Man-10000527 7447362 02

User Manual
LIGHTWEIGHT BOP
UP TO 10,000 PSI WORKING PRESSURE
MAN-10000527 – Original Instructions

Revision F - 27/11/2019
Copyright National Oilwell Varco, ©2017 Page 1 of 77

LIGHTWEIGHT BOP
This document applies to the following products:

• This document is applicable to all SLW, DLW and TLW Wireline Valves.
Published by:
Elmar
Tofthills Avenue,
Midmill Business Park,
Kintore, Aberdeen, AB51 0QP
Scotland, United Kingdom
No part of this document may be reproduced by any means without the written consent of
the publisher.
Whilst every care has been taken to ensure that the information in this document is
correct, no liability can be accepted by Elmar for loss, damage or injury caused by any
errors or omissions in this document.
Revision Date Amendments

REV F: MANUAL REWRITEN TO CURRENT FORMAT. MINOR
UPDATES TO ALL SECTIONS. INFORMATION ADDED REGARDING
F 27/11/2019 MANIFOLD CONFIGURATION (SEE SECTION 4.2.3). INFORMATION
ADDED REGARDING STORAGE AND TRANSPORTATION (SEE
SECTION 10)
Page 2 of 77 Copyright National Oilwell Varco, ©2019
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
TABLE OF CONTENTS
1 Introduction.................................................................................................................. 5
2 Safety & EHSRs ............................................................................................................. 6
2.1 General Safety ......................................................................................................... 6
2.1.1 Employee responsibility ............................................................................ 6
2.1.2 Employer responsibility ............................................................................. 7
2.1.3 Warnings, cautions and requirements ...................................................... 7
2.2 Equipment specific safety ........................................................................................ 8
2.2.1 Heavy equipment ...................................................................................... 8
2.2.2 Pressure Control ........................................................................................ 8
3 Physical Description .................................................................................................... 10
Table of Contents
3.1 Unit Overview ........................................................................................................ 10
3.2 Guide to the use of Elmar Drawings ...................................................................... 11
3.2.1 Identification of unit part number .......................................................... 11
3.2.2 Identification of components within a unit ............................................. 11
4 Functional Description ................................................................................................ 12
4.1 Unit Overview ........................................................................................................ 12
4.2 BOP Sub-Assembly ................................................................................................. 13
4.2.1 BOP Body ................................................................................................. 14
4.2.2 Hydraulic Cylinder Assembly ................................................................... 14
4.2.3 Manifold Arrangement ............................................................................ 16
4.3 BOP Adapter Assembly .......................................................................................... 23
4.4 BOP Ram Assembly ................................................................................................ 23
4.4.1 Constrictor™ Multiline Inner Seals .......................................................... 25
5 Specifications & Features ............................................................................................ 26
5.1 Specifications ......................................................................................................... 26
5.2 Standard Features.................................................................................................. 26
5.3 Design Standards ................................................................................................... 27
5.4 Operating Requirements ....................................................................................... 27
6 Assembly Instructions ................................................................................................. 28
6.1 Recommended WPCE Tool List.............................................................................. 28
6.2 Assembly Instructions............................................................................................ 29
6.2.1 O-ring Installation .................................................................................... 29
6.2.2 BOP Adapters/Body ................................................................................. 30
6.2.3 Manifold Block Assembly ........................................................................ 31
6.2.4 BOP Hydraulic Cylinders .......................................................................... 33
6.2.5 Ram Assembly ......................................................................................... 38
6.2.6 3.00” BOP Assembly ................................................................................ 40
6.2.7 4.06” BOP Assembly ................................................................................ 42
6.2.8 Protection Cage ....................................................................................... 44
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7 Operation ................................................................................................................... 45
7.1 Fundamental Rules for WPCE Equipment ............................................................. 45
7.2 Normal Operation .................................................................................................. 46
7.3 Sealing on Braided Line ......................................................................................... 46
7.4 Injecting Grease ..................................................................................................... 47
7.5 Bleeding Down Lubricators.................................................................................... 48
7.6 Equalising Pressure Prior to Opening Rams .......................................................... 49
7.7 Injecting Glycol/Methanol ..................................................................................... 49
7.8 Ram Removal Procedure ....................................................................................... 50
7.8.1 Ram Redress with BOP Upright ............................................................... 50
7.8.2 Ram Redress with BOP Lying Flat (Non-Preferred) ................................. 51
8 Maintenance & Testing ............................................................................................... 52
Table of Contents
8.1 Introduction ........................................................................................................... 52

8.2 Certified assemblies............................................................................................... 53
8.3 Maintenance schedules ......................................................................................... 53
8.4 Routine Maintenance ............................................................................................ 53
8.4.1 Before Every Job ...................................................................................... 53
8.4.2 After Every Job......................................................................................... 54
8.5 Major Maintenance ............................................................................................... 56
8.5.1 To Be Carried Out Once a Year ................................................................ 56
8.5.2 To Be Carried Out Every 5 Years .............................................................. 57
8.6 Testing.................................................................................................................... 57
8.6.1 Body Pressure Test Procedure ................................................................ 58
8.6.2 BOP Manifold Test Procedure ................................................................. 58
8.6.3 BOP Ram Test Procedure......................................................................... 58
8.7 Finalise maintenance tasks .................................................................................... 66
8.8 Maintenance Record Sheet ................................................................................... 66
9 Troubleshooting.......................................................................................................... 67
9.1 Troubleshooting Principles .................................................................................... 67
9.2 Troubleshooting table ........................................................................................... 67
10 Transportation, Spares, Accessories & Disposal ........................................................... 69
10.1 Storage ................................................................................................................... 69
10.2 Transportation ....................................................................................................... 69
10.3 Spares .................................................................................................................... 70
10.4 Accessories ............................................................................................................ 70
10.5 Disposal .................................................................................................................. 71
Appendices .............................................................................................................................. 72
Appendix 1: Maintenance Record Sheet ............................................................................. 73
Appendix 2: Contact Us........................................................................................................ 74
Customer Notes ....................................................................................................................... 75
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
1 INTRODUCTION
This user manual is intended for operating, maintenance and supervisory personnel.
This manual (supplied in digital format) is part of the unit documentation set and must be read
before initial equipment installation and operation.
The validity of the manual can be compromised by post-delivery engineering modifications or
regulatory changes that affect equipment use, ratings and limits. All Elmar engineering
changes are documented in as-built drawings, even after product delivery. This means the
latest drawings always take precedence over manuals. If in doubt, contact Elmar.
1 Introduction
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
2 SAFETY & EHSRS
WARNING
Ignoring the instructions in this manual can result in serious injury or death. All personnel
that work with this equipment must read and understand this manual. Only qualified
personnel are permitted to assemble, operate, and maintain this equipment.
2.1 General Safety

Electrical, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be
present in Elmar equipment. Therefore, pay special attention to safety when working with this
equipment.
2 Safety & EHSRs
• Meet all applicable codes, laws and local field regulations (including environmental
and additional owner/user company policy). This manual contains recommendations
but should not be assumed to satisfy all requirements of legal regulations.
• Read and understand each item in this manual and follow all procedures,
precautions and advice - never take short cuts. Always consider your safety and that
of others.
• Only use the equipment within its design scope to avoid damage or dangerous
situations.
This manual (in its most current revision) is a minimum requirement for all persons working
with Elmar equipment. All other current and applicable documents such as certification,
drawings, bill of materials, vendor documentation, etc., should be readily available at the
worksite.
2.1.1 Employee responsibility

• Never leave "operation-ready" equipment unattended.
• Keep equipment clean (accumulated dirt and dust can hamper unit operations and
may increase the risk of ignition).
• Correctly maintain and use equipment, apparatus, tools, and dangerous substances.
• Wear personal protection equipment (PPE) where necessary; for example, gloves
and protective footwear.
• Never work alone if there is a possibility of an accident.
• Keep loose clothing and long hair well away from moving mechanical parts.
• Remove rings, wristwatch, etc. before working.
• Never disconnect, change or remove safety devices, and use such devices correctly.
• Be aware of all emergency equipment and procedures (such as alarms, abandon
ship, etc.) and make sure they are in place and valid.
MAN-10000527/F TFO-10006156/A3
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• Do not use the equipment after an emergency without verifying that the cause of
the emergency has been removed or rectified.
• Immediately inform the employer and other workers of any situation that represents
a serious danger to safety and health, and of the shortcomings in protection
arrangements.
• Plan all operations including interdependencies with other equipment operations
• If equipment is tied down using rope/line/chains, attach a "flag" to signal their
location.
• During installation, maintenance and/or equipment inspection:
- where possible, make sure electrical/mechanical equipment is switched off
completely, and use a decal (or similar) to prevent unauthorized starting.
2 Safety & EHSRs

- always relieve system pressure before working on hydraulic and/or pneumatic
systems.
2.1.2 Employer responsibility

• Define the required competency of personnel working on the equipment (including
supervision) and provide the required consultation, information and training.
• Ensure that only trained, qualified and competent personnel can work on the
equipment.
• Ensure adequate safety equipment and emergency procedures are available (fire
extinguishers, PPE, escape routes, etc.), and that personnel are trained to use them.
• Ensure a suitable program for installation, operation, maintenance, periodic
inspection and testing of the equipment is defined, adhered to and recorded. The
program must meet or exceed as a minimum those requirements as defined in the
user manual and affiliated data book provided with the equipment.
• Do not allow work to proceed until a thorough examination and risk assessment of
the work site and equipment has been carried out. The examination should assess
(as a minimum) the condition of the work site and all critical components, plus the
equipment structure. Only give approval to proceed when controls to manage
potential risks are in place and measures are taken to mitigate potential
consequences.
2.1.3 Warnings, cautions and requirements

Equipment handling may involve residual risks which cannot be reasonably reduced by design.
To alert the user to potential hazards and recommend safe working practices, additional
information is provided as warnings, cautions and/or requirements:
• WARNING shows a relevant icon and the text WARNING with a description of the
hazard and the best practise to avoid it. Ignoring a warning can result in equipment
damage, serious injury and/or death.
TFO-10006156/A3 MAN-10000527/F
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• CAUTION shows a relevant icon and the text CAUTION with a description of the
hazard and the best practise to avoid it. Ignoring a caution can result in damage to
equipment.
• REQUIREMENT shows an icon and a description of the required PPE to minimise
possible safety risks.
Warnings, cautions and/or requirements are listed in the manual as a preceding step to a
potentially dangerous action. Never proceed to following step(s) if you do not comply with or
fully understand a Warning/Caution/Requirement. See the following examples:
WARNING
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual.
2 Safety & EHSRs
Only qualified personnel are allowed to assemble, operate, and maintain this equipment.
CAUTION
EQUIPMENT DAMAGE
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual.
Only qualified personnel are allowed to rig up, rig down, operate, or maintain this
equipment.
2.2 Equipment specific safety

2.2.1 Heavy equipment
• Never attempt to move heavy equipment without the aid of suitably rated lifting
equipment.
• Only hoist joined equipment after ensuring that the joined equipment has been
certified for single lifting by checking the certification in the Documentation Package
that came with your equipment.
• Make sure you cannot get trapped between a lifted load and a wall, fixed object, etc.
• Never walk under a hanging load or allow heavy objects to rest in an unstable
position.
2.2.2 Pressure Control

• Pressure control equipment must be used at the wellhead whenever pressure is
present or can potentially develop.
• All personnel operating wellhead equipment must be suitably qualified for all
operations to be undertaken.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
• All pressure control equipment must be pressure rated to a defined "Maximum

Working Pressure" (MWP) and Test Pressure (TP). A temperature rating must also be
defined for high temperature applications.
• Never use any piece of equipment that does not have a defined MWP rating.
• Never use pressure control equipment above its MWP rating or outside of its
temperature rating.
• Avoid causing hydraulic hammering. Open high-pressure valves carefully, build
pressure and flow gradually whenever possible.
• Always use the built-in alarm systems where applicable to monitor the status of
pressure circuits and other components (e.g. fluid levels, air supply, etc.). Check
these alarms regularly.
• Use only clean, unused hydraulic fluid of the viscosity and quality specified for the
2 Safety & EHSRs

unit and equipment to be controlled.
• Do not re-use fluids that are intended for once-only use.
• Never use or replace pressure fittings unless you are sure of the thread type, service
type, and MWP.
• Ensure that pressure control equipment is handled and secured in such a way that
external stresses are kept to a minimum, because any damage can affect the
pressure rating and life of the equipment.
• Never heat or weld any part of the pressure control equipment.
• Never tamper with pressurized equipment.
• Never tighten or loosen pressurized connections.
• Use ropes to align a pressure control string or lubricator; never pull on any hoses.
• Check the rating/compatibility of connections before pressure testing the complete
setup.
• Always pressure test the entire pressure system.
• Never fill the riser (or perform a pressure test) with diesel oil, because air in the riser
can compress and mix with diesel vapour and cause an explosion.
• Ensure that enough lubricator is available to cover the tool with at least 1 metre (3
ft.) of clearance (only applies to fixed structures; not semi-submersible rigs).
• Ensure that the pressure rating of a complete system is equal to the rating of the
lowest rated individual item (including pressure fittings, needle valves, gauges, etc.).
• Observe special precautions if H2S is present at the well site.
• Always replace equipment at ‘end of life’ for maximum pressure tests and design
lifetime.
TFO-10006156/A3 MAN-10000527/F
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3 PHYSICAL DESCRIPTION
3.1 Unit Overview

NOTE
The following unit overview is based on a Triple (TLW) BOP. The descriptions & labelling
may differ for SLW and DLW configurations.
For sub-assembly and component level breakdown of a specific BOP always refer to the
drawing(s) relating to that assembly.
3 Physical Description
Figure 1: BOP components
ITEM DESCRIPTION COMMENTS

1 BOP Body Can be supplied with fixed connections or interchangeable adapters
2 Cylinder Assembly Lightweight design with pressure balanced piston
3 Manifold Block Assembly Chemical/grease injection, pressure equalisation & monitoring
4 Thread Protector Supplied with equipment incorporating Quick Union Connections
5 Manual Ram Lock Used for locking and/or manually closing the rams
Supports the cylinder assembly during (dis)assembly (4” variants
6 Support Arm
only)
7 Ram Assembly Assembly depends on linesize. Ensure this is correct before use
MAN-10000527/F TFO-10006156/A3
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3.2 Guide to the use of Elmar Drawings
3.2.1 Identification of unit part number

• Part numbers and serial numbers can usually be found in the following places:
• Engraved on the body within the assembly.
• Stamped on an identification plate or banding that is fixed to an assembly.
3.2.2 Identification of components within a unit

• Identify unit part number as described above.
• Look at the drawing with the same number.
• The Bill of Material for this drawing will consist of sub-assembly numbers.
3 Physical Description
• Look at the drawing with the same number.
• The Bill of Material for this drawing will show the part numbers for individual
components. (In some cases, sub-assemblies reference further sub-assemblies
which then reference individual part numbers).
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
4 FUNCTIONAL DESCRIPTION
4.1 Unit Overview

The NOV Elmar Lightweight Wireline Valves, commonly referred to as BOP’s, have been
designed for use as part of a complete wireline intervention string. The primary purpose is
to provide a manageable safety barrier during remedial work on a wireline well. The valves
are designed to control well pressure by sealing around the wireline cable.
On braided line operations, the valves should always be used together with a grease
injection system and a line wiper.
In addition, the NOV Elmar Lightweight Wireline Valves may also be used for slickline
4 Functional Description
operations or other operations such as wireline shear/seal.

The NOV Elmar lightweight Wireline Valve is currently available with 3” to 4-1/16” through
bore, 10,000 psi maximum working pressure, H₂S or STD service and with the following ram
configurations:
• Single Hydraulic
• Dual Hydraulic
• Triple Hydraulic
Various quick union configurations can be supplied for the upper and lower connections.
To increase the flexibility of the NOV Elmar Lightweight Wireline Valve, each complete
assembly is composed of modular sub-assemblies as follows:
• BOP Sub Assembly, which contains the hydraulic cylinder assemblies and modular
manifold assembly
• BOP Upper quick connect adapter
• BOP Lower quick connect adapter
The NOV Elmar Lightweight Wireline Valves are supplied with NOV Elmar keyless Q-
GUIDETM rams, the line size for which they are dressed must be specified when ordering.
See relevant size Generic Assembly drawing.
The NOV Elmar Lightweight Wireline Valves incorporate the following features as standard:
• API 6A and NACE compliant (for H₂S versions)
• Third Party Design Approval
• Lightweight design, allowing easier handling and shorter rig-up heights
• Threaded quick unions, allowing the use of any NOV Elmar, Bowen or Otis type
quick union without changing the body. Body to quick union joint has an
elastomer seal as standard.
• Manifold blocks with integral equalisation, glycol and grease injection facilities
(single ram configurations do not include the grease and glycol injection facilities)
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
• Keyless Q-GUIDE™ ram design providing flexible ram configuration and positive
wireline guiding
• Maximum hydraulic working pressure 3,000 psi
• Ram position indicator rods
• Manually operated piston locks
This manual is a generic manual for all NOV Elmar Lightweight Wireline Valves with a
working pressure less than or equal to 10,000 psi.
Unless otherwise stated, the following information in this manual is provided for a Triple
and is typical for all other ram configurations.
4.2 BOP Sub-Assembly
The following major assemblies/parts make up the BOP Sub Assembly:
• BOP Body
• Hydraulic Cylinders
• Manifold Blocks
Figure 2 Bop Sub Assembly
The Triple NOV Elmar Lightweight Wireline Valve Assembly (TLW BOP) comprises of three
sets of rams mounted one above the other. When the rams are closed, hydraulic fluid is
pumped into the outer chamber of the cylinder assemblies, pushing the pistons (which are
connected to the rams) inwards. Oil from the inner chamber then returns to a reservoir.
Piston locks are provided as a back-up system. When the rams have been closed
hydraulically, the Lock Sleeves are manually screwed in to provide a piston lock facility for
additional safety. With the piston locks backing up the piston the BOP cannot be opened
hydraulically. To open the BOP, the piston locks must first be unscrewed. The rams remain
closed. Hydraulic pressure applied to the inner chambers will open the cylinder pushing the
piston connected to the rams. Hydraulic fluid in the outer chamber will be returned to the
reservoir.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
4.2.1 BOP Body

The BOP body is cast using aerospace techniques and is inspected by Radiography. The
body of the Elmar Lightweight Wireline Valve is manufactured from optimised alloy steel
and heat treated to meet NACE specifications covering H2S service
4.2.2 Hydraulic Cylinder Assembly

The hydraulic cylinders are considerably smaller than those on any other Wireline Valve
due to the balanced piston design. The piston has a passage to allow the well fluid to flow
to the back of the piston and into the end cap area, thus making the piston balanced. In
conventional wireline valve designs where the piston or stem are solid, the pressure from
the well creates a load on the piston or stem. This load has to be overcome by the hydraulic
actuators before the piston or stem can start moving. The force required from the
“Lightweight” hydraulic cylinders has to be sufficient to overcome seal friction and to
create an initial seal with ram elastomers only.

During closure of the Elmar Lightweight Wireline Valve, assuming the lock sleeve is not in
the protection position; the indicator rods can be seen moving as these are attached to the
piston. When the hydraulic cylinders are completely closed, the lock sleeves can be
threaded on to the end caps until the bearing washer comes into contact with the indicator
rods. This will ensure that the rams cannot be opened accidentally. If, in any case a
hydraulic failure occurs, the lock sleeve can be used to close the wireline valve. Position the
lock sleeve on the end cap so that the bearing washer comes into contact with the indicator
rods and turn the lock sleeve using the tool supplied. The panel valves must be opened to
allow free fluid flow. Due to the pressure balanced piston this should be relatively easy to
operate as friction of the seals is the only obstacle the piston has to overcome. In the case
of conventional wireline valve designs with solid pistons or stems it is very hard to close the
wireline valve manually as the work put in has to overcome the load created by well
pressure acting on the stem or piston.
As well as acting as a manual actuator and lock, the lock sleeve also prevents damage and
dirt ingress when in the protection position. Both functions of the lock sleeve can be
achieved by unthreading from the end cap, turning round the lock sleeve by 180º and
threading it back onto the end cap.
All cylinders have a vent hole located between the seal for well fluids and the seal for
cylinder hydraulics. The Lightweight Wireline Valve also has a vent on the end cap due to
the end cap being subjected to well pressure. The vent hole prevents gas and well fluids
from passing the ‘O’ ring seal on the stem of the hydraulic cylinder/end cap and
contaminating the hydraulic system. Any well fluids reaching the cylinder will have a dual
effect. Well fluid and pressure getting into the hydraulic system could migrate back to the
pump via the hydraulic hose. The pump and hose are not rated for high pressures and could
rupture. Gas getting into the hydraulic fluid could expand the fluid and cause the BOP to
open. High pressure well fluids could also cause the BOP to open.
The balanced nature of the piston design will lead to the presence of well fluid in the piston
and end cap and an associated risk of corrosion. The piston is protected from corrosion by
means of a TDC (Thin Dense Chromium) coating. During assembly the cavity at the back of
the end cap is also packed with grease to provide a further barrier against corrosion.
The cylinder has two positions for the ram guide rods, allowing the wireline valve to be
easily configured to invert the ram assemblies if required.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
WARNING
For maximum safety, the rams must be fully opened before attempting to remove the
cylinders from the BOP body.
The cylinders have recessed pockets to prevent the ram assemblies from dropping
unexpectedly upon removal.
The quick connect hydraulic couplers on the cylinder assembly are male and female to
prevent cross coupling of supply lines.
Figure 3 Location of Vent holes in the Cylinder Assembly
The 3” cylinders are CNC timed allowing any cylinder to be positioned in any valve body
cavity giving full flexibility in ram orientation. Once located in the BOP body the cylinders
are aligned using the captive alignment pins located in the BOP body.
The 4 1/16” cylinders are assembled with the correct orientation using a support clamp
which slides on support arms. An external lock ring on the cylinder body is screwed into
the BOP body whilst the cylinder is held in position. Once fully assembled an alignment pin
on the BOP body enters a groove on the cylinder to prevent any rotation and the support
clamp can be removed.
TFO-10006156/A3 MAN-10000527/F
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4.2.3 Manifold Arrangement

To manage the seal around the wireline a block style equalisation manifold is provided to
allow the pressure from below and above a closed BOP ram to be equalised. All equalising
valves in the manifold block have a metal to metal sealing arrangement with a replaceable
seat. In addition, the manifold also performs tasks involving the management of
pressurised fluid without the need for external pipework or valves and provides the
connections for grease injection between BOP rams for sealing in a cable and for
glycol/methanol injection or pressure testing. Provision is also made on the arrangement
for fitting a suitable pressure gauge (refer to spares and accessories).
All manifolds are engraved with schematics for easy operational understanding. In the
middle is a vertical line broken by circles which represent the well bore and rams
respectively. The remaining engraving represents the flow paths, equalizing valves and
check valves. Engraving on the right represents the manifold blocks on the front of the BOP
and vice versa.
Figure 4 Triple Wireline Valve Manifold Configuration
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Between the front and back manifolds the operator can carry out the following operations:
• read well bore pressures;
• bleed down lubricator risers;
• equalise across all ram assemblies;
• inject wireline grease between the rams;
• inject glycol between the rams.
The front manifold block assemblies have integral equalisation, grease and glycol injection
facilities. Each of the injection facilities are fitted with integral check valves. The rear upper
manifold assembly has pressure monitoring and lubricator bleed-off facilities. The rear
lower manifold assembly is a blank to plug off an existing port.
NOTE: A single configuration BOP has no grease or glycol injection points
It is assumed that a single BOP is purchased for slickline operations and the operator will
have the bleed off and pressure monitoring facility installed on one of the lubricator risers.
CAUTION
If using shear and seal rams in a Triple Lightweight Wireline Valve with the manifold
configured as standard these rams must be placed in the upper most ram bore so that
grease and glycol injection can be accomplished between the wireline rams.
If Shear and Seal rams are to be fitted to the lower cylinder bore the Manifold MUST be
reconfigured see Section 4.2.3.3.
The manifold assemblies on the front of the BOP must be arranged as described in the
following sections, depending on the location of the shear rams.
TFO-10006156/A3 MAN-10000527/F
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4.2.3.1 REAR MANIFOLD BLOCK

In all arrangements, the manifold assembly on the back of the BOP remains in the same
position
Figure 5: Rear Manifold Assembly
The rear manifold valves perform the following functions:

• Valve D - Controls communication to the gauge port.
• Valve E - Controls the bleed-off facility.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
4.2.3.2 Manifold Configuration for Shear Rams in the Upper Bore

Figure 3b shows the manifold configuration supplied as standard on Elmar 4” TLW BOPs;
This is the configuration required for wireline operations without shear rams (i.e. dual
barrier). When utilising shear rams in a TLW BOP with this manifold configuration the rams
must be configured as follows (as shown in Figure 6):
• Upper Rams – Non-inverted (shear)
• Middle Rams – Non-inverted
• Lower Rams – Inverted
Figure 6: Front Manifold Assemblies for use with Upper Shear Rams
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
The following diagrams show the connected pressure chambers between the closed rams
(black) when each of the valves A, B or C are opened individually.
• Yellow – Fluid from above the BOP.
• Blue – Fluid from manifold injection ports.
• Red – Fluid from below the BOP.
Figure 7: Fluid paths with the following valves open (from left to right): None, Valve A, Valve B, Valve C
In this configuration the main functions of the valves are as follows:

• Valve A - Controls communication between the upper cavity and above the upper
ram bore, allowing pressure equalisation across the upper/shear rams when open
and effecting a blind seal against well pressure when the valve and shear rams
are closed.
• Valve B - Controls communication between the lower cavity and the upper cavity
allowing pressure equalisation across the middle rams when the valve is open and
directing injected fluid below the middle ram when closed.
• Valve C - Can be opened to allow communication between the lower cavity and
below the lower ram bore.
• In order to affect a grease seal against well pressure in this configuration, Valves
B and C must both be closed to direct injected grease into the lower cavity
between the opposing middle and lower rams.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
4.2.3.3 Manifold Configuration for Shear Rams in the Lower Bore

Where the customer wishes to configure the TLW BOP with shear facility in the lower ram
bores (as shown in Figure 8), i.e.:
• Upper Rams – Non-inverted
• Middle Rams – Inverted
• Lower Rams – Non-inverted (shear)
The manifolds must be re-configured as per Figure 8 below:
Figure 8: Front Manifold Assemblies for use with Lower Shear Rams
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
The following diagrams show the connected pressure chambers between the closed rams
(black) when each of the valves A, B or C are opened individually.
• Yellow – Fluid from above the BOP.
• Blue – Fluid from manifold injection ports.
• Red – Fluid from below the BOP.
Figure 9: Fluid paths with the following valves open (from left to right): None, A, B, C
In this configuration the main functions of the valves are as follows:

• Valve A - Controls communication between the lower cavity and below the lower
ram bore, allowing pressure equalisation across the lower/shear rams when open
and effecting a blind seal against well pressure when the valve and shear rams
are closed.
• Valve B - Controls communication between the lower cavity and the upper cavity,
allowing pressure equalisation across the middle rams when the valve is open and
directing injected fluid above the middle ram when closed.
• Valve C - Controls communication between the upper cavity and above the upper
ram bore.
• In order to affect a grease seal against well pressure in this configuration, valves B
and C must both be closed to direct injected grease into the upper cavity
between the opposing middle and upper rams.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
4.3 BOP Adapter Assembly

The BOP Adapter assemblies are threaded quick unions allowing the use of any Elmar,
Bowen or Otis type quick union without changing the body. The body to quick union joints
have a metal-metal seal backed up by an O-ring.
Plastic thread protectors are supplied with the Elmar Lightweight quick union and steel
protectors are supplied with most other Bowen and Otis type connections.
4.4 BOP Ram Assembly

BOP rams are designed to seal the annular space around a wireline, shutting-off well
pressure to allow intervention in case of wireline damage or problems in maintaining a seal
at the grease head. The safety barrier is provided using one or more pairs of ram elements
which are brought together by hydraulic cylinders to close off the through bore and seal
around the wireline. When the BOP is closed and the pressure above the rams bled down,
the well pressure, acting behind the rams, assists in the actuation and helps to maintain a
positive seal. The Lock Sleeves can be used to lock the rams closed to prevent inadvertent
opening. In the closing stroke, the rams guide the wireline into a semi-circular groove in
the ram body to allow a fluid tight seal without damaging the line. The number of ram
assemblies required depends on the type of sealing function, the desired working pressure
of the wireline valve and the level of redundancy acceptable. The acceptable minimum
requirements are:
• If sealing round slickline, a minimum of one ram assembly is required to affect a
seal.
• If sealing round braided line, a minimum of two ram assemblies are required in
conjunction with a grease injection facility.
Figure 10: Electric Line (left) and Slick Line (right) Inner Seals
The sealing elements are made up of a rubber element sandwiched between two steel
plates, called an inner seal. This is embedded in the face of the ram body to provide the
seal around the cable. In the conventional design, braided or electric line rams have a
groove through the ram body and the inner seal sized close to the line diameter. A range
of rams and inner seals are available which are designed to be line size specific. Slickline
rams have a rectangular slot in the inner seal steel plates, and no groove in the rubber
element. Around the upper part of the ram body is an outer seal in the shape of a
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
horseshoe. The outer seal prevents well fluids from passing around the rams inside the
main BOP body. The inner and outer sealing elements join on the side of the ram body.
Guide rods for the rams are located in the cylinders to prevent the ram body from turning
and to ensure correct alignment. The use of guide rods provide the user with orientation
flexibility.
There are three common designs of ram in service:
1. Rams with standard guide plates which are fitted with separate guides (one located
on each ram) fixed to the ram body with countersunk screws.
Rams with integral guides where the guides form part of the ram body.
NOTE: In both types the guides are only located on one side of the ram body and the cable is
guided by the shaped part of the rams as they are being closed.
The Q-GUIDE™ style of ram has been developed by NOV Elmar to replace the
standard and integral guide style rams. The Q- GUIDE ™ is available for all sizes of BOP
wireline valves. Inner and outer seals used in the Q- GUIDE ™ are the same as used in
the standard and integral type ram bodies. The Q- GUIDE ™ ram provides a positive
alignment for the wireline. V-shaped flat guides on either side of the inner seal
restrict the wireline so that the section of line contacting the inner seal is always
centred and parallel to the BOP axis. The Q- GUIDE ™ has been designed to
accommodate eccentric set-ups. There are scenarios with the standard and integral
type rams where the wireline goes through the wireline BOP body at an angle and
can be trapped by the rams before falling in the cable groove.
NOTE: All Lightweight wireline valves will be supplied with Q-GUIDE™ style rams as standard.
See generic assembly drawing for relevant ram.
Figure 11: Q-GUIDE™ Ram
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
4.4.1 Constrictor™ Multiline Inner Seals

NOV Elmar has developed a universal, Constrictor™ Multiline Inner Seal where the line
groove in the ram body and the inner seal is sized for 5/16” line and the rubber seal is able
to expand and seal around any line up to 5/16” diameter at 15,000 PSI. The Constrictor™
Multiline Inner Seal allows switching between slickline, electric line and fishing operations
without changing rams.
NOV Elmar have also developed a Multiline seal that covers the larger wireline range from
5/16” to 15/32”. Contact your local NOV Elmar sales representative for further details.
Figure 12: Constrictor™ Multiline Inner Seal
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
5 SPECIFICATIONS & FEATURES
5.1 Specifications
The exact specification of each Lightweight Wireline Valve will vary depending on the
customer’s individual requirements. The following table gives details of the basic options
available:
Through Bore 3.00”
4.06”
Working 5,000 psi
5 Specifications & Features
Pressures 10,000 psi.

Service Standard
Sour Gas (H2S)
Ram Assemblies A line sized groove to suit the particular cable to be used.
A slickline specific profile allowing for multiple cable slickline operations.
Multiline Seals which cover a range of cable sizes with options for up to
15/32 wireline.
Manifold A standard Dual or Triple lightweight manifold facilitates equalisation,
pressure monitor, grease injection, glycol injection.
A single configuration BOP has no grease or glycol injection points
Upper and Lower All industry standard connections are available including NOV Elmar,
Connections Bowen, Otis and Flopetrol. Other connections can also be provided
including API flanges.
5.2 Standard Features

NOV Elmar Lightweight Wireline Valve assemblies have all the standard following features:
• All components are rated for H₂S service apart from end connections which
demand standard service steels.
• The BOP Sub Assembly is always rated to 10,000 psi and H₂S Service.
• Interchangeable Upper and Lower Adapter assemblies are used to change the
overall pressure and service rating.
• See Section 4 (Functional Description) for specific features that relate to each
sub-assembly.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
5.3 Design Standards

The NOV Elmar Lightweight Wireline Valve assemblies have been designed in accordance
with the following standards and given third party approval by Bureau Veritas:
• API 6A (Latest Edition)
• API 16A (Latest Edition)
• NACE MR 01 75 (Latest Edition) – for H₂S service only
• Norwegian Petroleum Directorate, the Facilities Regulations, Sept 2001
• SI 289, 1974
• SI 913, 1996
5 Specifications & Features

• SI 2306, 1998 – PUWER
Each Wireline Valve is designed to comply with the following requirements within API 6A:
• Pressure Rating (BODY ONLY) 10,000 psi WP / 15,000 psi TP
• Service Temperature Classes P, S, T, U & V (-29°C to 121°C)
• Manufacturing standards PSL 3
• Material Class EE-Sour Service
All wireline valves are supplied as standard with Nitrile elastomers for all sealing elements.
Other grades are available in seal kit form on request.
5.4 Operating Requirements

Each nominal size of wireline valve has slightly differing requirements in terms of the
hydraulic supply pressure and volumes. The volumes quoted are sufficient to close one
wireline valve. The flow rates quoted are sufficient to close one wireline valve within 30
seconds.
NOTE
The below volumes are sufficient to close a single ram BOP i.e. enough to operate 2
cylinders.
The quoted flow rate is that which is required to close a single ram BOP in 30 seconds.
WIRELINE VALVE in 3.00 4.06

Maximum Hydraulic Pressure psi 3,000 3,000
in3 16 42
Volume Close
(L) (0.26) (0.69)
in3 17 45.6
Volume Open
(L) (0.28) (0.75)
in3/min 35 85
Flow Rate
(L/min) (0.57) (1.40)
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
6 ASSEMBLY INSTRUCTIONS
WARNING
Please refer to Section 2 (Safety & EHSRs, p.6) for safety requirements. Ensure that all
personnel follow these requirements and wear appropriate PPE.
CAUTION
Only qualified personnel should be involved in assembly of the equipment.
6 Assembly Instructions
6.1 Recommended WPCE Tool List

• Clean work surface;
• Airline;
• Clean rags;
• Vice;
• O-ring pick;
• Grease brush;
• Plastic hammer;
• 3M Scotchbrite (Elmar Part No 893000);
• WD40 (Elmar Part No 881740 – 5 litres);
• Grease (Elmar Part No 881720);
• Anti-seize protective compound (Nickelslip)
Location Part Number
USA 8831028751
North America 8831028752
Middle East 8831028753
Far East 8831028754
Europe 8831028753
• PTFE thread tape (Elmar Part No 861900);

• Loctite 577 thread sealant (Elmar Part No 862200);
• Hydraulic Oil;
• Punch (appropriate size for collar make-up);
• Tool – SB Packing Removal (Elmar Part Number 971491);
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
• 12” adjustable spanner (pressure fittings/bottom sub);

• 7/64” Allen Key (piston/upper gland grub screw);
• 3/16” Allen Key (retaining nut grub screw);
• 3/4” socket set (lower gland);
• Valve Seat Locator Tool (Elmar Part Number 9701006772);
• Valve Seat Removal Tool (Elmar Part Number 981053);
6.2 Assembly Instructions

WARNING
This entire procedure and associated assembly drawings must be read and understood by all
personnel involved in the assembly before commencing work.
CAUTION
Ensure that all parts are thoroughly cleaned and free from damage or corrosion before
assembly.
6.2.1 O-ring Installation

CAUTION
Follow the points below to avoid damage to O-rings during installation
• Check all components are clean and free from damage and corrosion.
• Tape all threads over which the O-ring will pass. O-rings should never be passed
over unprotected sharp edges.
• Use an O-ring lubricant
• Double check O-ring to ensure correct size
• Avoid over stretching the O-ring
• Avoid twisting or rolling the O-ring
• Where only one back-up ring is used, it must be placed between the O-ring and
pressure facing surface (Fig 13).
BACK-UP RING O-RING
PRESSURE DIRECTION
PRESSURE FACE
Figure 13: Elastomer Assembly Example
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
6.2.2 BOP Adapters/Body
NOTE: Clean all parts thoroughly prior to assembly.

Inspect BOP body adapter connections, paying particular attention to the seal
surfaces and threads. If required apply WD40 and lightly smooth using Scotchbrite to
clean up surface.
Identify the BOP body orientation by checking the assembly drawing.
NOTE: Reference should be made to the manifold block mounting holes which will
indicate the correct orientation.
Identify the lower adapter and apply a coat of grease to the O-ring grooves.
Fit the appropriate seals into position on the lower adapter.

Apply grease to the lower adapter internal threads and the relevant BOP body
threads.
Apply grease to the standard collar threads.
Locate the standard collar over the lower adapter.
Fit the lower adapter onto the BOP body and tighten using a ‘C’-Spanner.
NOTE: For ease of assembly, it is suggested that the lower adapter and BOP body is
now mounted onto a test stump. Ensure the test stump is securely fastened to an
appropriate mounting table
Identify the upper adapter and apply a coat of grease to the O-ring groove.
Fit the appropriate O-ring into position on the upper adapter.
Apply grease to the upper adapter internal threads and the relevant BOP body
threads.
Fit the upper adapter onto the BOP body and tighten using a ‘C’-Spanner.
Figure 14: Bop Adapters fitted to the 3" TLW BOP Body
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
6.2.3 Manifold Block Assembly
NOTE: Clean all parts thoroughly before beginning assembly.

Apply grease to the valve seat and position on the end of the Valve Seat Locator Tool
9701006772.
NOTE: Use the grease to hold the seat onto the tool.
NOTE: Ensure the conical sealing face of the valve seat is facing the correct direction.
Locate the valve seat into the manifold block and using a hydraulic press, force the
valve seat into position
NOTE: The rear manifold dump valve does not have a removable seat.
Figure 15: Valve Seat shown in position
CAUTION
Once fitted in the factory the valve seat does not need removed. If for any reason the valve
seat gets damaged and requires replacing, it is suggested that the manifold be returned to
Elmar.
For reference only, the Valve Seat Removal Tool (Elmar Part No 981053).
NOTE: Check positions of the PTFE back-up rings (if applicable). Scarf cut at 45º the
PTFE back-up rings so that they can be assembled onto the valve stem.
Apply Nickelslip to the valve stem groove and fit the relevant O-ring and back-up ring.
Apply Nickelslip to the valve stem threads and screw into the manifold block using a
5/16” spanner.
Position the lock washer over the valve stem.
Apply Nickelslip to each PH screw and screw into the manifold using a small
screwdriver to secure the lock washer in place.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
Figure 16: Equalisation valve shown fitted in manifold (Elastomers not shown)
Repeat steps 3 to 6 for all equalisation valves.

For the 3” grease injection front manifold apply PTFE tape or Loctite 577 onto the
check valves. Locate check valves in the grease and glycol injection ports, ensuring
that the arrow head stamped on the check valve points into the bore of the manifold.
OR
For the 4 1/16” grease inject manifold the check valves are mounted inside swivel
elbows. Ensure the check valve opens inwards towards the bore of the manifold.
Assemble all O-rings and apply some grease to the sealing surfaces before fully
screwing into manifold block.
Apply PTFE tape and Loctite 577 to the Grease injection coupler then locate and
tighten onto the check valve (at the grease injection port).
Apply PTFE tape and Loctite 577 to the hex plug, then locate and tighten onto the
Grease injection coupler.
Apply PTFE tape and Loctite 577 to the hex adapter then locate and tighten onto the
check valve (at the glycol injection port).
Apply PTFE tape and Loctite 577 to the QC coupler, then locate and tighten onto the
hex adapter.
Turn the manifold block so that the O-ring grooves can be seen on the back of the
manifold and apply grease into the O-ring groove and then locate the relevant O-ring.
Using the same assembly instructions, assemble all other manifold blocks so that they
are ready to be mounted onto the BOP body.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
6.2.4 BOP Hydraulic Cylinders
NOTE: Clean all parts thoroughly before beginning assembly.

Apply grease to the O-ring grooves.
PTFE back-up rings so that they can collapse on assembly.
Fit all O-rings and back-up rings in the cylinder. Refer to the product specific assembly
drawing.
Apply a thin coating of grease to the piston O-ring groove and fit the relevant O-ring.
Coat the hydraulic cylinder bore and piston with hydraulic oil.
Insert the piston into the cylinder bore as square as possible.
Hammer down with a plastic hammer until the piston passes through the elastomers
in the hydraulic cylinders and the threads that the ram nut attaches to are accessible
at the other end of the cylinder.
Apply Nickelslip to the piston external threads and the ram nut internal threads.
Screw the ram nut onto the piston and secure firmly.
NOTE: Both the piston and the ram nut have flats machined on them to
accommodate spanners.
Grip the ram nut and the end of the piston with a spanner and tighten. Dress up any
marks left by these tools.
Apply Nickelslip to the grub screw.
Position the locking insert into the ram nut, then locate and fasten the grub screw
behind it using a 1/8” allen key until it bottoms out.
NOTE: The locking insert is manufactured from PTFE and is required to grip into the
piston threads to act as a locking device. DO NOT OVER TIGHTEN THE GRUB SCREW
Figure 17: Grub screw into the Ram Nut
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
Using a plastic hammer, knock the ram nut so that the piston travels back to the fully
open position and the ram nut bottoms out on the cylinder.
Stand the cylinder on its end so that you can see into the cylinder and position the
piston so that the indicator groove is in the thread area.
Apply a coat of hydraulic oil or thin grease to the indicators.
Locate the three indicators into the groove on the piston.
Hammer down the piston with a plastic hammer so that the indicators are located in
the piston seal area.
TIP: Positioning the piston so that the indicator groove is in the thread area will allow
the indicators to be located into the groove. Once the indicators are located, slightly
tap the piston so that indicators are then in the seal relief diameter. Once in this
position the cylinder should prevent the indicators from falling out of the groove
CAUTION
Do not move further in than necessary as this can lead to problems when assembling the end
cap to the cylinder
Figure 18: Indicators housed in the Piston seal area
Apply grease to all elastomer grooves on the end cap.

PTFE back-up rings so that they can collapse on assembly.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Fit all O-rings and back-up rings in the end cap. Refer to the product specific assembly
drawing..
Ensure the internal cavity at the back of the end cap is full of grease before assembly.
CAUTION
The end cap is subjected to well fluids and pressure. The internal bore and piston seal
diameters have a corrosion resistant coating, but it is advised that this area is properly
maintained.
Apply grease to the cylinder internal thread and the mating end cap external thread
and the slots on the end cap.
NOTE: There are nine holes machined in the end cap. Only three holes are machined
right through the end cap. Ensure these holes are the ones aligned with the indicators
Locate the end cap over the three indicators.
Using a plastic hammer, gently knock the end cap so that the piston passes the
elastomers in the end cap bore. Stop when the end cap threads touch the cylinder
threads.
Before screwing on the end cap, use a plastic hammer, and knock the ram nut so that
the piston is open again.
CAUTION
The piston has to be in the open position when screwing on the end cap to avoid excess
bending on the indicators.
TIP: For ease of assembly, position the cylinder into one of the cavities on the BOP
body
CAUTION
Do not grip the cylinder while screwing on the end cap as excessive deflection of the cylinder
may cause thread or seal bore damage.
Figure 19: Position of Piston before screwing in the End Cap
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
Locate the BOP Tool 974216 into the hole on the end cap and screw the end cap into
the cylinder.
TIP: Slightly tapping the end of the end cap with a plastic hammer while turning will
aid the thread start.
Apply a coat of grease onto the bearing washer and locate into the lock sleeve.
Locate the circlip into the lock sleeve to retain the bearing washer using a small
screwdriver.
Locate the O-ring onto the groove on the lock sleeve.
NOTE: The O-ring on the lock sleeve is for protection against dirt ingress and is used
as an anti-vibration lock during transportation. This O-ring is never subjected to
pressure.
Apply a coat of grease onto the internal thread of the lock sleeve and the external
thread of the end cap.
Locate the lock sleeve onto the end cap so that the bearing washer contacts the
indicators.
Locate the BOP Tool 974216 through the two holes on the lock sleeve and screw in
the lock sleeve so that the piston is being moved manually. Continue until full stroke
has been achieved.
Figure 20: Cylinder fully closed using the Lock Sleeve
TIP: If fitted remove the complete cylinder assembly from the BOP body at this point.
NOTE: Before positioning the guide rod into the cylinder ensure you are familiar with
the ram orientation (inverted or non-inverted).
Apply Nickelslip onto the guide rod thread and screw into the relevant hole in the
cylinder body using a 7/16” spanner.
With the piston in the fully closed position fill the closed chamber with hydraulic oil.
Apply PTFE tape or Loctite 577 onto the female QC coupler threads. Insert and tighten
into the cylinder CLOSED port.
Apply PTFE tape or Loctite 577 onto the male QC nipple threads. Insert and tighten
into the cylinder OPEN port.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Unthread the lock sleeve from the end cap and turn it around by 180º then thread it
back onto the end cap so that it is in the indicator protection position.
NOTE: The following steps apply to 4 1/16" Cylinders only:
Apply grease to inside of the lock ring and assemble over the cylinder body - ensure
the parallel grooves match up as shown in the assembly drawing. Secure in place
with retainer ring and button head screws. Check the lock ring is free to rotate
around the cylinder body.
Position the stainless-steel support clamp retainer and circlip as shown on the
assembly drawing.
Repeat steps 1 to 37 for each hydraulic cylinder.
Figure 21: Lock Sleeve in the protection position
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
6.2.5 Ram Assembly
OUTER SEAL
GUIDE SCREW
GUIDE PLATE
RAM BODY LH
SEAL INNER SEAL

RETAINER
SCREW
RAM BODY RH
OUTER SEAL OUTER SEAL
RAM BODY LH
RAM BODY LH
INNER SEAL
INNER SEAL
RAM BODY RH
RAM BODY RH
SEAL RETAINING SEAL RETAINING

SCREW SCREW
Figure 22: Standard (top), Q-GUIDE™ (left), and Integral (right) Ram Assemblies
1. Grease the ram body and install the outer seals. Ensure the seal is flush with the ram
body diameter. Tap into place using a plastic hammer to ensure a perfect fit. Take
great care not to damage the seal.
Fig 22: Outer Seal
2. Grease the inner seals and install in position in the ram body.
Nickelslip the inner seal retaining screws and insert into position. Tighten all four
screws equally. Check that the inner seal is still free to move.
Figure 23: Braided (left) and Slick Line (right) Inner Seal
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
For standard rams with guide plates only: Nickelslip the ram guide screws. Fit top
ram guides (one to each ram) and screw into place. Fit bottom ram guides and screw
into place.
Ensure that the hydraulic cylinders are fully closed so the stem can be accessed for
mounting the ram.
For installation of non-inverted rams, ensure that outer seals are positioned to seal
towards the top of the ram bore.
For inverted rams, rotate the body of the ram on the cylinder stems to ensure the
outer seals are positioned to seal towards the bottom of the ram bore.
Pump the hydraulic cylinders open so that the rams locate in the cylinder pockets.
NOTE: This orientation is likely to apply to a triple bop being used for braided line work.
Orientation of rams are job specific.
All ram assemblies should be non-inverted for slickline work. Lowest ram assembly
should be inverted for braided line work.
NOTE: Refer to Section 7.8 7.8 for ram removal procedure.
WARNING
As soon as an inverted ram body clears the cylinder pocket, it will fall off the stem.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
6.2.6 3.00” BOP Assembly

Figure 24: 3" TLW BOP Assembly exploded view
NOTE: The internals of the BOP body has a corrosion resistant coating. Do not remove
this coating with Scotchbrite.
1. Inspect body internals, paying particular attention to seal surfaces. Apply WD40 and
lightly smooth using Scotchbrite to clean up surface, if required.
NOTE: The alignment pin has to be located from the side shown
2. Grease the alignment pins and locate them into the bop body. (See Figure 25)
CAUTION
Do not grip the cylinder while screwing on the end cap as excessive deflection of the cylinder
may cause thread or seal bore damage.
NOTE: Check the orientation of the hydraulic cylinders to ensure that the rams are in
the correct position.
NOTE: Ensure that the cylinder is fully open and the ram is captive in the cylinder
pocket.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Figure 25: Alignment Pin location
3. Grease the rams, seals, cylinder thread, BOP body threads and cylinder bores.
4. Screw a ram /cylinder assembly to the BOP until it bottoms out.
5. Back off the cylinder until the groove lines up with the alignment pin. This does not
have to be exactly horizontal as the alignment pin will pull the cylinder in line when
locating.
6. Screw the alignment pin into the cylinder groove using the 3/8” allen key supplied
with the BOP tool 974216.
7. Repeat steps 1-6 for all of the cylinder assemblies.
NOTE: IMPORTANT MANIFOLD INSTRUCTIONS – Apply tightening torque 25-35 lbf-ft to
all SHC screws. Failure to do so may result in a leak at the manifold.
8. Blow out manifold block ports and threaded mounting holes with an airline to ensure
they are free of debris.
9. Apply grease to the BOP body and manifold block mating faces.
10. Nickelslip the SHC screws that are used to mount the manifold block.
11. Locate the manifold block into position and screw home the SHC screws to secure.
12. Repeat steps 8 to 11 to mount the other manifold assemblies to the BOP body.
13. The BOP can now be removed from the stump that was being used for assembly
purposes.
WARNING
When lifting the BOP ensure the appropriate lifting equipment is being used (See Section 8
for accessories).
14. Position the assembled BOP onto a wooden pallet taking care not to damage any of
the manifold blocks or threads when lying down the assembly.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
6.2.7 4.06” BOP Assembly

Figure 26: 4 1/16"TLW BOP Assembly exploded view
NOTE: The internals of the BOP body has a corrosion resistant coating. Do not to
remove this coating with Scotchbrite.
Inspect body internals, paying particular attention to seal surfaces. If required apply
WD 40 and lightly smooth using Scotchbrite to clean the surface.
Ensure Alignment Pin (Stainless Steel cap screw) is fixed in place. (See Figure 27)
NOTE: Check the orientation of the hydraulic cylinders to ensure that the rams are in
the correct position.
NOTE: Ensure that the cylinder is fully open and the ram is captive in the cylinder
pocket.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Figure 27: Alignment Pin location
3. Grease the rams, seals, lockring thread, BOP body threads and cylinder bores.
Attach the support bracket assembly onto cylinder and position on support arms.
Slide cylinder assembly in until the lockring thread contacts the BOP body.
Screw in lockring (using tool 974216) until it bottoms out.
Remove support bracket and repeat steps 1-6 for all of the cylinder assemblies.
NOTE: IMPORTANT MANIFOLD INSTRUCTIONS – Apply tightening torque 25-35 lbf-ft to
all SHC screws. Failure to do so may result in a leak at the manifold.
Blow out manifold block ports and threaded mounting holes with an airline to ensure
they are free of debris.
Apply grease to the BOP body and manifold block mating faces.
Nickelslip the SHC screws that are used to mount the manifold block.
Locate the manifold block into position and screw home the SHC screws to secure.
Repeat steps 8 to 11 to mount the other manifold assemblies to the BOP body.
The BOP can now be removed from the stump that was being used for assembly
purposes.
WARNING
When lifting the BOP ensure the appropriate lifting equipment is being used (See Section 8
for accessories).
Position the assembled BOP onto a wooden pallet taking care not to damage any of
the manifold blocks or threads when lying down the assembly.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
6.2.8 Protection Cage

Refer to the Operation and Maintenance Manual MAN-0026.
When rigging up the BOP Assembly onto the well, ensure the injection, and dump hoses
are supported from the manifold using the support bars supplied on the cage to prevent
any unnecessary stress on the hose connections
Figure 28: BOP with hoses rigged up
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
7 OPERATION
WARNING
Please refer to Section 2 (Safety & EHSRs) for safety requirements. Ensure that all personnel
follow the requirements and wear appropriate PPE.
CAUTION
Ensure all equipment has been fully serviced before commencing operation. Do not assume
serviceable equipment on the last job will be serviceable again. Refer to Section 8
(Maintenance & Testing) for more details.
7 Operation
WARNING
All instructions in this section assume no Shear rams are fitted and Rams and Manifolds
configured as per section 4.2.3.2. Refer to Figures 5 and 6 for Valve identification.
If BOP is fitted with shear rams consult Section 4.2.3 and adjust the following steps
accordingly.
7.1 Fundamental Rules for WPCE Equipment

The following fundamental rules apply to all operations with WPCE Equipment.
• All equipment used for pressure control operations must be pressure rated to a
defined Working Pressure (WP) and a Test Pressure (TP). For high temperature
applications, a Temperature Rating must also be defined.
• Pressure control equipment shall never be used above its WP rating, or outside of
its temperature rating.
• In a string of WPCE equipment, the WP of the weakest component gives the
string overall pressure rating.
• All WPCE components holding pressure must have valid certification.
• All WPCE components holding pressure must have a quality file.
• All WPCE equipment used on the wellsite is qualified for its use by passing an
annual hydrostatic body test and an operational check at WP.
• A wellsite pressure test must be carried out after set-up and before opening the
well on each job. The Maximum Allowable Working Pressure during the job
should equal the minimum wellsite test pressure.
• All crews operating WPCE equipment must be qualified to carry out pressure
operations.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
7.2 Normal Operation

Observe all safety considerations (Refer to Section 1 for general safety information) and
site rules.
Before operation of the wireline valves refer to Section 8, Maintenance and Testing to
ensure the equipment has been fully serviced and the necessary ‘Pre-job Checks’ have been
carried out. Do not assume that serviceable equipment on the last job will remain
serviceable.
During normal well site operation it is best practice to have all block manifold valves closed.
Each of the following procedures assume this is the case.
Each equalisation valve consists of a stem, seat and elastomer seals. The seat does not get
removed once fitted. The stem has a male hex drive which is operated by a spanner.
Rotating the stem clockwise closes the valve. ANTI-CLOCKWISE opens the valve. Care
should be taken not to over tighten the stem, as too much torque will reduce the seat life
and round the stem flats. Only enough torque should be applied to generate a seal.
7 Operation
Connect a suitable dump hose to the dump port and lead off to an area well away from
personnel.
WARNING
Ensure hose the end is tied down and terminates in a ”T”. Consider topography and weather
conditions such as wind direction etc
A pressure gauge manifold rated to the appropriate pressure should be attached to the
rear manifold block for pressure monitoring (Refer to Section 8 for spares and accessories).
7.3 Sealing on Braided Line

The ram face effectively seals around the outer surface of a wire line by displacement of an
elastomer which flows into the crevices of the outer strands. To counteract fluid or gas
leakage, through the inner and outer strands of braided cable, grease needs to be injected
at a higher pressure than the well so that both sets of rams make a positive seal. This is
particularly relevant if the line is new, small openings can allow substantial leakage which
can often be observed as gas/fluids spraying out of the line above the sealed rams.
If the requirement arises to close the BOP around the cable, then grease injection should
be used to pack off the cable and create a reliable seal. At high pressures it may take some
time for a seal to stabilise.
CAUTION
Unseasoned or new cable is particularly difficult to obtain a reliable grease seal with and
every care should be taken to avoid using the equipment to seal on new or clean cable.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
7.4 Injecting Grease

NOTE: Refer to Elmar Grease and Hydraulic Control Module operating procedures.
Ensure all valves are closed on the manifold blocks.
CAUTION
Rotating the stem clockwise closes the valve, while anti-clockwise opens the valve. Care
should be taken not to over-tighten the stem, as too much torque will reduce the seat life
and round the stem flats. Only enough torque should be applied to generate a seal.
Close the lower most set of rams (inverted) from the module control panel. Leave
the hydraulic pump on the Hydraulic Control Module stalled against the BOP close
function.
Begin to inject grease at approximately 1.2 times the well pressure above the lower
7 Operation
set of rams through the grease injection connection on the manifold.
Whilst continuing to inject grease, close the upper most set of rams from the control
panel. Leave the hydraulic pump on the Hydraulic Control Module stalled against the
BOP close function.
Screw in lock sleeves to provide safety back-up on both sets of rams.
A suitable hose should already be connected to the dump port and lead off to an area
well away from personnel.
WARNING
Ensure the hose end is tied down and terminates in a”T”. Consider topography and weather
conditions such as wind direction etc
When the grease injection rate has stabilised/stopped then the lubricators can be
bled down.
CAUTION
If using shear and seal rams on a Triple Wireline Valve, the operator MUST be aware of the
orientation and position of each set of rams and ensure the correct manifold configuration
is in place. Ref Section 4.2.3
NOTE: In a Triple Wireline Valve the middle set of rams are only used in case of failure
to the upper most set of rams. In normal operations, the upper most and lower most
rams are closed and grease injected between the two. In case of failure of the upper
most rams to hold a seal, the middle ones can be closed, and the upper most set
serviced after ensuring that a seal has been achieved with the middle set.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
7.5 Bleeding Down Lubricators
WARNING
The following steps assume no Shear rams are fitted and Rams and Manifolds configured
as per section 4.2.3.2. Refer to Figures 5 and 6 for Valve identification.
If BOP is fitted with shear rams consult Section 4.2.3 and adjust the following steps
accordingly.
Ensure valve B is closed.

A suitable hose should already be connected to the dump port and lead off to an area
well away from personnel.
When ready to bleed off pressure, slowly open valve A.
7 Operation
WARNING
Risk of high pressure and high velocity poisonous gasses and fluids.
CAUTION
If there is high pressure gas, the valves should be closed slowly, and the flow choked to
avoid freezing.
WARNING
If freezing does occur and the gauge is reading ‘0’ there may still be pressure in the
lubricators due to the formation of hydrates.
Monitor lubricator pressure using the pressure gauge manifold connected to the rear
manifold.
WARNING
Before disconnecting any wellhead equipment quick unions ensure that all residual
pressure, which may be trapped inside the WPCE string, is fully bled off. A sure sign of
trapped pressure is an unusually tight connection or a stiff hose.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
7.6 Equalising Pressure Prior to Opening Rams
WARNING
If BOP is fitted with shear rams consult Section 4.2.3 and adjust accordingly.
Ensure fit for purpose equipment is attached above the BOP.

Remove the lock sleeves from both upper and lower sets of rams.
Start injecting grease at the grease injection head (if applicable).
Stop injecting grease between rams (if applicable).
Ensure valve A is closed.
Slowly open valve D to allow pressure to equalise across the lower set of rams.
7 Operation
Slowly open valve C to allow pressure to equalise across the middle set of rams,
monitoring the well pressure rise on the pressure gauge manifold.
When well pressure is reached open all ram assemblies.
7.7 Injecting Glycol/Methanol

Under certain conditions hydrates may form at the BOP. Hydrates usually form when water
is produced with the gas. Glycol is used to prevent the formation of hydrates. Methanol is
used when hydrates have already formed. To combat this glycol or methanol may be
injected through the manifold to ease the situation.
WARNING
If BOP is fitted with shear rams consult Section 4.2.3 and adjust accordingly.
Close all the equalisation valves A, B, C & D.

To inject glycol (or methanol) to all three rams:
(a)Open valves C & D;
(b)Inject glycol through the injection port;
(c)When finished close valves C & D.
To inject glycol (or methanol) between the middle and upper set of rams:
(a)Open valve C;
(b) Inject glycol through the injection port;
(c)When finished close valve C.
To inject glycol (or methanol) between the middle and lower set of rams:
(a)Inject glycol through the injection port with all equalisation
valves closed.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
7.8 Ram Removal Procedure

Ensure BOP is free of pressure and drained of any test fluid.
Apply hydraulic pressure to open rams fully.
Unscrew the hydraulic cylinder from the BOP body using an appropriately sized punch
to back off the lock ring.
CAUTION
The Circlip to the outside of the lock ring should not be removed.
TIP
Due to a combination of the tight fit of the rams in the BOP bores and the weight of these
cylinder assemblies, these do take reasonable effort to back off due to high friction
7 Operation
between threads as they attempt to pull the rams through the bore. There are two ways of
assisting the removal of these cylinders:
1. Use a longer/extended punch to apply greater force when unscrewing the lock rings.
2. If when applying method 1 it is found that excessive effort is required, functioning the
rams a minimal amount in the close direction will relieve the pressure between the
two mating threads allowing them to spin off with relative ease.
Once the lock ring is completely disengaged from the BOP body, it is essential that
you return the rams to the fully open position.
Ensure all hydraulic pressure has been dumped and disconnect the hydraulic hoses
at the QC Couplings.
The cylinder assembly can now be pulled back fully on the support arms.
NOTE
This will not apply to 3” BOPs as these are not fitted with support arms.
7.8.1 Ram Redress with BOP Upright
7.8.1.1 Non-Inverted Rams

Reattach the hydraulic fittings and pump the rams to the fully closed positions.
The rams can now be lifted clear of the stems
NOTE
For larger BOPs, lifting equipment should be used for this operation.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
7.8.1.2 Inverted Rams

Secure rams using lifting equipment.
Reattach the hydraulic fittings and pump the rams to the fully closed position.
WARNING
As soon as an inverted ram body clears the cylinder pocket, may fall clear from the stem.
7.8.2 Ram Redress with BOP Lying Flat (Non-Preferred)

Reattach the hydraulic fittings and pump the rams to the fully closed position.
Secure rams using lifting equipment.
7 Operation
The rams can now slide off the stems.
NOTE
The rams will now need to tip sideways once clear of the stem before being lifted clear.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
8 MAINTENANCE & TESTING
WARNING
Refer to Section 2 (Safety & EHSRs) for safety information before carrying out any
maintenance and testing routines.
WARNING
The BOP assembly is heavy; check that the lifting equipment can support this load. Never
position yourself under the suspended load.
8 Maintenance & Testing
CAUTION
Refer to build specific assembly drawings for equipment details, e.g. seal kit part numbers
and service details.
CAUTION
Equipment needs to be maintained properly to perform as designed.
8.1 Introduction
Only qualified and trained personnel should perform maintenance on Elmar units. The
maintenance procedures described here include:
• Scheduled periodic (preventive); (e.g. cleaning, inspecting and testing
components, filling fluid levels and lubricating moving parts)
• Corrective (troubleshooting and repairing any malfunctions, plus
calibrating/adjusting)
• Exchanging parts (according to operational requirements)
The assembly can experience extreme forces and rugged conditions, so scheduled
maintenance is regularly required to prevent equipment damage and potential hazards.
Inspections and tests should be carried out daily before working with the assembly, but
regular maintenance must be performed. See Section 8.4 for full details of routine
maintenance.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
8.2 Certified assemblies

Your WPCE may include assemblies which are certified. These assemblies may only be
serviced by competent personnel, otherwise the certification (and possibly the warranty)
for the assembly becomes invalid. A certified assembly is identified by its own data plate
with serial number and is listed as a single top-level part number in the drawings and spare
parts lists. If a fault is detected in a certified assembly, do not attempt a repair yourself, but
always contact NOV Elmar for advice (see Contact Us in the appendices).
8.3 Maintenance schedules

All WPCE should be surveyed at regular intervals and at least once per year. An annual
survey usually consists of a visual inspection with dimensional checks for ovality of tubulars
and threads. For all jobs over 5,000 psi, the hydrostatic body test and operational test
should not be older than 3 months. A verification procedure should also be carried out after

every job where the WPCE has been subjected to extraordinary conditions, such as rough
handling, bending, accidental drops, corrosive fluids, unexpected H₂S or CO₂ during
standard service, or replacement of major parts.
All surveys and tests should be recorded in the equipment service record.
8.4 Routine Maintenance
8.4.1 Before Every Job

• Check the equipment maintenance record sheet to ensure the equipment has
been maintained by competent personnel.
• Check all threads, seals, and sealing surfaces for damage that might impair
sealing. Repair or replace as necessary.
• All grease injection and hydraulic hoses shall be unreeled and carefully inspected
for damage over their entire length.
• Open and close each set of rams using the hydraulic function. While rams are
closed, apply the manual locks to ensure that they traverse the full distance
required. The locks must then be fully opened to permit the rams to fully open.
• Carry out test procedure to working pressure.
• Verify that well site test pressure does not exceed the working pressure rating of
that of the equipment.
• Pressure test the complete hook-up.
• Close all equalising valves on the manifold block.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
8.4.2 After Every Job
CAUTION
Fully dismantling and cleaning all parts that have been exposed to well fluids and debris
will extend the life of the product. The time between the end of the job and maintenance is
when the equipment is most at risk from corrosion.
CAUTION
Avoid steam cleaning any internal bores that have corrosion resistant coatings. Grease the
internal bores using a cloth/swab.
These coatings are sacrificial and may need re-applied periodically.
• Remove the cylinder assemblies from the BOP and clean the BOP thoroughly to
remove any residual well deposits.
CAUTION
If the job contained any of the following then it is advisable to strip the cylinder and
manifold assemblies, replacing all seals which are exposed to well pressure;
• Extended Exposure to well fluids (>48 hours)
• H2S
• High pressure gas
• Function each cylinder assembly until it is fully extended and remove the ram
assemblies. Thoroughly clean the cylinder ram pocket.
• Remove all well pressure seals from the ram assemblies, upper & lower BOP
connections (if fitted with Quick Union Connections) and cylinder/BOP body
connection pin.
• Inspect all threads for damage and wear.
• Inspect all seals and sealing surfaces, replacing any damaged seals and back-ups.
CAUTION
Normal wear on inner seals will be a moderate amount of extrusion downstream of the
pressurised side. When usage has resulted in any noticeable loss of rubber or the bond
between the metal and rubber is separating – REPLACE THE SEALS
• Apply corrosion inhibitor to the cylinder ram pockets. Ensure that the piston is
retracted fully into the hydraulic cylinder before application.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Figure 29: Cylinder Ram Pocket

WARNING
Corrosion inhibitor spray (part number 883050) or any anti-seize compound should not be
used in any sealing areas or within hydraulic chambers. Black grease (part number 882200)
should be used instead.
• Ensure all manifold valves are in the fully open position. Pump grease into the
manifold blocks until clean grease can be seen exiting through the hole in the
main through bore.
• Reassemble the BOP as per the assembly procedure in Section 6, being careful
not to damage any of the seals and ensuring that all sealing areas are free from
contaminants and have been suitably greased.
CAUTION
Check that the rams and seals are suitable for the intended wireline.
• Insert the grease nipple supplied with the BOP assembly into the port on the
cylinder assembly shown in the image overleaf. Inject grease until clean grease is
seen exiting around the stem.
• Check the operation of the piston locks
CAUTION
The piston locks must be fully backed off to permit the rams to fully open.
• Function test the cylinders by opening and closing the rams.

• Carry out a working pressure test to inspect the integrity of the seals and check
for leaks (see Section 8.6). During the pressure test, complete function tests of
the hydraulic cylinders & manifold block.
• Complete a maintenance record sheet and affix dated chart.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
8.5 Major Maintenance

Renewal of certification requires a detailed survey and performance verification carried out
under the control of a certification agency. The need and frequency of such certification
renewal shall be determined by local regulations, (typically every five years). All WPCE
pressure containing equipment should undergo a major re-certification every five years
based on the following general procedures:
• Visual inspection.
• Random thickness tests on risers, BOP, tool trap, ball check valve, tool catcher,
and general bodies using direct measurements, ultrasonic, or X-ray. Refer to
Elmar Technical Bulletin TB-735 for the procedure for finding minimum
acceptable wall thickness on pressure control equipment.
• Dye penetration or MPI examination on threads or any damaged area determined

at visual inspection.
• Hydrostatic body test to Test Pressure.
• Function tests at Working Pressure.
• Review of Quality Files.
CAUTION
All WPCE having undergone three 5-year major re-certifications should be retired before
the fourth re-certification is due.
8.5.1 To Be Carried Out Once a Year

1. Ensure all relevant routine maintenance has been performed and is up to date.
2. Replace all O-rings, inspecting all components and sealing surfaces for corrosion or
damage along the way. Pay particular attention to the surfaces below the rams.
3. Rebuild BOP using seal kits and pressure test to Test Pressure.
4. Function test at Working Pressure.
5. Complete maintenance record sheet and affix dated chart.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
8.5.2 To Be Carried Out Every 5 Years

1. Carry out a complete disassembly of all components.
2. Remove all O-rings.
3. Inspect all components and sealing surfaces for corrosion and damage.
4. Magnetic Particle Inspection (MPI) of all parts.
5. Re-coat wetted areas if required.
6. Rebuild BOP using seal kits and any necessary new parts.
7. Pressure test to the required Test Pressure.
8. Function test at Working Pressure.

9. Third party certificate of final test and inspection, certificate of conformity, and lifting
certification (BOP Cage).
10. Complete maintenance record sheet and affix dated chart.
8.6 Testing
The pressure rating of any item is expressed in pounds per square inch (psi) and it is shown
as a test pressure (TP) rating and a working pressure (WP) rating.
Every item of pressure control equipment has a pressure rating, and care must be taken to
ensure that no item is used in a situation that might cause its working pressure to be
exceeded. Although the test pressure rating is always higher than the working pressure
rating, the difference between the two must never be considered as a safety margin. This
is because the actual use of the equipment under field conditions involves forces that result
from both well pressure and mechanical stress. For this reason, all pressure control
equipment must be handled and secured in such a way that the external stresses are kept
to an absolute minimum.
The overall WP rating of the assembled equipment shall be equal to the rating of the
weakest component. All components used shall have a valid dated test record; including a
hydrostatic body test to TP. Equipment lacking a current test record should not be used.
The well site TP should never exceed the equipment WP rating.
The wellsite TP shall be 1.2 times maximum potential wellhead pressure (MPWHP). If no
wellhead pressure is expected, the equipment shall be tested at 25% of its WP rating. All
wellsite pressure testing, and the pressure test values obtained should be noted on the
equipment service report. The use of a pressure recorder (chart or film) is recommended
during wellsite pressure testing.
All adapters, flanges etc., should be tested. It is recommended to test as much of the
equipment as possible whilst assembled together. Valves must be in the partially open
position during the body test. Test plugs with a pressure rating equal to or higher than the
equipment that is being tested shall be used to cap open ended components.
Adequate warning signs should be displayed, and all unnecessary personnel cleared from
the pressure testing location during the pressure test.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
WARNING
Trapped air requires considerable time to compress and when it is compressed is highly
dangerous. It has enough energy to separate parts with considerable force.
Always ensure air is completely bled from the system prior to pressure testing.
WARNING
Clear the area of all unnecessary personnel and ensure procedures are in place to prevent
access to all unauthorised personnel during testing. Pressure testing should only be
performed by competent personnel.
CAUTION
No leakage is acceptable in any of the following test procedures unless stated otherwise. In
the event of a leak, appropriate maintenance action should be taken. See Section 9
(TROUBLESHOOTING) for more information.
8.6.1 Body Pressure Test Procedure

1. Locate the test plug and test cap onto their appropriate ends.
2. Bleed off all air within the assembly.
3. Ensure all external surfaces are dry.
4. Pressure test to Test Pressure for 3 minutes.
5. Reduce pressure to zero and repeat test for 15 minutes minimum.
No leakage acceptable
CAUTION
No leakage acceptable.
8.6.2 BOP Manifold Test Procedure

Refer to relevant manifold assembly drawing for test procedure.
8.6.3 BOP Ram Test Procedure

If a test is conducted to the full test pressure, the rams should be open to prevent any
unnecessary damage to the ram seal. Testing with the rams closed should not be conducted
above the rated working pressure of the BOP. It is advisable to close the rams on a solid
test rod of the correct size rather than using a braided line. When closing on a braided line
the seal extrudes into the voids between the armour wires. Not all the deformation in the
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
rubber is reversible and the rams will lose the ability to seal on a different section of the
line. In any case, new cables will often leak due to fluid passing between the inner and outer
armour strands and give the impression that the rams are not sealing properly.
Elmar designed test rods should be ordered to match the maximum line size for which the
ram seals are dressed. The table below shows the relevant part numbers.
TEST ROD ASSEMBLY
PART NUMBER LINE SIZE (ROD DIAMETER) TEST LOAD (KG)
974956 3/16” 500
973440 7/32” 500
9701006370 1/4” 650

980551 9/32” 1000
974957 5/16” 1000
9701049696 11/32” 500
972775 3/8” 1000
973114 .390” 1000
974959 7/16” 1000
974958 15/32” 1000
981256 1/2” 1000
WARNING
Only Elmar designed test rods are suitable for testing. BOP Test Rods should not be made
locally.
Test rods should be inspected regularly and re-tested to test load annually.
CAUTION
The ram seals are limited by API specification to working pressure only.
When testing the shear and seal rams, DO NOT use a test rod as these can damage the
shear blades and reduce effectiveness and lifespan.
8.6.3.1 Ram Function Test Procedure

1. Assemble BOP complete with test plug and stump.
2. Connect appropriately rated gauge to manifold assembly.
3. Open all manifold valves.
4. Bleed off air via the test plug and pressure to Working Pressure through the test
stump, observe each set of rams closing and opening fully, bleed to zero through test
stump.
TFO-10006156/A3 MAN-10000527/F
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5. Close all manifold valves.

6. Remove test plug.
8.6.3.2 Shear/Seal Ram Test Procedure

1. If fitted, close shear/seal rams.
2. Pressure to Working Pressure through the test stump, hold for 3 minutes minimum,
bleed to zero.
3. Pressure to Working Pressure through the test stump, hold for 15 minutes minimum,
bleed to zero.
4. Pressure to 300 psi through the test stump, hold for 3 minutes minimum, bleed to
zero.
5. Open shear/seal rams and disconnect hydraulic supply to ensure that the ram is
omitted from further testing.
NOTE
For correct method of fitting shear blades and carrying out shear tests refer to TB-
10006406
8.6.3.3 Ram Sealing Test Procedures

1. Identify the correct configuration of rams.
2. Insert the correct test rod for each test.
3. Ensure all rams are open except those indicated.
4. Ensure the lower tab of the test rod has been pulled up hard against the lowest ram
being tested
5. Ensure all manifold valves are closed except those indicated.
6. Pressure to Working Pressure, hold for 3 minutes minimum, bleed to zero.
7. Pressure to Working Pressure, hold for 15 minutes minimum, bleed to zero.
8. Pressure to 300 psi, hold for 3 minutes minimum, bleed to zero.
9. Repeat steps 3-8 as required until all rams have been tested.
WARNING
If the welded tab on the base of the test rod is not positioned closely against the underside
of the lowest closed ram, the rod may slip during testing (see Figure 30, p.61).
At worst, this can cause the entire rod to be rapidly and violently ejected from the top of
the BOP, potentially causing damage to seals, facilities and personnel.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP

Figure 30: Test rod shown positioned correctly
WARNING
If pressure testing through any of the grease or glycol injection lines, bleed off pressure
using the equalisation valves. The check valves in the injection line will prevent pressure
from bleeding off within the BOP when pressure is dumped through the control module.
If bleeding off using the equalisation valves, it is recommended that pressure be directed
into fluid filled cavities – i.e. below the rams and through the test stump.
WARNING
Use of shear rams and standard ram orientation is entirely at the discretion of the end user.
For configurations not shown, testing shall be carried out to ensure that all rams have been
tested against Working Pressure as described in Section 8.6 whilst maintaining
communication to the gauge.
WARNING
When testing shear rams do not insert a test rod
In the following diagrams a shear ram can be considered in the same way as a non-inverted
ram.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
8.6.3.3.1 SLW Configurations

Figure 31: Valve labels for SLW manifold assemblies
SETUP TEST NUMBER CLOSED RAMS PRESSURE THROUGH
1 Single ram Test Stump
MAN-10000527/F TFO-10006156/A3
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8.6.3.3.2 DLW Configurations

Figure 32: Valve and injection port labels for DLW manifold assemblies
1 Upper Test Stump
2 Lower Test Stump
Upper
1 & Manifold Injection Port
Lower (inverted)
TFO-10006156/A3 MAN-10000527/F
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8.6.3.3.3 TLW Configurations (Including Shear Rams fitted in top ram)

Figure 33: Valve and injection port labels for TLW manifold assemblies
1 Upper Test Stump
2 Middle Test Stump
3 Lower Test Stump
1 Upper Test Stump
Middle
Lower (inverted)
MAN-10000527/F TFO-10006156/A3
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8.6.3.3.4 TLW Configurations (Including Shear Rams fitted in bottom ram)

Figure 34: Valve and injection port labels for TLW manifold assemblies
1 Upper Test Stump
2 Middle Test Stump
3 Lower Test Stump

Upper
Middle
2 Lower (inverted) Test Stump
TFO-10006156/A3 MAN-10000527/F
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8.7 Finalise maintenance tasks

This procedure should be performed at the end of each maintenance session (a
maintenance session consisting of one or more maintenance procedures).
1. Remove all tools and materials from the work area.
Make sure the unit and the work area around the unit is left in a safe state as
described in Section 2
Dispose of used materials/liquids according to local environmental regulations.
WARNING
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
Report any unit damage or discrepancies.
8.8 Maintenance Record Sheet

To ensure equipment operates at the designed effectiveness throughout its lifespan,
proper maintenance must be performed at all recommended intervals detailed in this
Section. To ensure this maintenance is carried out, Elmar recommends keeping a
maintenance record sheet of all work done on the equipment. As companies may have
their own procedures in place for recording maintenance, there is a simple maintenance
record sheet included in the Appendix 1 that can be used as a guide for the information
required.
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
9 TROUBLESHOOTING
9.1 Troubleshooting Principles

This section offers information for troubleshooting various problems encountered while
operating the equipment.
If you encounter a problem that is not covered here or cannot be corrected by the
suggested remedy, please contact Elmar for technical guidance. Support contact
information is provided in the appendices to this manual. We are always grateful for
customer feedback.
9.2 Troubleshooting table
9 Troubleshooting
PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY
Leakage at the (a) Damage to the O-Rings (a) Replace faulty parts.
connections: and/or seal surfaces
(a) Manifold Valves open. (a) Review and close the

required valves.
(b) Test rod diameter (b) Check.
incorrect.
(c) Rams not dressed for the (c) Check.
correct cable size.
(d) Ram orientation not (d) All ram assemblies should be
correct for pressure direction.
non-inverted for slickline work.
middle or lower ram assembly should
be inverted for braided line work.
(e) Inner/Outer seals are in (e) Check and replace.
Cannot achieve a seal on a poor
test rod condition.
(f) Rams do not close. (f) Check for sufficient hydraulic
supply.
Seals on hydraulic cylinder piston
damaged or worn allowing
bypass.
Rams obstructed.
Check the hoses are connected
properly. If the hydraulic hoses
are reversed, the rams will
operate in reverse.
TFO-10006156/A3 MAN-10000527/F
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PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY
(a) Valve open. (a) Turn clockwise to close.
(b) Seals/damaged or missing (b) Inspect and replace as necessary.

Equalisation valve does not on the valve stem.
seal or leaks.
(c) Metal surface (c) Inspect and replace as necessary.
damaged/corroded on stem or Return to Elmar if the valve seat is the
seat problem,
(a) Seals/damaged or missing (a) Inspect and replace as necessary.
Injection check valves do on the valve stem.
not seal or leaks: (b) Metal surface (b) Inspect and replace as necessary.
damaged/corroded on valve.
9 Troubleshooting
(a) Seals damaged/missing. (a) Inspect and replace as necessary.

Manifold leaks between the
BOP body and the block: (b) Manifold SHC screws are (b) Tighten to the required torque
not tight enough. (Refer to section 6.2.5)
(a) Valves closed. (a) Review and correct as necessary.
(b) Manifold hydrated or

Cannot equalize across BOP: (b) Inject glyco/methanol into the
plugged.
manifold until solved.
NOTE: Do not exceed BOP max.
working pressure.
Well fluids leaking out of vent (a) Piston stem seal (a) Inspect and replace as necessary.
hole in cylinder or end cap: damaged/missing.
Hydraulic fluids leaking out of (a) Piston stem seal (a) Inspect and replace as necessary.
vent hole in cylinder or damaged/missing.
endcap:
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
10 TRANSPORTATION, SPARES, ACCESSORIES &

DISPOSAL
10.1 Storage
Before storing any BOP assembly for an extended period, Routine Maintenance should be
carried out as per Section 8.5.2.
10 Transportation, Spares, Accessories & Disposal

In addition to the steps followed in Section 8.5.2. where possible flooding the BOP bore
with oil or corrosion inhibitor post cleaning will help prevent corrosion. If this option is
taken the BOP should be flooded and each set of rams cycled closed/open to ensure the
areas behind the rams are coated as far as reasonably practicable.
The BOP assembly should always be stored with:
• The manifold equalisation valves open;
• The rams in the fully open position;
• The lock sleeve in position to protect the indicators;
• Top and bottom quick union threads and seal surfaces protected;
• Protection from moisture ingress;
Whenever possible, the BOP should be enclosed in a protective cage during use and stored
in the transport frame when not in use. Care should be taken to ensure that the injection
couplings are left unobstructed and not subjected to any loads or impacts.
10.2 Transportation
Before transporting any BOP assembly, Routine Maintenance should be carried out as per
Section 8.5.2.
The BOP assembly should always be transported with:
• All fluids drained.
• All bores coated with a light oil/corrosion inhibitor.
• The manifold equalisation valves closed.
• The lock sleeve in position to protect the indicators.
• Top and bottom quick union threads and seal surfaces protected.
• Protection from moisture ingress.
Whenever possible, the BOP should be enclosed in a protective cage during use and stored
in the transport frame when not in use. Care should be taken to ensure that the injection
couplings are left unobstructed and not subjected to any loads or impacts.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
10.3 Spares
Use only NOV Elmar recommended spares.
For seal kit part numbers and spares parts, refer to the relevant Technical Illustration
supplied with the equipment.
Recommended spares:
• Seal Kit
• Ram Inner Seals

• Ram Outer Seals
10.4 Accessories
NOV Elmar can supply a range of accessories for handling, testing and assembling the
Lightweight Wireline Valve. The use of any other accessories is NOT recommended as this
could lead to damage that may result in failure of the equipment.
NOV Elmar can supply adapters for various quick union sizes. Contact the NOV Elmar Sales
Department for details.
For accessories that do not have part numbers stated contact the NOV Elmar Sales
Department for details. The part numbers for these accessories may change depending on
the quick union being used.
Recommended Accessories:
• Quick Union Test Plug
• Quick Union Test Stump/Cap
• Test Stump Mounting Table
• Quick Union Lift Bail
• Male thread protector (steel or plastic)
• Female Thread Protector (steel or plastic)
• Protection Cage
• Test Rod (see Section 8.6.3)
• Drift Gauge (contact local NOV Elmar sales team for appropriate part)
• ‘C’ Spanner
• Non-Marking Strap Wrench (part number 840957)
• Grease (part number 881720)
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
• Anti-seize protective compound (Nickelslip):

Location Part Number
USA 8831028751
North America 8831028752
Middle East 8831028753
Far East 8831028754
Europe 8831028755

• Y Hose assembly for BOP OPEN (part number 691000)
• Y Hose assembly for BOP CLOSED (part number 691100)
10.5 Disposal
When the product approaches its twentieth service year it should be retired.
Ensure that the product is disposed of in a responsible manner and that any local legislation
is observed. NOV Elmar can assist if required.
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
APPENDICES
This section contains the following appendices:
Appendix 1: Maintenance Record Sheet
Appendix 2: Contact Us
Appendices
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
DATE TYPE OF
PERFORMED BY VERIFIED BY COMMENTS
PERFORMED MAINTENANCE
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
Appendix 2: Contact Us
Manufacturing Locations Address Telephone, Fax and E-mail

Tofthills Avenue, Midmill Business Park,
Tel: +44 1224 740261
Kintore,
Elmar - UK Fax: +44 1224 743138
Aberdeen, AB51 0QP
Elmar-UK@nov.com
8017 Breen Road
Houston, Tel: +1 346 223 5000
Elmar - USA
TX 77064 Elmar-Americas@nov.com
United States of America
Appendix 5: Contact us
Oilfields Supply Center B-17

Tel: +971 4 810 0100
Jebel Ali Free Zone
Elmar - UAE Fax: +971 4 883 7087
P.O. Box 18633
Elmar-Dubai@nov.com
Dubai, United Arab Emirates
7 Loyang Way
Tel: +65 6546 0928
Singapore
Elmar - Singapore Fax: +65 6546 0927
508721
Elmar-Singapore@nov.com
Singapore
6771 - 84 Street SE
Tel: +1 403 319 2333
Elmar – Canada Calgary, Alberta
Fax: +1 403 319 2337
(Dynawinch Products) T2C 4T6
Elmar-Canada@nov.com
Canada
Regional Sales, Rental & Service Telephone E-mail

Al-Khobar, Saudi Arabia Tel: +966 3 887 9270 Elmar-Dubai@nov.com
Perth, Australia Tel: +61 8 6279 5799 ct-aus-perth@nov.com
Stavanger, Norway Tel: +47 51 81 81 81 Elmar-NorwaySales@nov.com
Groot-Ammers, Netherlands Tel: +44 1224 740261 Elmar-NL@nov.com
Louisiana, USA Tel: +1 337 839 0024 ext. 201
Representative Offices Telephone

Beijing, China Tel: +86 10 8485 1973
Moscow, Russia Tel: +7 495 287 2691
Port Harcourt, Nigeria Tel: +234 908 781 0461
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
CUSTOMER NOTES
TFO-10006156/A3 MAN-10000527/F
LIGHTWEIGHT BOP
MAN-10000527/F TFO-10006156/A3
LIGHTWEIGHT BOP
Published by:
Elmar
Tofthills Avenue,
Midmill Business Park,
Kintore, Aberdeen, AB51 0QP
No part of this document may be reproduced by any means without the written consent of
the publisher.
Whilst every care has been taken to ensure that the information in this document is
correct, no liability can be accepted by Elmar for loss, damage or injury caused by any
errors or omissions in this document.
TFO-10006156/A3 MAN-10000527/F

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User Manual

MAN-10000527 – Original Instructions

Copyright National Oilwell Varco, ©2017 Page 1 of 77

This document applies to the following products:

Revision Date Amendments

Page 2 of 77 Copyright National Oilwell Varco, ©2019

Copyright National Oilwell Varco, ©2019 Page 3 of 77

8.1 Introduction ........................................................................................................... 52

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Copyright National Oilwell Varco, ©2019 Page 5 of 77

2 SAFETY & EHSRS

2.1 General Safety

2.1.1 Employee responsibility

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2 Safety & EHSRs

2.1.2 Employer responsibility

2.1.3 Warnings, cautions and requirements

Copyright National Oilwell Varco, ©2019 Page 7 of 77

2.2 Equipment specific safety

2.2.2 Pressure Control

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• All pressure control equipment must be pressure rated to a defined "Maximum

2 Safety & EHSRs

Copyright National Oilwell Varco, ©2019 Page 9 of 77

3.1 Unit Overview

Figure 1: BOP components

ITEM DESCRIPTION COMMENTS

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3.2 Guide to the use of Elmar Drawings

3.2.1 Identification of unit part number

3.2.2 Identification of components within a unit

Copyright National Oilwell Varco, ©2019 Page 11 of 77

4.1 Unit Overview

operations or other operations such as wireline shear/seal.

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4.2 BOP Sub-Assembly

Figure 2 Bop Sub Assembly

Copyright National Oilwell Varco, ©2019 Page 13 of 77

4.2.1 BOP Body

4.2.2 Hydraulic Cylinder Assembly

create an initial seal with ram elastomers only.

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Copyright National Oilwell Varco, ©2019 Page 15 of 77

4.2.3 Manifold Arrangement

and vice versa.

Figure 4 Triple Wireline Valve Manifold Configuration

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Copyright National Oilwell Varco, ©2019 Page 17 of 77

4.2.3.1 REAR MANIFOLD BLOCK

Figure 5: Rear Manifold Assembly

The rear manifold valves perform the following functions:

Page 18 of 77 Copyright National Oilwell Varco, ©2019

4.2.3.2 Manifold Configuration for Shear Rams in the Upper Bore

Copyright National Oilwell Varco, ©2019 Page 19 of 77

In this configuration the main functions of the valves are as follows:

Page 20 of 77 Copyright National Oilwell Varco, ©2019

4.2.3.3 Manifold Configuration for Shear Rams in the Lower Bore

The manifolds must be re-configured as per Figure 8 below:

Copyright National Oilwell Varco, ©2019 Page 21 of 77

In this configuration the main functions of the valves are as follows:

Page 22 of 77 Copyright National Oilwell Varco, ©2019

4.3 BOP Adapter Assembly

4.4 BOP Ram Assembly