maximum Working Pressure .......................................................................................................... 10,000 psi
Hydraulic Working Pressure .................................................................................... 1,500 psi (3000 psi Max.)
Service ........................................................................................................................ H2S, NACE MR-01-75
Weight

Single w/Booster ......................................................................................................................... 2,500 lbs

Hydraulic Volumes

Shear / Seal w/Booster (M60ES56-ACT9)

Open (per set) .............................................................................................................583.24:1 cu. in.
Close (per set) ............................................................................................................590.46:1 cu. in.
Hydraulics/Wellbore Ratio

Shear / Seal Actuator w/Booster (M60ES56-ACT9) ........................................................................ 23.18:1

Tightening Torques

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

End Flanges 15ksi ..................................................................................................................... 962 ft. lbs.
End Flanges 10ksi ..................................................................................................................... 401 ft. lbs.
Side Outlet 15ksi ....................................................................................................................... 188 ft. lbs.
Side Outlet 10ksi ....................................................................................................................... 118 ft. lbs.

SHEAR / SEAL ACTUATOR W/ BOOSTER QTY TORQUE

Item 25: SHCS 2002-3790B 4 160 ft. lbs

Item 23: SHCS 2002-3791B 6 335 ft. lbs

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7.0 M60ES54-SA19X
5.12 10K ES SINGLE BOP W/ BOOSTERS
Reference drawing M60ES54-SA19X-GAD-001

H2S & NORTH SEA

ITEM QTY DESCRIPTION
PART NO.
1 M601005666B 1 BODY 5.12 10K ES SINGLE
2 M60ES56-ACT9 2 15K ACT S/S 7'' PISTON W/ BOOSTER
3 P601004733B 12 STUD 1.125-8UN X 6.00
4 7937-0818B 12 NUT 1.125-8UN
5 M60ES56-SUG1 1 CONN GUARD ASSY
6 7933-4169 1 GASKET RING API BX-169
7 7934-9094R 1 PLUG ASSY API PORT .562
8 2000-FP54 1 FLANGE PROTECTOR
9 EQ15-0001X 1 EQUALIZING VALVE ASSY
10 P601004717B 8 STUD .750-10UN X 3.88
11 7937-0512B 8 NUT .750-10UN

M60ES56-SUG1 CONN GUARD ASSY

H2S & NORTH SEA
ITEM QTY DESCRIPTION
PART NO.
5-1 2002-3726 2 CONNECTOR GUARD
5-2 7935-0603 4 SHCS .375-16UNC X .750
5-3 7959-9006 4 LOCK WASHER .375

M60ES54-SA19X-GAD-001

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8.0 M60ES56-ACT9
SHEAR/SEAL ACTUATOR W/BOOSTER
Reference drawing M60ES56-ACT9-ART-001
Disassembly - Open the bonnets. See bonnet open and close, section 4.0 ; vent all hydraulic
pressure to zero. Remove the rams and remove set screw (19), rod head (16) and guide (17).
Remove the bonnet seals (1-9). Remove socket head cap screws (21). Remove socket head cap
screw (22) and remove slide (7) and lock screws (8) from slidelock cap (6). Remove retainer (1-
4)Bushing (29) and Seal (1-3) from slidelock cap (6). Remove buttonhead screw (27) and remove
leaf spring (28) from slide (7).

Remove secondary rod (11) from piston rod (13) and then remove secondary piston (12) from
secondary rod (11). Remove seals (1-14 & 1-15). Remove secondary cylinder (5).
Remove socket head cap screws (25) and (23). Remove end cap (6). Remove O-rings (1-10) and
(1-11). Remove retainer ring (1-4), seal (1-3), bushing (29), and O-Rings( 1-16). Remove change
cylinders (3) and main cylinder (4) from bonnet (2). Remove piston (14) and T-seal (1-1) from bonnet
(2). NOTE: Do not remove piston from rod.
Support weight of bonnet (2) and remove ram change rod (9) and (10) from body with Allen wrench.
NOTE: Do not scratch surfaces of ram change rods. Note specific location of change rods as they
have differing thread sizes. Remove O-rings (1-8) from body.
Remove T-seals (1-2) from ram change rods (9) and (10). Remove O-rings (1-10) and (1-11).
Remove retainer ring (1-5), seals (1-6) and retainers (1-7) from bonnet (2). Remove retainer ring (1-
5). Remove bushings (30) and seals (1-6) from bonnet (2). 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 seal (1-6), bushing (30), retainer (1-5) into bonnet (2). Install seal (1-6), retainer (1-7) and
retainer ring (1-5) into bonnet (2). Install O-rings (1-10) and (1-11). Install T-seals (1-2) onto ram
change rods (9) and (10). Install O-rings (1-8) into body.

NOTE: Do note scratch surfaces of ram change rods. Note specific location of change rods as they
have differing thread sizes. (9) = 1.250-8unc, (10) = 1.125-8unc.

Insert ram change rods (9) and (10) thru bonnet (2). Support weight of bonnet (2) and thread ram
change rods (9) and (10) into body with Allen wrench. Install T-seal (1-1) onto piston (14). Install
piston rod assembly (13) and (14) into bonnet (2). Install ram guide (17) and rod head (16) secure
with set screw (19). Install main cylinder (4) and change cylinders (3). Install seal (1-3), bushing (29)
and retainer ring (1-4). Install O-rings (1-10) and (1-11) into end cap (5). Install end cap (5) with
socket head screws (23) and (25). Install seal (1-3), pip O-Rings (1-16) and bushing (29). into End
Cap (5). Install End Cap (5) over piston rod (11) Install seals (1-6) and retainer (1-5) over piston rod
(13) and into end cap (5). Install slide lock cap (6) and secure with socket head cap screws (21)
tighten in an alternating diagonal pattern. Install leaf spring (28) onto slide (7) with button head screw
(27). Install lock screw (8) into slide (7) secure with retainer (1-4). Install slide (7) into slidelock cap
(6) secure with socket head cap screw (25). Install bonnet seal (1-8) and O-rings (1-9).
Actuator can now be tested and functioned per section 4.0 operations.

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M60ES56-ACT9
SHEAR/SEAL ACTUATOR W/BOOSTER
Reference drawing M60ES56-ACT9-ART-001

ITEM -25°F H2S & NORTH SEA QTY DESCRIPTION

1 M60ES56-SK13 1 SEALS KIT
2 2003-0314B 1 BONNET
3 2002-3787B 2 CHANGE CYLINDER
4 2003-0312B 1 CYLINDER
5 M601005592B 1 SECONDARY CYLINDER
6 M601005643B 1 END CAP
7 9905-2933B 1 SLIDE
8 9905-2934B 1 LOCK SCREW
9 2002-3788B 1 CHANGE ROD CLOSE
10 2002-3789B 1 CHANGE ROD OPEN
11 M601005642B 1 SECONDARY ROD
12 9905-2925B 1 SECONDARY PISTON
13 M601005612B 1 PISTON ROD
14 M601005611B 1 PISTON
15 9900-6211B 1 GASKET
16 2002-3753B 1 ROD HEAD
17 2002-3752B 1 RAM GUIDE
18 2002-3792 1 GUIDE STUD
19 7941-0301 1 SSCR
20 7934-0202 5 PLUG
21 M601005652B 6 SHCS
22 M601009555B 2 SHCS
23 2002-3791B 6 SHCS
24 2002-3755B 4 BONNET BOLT
25 2002-3790B 4 SHCS
26 9905-2938 1 SHCS
27 7943-0402 1 BHCS
28 9905-2935 1 LEAF SPRING
29 7830-0088 2 BUSHING
30 7830-0239 2 BUSHING

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M60ES56-SK13*
SEAL KIT F/ SHEAR/SEAL ACTUATOR W/BOOSTER
Reference drawing M60ES56-ACT9-ART-001

*SERVICE SPECIFIC PART NUMBER

ITEM M60ES56-SK13 M60ES56-SK13B QTY DESCRIPTION
-25°F H2S & NORTH SEA -50°F ARCTIC
1-1 7951-3439 7951-A439 1 T-SEAL
1-2 7951-3326 7951-A326 2 T-SEAL
1-3 7821-1379 7821-1379B 2 SEAL POLYPAK DEEP B
1-4 7826-1756 7826-1756 2 RETAINER RING INTERNAL
1-5 7826-2127 7826-2127 4 RETAINER RING INTERNAL
1-6 7821-1622 7821-1622B 5 SEAL POLYPAK DEEP B
1-7 7830-0240 7830-0240 2 RETAINER
1-8 7813-3223 7813-A223 2 O-RING
1-9 7813-4258 7813-A258 2 O-RING
1-10 7813-3229 7813-A229 4 O-RING
1-11 7813-3363 7813-A363 2 O-RING
1-12 7813-3225 7813-A225 1 O-RING
1-13 7813-3241 7813-A241 1 O-RING
1-14 7950-3324 7950-A324 1 T-SEAL
1-15 7951-3342 7951-A342 1 T-SEAL
1-16 7813-3220 7813-A220 2 O-RING

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M60ES56-ACT9-ART-001

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9.0 EQ15-0001X
EQUALIZING VALVE 15K NACE
Reference Drawing EQ15-0001X-ASM-002

Disassembly
Remove the equalizing valve bonnet (1). NOTE: LEFT-HAND THREAD. Use a 1/4 allen wrench &
rotate right-hand to remove the equalizing valve stem (2), seat (3), and spacer (4-3). Remove and
discard O-ring (4-1).

Remove the equalizing valve seat (3) using a short piece of heavy wire with a hook bent on the end.
Remove three seals (4-2). Take care not to damage the sealing surface. NOTE: If the seat is stuck,
hold the hooked wire in place with the 1/4 allen wrench while you pull on the wire.

Assembly
Install O-ring (4-1) on the equalizing valve bonnet (1). Install the stem (2) into the bonnet, rotating it
to the full open position. Install the spacer (4-3), note: beveled side in first. Install three seals (4-2),
smooth side in, lip side out. Use the equalizing valve seat for a tool to push the seals into the
bonnet.

Install three seals (4-2) into the body. When both seals are in place, install the seat (3).

Check to assure that the stem (2) is in the fully opened position, install the bonnet/stem assembly.
NOTE: left-hand thread.

CLOSE THE EQUALIZING VALVE!!

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EQ15-0001X
EQUALIZING VALVE PARTS LIST
Reference Drawing EQ15-0001X-ASM-002

ITEM -25°F H2S & NORTH SEA QTY DESCRIPTION

1 7909-2425B 1 BONNET
2 7909-2426XB 1 STEM
3 7909-2427XB 1 SEAT
4 EVA6-S000* 1 SEAL KIT

EVA6-S000*
SEAL KIT FOR STANDARD EQUALIZING VALVE
Reference Drawing EQ15-0001X-ASM-002

*SERVICE SPECIFIC PART NUMBER

EVA6-S000
ITEM EVA6-S000B QTY DESCRIPTION
-25°F H2S &
-50°F ARCTIC
NORTH SEA
4-1 7813-4918 7813-A918 1 O-RING
4-2 7817-0371 7817-0371B 6 SEAL
4-3 7808-1427 7808-1427 1 SPACER
4-4 7940-2501 7940-2501 1 ALLEN WRENCH (NOT SHOWN)

Reference Drawing EQ15-0001X-ASM-002

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10.0 ES5R-VS**L
SHEAR/SEAL RAM
Reference Drawing M60ES5R-VS00-ASM-002

Disassembly - Remove socket head cap screw (4) and blade assembly (5 or 6) by pushing
assembly out the side of the ram body (1 or 2). Remove blade retainer (7) from blade assembly.
Remove rear seal (3). Clean and inspect all parts before replacement.

Assembly - Place blade retainer (7) into blade assembly (5 or 6) while holding blade retainer (7) in
position in the blade assembly (5 or 6). Slide both into position in the ram body (1 or 2). Secure in
place with socket head cap screw (4). Install rear seal (3) to fit flush with surface of ram body (1 or
2).

M60ES5R-VS**AL
SHEAR/SEAL RAM
Reference Drawing M60ES5R-VS00-ASM-002

SERVICE SPECIFIC PART NUMBER

ITEM ES5R-VS**L ES5R-LS**B QTY DESCRIPTION
-25°F H2S & NORTH SEA -50°F ARCTIC

1 2002-3739B 2002-3739B 2 RAM BODY, LH

2 2002-3740B 2002-3740B 2 RAM BODY, RH

3 7805-2437 7805-2435 2 REAR SEAL

4 7935-0606 7935-0606 2 SHCS

5 8505-59** 8505-82** 1 SHEAR SEAL INSERT, LH

6 8505-57** 8505-81** 1 SHEAR SEAL INSERT, RH

7 8505-5421 8505-5421 2 BLADE RETAINER

SIZE VARIABLE CODE **

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

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ES5R-VS**L
SHEAR/SEAL RAM

M60ES5R-VS00-ASM-002

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