Hi-Kalibre Equipment Ltd.

Operator’s Manual
4-1/2” IF NC50 X 4-1/2” IF NC50 Upper Kelly Valve/IBOP 4184A-DB-IF-SER

Table of Contents

1.0 Maintenance Intervals

1.1 Inspection Intervals
1.2 Testing

2.0 Assembling and Dismantling the Valve

3.0 Parts and Storage

The performance, safe operation, and integrity of Hi-Kalibre Equipment’s top drive valves/
IBOP’s depend on proper and sound maintenance practices. This manual is intended to provide
Hi-Kalibre’s minimum recommended inspection and maintenance schedules. In addition to
the recommended intervals suggested within, all valves should be inspected after periods of
rough drilling, excessive jarring, or any other exceptional conditions that might lead to
fatigue failure. Hi-Kalibre Equipment Ltd will not assume responsibility or liability for any
equipment that has been repaired, rebuilt or otherwise serviced outside of Hi-Kalibre’s facilities.

The valve you have purchased is a dual crank (two operating stems), dual ball upper valve, is
10,000 PSI WP (15,000 PSI shell test), has NACE internals, with 4-1/2” API IF NC50 box up by
4-1/2” API IF NC50 box down. The valve can be opened across the full pressure range with
equalization of pressure.

The valve itself requires very minimal maintenance, however proper inspections and care of use
should always be exercised. Only qualified personnel should inspect, or service the valve.
Proper record keeping should include the inspection dates, thread conditions, service dates, items
replaced or repaired, lot tracking information, and pressure test record as per API spec 7-1.

1.0 Maintenance Intervals

In order to maintain a proper working condition IBOP valve, you must ensure that if the rig is
going to be shutdown or racked for any period of time that the IBOP valve is flushed with
water. This will help clean out mud and contaminants from the valve. To do this, turn the
ball to the ½ open/close position and thoroughly flush the valve with water, functioning it
back and forth to work lose the stems. Once this is done, test the valve at low pressure, 1000
PSI and function test it so as to operate it under pressure. This will also help in dislodging
any mud from the seat springs thus preventing the likelihood of your valve sticking or being
difficult to operate. Make sure the valve is returned to the open position and stored properly.

1.1 The upper box connection is 4-1/2” IF NC50 and the lower box is also a 4-1/2” IF NC50 API
tool joint. The tool joints should be inspected on a regular basis using wet magnetic particle
inspection methods, performed by a qualified inspector. It may require the removal of the
valve from the load path in order to properly inspect the body. One operating day is if the
valve was used for any portion of a day what-so-ever.
 Hi-Kalibre Equipment Ltd. Operator’s Manual
4-1/2” IF NC50 X 4-1/2” IF NC50 Upper Kelly Valve/IBOP 4184A-DB-IF-SER

Pin and Box connections 180 days inspect for wear and/or cracks
Valve body (stem holes) 180 days inspect for wear and/or cracks
Complete shop teardown 300 days full teardown, inspection, and service

1.2 The valve should be pressure tested and function tested on a regular basis in order to ensure
the valve is working properly. Minimum testing requirements should be once every 30 days,
or per the users’ company policies at the rig, taking into account drilling activities at the time
testing is required.

2.0 ASSEMBLY AND DISMANTLING INSTRUCTIONS 4184A-DB-IF-SER

REFERENCE: DWG 4184A-DB-IF-SER exploded view

A. Assembly:
Items required: Plastic maul or bar, tube of all purpose grease
1. Lay out all of your parts and inspect them for damage. All parts should be clean and free
from debris. Make sure you have the proper parts as per the drawing.
2. Begin by installing the o-ring seals and energizers from the seal kit (13). The o-rings
may be stiffer than normal due to their properties and durometer. Install the 2 o-rings on
the stem inserts (3) making sure not to twist them on. Install the o ring and stem seal
assembly on the operating stems (4 & 5) making sure that the energizers on the stem seal
assembly are in straight. Install the o rings and energizers on the lower seat (9), as well
as the upper seat (7).
3. Make sure the valve body (1) is clean and free from debris. It is a good practice to take
an air grinder with a small wire brush attachment and buff out the internals of the valve.
Spray some WD40 or similar lubricant into the body before buffing. Once the body
internals, including the stem holes are clean, you are ready to begin the assembly process.
It is easier to assemble the valve with the body in an upright position.
The assembly procedure is the same for both the upper ball valve and lower ball valve.
Pay attention to which hole the master and slave stems are going into. The left of the
valve body always refers to the left side when you have the milled ID window facing
you.
4. Begin by installing the wave spring set (12) into the lower seat pocket in the body. Make
sure the spring is all the way in place so as to not tilt or bind the lower seat.
5. Install the lower seat (9) into the lower seat pocket of the body. Keep the seat straight
and level and make sure it freely slides into the lower seat pocket. Push the seat in until it
is all the way into the lower seat pocket. Check to make sure the seat moves up and
down freely.
6. Next we are going to install the stem inserts (3) into the stem holes. Apply a medium
film of grease to the o rings on the stem inserts. Through the box connection of the valve
body, slide the insert into the stem hole making sure to align the locking cam with the
recess machined into the body. The stem inserts (3) are interchangeable and it does not
matter which hole each one goes in. Make sure that the inserts are pushed into the stem
hole all the way. The flange face of the insert should be right up against the valve body
internal cams.
7. Once the 2 stem inserts (3) are in, we are ready to install the master (4) and slave (5)
operating stems. These must be installed in the proper holes otherwise the valve will not
operate properly, or at all. Begin by installing the master stem (4) P/N: 4100DS-M-06
 Hi-Kalibre Equipment Ltd. Operator’s Manual
4-1/2” IF NC50 X 4-1/2” IF NC50 Upper Kelly Valve/IBOP 4184A-DB-IF-SER

into the left stem hole. The left stem hole is the hole to the left when you are facing the large
milled ID window and are working on the top end of the valve. Make sure to lubricate the o
ring and stem seal assembly before installing the stem. Make sure the stem is pushed in all
the way until the face touches the face of the stem insert.
8. Now install the slave stem (5) P/N: 4100DS-S-06 into the right stem hole. Again, the
right side refers to the right side when facing the large milled ID window. Make sure the
stem is pushed in all the way. Check the operation of both stem, make sure that the
indicators travel between the open and close windows as you operate the stems. (When
assembling the lower valve with the window towards you and the NC84 box down the
slave goes in the left hand stem hole so that it ends up on the same side as the other slave
stem).
9. Now install the universal joints (u-joints) (2) into the stems (4 & 5). Turn the stems and
u-joints so that the stem keyway is horizontal and the u-joint key way is vertical.
10. Take the ball (6) and apply a light clean film of grease to the outside diameter of the ball.
Lower the ball into the bore and align the keys in the ball (6) with the vertical keys on the
u-joints (2). Lower the ball (6) until it rests on the lower seat (9). You may have to
slightly wiggle the ball to get it to slide all the way down to the lower seat.
11. Apply grease to the o ring on the upper seat (7). Lower the upper seat (7) into the valve
body (1) bore. The seat should go all the way in until it is just below or flush with the
lower edge of the retainer ring groove.
12. It may require that the ball (6) be depressed by pushing on it with a plastic maul to move
it down enough to get the upper seat (7) all the way in. With the ball pushed down and
the upper seat (7) below the groove, install the first long section of the split retainer ring
(10). There will be two long sections and two short sections. We want to install the long
ones first. Place the first long piece in the groove from roughly a 1 o’ clock position to
the 5 o’clock position. The second long piece is installed from the 7 o’clock position to
the 11 o’clock position when looking down from above. This should leave just enough
room to install the two small sections of the split retainer ring into the groove. Make sure
the small gaps between sections are roughly equal.
13. Install the lock ring (8) into the top of the split retaining ring (10). Make sure it is
pressed in all the way and resting on the shoulder of the split ring. The small radiused
groove should be visible. Install the spiral retainer ring (11) into the groove, locking in
the lock ring and split ring.
14. Now the valve assembly is ready to be pressure tested. Test periods will be as per your
company policies, but should not be less than 5 minutes hold time after the desired
pressure has been reached. The valve is 10,000 PSI working pressure from both the pin
and box end. The shell test should be conducted with the ball in the half open/closed
position. The shell test is done at 15,000 PSI. All tests should at a minimum be as per
API Spec 7-1, 1st edition. The valve will be tight to operate after assembly. Shop testing
has shown that pressure testing and operating the ball and stems will reduce the torque
required to operate the valve.
15. Apply thread protectors and the valve is ready for use. Make sure to include the 3/4”
operating handle for manual operation.

B. Dismantling:
Items required: screw driver, plastic maul
1. Dismantling is very easy and just the opposite of the assembly process. Begin by
removing the wire retainer ring (11). This can be accomplished by using a small flat
tipped screw driver, inserting it in the bent ends of the ring, and wiggling it around until
the ring is removed from the groove. Keep all removed parts in a container for cleaning
and traceability purposes. All parts are marked with part numbers and unique
manufacturing lot numbers traceable to the original certification paperwork.
 Hi-Kalibre Equipment Ltd. Operator’s Manual
4-1/2” IF NC50 X 4-1/2” IF NC50 Upper Kelly Valve/IBOP 4184A-DB-IF-SER

2. Remove the lock ring (8). Pry the lock ring out using the groove in the inside
of the ring.
3. Remove the small sections of the split ring (10) first. Remove them by gently prying
between the ridge on top of the ring and the wall of the valve body (1) itself. Remove the
two longer sections from the body. If there is some small spring load on the ball and the
last sections will not come out, the ball can be depressed once again and then remove the
last sections.
4. Remove the upper seat (7) from the valve. Simply pry it out by hand, being careful not to
damage the sealing areas of the seat at all.
5. Remove the ball (6) from the valve. This can be done by laying the valve down on its
side and tapping the ball out from the pin end using the plastic maul.
6. Now remove the stems (4 & 5), the stem inserts (3), and the u-joints (2). This can be
made easier if problems are encountered by using the operating handle provided and
tapping it down onto the stems (4 & 5) from above. The u-joints, inserts, and stem
should drop; into the bore of the valve and can then be removed from the box end of the
valve.
7. Now that the stems are out of the valve, we can remove the lower seat. The lower seat
can either be removed by pulling on it from the box end, or by pushing on it from the pin
end. Take out the wave spring (12) after the lower seat is out.
8. Now that all the parts are out of the valve, remove all of the o rings and energizers from
the parts and discard them. Clean all of the parts thoroughly and dry them off for
inspection. Inspect all of the parts for wear and or damage. Order replacement parts
individually, or by ordering complete major repair kits.
9. Clean and inspect the valve body (1). At the time of inspection, in addition to a thorough
visual inspection, the treads should be gauged and checked for damage, as well as having
a full magnetic particle inspection performed. The entire body should be checked,
including the threads and stem holes. Once fully cleaned and inspected, the valve can be
re-assembled and put back into service.

Major Repair Kit: P/N: 4185A-SDB-MRK includes ALL internal parts

Minor Repair Kit: P/N: 4185A-SDB-SK includes all soft seals only

For service and/or operating problems, or inquiries, contact your nearest supplier’s office or Hi-Kalibre
Equipment Ltd. directly.

3.0 Storage
The valve should be stored in an upright position, with the valve in the open position. Proper
thread protectors should be installed as well. Do not store the valve in areas of high heat, or
extreme cold, as this may cause fatigue on the rubber sealing elements inside the valve. Always
make sure the valve is stored after it has been thoroughly cleaned. Do not allow the valve to sit
with drilling fluids/muds for extended periods of time. Always pressure test your valve before
storing it and before placing it back into service after any extended period of storage. Always
make sure you take proper precautions in accordance with each particular situation specific to
your application in order to ensure long life, and superior service of your Hi-Kalibre valves.
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 4184A-VM-01-IF BODY
2 4 4100DS-A-07 U JOINT
3 4 4150DS-A-08 INSERT
4 2 4100DS-M-06 STEM 19
5 2 4100DS-S-06 STEM (SLAVE) 3 11
6 2 4165-E-09 BALL 8
7 2 4100-E-04-M UPPER SEAT 19
8 2 4100-E-02 LOCK RING 10
19
9 2 4100-E-05-M LOWER SEAT 4 19
10 2 4100-E-03 SPLIT RING 7
3
11 2 WHTA-362-INX RETAINER RING
2
12 2 3495-10-08-4 WAVE SPRING 19 6
19 1 4185A-SDB-SK SEAL KIT
5 1 9

12
2 19

17 2

19
5
9

6 19

7 3
2
19
10 4 19

8 19
11
3

19

NOTES: DATE: Sept 2,2005 SERIES NUMBER: 4184A-DB-IF-SER

HI-KALIBRE
-USES HK-4186-11A HEX DRIVE
DRAWN BY: GDL WORKING PRESURE: 10,000 PSI EQUIPMENT LTD.
PHONE # 780-435-1111
CHECKED BY: KR MAJOR REPAIR KIT: 4185A-SDB-MRK FAX # 780-436-5164
9816-45 Avenue
MADE IN CANADA Edmonton , Alberta
PATENTS APPLY APPROVED BY: BB WEIGHT: 203 LBS Canada