Elmar Hydraulic Compact BOP Assembly

Assembly Instructions

SECTION 6

ASSEMBLY INSTRUCTIONS

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Section 6 – Page 1
 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

6 ASSEMBLY INSTRUCTIONS

THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH THE PRODUCT
SPECIFIC ASSEMBLY DRAWINGS AND BEFORE CARRYING OUT ANY OF THE FOLLOWING
ACTIONS

6.1 Tools List

- Clean Work Surface;
- Airline;
- O-ring pick;
- Narrow grease brush (12" handle);
- Plastic hammer;
- Grease L-881720;
- Hydraulic oil;
- PTFE thread tape L-861900;
- Clean rags;
- 3M Scotchbrite;
- Loctite 577 thread sealant L-862200;
- Anti-seize protective compound (Copperslip) L-882940;
- 2" dia brass punch (12" long) for piston to hydraulic cylinder;
- Elmar lock ring tightening tool L-972699;
- 11mm socket (for grease nipple in end cap);
- 12" Stilson (for stem end and elbow);
- 12" adjustable spanner (for indicator rod);
- Vice;
- Large screwdriver (to screw piston lock into end cap);
- 'C' spanner (for tightening end cap into body);
- 15" circlip pliers (to suit circlip retaining locking ring);
- Tool – Ratchet 3/8” BOP Cartridge Valve (L-973132);
- Tool - Swivel Allen Wrench BOP Cartridge Valve (L-890066);
- Tool - Cartridge Valve Seat Tool (L-981053);
- Tool - Cartridge Valve Seat Seal Setter (L-972776);
- Small fanblade screwdriver (for cartridge valve cap screw);
- 3/16 Allen key (for support clamp grub screws);
- 5/32" Allen Key (for inner seal retaining screws);
- 3/8" Allen key (for manifold block screws and cartridge valve stem);
- 7/8" Spanner (for male Snaptite and grease injection port).
- Grease Nipple L-980108.

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

REMEMBER...”SAFETY IS EVERYONE'S RESPONSIBILITY”

• Do use eye protection when using power tools.
• Do wear protective footwear.
• Do wear gloves or use barrier cream to protect your hands.
• Do keep loose clothing and long hair well out of the way of moving mechanical
parts.
• Do remove rings, wristwatch etc, before working.
• Do change out of oil-soaked clothes and do not keep oily rags in your pocket.
• Do ensure that any lifting or jacking equipment has a safe working load rating
adequate for the job.
• Do get someone to check periodically that all is well when working alone.

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

6.2 Manifold Block Valve Assembly

6.2.1 Cartridge Valve Assembly O-RING

VALVE SEAT

TEFLON SEAL
GLAND

BACK-UP

BACK-UP

VALVE STEM

TEFLON SEAL GLAND

VALVE SEAT

BACK-UP

VALVE STEM
PH SCREW

O-RING BACK-UP
PH SCREW

Step Action

NOTE: Clean all parts thoroughly before beginning assembly.

1 Place Teflon back-up rings in boiling water and leave to expand.
2 Screw valve seat onto the valve seat tool.
3 Place heated back-up rings (2 off) around the valve section and flatten out on the
valve seat.
NOTE: O- Rings and Back-ups
Probably the best way to avoid damage to O-rings during installation is:
(a) Check all components for cleanliness before installation
(b) Tape all threads over which O-rings will pass. O-rings should never be forced over
unprotected sharp edges.
(c) Use an O-ring lubricator.
(d) Double check O-ring to ensure correct size
(e) Don’t over stretch the O-ring.
(f) Prevent the O-ring from rolling or twisting during assembly
(g) Where only one back-up ring is used, it must be placed between the O-ring and the
pressure face.
BACK-UP RING O-RING

PRESSURE DIRECTION

PRESSURE FACE

4 Apply grease between the back-ups and manually flatten out. Put on the O-ring and
apply grease.
5 Stab the seat into the seal setter tool and screw the valve seat tool out of the seat.
6 Repeat 5, above, again so that 2 off seats are in the seal setter tool.
7 Remove 1st seat (screw valve seat tool in). Apply more grease and stab into block.

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 Elmar Hydraulic Compact BOP Assembly
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Step Action

8 Repeat again for all valves.

9 Apply Copperslip to valve stem thread and screw into the gland until the head is
flush with the gland.
10 Slip on the Teflon valve seal over the stem.
11 Apply Copperslip to the gland threads and screw into the manifold block.
12 Repeat for all cartridge valves.
12 Put the block in a vice and tighten each valve.
13 Apply Copperslip to each cartridge valve panhead screw and screw into each valve
gland.
GAUGE PIN
6.2.2 Manifold Block
O-RING BACK-UP
O-RING BACK-UP
BACK-UP
O-RING
GAUGE ARM
HEX PLUG

HEX PLUG
UPPER MANIFOLD CHECK VALVE
BLOCK
O-RING
O-RING O-RING
O-RING
BACK-UP
ELBOW
MANIFOLD PLUG
BACK-UP HEX NIPPLE
O-RING

HUBER UNION

HEX PLUG
MIDDLE MANIFOLD
BLOCK

CARTRIDGE VALVE
ASSEMBLY O-RING
SOCKET HEAD
CAP SCREW BACK-UP

LOCK O-RING
WASHER
BACK-UP
MANIFOLD PLUG

SOCKET HEAD
CAP SCREW ELBOW

REDUCING NIPPLE
LOWER
MANIFOLD
BLOCK QC COUPLER

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

Step Action

NOTE: Clean all parts thoroughly before beginning assembly.

1 Apply Copperslip to lock washer socket head screw and screw the lock washer into
the block and repeat for each cartridge valve.
2 Fit O-rings onto check valves and apply grease.
Locate check valves in upper (grease) and lower (glycol) injection ports, taking care
not to damage the O-rings. Ensuring also that the arrow stamped on the check
valve points into the bore of the housing and threaded port should be outermost.
NOTE: Only one check valve will be featured on type ‘B’ manifolds. None are required on
type ‘A’ manifold blocks, therefore steps 3-6 will not apply.
3 Fit external O-rings (2 off each) on upper and lower elbows.
4 Screw elbows into upper and lower ports and tighten, then back off until the ports
face the front.
5 Tape and Loctite nipple fitting into top port (grease injection port) and insert Huber
assembly. Tighten using a spanner.
6 Tape and Loctite nipple fitting into lower port (glycol injection port) and insert female
Walther coupler into fitting (only applicable to type ‘C’ manifolds).
7 Tape and Loctite the dump valve plug into the upper block and tighten.
NOTE: Etching on manifold blocks will indicate location of dump port.
8 Fit upper, middle and lower back-ups and O-rings onto gauge pin. Note orientation
for the middle port pressure.
9 Grease and stab gauge pin through arm using a plastic hammer.
10 Grease and screw into port and tighten using a 12 inch adjustable spanner.
11 Tape and Loctite ½ “ hex plug into gauge arm port.
12 Grease and install back-ups and O-rings onto manifold block plugs.
13 Insert plugs into manifold rear face and between manifold blocks.
14 Join manifold blocks (if applicable).

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

6.3 BOP Main Body and Hydraulic Cylinders

O-RING
BACK-UP
BACK-UP
O-RING
HYDRAULIC CYLINDER
STEM O-RING
BACK-UP
GUIDE ROD O-RING
O-RING BACK-UP
BACK-UP INDICATOR ROD
QC NIPPLE O-RING
REDUCING NIPPLE O-RING
BACK-UP
QC COUPLER PISTON GREASE NIPPLE
REDUCING NIPPLE POSITION
INDICATOR LOCK RING
PISTON LOCK

END CAP

END CAP SLEEVE

CIRCLIP

RETAINER SCREW
BACK-UP
BACK-UP (TEFLON) BACK-UP CYCLINDER
BACK-UP O-RING SUPPORT CLAMP
O-RING O-RING BACK-UP O-RING
RETAINER SCREW
O-RING BACK-UP

O-RING

GREASE NIPPLE
END CAP SLEEVE

GUIDE ROD

PISTON LOCK
INDICATOR ROD
POSITION
INDICATOR

HYDRAULIC STEM O-RING PISTON END CAP

CYLINDER
CIRCLIP
LOCK RING CYCLINDER
SUPPORT CLAMP WITH
RETAINER SCREW

Step Action

1 Clean all parts thoroughly before beginning assembly.

2 Apply grease to the O-ring grooves;

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

Step Action

3 Fit all O-rings and back-ups in the hydraulic cylinder. Refer to Figure 3 and the
product specific assembly drawing.
NOTE: Check position of Teflon back up ring (if applicable). Place Teflon back up ring in
boiling water to expand before fitting.
4 Check for remaining dirt and clean if necessary.
5 Fit piston O-rings and back-ups internal and external
6 Fit end cap external O-ring and internal O-ring and back up (3" BOP has a Polypak
seal only).
7 Grease the hydraulic cylinder bore and piston (outer and inner).
8 Insert the piston into the cylinder bore as square as possible.
9 Hammer down with a plastic hammer through the bore using the 12” brass punch.
10 Hammer all the way home keeping the piston square.
11 Apply Copperslip to the stem threads. Grease the stem shaft and the cylinder bore
internals.
12 Insert the stem into the cylinder and tap through the O-rings until located into the
piston with the threads accessible.
13 Screw the piston indicator onto the stem hand tight.
14 Hammer the end of the stem back through until the piston indicator hex is
accessible.
15 Grip the end of the stem with a Stilson and tighten the indicator on to the piston
indicator.
16 Dress up any marks left by the Stilson on the machined end of the stem.
17 Apply Copperslip to the indicator rod threads and screw into the position indicator
and tighten with a spanner on the milled flats.
18 Anchor the hydraulic cylinder horizontally, in a vice if possible.
19 Grease the piston lock threads and screw into the end cap.
20 Screw the end cap sleeve over the end cap (not applicable to 3").
21 Grease the cylinder body threads and the piston indicator.
22 Grease the end cap threads.
23 Screw the end cap assembly into the cylinder body and tighten.
24 Remove assembly from the vice and stand up on bench (largest diameter down).
25 Grease the inside of the lock ring and slip over the cylinder body.
26 Fit the circlip using the 15” circlip pliers to retain the lock ring.
27 Rotate the lock ring to expose one of the two cylinder vent holes.
NOTE: Only one hole is drilled in earlier type collars. In later collars all the holes are drilled
through.

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Step Action

28 Locate an extension grease nipple (provided in the BOP cage) into one of the vent
holes and pump in grease. Pump grease until it exits through the other vent hole.
29 Remove the nipple and return it to the BOP cage.
30 Apply PTFE tape and Loctite 577 on the Snaptite threads of the male QC Coupler.
Insert and tighten into cylinder body.
31 Slip the support clamp over the cylinder body (not applicable to 3"). Apply
Copperslip to retaining screw. Line up the hole in the support clamp with the insert
in the cylinder body and tighten screw (one each side of cylinder body).
32 Apply PTFE tape and Loctite 577 on the Snaptite threads of the female QC
Coupler. Insert and tighten into cylinder body.
33 Apply Copperslip to grease nipple and insert into end cap. Tighten with 11mm
socket.
34 Apply Copperslip to guide rod threads and screw into the cylinder body. Choose the
correct hole according to the desired ram orientation.
35 Repeat steps 1 to 34 for each hydraulic cylinder.

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

6.4 Ram Assembly

OUTER SEAL

GUIDE SCREW

GUIDE PLATE

RAM BODY LH

SEAL INNER SEAL

RETAINER
SCREW

RAM BODY RH

Standard Ram

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

Q-Guide Ram Integral Ram

Step Action

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.

Outer Seal
2 Grease the inner seals and install in position in the ram body.

Inner Seal (Electric) Inner Seal (Slick Line)

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

Step Action

3 Copperslip the inner seal retaining screws and insert into position. Tighten all four
screws equally. Check that the inner seal is still free to move.
4 Earlier ram guides with guide plates only:
Copperslip the ram guide screws. Fit top ram guides (one to each ram) and screw
into place. Fit bottom ram guides and screw into place.
5 Ensure that the hydraulic cylinders are fully closed so the stem can be accessed for
ram mounting.
6 Fit the upper and middle ram assemblies to the hydraulic cylinder stems, ensuring
that the outer seals are positioned to seal towards the top on the upper and middle
rams.
7 On the lower (inverted) rams rotate the body of the ram on the hydraulic cylinder
stems to ensure that the outer seals are positioned to seal towards the bottom of
the hydraulic cylinder. Check the position of the guide rods.
8 Pump the hydraulic cylinders closed 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

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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

6.5 BOP Assembly MANUAL HANDLE

UPPER ADAPTER
ASSEMBLY

CYLINDER
SUPPORT ARMS

CYLINDER
ASSEMBLY

MANIFOLD
BOP SUB ASSEMBLY
ASSEMBLY

LOWER ADAPTER
ASSEMBLY

Step Action

1 Inspect body internals, paying particular attention to seal surfaces. Apply WD40 and
lightly smooth using Scotchbrite to clean up surface, if required.
NOTE: Body internals are coated with corrosion inhibitor. Do not over-smooth.
2 Grease O-ring grooves in upper and lower BOP adapter threads.
3 Identify the BOP body orientation by checking the assembly drawing.
NOTE: On later designs reference should be made to the manifold block locating holes
which will indicate the correct orientation.

4 With the BOP lying horizontally, place the hydraulic cylinder assemblies on the flat
alongside the BOP in their respective positions.

NOTE: Check the orientation of the hydraulic cylinders to ensure that the rams are in the
correct orientation.
5 Grease the rams, seals, BOP body threads and the hydraulic cylinder lock ring.
6 Copperslip the cylinder support arms and fit to the BOP body
NOTE: Do not tighten the support arms at this stage. Slight adjustments may need to be
made to allow for fitting (not applicable to 3” BOPs).
7 Assemble each ram/hydraulic cylinder assembly to the BOP. Use of a plastic
hammer may be required to overcome the resistance from the seals.
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 Elmar Hydraulic Compact BOP Assembly
Assembly Instructions

Step Action

NOTE: Ensure that seals are not damaged.

Assistance may be required to support the weight of the cylinder during this
operation. To assist screwing the hydraulic cylinder assembly into place, place the
manual handle on the piston lock and lightly tap with a hammer. Resistance should
be slight. If in doubt check.
8 Apply Copperslip to socket head cap thread and screw into the end of each support
arm with washer (12 off) (not applicable to 3” BOPs).
9 Completely tighten the support arms.
10 Identify the lower adapter and fit the appropriate seals and seal ring (if applicable).
11 Grease the lower adapter external threads and relevant BOP body threads.
12 Fit lower adapter to the BOP body and tighten using a 3/8" punch.
13 Locate collar inserts as a matching pair around the body of the lower adapter.
NOTE: These inserts must match with the collar ring.
14 Grease collar ring and screw over inserts on lower adapter.
NOTE: Too much grease can cause problems with inserts locking inside the collar ring.
15 Line up the markings and insert the grub screws.
16 Insert Spirol pins, in clockwise direction to ensure removal by 'easy out', when
required.
17 Fit male thread protector to the lower adapter assembly.
18 Identify the upper adapter and fit the sealing ring (if applicable) and appropriate
seals.
19 Apply grease to the adapter external threads and BOP body threads.
20 Fit upper adapter to the BOP body and tighten using a 3/8" punch.
21 Fit the female thread protector.
22 Blow out manifold block ports and threaded fitting holes with an airline.
Blow out BOP body threaded fitting holes and tap the holes to ensure that they are
free of debris.
23 Lay the BOP body horizontally on the flat, with the manifold block ports uppermost.
24 Grease the face of the BOP and manifold block fitting faces.
Copperslip the manifold block screws.
25 Position the manifold block assembly and lightly tap with a plastic hammer into
position.
26 Screw home the 12 off 3/8" screws and tighten progressively in a clockwise
sequence to ensure equal tightness.

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Section 6 – Page 13