PBL

SERVICE &
INSPECTION
MANUAL
Not a controlled document if printed. Individuals with uncontrolled copies are responsible for ensuring the use of
the last current version. This document is property of DSI FZE and is protected by copyright and other proprietary
rights laws. This document shall not be reproduced, copied, or transmitted in any form without express consent
of DSI FZE.
 DSIFZE-OPS-WI-100.8
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REVISION HISTORY

Rev. Date Reason for issue Prepared Reviewed Approved

Suraj Ross
1 14 May 2013 Changed format of Manual Sarafudheen MK
Varma DV Landry
Suraj Ross
2 4 July 2013 Changes to section 5 Sarafudheen MK
Varma DV Landry
Suraj Ross
3 3 Feb 2014 Gr.Errors & change in Sec 2 & 4 Sarafudheen MK
Varma DV Landry
Suraj Ross
4 8 Nov 2014 Change in Doc ID as per QMS Sarafudheen MK
Varma DV Landry
Loctite changed from 242 to Loctite 243. Suraj Gernot
5 27 May 2016 Richard Earle
LPT of Sleeves. Spring pitting Varma DV Bauer
Suraj All BDM,RMs, Eng Gernot
6 21 Sep 2017 See description in below table
Varma DV team & Service Mgr Bauer
Suraj Gernot
7 7 Dec 2017 Part List Sarafudheen MK
Varma DV Bauer
Suraj Sarafudheen MK, Lachlan
8 31 Oct 2020 See description in below table
Varma DV Carlo Amedeo D’Sa

Revision Change Description

1 Changed manual format from old to new

2 Added low pressure test as an option if client requires, in Section 5

3 Font error in Sec 1.6. Discrepancy found in sections 2 & 4; sorted out.
Changed document number from QAQC 004 Issue 1, May 2013 to DSI-WI-75-001 as per QMS. Guide Pin
4
inserting procedure, Sec 4.3
Loctite 242 Opr. Temp up to 150 deg c and Loctite 243 up to 180 deg c. Added LPT inspection of Sleeves.
5
Corrosion/ pitting on Springs
Added visual inspection of Main body, Sleeves, ball Seat, Inserts, storage condition of Seals & balls. Deleted
6 molykote from section 8, added troubleshooting section, made some changes in formatting, added wording
‘Excessive in spring inspection. Added parts list
7 Added ‘Section-10 (Part List)’ for identification of parts and each part linked to the part list with a ‘# number’
Changed Document ID as per IMS. Added rejection criteria for Retainer nut and Top sub. Incorporated recut
specs, acceptance criteria and inspection procedure into the Service Manual. Deleted function test, instead
8
during assy, sleeve is completely pulled and checked. Added retainer nut measurement calculation. LP test
made mandatory, HP test made standard – 5000 psi.

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TABLE OF CONTENTS

SL Content Page#
1 Introduction 6-8

1.1 Scope 6

1.2 Quality, Health, Safety & Environment 6

1.3 Personnel Qualification 6

1.4 Responsibility 7

1.5 Service Documentation 7

1.6 List of Tools & equipment required for service 8

2 Disassembly 9

3 Inspection & Measurement 10 - 16

3.1 Sleeve (Visual Inspection) 11 & 12

3.2 Ball Seats (Visual Inspection) 13

3.3 Port / Locking Inserts (Visual Inspection) 13

3.4 Main Body (Visual Inspection) 14

3.5 Spring (Visual Inspection) 15

3.6 Guide Pin (Visual Inspection) 16

3.7 Retainer Nut & Top Sub (Visual Inspection) 16

4 Assembly Procedures 17 - 25

4.1 Testing of Ball Seats & Locking Inserts 17

4.2 Sleeve & Seat Assembly 18

4.3 Main Body Assembly 20

4.3.1 Retainer Nut Calculation 21

4.4 Ball Catcher Body Assembly 25

5 Hydrostatic Test Procedure 26

6 Paint & Stenciling 27

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7 Re-Release Procedure 27

8 Storage 27 - 28

a. Seals 27

b. Balls 28

c. Tools 28

9 Troubleshooting 28 - 30

9.1 Guide Pin 28

9.2 Port Insert 28

9.3 Retainer Nut 29

9.4 Sleeve Assembly 29

9.5 Ball Seat 30

10 Parts List 31 & 32

Annex-1 PBL Assembly Acceptance Criteria 33

Annex-2 Ball Catcher Cage Acceptance Criteria 34

Annex-3 Lubricant Specifications 35

Annex-4 Main Body Recut Specifications (4-3/4” & Larger Tools) 36

Annex-5 Ball Catcher Body Recut Specifications (4-3/4” & Larger Tools) 37

Annex-6 Top Sub Recut Specifications (4-3/4” & Larger Tools) 38

Annex-7 Recut Specifications (2-7/8” Tools) 39

Annex-8 Recut Specifications (3-1/8” Tools, 2-3/8 Reg End connection) 40

Annex-9 Recut Specifications (3-1/8” Tools, 2-7/8 HT PAC End connection) 41

Annex-10 Recut Specifications (3-1/2” Tools) 42

Annex-11 Recut Specifications (4-1/8” Tools) 43

Annex-12 Procedure for Inspection of PBL Circulating Subs 44 - 49

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1. INTRODUCTION
1.1. Scope

This manual outlines the disassembly, inspection, assembly and testing of the PBL sub. It is written
for the purpose of aiding the employees of DSI, its agents and affiliates, who through the
authorization of DSI, have been selected and trained to operate, test, and maintain the products
specified here within.

1.2. Quality, Health, Safety and Environment

The task outlined in this manual will be completed with the goal of minimizing accidents and injury
to all personnel and all first aid injuries are to be reported and recorded.

The tasks will be undertaken with the safest working conditions possible with all personnel trained
in Manual Handling procedure; all personnel must wear Personal Protection Equipment (PPE).

The task will be completed with maximum attention paid to the environment and every effort made
to avoid any environmental incident.

All wastes generated shall be disposed of as per local laws and regulations, in an environmentally
friendly manner.

The following symbols are used in this manual:

DESCRIBES A POSSIBLY DANGEROUS SITUATION.

DISREGARD CAN LEAD TO MINOR INJURY.

DESCRIBES A POSSIBLY DANGEROUS SITUATION.

DISREGARD CAN LEAD TO DEATH OR SEVERE INJURY

USEFUL INFORMATION & OPERATING HINTS

1.3. Personnel Qualifications

Personnel involved in the performance of work functions specified in this procedure shall be
trained and Certified by DSI specialized Engineers.

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1.4. Responsibility

The Global Operations Manager shall be responsible for ensuring that an adequate system is in place
for receiving these proprietary Tools, initial Inspection, disassembly, general processing, servicing,
testing, final assembly, marking/ stencilling and final protection/ despatch is carried out in
accordance with applicable DSI procedures

The QHSE department shall be responsible for ensuring that DSI procedures are incorporated into
this manual and any new updates, changes in specific Work Instructions are reflected/ changed
accordingly into this procedure and re-issued to the area/ department / specific personnel who work
with the DSI Tools and equipment.

The DSI certified technicians shall be responsible for ensuring that servicing, testing,
assembly/disassembly of Tools and equipment are carried out in accordance with applicable DSI
Procedures, Work Instructions and acceptance criteria as given by DSI Specifications.

1.5. Service Documentation

All measurements, serial numbers of the tool and of all individual components (where available), and
test results shall be recorded on the latest revision of the PBL Service Report Format, Doc# DSIFZE-
OPS-FM-002.

A service report package for an assembled tool shall include the below;

• Completed Service Report

• Test Chart (For Ball Seat, Insert & Hydrostatic Test)
• Completed Technical Specifications Sheet and
• Inspection Reports

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1.6. List of Tools & equipment required for service

Sl Description Qty
1 Chain Wrench, 32“ Long (preferable) 1 No.
2 Pipe Wrench, 48“ Long 1 No.
3 Retainer Nut Wrench 1 No.
4 Port Insert Wrench 1 No.
5 Screw driver 1 Set
6 Allen Key, 3/8“ 1 No.
7 Box socket with T-Handle, 22mm 1 No.
8 Torque Wrench, Range- 50 to 250 ft/Lbs , ½“ Drive (calibrated) 1 No.
9 Ø3/4” x 2 m long Threaded Rod assembly (includes 3 x nuts, required 1 Set.
drilled balls and U-plate)
10 Adjustable Spanner, 300 mm 1 No.
11 Box spanner, 28mm 1 No.
12 Torch 1 No.
13 Thread Tap, 0.750-10 UNC 1 Set
14 Number & Letter Punch, 3/8“ 1 Set
15 Monkey Grip, ½“ 1 No.
16 ID & OD Calipers, 12“ 1 Each
17 Digital Vernier Caliper, 12“ (Calibrated) 1 No.
18 Pneumatic Buffer 1 No.
19 Angle Grinder, 4“ 1 No.
20 Assorted buff wheels, wire brushes & soft stone to suit pneumatic buffer 1 No.
21 Sanding pads & Grinding wheel to suit angle grinder 1 No.
22 Rough & Smooth Emery paper 1 Roll ea.
23 Electric Drill 1 No.
24 Honing spider fitted to SS rod (2m) 1 No.
25 Hydraulic Test Pump 1 No.
26 Ball Seat & Insert Test unit 1 No.
27 Barton Chart Recorder, Range 0-10000 Psi 1 No.
28 Chart Paper, 0-10,000 psi As required
29 WD- 40 spray As required
30 KOPR KOTE (thread compound) As required
31 Hydraulic Oil, (Grade 32 preferable) As required
32 Multipurpose Grease As required
33 Loctite, 243 As required
34 Paint, Traffic Blue As required
35 White Spray paint As required
36 Cotton Rags As required
37 Long Brush, 2“ (for application of thread compound) 1 No.
38 Paint Roller brush, 4“ 1 Pkt
39 Measuring Tape- 5 m 1 No
40 Hammer, 2.5 lb 1 No.
41 Stencil (PBL BY PASS SYSTEMS & BALL SHEARING PRESSURE) Letter size- 4“ 1 Each
Min.

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2. DISASSEMBLY

- Refer to Section 10 for Parts Identification.

- All threads are right-handed unless otherwise designated.

a) Un-Torque and Remove Ball Catcher Body (#2) from Main Body (#1).
b) Remove Ball Catcher Cage (#4) from Ball Catcher Body (#2). Discard any Activation and De-
Activation Balls that may be found in the Ball Catcher Cage (#4). Never reuse a used activation
ball. The steel balls may be cleaned and reused if there are no pitting or washouts.
c) In case the PBL has a Locking Ball in the Port Insert (#12), insert a threaded rod along with a
proper Ball and Plate to keep the Sleeve Assy. (#6) & Spring (#7) in place. Tap and push the locking
ball into the tool using a small steel pipe / bar and hammer; discard the locking ball.
d) For 5 ¼” and smaller tools, un-Torque and remove Top Sub (#3) from Main Body (#1).
e) For 6 ½” and larger, insert appropriate Retainer Nut Wrench (#13) into top of Main Body (#1) and
un-torque Retainer Nut (#5). If there is difficulty in removing Retainer Nut (#5), refer to Section
9.3.

Use precaution while removing the Top Sub (#3) or Retainer Nut (#5) as the
Sleeve Assy. (#6) has preload pressure pushing on the Top Sub/ nut

f) Remove Guide Pin (#11) and Locking / Port Inserts (#12) from Main Body (#1). Retain these for
further inspection. If Guide Pin (#11) & Inserts (#12) are difficult to remove, refer to Section 9.1
& 9.2
g) Take out the Sleeve Assy. (#6) and Spring (#7) from the Main Body (#1). If there is difficulty in
removing the Sleeve Assy. (#6), refer to Section 9.4.
h) Remove Spiral Lock (#8) & Ball Seat (#9) from I.D. of Sleeve Assy. (#6). Retain both the Spiral Lock
(#8) and Seat (#9) for further inspection. If the Spiral Lock (#8) is damaged making it difficult to
remove the Ball Seat (#9), refer to Section 9.5.
i) In 4-1/8” or smaller sizes, un-torque Stem from Sleeve Assy. Remove Ball Seat (#9) from Sleeve.
j) Remove all Seals and O-rings from all tool components. Immediately discard all Seals as these
cannot be re-utilized.
k) Thoroughly steam clean all parts & prepare for inspection. It is good practice to keep all
components of a PBL Tool together for re-assembly into the same tool.

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3. INSPECTION & MEASUREMENT

a) Once cleaned, the Sleeve Assy (#6), Spring (#7), Guide Pin (#11), Main Body (#1), Ball Catcher
Body (#2), Ball Catcher Cage (#4), Port / Locking Inserts (#12), Retainer Nut (#5), Ball Seat (#9) &
Top Sub,#3 (if applicable) should be visually checked for washout, threads, tool face damage and
all other damage which could possibly cause a tool failure.
b) If a pitting/ Spring impression above 3 mm deep is observed on the Sleeve Assy. Stem, it should
be rejected.
c) If excessive corrosion or pitting (> 2mm) is observed on Spring (#7), it must be scrapped.
d) Verify whether Spring (#7) length conforms to “PBL Assembly Acceptance Criteria”; If not, it must
be replaced.
e) Check Ball Catcher Cage (#4) for any wash out. Refer to ‘Ball Catcher Cage Acceptance Criteria’
f) After visual inspection, the Main Body (#1), Ball Catcher Body (#2) & Top Sub, #3 (if applicable)
must be inspected in accordance with DSI PBL Inspection Procedure.
g) Liquid Penetrant Test (LPT) inspection must be carried out on the Sleeve (#6).
h) Measure Main Body (#1) & Ball Catcher Body (#2) lengths as per ‘Recut Specifications’
i) If measurements are less than required, the Subs cannot be put into service. They need to be
quarantined.
j) If any connection requires re-work, follow guideline on ‘Recut Specifications’
k) Ensure the I.D. of the Main Body (#1) is free from any rust, mud, machining chips or other debris.
Thoroughly clean as required prior to assembly.

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3.1 Sleeve (Visual Inspection)

Prior to performing LPT inspection of the Sleeve, carry out a visual inspection in order to identify pitting
on the coating area & washouts in the port area. If any, the Sleeve must be scrapped. A few examples
are shown below;

Fig A & B: Washout around the port area of the Sleeve, including un-uniform washout will prevent sealing of the Steel Balls
during deactivation, gradually increasing the washout area further preventing deactivation of the tool. Sleeve can be scrapped.

Fig C: Any sort of pitting / flaking on the tungsten carbide Fig D: Do not use the Sleeve if the Stem is not torqued or
coating of the Sleeve is unacceptable. If used, this could lead to unscrewed from the Sleeve barrel; do not attempt to fix the
damage of the seals. Ship to DSI FZE for repairs. Sleeve Assembly. Ship to DSI FZE for repairs.

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Sleeve (Visual Inspection) - Continued

Fig E: If the keyway on the stem is not aligned to the port, it Fig F: Guide pin impressions on the key way are a cause for
shall be rejected. Ship to DSI FZE for repairs. rejection of Sleeves. Ship to DSI FZE for repairs.

Fig G & H: Presence of cracks on the sleeve stem shall lead to rejection of the sleeve assembly. Ship to DSI FZE for repairs.

Reject If > 3mm deep

Fig I: Spring impressions above 3 mm deep shall be rejected.

Ship to DSI FZE for repairs.
* Contact your DSI representative before disposing off / shipping back Sleeve assemblies.
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3.2 Ball Seats (Visual Inspection)

Prior to testing, visually check ball Seats for any washout at the lugs and/or the Ball sealing area as
shown below.

Lugs

Ball sealing area

Fig J & K: Washout at the areas indicated above is a cause for rejection of the Seat

3.3 Port / Locking Inserts (Visual Inspection)

Port Inserts / Locking Inserts need to be visually inspected prior to testing. Check for washout at the
Ball Sealing area.

Fig L & M: Washout around the Port Inserts as shown above is a cause for rejection because;
1. A proper seal is not created when the locking ball is in place thereby preventing pressure build-up.
2. The Locking Ball shears at a very low value.

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3.4 Main Body (Visual Inspection)

If there are any wash out at the ports, ensure that the washing is not extending up into the area where
the insert threads reside when fully seated.

Any washing near or over the seal groove area is deemed as Damaged Beyond Repair.

Fig N: Any washing near or over the seal groove area as seen in the
above picture is not acceptable.

Fig O: Washout extending into the thread area of the insert port preventing perfect seating of the insert is a
reason for rejection of the Main Body.

* CONTACT YOUR DSI REPRESENTATIVE FOR FINAL DECISION ON REJECTING A MAIN BODY.

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3.5 Springs (Visual Inspection)

Measure length of the spring and verify if it conforms to dimensions mentioned in the ‘Acceptance
criteria’. If excessive pitting (>2mm) and/or corrosion is found on the springs, it must be scrapped.

Fig P & Q: Cracks & excessive pitting as shown above is not acceptable

Fig R & S: Rusted and corroded springs as shown above are not fit for use.

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3.6 Guide Pin (Visual Inspection)

Prior to assembly, in additional to verifying the length of the stem on the acceptance criteria, visually
check guide pin for cracks on the hexagonal slot head and washout or damage at the stem.

Fig T & U: Guide pins with washed out or broken stems shall be rejected. Fig V: Cracks on the Hexagonal slot head of the
Guide pins are a cause for rejection

3.7 Retainer Nut & Top Sub (Visual Inspection)

Watch out for sleeve impressions on the retainer nut face and the pin nose of the top sub. Up to 2 mm
impression is allowed on the Retainer but, this must be polished prior to use.

Fig W: Sleeve impressions above 2 mm on the Fig X: Sleeve impressions on the top sub pin
retainer nut face is a cause for rejection. nose is a cause for rejection. The pin shall be
reworked provided the minimum length is
maintained as per the recut limits.

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4. ASSEMBLY PROCEDURES

Before starting, make sure you know the customer requirement of the below;
✓ Required Ball shearing pressure and Locking Ball shear pressure.
✓ Ball type (Torlon / Ertalyte / Fast Ball).
✓ Seal type (Hot Hole / Anti Explosive Decompression – EDR / High Temp. seal).
✓ No-Go requirements.
✓ Threaded connection.
✓ Finger Trap requirements.

Sizes 5-1/4” and below tools use Torlon balls as standard instead of the
Ertalyte Balls.

Clean all parts so they are free of contaminants, making sure all parts are de-burred and coated surfaces
are clean.

Ensure the Main body (#1), Ball catcher body (#2), Top Sub (#3) (if applicable) and Sleeve (#6) have been
NDT Inspected as per ‘PBL Inspection Procedure’.

- For part identification, refer to Section10

- All threads are right-handed unless otherwise designated.

4.1. Testing of Ball Seats (#9) & Locking Inserts (#12)

a) Place the Ball-seat (#9)/Locking insert (#12) with the suitable test adaptors into the test unit.
b) Place the ball (according to the size of tool) on to the Ball-seat (#9) / Locking insert (#12).
c) Connect the pump out let and apply pressure until the ball shears.
d) Record the ball shearing pressure on a Barton chart and attach with the tool service report.
e) Ensure the ball shearing pressure for the Ball seat is as per requirement.
f) Locking insert shear pressure must be a minimum of 1000 psi and a maximum of 500 psi
lesser than the Ball seat pressure.
1. In case of unavailability of low-pressure Seats & Inserts, carefully
grinding the lugs with a pneumatic buffer & emery wheel will lower the
pressure.
2. While shop testing of Ball seats, it is normal for the ball to not completely
shear through the seat. This is due to the low volume and/or intermittent
pumping.

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4.2 Sleeve & Seat Assembly (#6)

a) Inspect Sleeve for sharp edges where the coating meets the Port Hole and at the pin end of
the Sleeve (grind and polish if necessary).
b) Visually inspect tungsten carbide surface for wash out, cracks or pitting.
c) Ensure one Port Hole is in alignment with key way on the stem.
d) Ensure the Spring (#7) fits over the pin (Stem) of the Sleeve with little to no resistance (grind
Spring, if necessary, to remove any sharp edges).
e) Ensure the I.D. of the Stem pin end is free from any ridges or lips.
f) Buff out any rust inside of the Barrel and note the condition of the Spiral Lock grooves.
g) Install tested Ball Seat (#9) (with Seat radii facing toward the largest opening of the Sleeve)
with O-ring; coat with the recommended lubricant.
h) For 650 SSBB and 675 SSBB, install Dart Seat (#10) with O-ring before installing the Ball Seat
(#9).
i) For 4 ¾” to 9 ½” put O-ring on Seat and lubricate with recommended lubricant. Slide Ball Seat
(#9) past the farthest Spiral Lock Groove in the Sleeve Assy., making sure that the bevel on
the lugs is facing up. Tap Seat to ensure all the way down. Install Spiral Lock (#8) so that the
outside end of the Spiral Lock (#8) is directly opposite of the Port Hole for easy removal. See
Figure-1.
j) For 4-1/4” & smaller, put O-ring on Ball Seat (#9) and lubricate (with recommended
lubricant). Remove the Stem from the Barrel of the Sleeve & insert Ball Seat #9 (make sure
bevel on lugs is down) Apply thread locking compound (Loctite 243) to threads of Stem &
replace the Stem. Ensure Guide Pin groove is in alignment with port hole in Sleeve. See
Figure-1A.

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Include for 650 & 675 SSBB Tools

FIGURE 1- Sleeve & Seat assy. of 4-3/4” to 12” PBL Tools

FIGURE 1A- Sleeve & Seat assy. of 4-1/4” & smaller sizes

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4.3. Main Body Assembly

a) Place Main Body (#1) on bench vice.
b) Install O-rings on tested Locking Inserts #12 (2 or 3 qty depending on the number of ports).
Apply thread locking compound (Loctite 243) to Locking Insert (#12) threads. Install Locking
Inserts (#12) into Ports and tighten utilizing Port Insert Wrench (#14). Torque with a
calibrated torque wrench as per limits mentioned in PBL ‘Assembly Acceptance criteria’.
c) Ensure Inserts do not protrude from Main Body O.D.
d) Rotate Main Body (#1) so Guide Pin hole is facing upwards.
e) Perform a dry run of the Sleeve assembly (#7) by inserting it fully into the Main Body (#1).
Check and ensure that the Main body ports and the ports on the sleeve are aligned, and the
keyway on the stem is aligned to the guide pin port. Pull out the sleeve, it should move with
no restriction.
During the dry run, ensure the sleeve port and key way is fully aligned with
the Main body port hole and guide pin port. If not, the sleeve shall be
rejected.
f) Install and hand tighten an old guide pin (without o-ring) into the guide pin port. This is for
reference only, to guide the sleeve.
g) Lubricate with recommended lubricant and Install Main Body Seals (4). See Figure 2. The lip
or ridge of the Seals should all face away from the Port Hole. See Figure 2A. Lubricate Main
Body (#1) I.D. with recommended lubricant.
h) Apply recommended lubricant to Sleeve Stem and slide Spring over it.
i) Slide Sleeve Assy. (#6) and Spring (#7) into the Main Body (#1), so that Guide Pin Groove on
Stem lines up with Guide Pin (#11).
j) Push in as far as possible ensuring Stem Groove is aligned with Guide Pin (#11).
k) Ensure Locking Inserts (#12) do not interfere with movement of Sleeve Assy. (#6)
l) From the box end, insert threaded rod with ball attachment (appropriate to the tool size
being built). Place a U-Plate at the pin end of the Main Body and fasten the nut as the sleeve
begins to move towards the Pin. See Figures 3 and 3A (5-1/4” & Below).
m) Once all the retainer nut threads are visible in the Main Body, lubricate with ‘KOPR KOTE’ and
Install Retainer Nut (#5) (with O-rings) or Top Sub (#3) and tighten. Retainer Nut (#5) has a
special wrench (#13) used in conjunction with a 48” pipe wrench; hand tight is sufficient.
Measure distance of retainer nut from box shoulder of Main Body. Refer Section 4.3.1 for
calculation.
Retainer nut shall be installed once all retainer nut threads are visible
in the Main Body. Proceed with next step only after installing Retainer
Nut or Top Sub to prevent any possible injury.
n) Release the pressure on the threaded rod until the sleeve touches the Retainer Nut. With
a permanent marker, make a mark a on the sleeve from the Main Body port hole.
o) Fully compress the Sleeve Assy. (#6) until the ports on the sleeve aligns with the ports on
the Main Body.

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p) Release threaded rod and watch for a smooth recoil of the Spring. No bouncing or sticking
should be evident; remove threaded rod. Smooth recoil of the spring and sleeve confirms
that the springs and seals are in good condition.
q) Ensure the sleeve has returned to its initial position by verifying the mark on the sleeve.
r) Remove the old guide pin from the Main Body.
s) Install O-rings on Guide Pin (#11), lubricate O-rings with recommended lubricant, and apply
thread locking compound (Loctite 243) to threads of Guide Pin (#11).
t) Insert and torque Guide Pin (#11) (with a calibrated torque wrench as per limits mentioned
in PBL Assembly Acceptance criteria) into Main Body (#1). Guide Pin (#11) should not stick
out from O.D of Main Body (#1), grind if necessary.

Ensure that once installed, the Guide Pin (#11) will prevent the Sleeve
Assy. (#6) from rotating.

4.3.1 Retainer Nut Calculation

a) Measure Dimension ‘A’ (distance from centre of the guide pin port to the box shoulder).
b) Subtract the actual measured value from Dim. A in the table below, as per the tool size.
c) Subtract the value obtained (in the previous step) from Dim. B in the table below, as per the tool
size.
d) The resultant dimension should be equal to the ‘actual dimension’ of the retainer nut.
Example:
Actual Dimension ‘A’ on a recut 6-3/4” tool = 35”
Dim. A (Ref. New) from below table for 6-3/4” tool = 36”
Dim. B (Ref. New) from below table for 6-3/4” tool = 8.25”
Dim. A (Ref. New) – Actual Dim. A = X
Dim. B (Ref. New) – X = Retainer Nut measurement.
36” – 35” = 1”
8.25” – 1” = 7.25”
Distance of retainer nut = 7.25” (Actual measurement should match this value)

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FIGURE 2- Main Body Seal Installation

FIGURE 2A- Main Body Seal Orientation

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FIGURE 3- Main Body assembly for new 3-1/2”, 6-1/2” & Larger Sizes

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FIGURE 3A- Main Body assembly for 5-1/4” & Smaller sizes

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4.4. Ball Catcher Body Assembly

Ball Catcher Body Assembly can also be carried out after the Hydrostatic
Pressure Tests.

a) Insert Ball Catcher Cage (#4) into Ball Catcher Body (#2) with No-Go towards pin of Sub.
b) If required, place the bottom Ball Trap Block/ Finger Trap (#15) on top of the Ball Catcher
Cage (#4) as shown in the below image. Once the finger trap is utilized downhole, the spring
must be replaced.

Finger Trap Installed in a BC Body

FINGER TRAP PART

TOOL SIZE
NUMBER
4-3/4” 475BP44
6-3/4” 675BP44
8-1/4” 800BP44

c) Dope pin end of Main Body (#1) with “KOPR KOTE”.

d) Thread Ball Catcher Body Box (#2) to Main Body (#1) Pin.
e) Torque all connections (Including Top Sub, if utilized) as per torque limits mentioned in
PBL Assembly Acceptance criteria. Else, connections shall be marked / taped as ‘Loose
Joint’.

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5. HYDROSTATIC TEST PROCEDURE

a) Position tool on test stand saddles to where the binding strap will fall about a foot from the
box end of the tool. It is not required to test complete tool; assembled Main Body only is
acceptable. 5 ¼” and smaller require torqued top sub on main body assembly
b) Secure tool to saddle with binding strap tight enough to keep tool from rotating
c) Install nubbins (according to connection size) on both ends & plug in hose fitting to the pin
end of main body.
d) Add water pressure and allow tool to fill and bleed off trapped air.
e) Place a chart in the Barton chart recorder (or similar) & turn on the timer.

Clear all personnel from test area before pressurizing the tool.

f) Perform a Low-Pressure test at 500 psi for 5 minutes.

g) Pressure system to 5000 P.S.I and hold for 15 minutes.
h) Allowable pressure drop is 5% on higher end (for both L.P & H.P Tests).
i) Check for any leaks in the tool. Leaks will be visible around port holes, guide pin, test nubbins
or hydraulic fittings.
j) If a leak is detected, tool must be bled off from the valve on the control panel
k) If leak was around port holes, disassemble and main seals need to be changed. (CHECK FOR
DEBRIS IN SEAL GROOVES)
l) If leak was around the guide pin, remove guide pin and change o-rings on guide pin
m) If leaking occurred around test nubbins, tighten down more, or if need be replace nubbin O-
rings
n) If no leakage is present, allow tool to settle for a few minutes, ensuring pressure did not drop
below the allowable pressure drop of 5% on higher end.
o) Remove hose from nubbin and nubbins from tool.
p) Make sure that the activation ball has been removed from the tool
q) Attach Barton Chart with the tool service report.

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6. PAINT & STENCIL

a) Do not let paint come into contact with the Sleeve through the Port Holes
b) Use the appropriate tool stencil
c) Label the proper I.D., O.D. and Connection type. Also label any Body Connection; Ball Seat &
Locking Insert pressure ratings.
d) Place clean grease in ports and wrap with tape.
7. RE-RELEASE PROCEDURE

This procedure states the minimum requirements for the re-release of an unused PBL tool. Customer
requirements take priority.

Tool needs to be completely inspected & re-serviced if a period of 6

months has been exceeded from initial inspection and assembly
a) Perform visual inspection of OD & connections and check ID of tool.
b) Perform testing as mentioned in Section 5.
c) Check ID for any restrictions.
d) Repaint and re-stencil tool (if required) as mentioned in Section 6

8. STORAGE

a) Seals: Generally, O-rings (elastomers) should be kept in their original packaging and stored in
a cool, dry, low light area (away from UV & Fluorescent light). They should also be kept as
dust free as possible. All elastomers are susceptible to physical damage. Use care and caution
when using tools and/or sharp objects.
• Temperature – below 1000 F (380 C)
• Humidity – less than 75% (AU/EU less than 65%) if not stored in sealed moisture proof bags
• Light – protected from light sources especially direct sunlight or intense artificial light.
• Ozone – storage rooms shall not contain any equipment that is capable of generating ozone
such as generators and electrical equipment
• Shelf Life – 10 Years - Elastomers are age controlled by the cure date (the date the rubber
is fully cured). The cure date is stated in terms of the quarter and the year (example:
2Q01 = second quarter of 2001). The shelf life is the maximum period from the cure
date, to the date the product is used
b) Balls: Store primarily at room temperature, away from sources of ultra violet rays and in
a relatively moisture free environment.

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A storage temperature range of -60oC to +55oC is not expected to have an influence on the
shelf life of both Ertalyte and Duratron T4301 PAI (Torlon).
Shelf life of Ertalyte, Torlon & Fast balls is 15 years.
c) Tools: All serviced tools must be stored indoors / under covered area. All threaded
connections shall be protected with a layer of phosphate cote and/or thread compound and
have thread protectors installed on them.

9. TROUBLESHOOTING

Below are the guidelines for troubleshooting common issues encountered during disassembly of the PBL
subs

9.1. Guide Pin (#11)

Always prior to removal of the Guide Pin, the hexagonal socket of the Guide Pin must be
thoroughly cleaned and a correct size Allen key must be used. DO NOT use heat unless the
Guide Pin cannot be removed using usual methods.
• Method 1: Insert an extension pipe onto the Allen key and loosen the Guide Pin while
ensuring that the Allen key does not slip and the hexagonal socket does not get
deformed.
• Method 2: Using a torch tip, slowly but thoroughly heat the body around the Guide
Pin. The Guide Pin can then be removed by using an Allen Key and an extension pipe.
• Method 3: If the hexagonal socket on the Guide Pin is deformed, the Guide Pin can be
removed by welding a flat washer or an appropriate bolt to the Guide Pin. It can be
then removed with the use of a pipe wrench to grasp the washer / bolt.

Once heated, allow the Body & Guide Pin to cool slowly. DO NOT use
water or any other liquids to quench the Guide Pin or surrounding area.
Quenching will contribute to cracking of the Guide pin and/or the port
hole.

9.2. Port Inserts (#12)

Always prior to removal of the Inserts, the port hole must be thoroughly cleaned and a proper
Insert Wrench, Allen Socket & T-Handle must be used. DO NOT use heat unless the Insert
cannot be removed using usual methods.
• Method 1: Insert an extension pipe onto the T-Handle and loosen the Insert while
ensuring that the Insert Wrench does not slip.
• Method 2: Using a torch tip, slowly but thoroughly heat the body around the Insert.
The Insert can then be removed by using an Insert Wrench, Allen Socket, T-Handle
and an extension pipe.

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• Method 3: Heat the insert until it is red hot and allow it to cool for some time. Now
try to break the insert with a heat treated chisel.
Once heated, allow the Body & Insert to cool slowly. DO NOT use water
or any other liquids to quench the Insert or surrounding area. Quenching
will contribute to cracking of the port hole.
9.3. Retainer Nut (#5)

Prior to removing the Retainer Nut, the area before the Retainer Nut must be thoroughly
cleaned free from debris and/or scaling.
If there is difficulty in removing the Retainer Nut, try the following methods in the order given
below. DO NOT use heat unless the Retainer Nut cannot be removed using usual methods.
• Method 1: Insert a Retainer Nut Wrench into the Retainer Nut and try to loosen the
Nut with a 48” Pipe Wrench and a long extension pipe.
• Method 2: A belt may be secured with a shackle onto the Pipe Wrench and using an
Overhead Crane, lift the pipe wrench to loosen the Retainer Nut
• Method 3: Place the Main Body into a Break out machine and loosen the Retainer Nut.
(The Retainer Nut Wrench may require to be welded onto a larger diameter pipe
depending on the clamping capacity of the Break Out Machine)
• Method 4: Using a torch tip, slowly but thoroughly heat the OD of the tool where the
Retainer Nut is located. Once heated, try to loosen the Retainer Nut as mentioned in
Method 1 above. Allow the Body to cool slowly. DO NOT use water or any other liquids
to quench the body after heating.
9.4. Sleeve Assy. (#6)

Quite often on an excessively used tool or when a used tool is stripped down after prolonged
periods, the Sleeve assy. cannot be easily removed from the Main Body (#1) due to presence
of debris and drying up of the drilling fluid. Follow the below methods for the removal of
Sleeve Assy.

• Method 1: To prevent damage to the sleeve stem, from the Main Body pin side, insert
a solid metal block (preferably made of brass) large enough to cover the sleeve stem
and then use a solid bar to hammer out the sleeve from the Main Body(#1).

• Method 2: The sleeve Assy. can be pushed out by using a Jar Tester or a hydraulic
press.

• Method 3: A hollow plunger cylinder, pump, U-Plate and a threaded rod can be
used to pull out the sleeve from the Main Body (Fig 4).

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Fig 4: Pulling out a stuck sleeve with a Plunger cylinder and pump.

9.5. Ball Seat (#9)

If the tip of the Spiral Lock (#8) is damaged, making it difficult to remove the ball seat, then
the Spiral Lock (#8) can be machined out in a lathe and if needed can be pushed out of the
Sleeve Assy. (#6) with a hydraulic press.

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10. PARTS LIST

#1 Main Body #2 Ball Catcher Body

#3 Top Sub #4 Ball Catcher Cage

Stem
Sleeve

#5 Retainer Nut #6 Sleeve Assy.

#7 Spring #8 Spiral Lock / Retaining Ring

#9 Ball Seat #10 Dart Seat

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#11 Guide Pin #12 Locking Insert / Port Insert

6-3/4” SSBB

8-1/4” & 6-3/4” STD

#14 Locking Insert Wrench /

#13 Retainer Nut Wrench
Port Insert Wrench

#15 Finger Trap / Ball Trap Block #16 Seat Spacer (SSBB)

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ANNEXURE-1: PBL ASSEMBLY ACCEPTANCE CRITERIA

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ANNEXURE-2: BALL CATCHER CAGE ACCEPTANCE CRITERIA

TECHNICAL SERVICES BULLETIN

TOOL TYPE PBL Sub

TOOL SIZE All Sizes
EFFECTED COMPONENT Ball Catcher cage

This Technical Service Bulletin is issued to provide an acceptance criterion for reusing a ball catcher
cage with wash out.

The cage washout is normal as the flow is concentrated at the bottom of the cage while the fluid exits
the tool.

‘THIS WASHOUT DOES NOT AFFECT THE INTEGRITY/ FUNTIONING OF THE PBL SUB’ as the Ball catcher
is intended to house the used balls only.

However, if the wash out rates exceed the minimum required values mentioned in the table below, it
is recommended to be replaced with a new cage.

Dimension ‘A’ when Dimension ‘A’

Tool Size
new minimum requirement
4-3/4” 1.18” 0.6”

6-3/4” 1.31” 0.65”

8-1/4” & above 1.66” 0.8”

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ANNEXURE-3: LUBRICANT SPECIFICATIONS

TECHNICAL SERVICES BULLETIN

TOOL TYPE PBL Sub
TOOL SIZE All Sizes

EFFECTED COMPONENT Tool Lubrication

This Technical Service Bulletin is issued in order to highlight the use of the correct grease and lubricating
oils for servicing of the PBL sub.

Proper selection of grease and lubricating oils is critical to ensure effective functioning of the tool. The
recommended grades of grease and lubricating oils are as mentioned below;

APPLICATION LUBRICANT TYPE

Recommended – Jet Lube Alco EP 73 plus

Lubrication of seals, spring, sleeve stem and Alternative – Equivalent Lithium /

Main body ID
For threads of guide pins and port inserts
For retainer nut threads and tool joint
connections
Aluminium complex greases having an
operating range of at least -32 deg C to 230
deg C.
Recommended - Loctite 243.
Alternative – Medium Strength thread
locking compounds of equivalent brands
having a temperature resistance of at least
180 deg C.
Recommended – Jet Lube KOPR-KOTE
Alternative – Zinc or copper tool joint
compounds as recommended by API.

For covering ports on Main body for Normal NLGI grade 2 mechanical grease.
shipping & storage

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ANNEXURE-4: MAIN BODY RECUT SPECIFICATIONS (4-3/4” & LARGER

TOOLS)

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ANNEXURE-5: BALL CATCHER BODY RECUT SPECIFICATIONS (4-3/4” &

LARGER TOOLS)

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ANNEXURE-6: TOP SUB RECUT SPECIFICATIONS (4-3/4” & LARGER TOOLS)

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ANNEXURE-7: RECUT SPECIFICATIONS (2-7/8” TOOLS)

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ANNEXURE-8: RECUT SPECIFICATIONS (3-1/8” TOOLS, 2-3/8 Reg Conn.)

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ANNEXURE-9: RECUT SPECIFICATIONS (3-1/8” TOOLS, 2-7/8 HT PAC Conn.)

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ANNEXURE-10: RECUT SPECIFICATIONS (3-1/2” TOOLS)

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ANNEXURE-11: RECUT SPECIFICATIONS (4-1/8” TOOLS)

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ANNEXURE-12: PROCEDURE FOR INSPECTION OF PBL CIRCULATING SUBS

1.0 Scope
1.1. This procedure covers the NDT inspection and dimensional requirements for DSI PBL Tools.

2.0 References
• API Recommended Practice 7G, Latest Edition
• DS-1 Standard, Volume – 3, Latest Edition
• DS-1 Standard, Volume-4 (Specialty Tools), Latest Edition: Type A Tools, Dimensional 3 inspection.
• Main Body, Ball Catcher & Top Sub recut specifications, Latest Revision.

3.0 Personnel
3.1. Personnel performing inspections per this procedure shall be:
3.1.1. Certified in accordance with requirements of DS-1 standards
3.1.2. Level II MPI and LPT certifications are required to perform magnetic particle inspection.
3.1.3. Trained per this procedure.

4.0 Equipment Calibration

4.1. Applicable equipment shall be calibrated in accordance with procedures set forth by the OEM at the
following intervals.

Equipment Description Calibration Intervals

Visible Light Meter 6 Months
Ultraviolet Light Meter 6 Months
Magnetizing Coil 6 Months
UT Unit 6 Months
Pit Depth Gage 4 Months
CD Box 6 Months
Amperage Box 6 Months
Lead Gage/Standard 4 Months
Yoke 6 Months
Calipers (dial or vernier) 6 Months
Gauss Meter 6 Months

5.0 Examination Process

5.1. Preparation

5.1.1. All areas to be inspected shall be cleaned to a degree that shiny metal surfaces are visible and free
of any contaminants, such as grease, dirt, scale, rust, paint, etc.

5.1.2. Any obstruction to an area of interest shall be noted on the inspection report.

5.2. Process Controls

5.2.1. Particle Concentration – shall range from 0.1 – 0.4 ml / 100 ml when measured using a 100 ml
centrifuge tube, with a minimum settling time of 30 minutes. Particle solution shall be
sufficiently agitated, and hose drained off prior to settling test and inspection. Sample shall be
viewed under black light to ensure contamination is not present.

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5.2.2. Blacklight Intensity – shall be measured with a ultraviolet light meter each time the light is turned
on (after warm up for mercury vapor bulbs), after every 8 hours of operation, and at the
completion of the job. The minimum intensity shall be 1200 µ watts / cm² at 15” from light meter.

5.2.3. White Light Intensity – shall be verified at the inspection surface prior to inspection. A maximum
of 2 ft. candles of white light is allowed during black light inspection. For visual inspection a
minimum of 50 ft. candles is required.

5.3. MT Inspection
5.3.1. MPI Body Inspection (Class A1) – shall be performed on all new manufactured tools as well as used
tools by using either the dry magnetic or wet fluorescent magnetic particle technique with an
active DC field to detect transverse and three-dimensional flaws.

5.3.2. MT Connection & Port Hole Inspection (Class A1/A2) – shall be performed on unused tools, that
have already been inspected as per DS-1 class A1 previously, using the wet fluorescent continuous
method to detect transverse discontinuities.

5.3.2.1. Equipment Required:

• 100 ml Centrifuge Tube
• Burma Castrol Strip
• Ultraviolet Light Meter*
• Blacklight
• Coil (FWDC or HWDC) *
• Magnaflux MG 410 or equivalent
• Black Canvas Cape
• Inspection Mirror
• Permanent Metal Marker
(*) Current Calibration Required

5.3.2.2. Magnetization – Connections shall be magnetized longitudinally with the

applicable magnetizing coil. The following may be used as an estimate for determining
proper amperage:

I = O.D. *(1200/N)

Where: I = amperage
O.D. = outside diameter
N = number of coil turns

5.3.2.3. Magnetization Current – activation and magnetic particle solution application shall be
performed simultaneously. The magnetizing current shall remain on for at least 2 seconds
after the solution has been distributed. Field direction and strength shall be verified using
a Burma Castrol strip. A minimum of 3 lines is required with current on. Uniform field
intensity is required around the entire circumference of the part. Magnetic particle
solution shall be agitated before each application and periodically during use.

If the part is less than 6’ in length, connections must be magnetized with opposite
polarity.

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5.3.2.4. Examination – The threaded area along with the shoulder and face of the connections shall
be examined. The ID and OD past the thread shall also be examined. Puddles shall be rolled
and re-processed.

5.3.2.5. Acceptance Criteria – Any discontinuity shall be cause for rejection.

Discontinuities may be proven up with the authorization of a DSI supervisor. Any deviation
from this procedure must first be approved and signed off by a DSI Supervisor.

5.4. Sleeve Inspection

5.4.1 Liquid Penetrant examination to be carried out on the coating area of the sleeve and ID of the
sleeve barrel. Look out for crack indication in the ball seat area of the sleeve at the change in cross
section.

5.4.2 MPI Inspection to be carried out on the Sleeve stem.

5.4.3 Pitting, erosion, cuts, gouges on sealing areas of the sleeve or flaking or peeling of the coating
shall be a cause for rejection.

5.4.4 Any cut, gouge, spring impressions or similar imperfections, on the stem, deeper than 1/8th of an
inch shall be a cause for rejection.

5.4.5 If the keyway on the stem is not aligned to the sleeve port, the sleeve shall be rejected.

5.4.6 The port edges on the ID of the sleeve shall remain sharp or uniformly rounded. If there is
ununiform washout, the sleeve shall be rejected.

5.5 Visual Examination

5.5.1 Visual inspection – shall be used to examine the condition of the connections, ID, and OD for
damage. A minimum of 50-foot candles of white light is required.

5.5.2 Equipment

• Hard and ground profile gages

• Visible Light Meter
• Lead Gage and Standard*
(*) Current calibration required

5.5.3 Visual

5.5.3.1 Cracks – All connections and surrounding bodies shall be free of visible cracks and heat
checking.

5.5.3.2 Bevel Width – An approximate 45-degree OD bevel at least 1/32” wide shall be present
for the full circumference of the connection.

5.5.3.3 Thread Surfaces – Thread roots shall be free of all pitting. Thread surfaces shall be free of
other imperfections that appear to penetrate below the thread root, occupy more than
1-1/2” in length along any thread helix, or exceed 1/16” in depth or 1/8” in diameter.
Raised protrusions must be removed with a hand file or “soft” (nonmetallic) buffing

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wheel. The thread profile shall be checked with a hardened and ground profile gage after
any buffing or filing of the threads.

5.5.3.4 Box Swell – A straightedge shall be placed along the longitudinal axis of the box OD. If visible
gaps exist between the straightedge and the OD surface, the OD must be measured using
calipers. Compare the OD at the bevel to the OD 2” (±1/2”) away from the bevel. If the OD
at the bevel is greater by 1/32” or more, the connection shall be rejected.

5.5.3.5 Seal Surfaces – The seal surfaces shall be free of raised metal or corrosion deposits detected
visually or by rubbing a metals scale or fingernail across the surface. Any pitting or
interruptions of the seal surface that are estimated to exceed 1/32” in depth or occupy more
than 20% of the seal width at any given location are rejectable. No filing of the seal shoulders
is permissible.

5.5.3.6 I.D. Seal Groove – shall be visually examined for washout and imperfections that may be
detrimental to the service of the tool. All washout or imperfections must be marked and
reviewed by the DSI supervisor to determine whether it is rejectable or acceptable.

5.5.3.7 Refacing – If refacing is necessary, only enough material to correct the damage shall be
removed. Refacing limits are 1/32” on any one removal and 1/16” cumulatively.

5.5.3.8 Thread Profile – A hardened and ground profile gage shall mesh with the thread load and
stab flanks so that no light is visible at any of the flanks or thread roots. Visible gaps
estimated to be no greater than 1/16” on no more than two thread crests are permissible.
Uniform flank wear estimated to be less than 0.010” is permissible. However, any visible
gaps at the thread flanks will require lead gage measurements.

5.5.3.9 Pitting – That is measured or visually estimated to be deeper than 1/8 inch shall be cause for
rejection.

5.5.3.10 Shoulder Flatness – Shall be verified on boxes by placing a straightedge across the diameter
of the shoulder and rotating the straight edge at least 180 degrees along the plane of the
shoulder. Any visible gaps shall be cause for rejection.

5.5.3.11 Eccentric Wear – Shall not exceed 30% of the nominal thickness.

5.6 Dimensional – Covers the dimensional inspection requirements of rotary shouldered connections on PBL
tools.

5.6.1 Equipment
• I.D. and O.D. set calipers
• 12” metal rule graduated in 1/64” increments
• Engineer Tape

5.6.2 Dimensional Measurements – The dimensions shall be taken and recorded on the standard
inspection form. Dimensional tolerances shall be in accordance with DS-1 volume 3, latest
edition. Any equipment out of tolerance shall be rejected.

If the Main body, Ball Catcher Body and Top Sub do not meet the minimum length
requirements as outlined in the Recut specifications, it shall be rejected.

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5.7 Bore Back Waiver – The box ends of the PBL Tools (Main Body & Ball Catcher Body) do not accommodate
“Bore Back” features due to this feature interfering with the assembly / design of the tool. All tools that
have a top sub shall have a bore back.

5.8 MT of Port Holes

5.8.1 General

This section covers the examination of port holes of PBL tools for transverse discontinues, using the wet
fluorescent magnetic particle with a continuous HWDC or FWDC D.C. field.

5.8.2 Equipment

- 10” HWDC or FWDC Coil*

- Burma-Castrol Strip
- Magnaflux MG 410 or equivalent
- Visible Light Radiometer *
- UV Light Meter*
- Centrifuge tube
* - Current calibration required

5.8.3 Procedure and Acceptance Criteria

5.8.3.1 Verification of Field Intensity and Direction:

Proper field magnitude and orientation shall be verified with the Burma-Castrol strip
on the inspection surface. All 3 lines must be visible.
5.8.3.2 Examination:
Visual examination shall be performed on ID seal grooves.
All Port Holes (Guide pin, side ports, etc..) shall be examined for transverse
discontinuities. A minimum of 1200 µ watts/ cm² at 15” from light meter
Areas with questionable indications shall be recleaned and reinspected.
5.8.3.3 Acceptance Criteria:
Visible washouts in ID seal groove area shall be reviewed.
Any discontinuity shall be cause for rejection. Grinding to remove cracks is not
permitted. Instead, radii up to a maximum of R.125 can be machined to remove the
cracks. An example is shown below;

Other imperfections shall not exceed the specified limits given in DS-1.

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5.9 Color Code for inspection findings

White OK
Red Cracked / Scrap / DBR
Yellow Shop Repairable
Green Field Repairable

6.0 Reporting:

The following reports shall be completed:

• Standard Inspection report

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- End of the Document –

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