Supercedes:

Shaffer Engineering Standards/Specifications

DIRECT DRIVE VALVE (DDV) ASSEMBLY AND REPAIR PROCEDURE NEW

 Varco Shaffer, Inc. 2002, 2001

Copyrighted as an unpublished work 66329 Added para. 4.3.2 and 7/19/02 A
ALL RIGHTS RESERVED RGH Section 5.0.
SHAFFER 0464-1 10/05/92 EC # Revision Description Date Rev. Ltr
This work contains the CONFIDENTIAL AND Engineering
Prepared Checked Approved Release Number Date
PROPRIETARY INFORMATION of Varco Shaffer,
Inc. Neither this document nor any information A -X080043
disclosed herein shall be reproduced in any form,
used, or disclosed to others for any purpose,
MJH TN FLS 58781 3/13/01
including manufacturing, without the express written 3/01 3/01 4/01 Title Page
permission of Varco Shaffer, Inc.
 Supercedes:
Shaffer Engineering Standards/Specifications

DIRECT DRIVE VALVE (DDV) ASSEMBLY AND REPAIR PROCEDURE NEW

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A -X080043
any form, used, or disclosed to others for any
purpose, including manufacturing, without the ALL RIGHTS RESERVED
express written permission of Varco Shaffer, Inc.
SHAFFER 0464-2 10/05/92 Sheet 1 of 5 Rev. A
 Supercedes:
Shaffer Engineering Standards/Specifications

DIRECT DRIVE VALVE (DDV) ASSEMBLY AND REPAIR PROCEDURE NEW

1.0 SCOPE

This procedure provides instructions on the assembly and repair of the Direct Drive
Valve (DDV) and the Fluid End.

2.0 REFERENCE DOCUMENTS

DDV Installation Drawing - 20005923D

3.0 EQUIPMENT REQUIRED

The following special tools are required for repair:

P/N 7401350 Seal Kit, DDV Valve

P/N 20001543 Seat Removal Tool
P/N 20001544 Seat Installation Tool
P/N 20001545 O-ring Installation Tool
P/N 20002953 Orifice Torque Wrench
P/N 20005648 1/16” Hex Wrench
P/N 20005646 5/32’ Hex Wrench
P/N 20005649 O-ring Removal tools, pick and/or industrial tweezers

All of these tools are included in the Shaffer Tool Kit, P/N 20005657.

4.0 DIRECT DRIVE VALVE (DDV) - FLUID END REPLACEMENT/REPAIR

Refer to drawing 20005923D.

4.1 Preliminary Setup

4.1.1 Clean an area to work

4.1.2 Have all tools close at hand prior to repair.

4.1.3 No lubrication is used during reassembly of the components.

4.1.4 All components need to be completely dry and free of contaminates

prior to reassembly.

4.1.5 Verify the rubber goods in the seal kits are not past their expiration
dates. DO NOT use rubber goods past their expiration dates.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A -X080043
any form, used, or disclosed to others for any
purpose, including manufacturing, without the ALL RIGHTS RESERVED
express written permission of Varco Shaffer, Inc.
SHAFFER 0464-2 10/05/92 Sheet 2 of 5 Rev. A
 Supercedes:
Shaffer Engineering Standards/Specifications

DIRECT DRIVE VALVE (DDV) ASSEMBLY AND REPAIR PROCEDURE NEW

4.2 Repair of DDV

4.2.1 Pressure down the pod pilot system. Remove the interconnecting
cable from the DDV and the DDV from the SPM or pocket.

4.2.2 Clean loose contamination and debris from DDV Assembly.

4.2.3 Separate the fluid end body from the solenoid by moving the four
button head capscrews, #16, using an 1/16” hex wrench. Retain the
screws for reassembly.

4.2.4 Carefully remove the fluid, #15, end from the solenoid, #19, by
grasping the fluid end and solenoid and pulling it apart.

CAUTION: Caution must be used due to the armature, #18,

armature spring, #13, and the plunger, #17, may come
out of the assembly.

4.2.5 Remove the plunger, #17, from the solenoid end of the body, #19.
Remove the armature, #18, and armature spring, #13, from the
solenoid, #19. Do not discard these components.

4.2.6 Remove the O-ring, #5, and the backup rings, #6, from the solenoid
end of the body. It is recommended that the O-rings and backup rings
be cut in half immediately after removal. This will alleviate the
possibility that the components are mistakenly reused.

4.2.7 Reinstall the fluid end, #15, (Without the above mentioned
components) into the solenoid, #19, using two button head capscrews,
#16, located 180 degrees apart. Snug capscrews, #16. This step is
included to prevent damage to the cage, #20, and the plunger, #17.

4.2.8 Remove the orifice, #14, using a 5/32” hex wrench, P/N 20005646.

CAUTION: Removal of the orifice with the plunger in place may

cause permanent damage to the plunger.

4.2.9 Remove the fluid end body, #15, from the solenoid, #19.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A -X080043
any form, used, or disclosed to others for any
purpose, including manufacturing, without the ALL RIGHTS RESERVED
express written permission of Varco Shaffer, Inc.
SHAFFER 0464-2 10/05/92 Sheet 3 of 5 Rev. A
 Supercedes:
Shaffer Engineering Standards/Specifications

DIRECT DRIVE VALVE (DDV) ASSEMBLY AND REPAIR PROCEDURE NEW

4.2.10 The Seat Removal tool, P/N 20001543, is used to push the seats (2, 3),
cage (20), ball (1), O-ring (11), and the screen (4) from the body (15).
Insert the seat removal tool into the solenoid side of the fluid end body
and push the interior components out through the orifice end of the body.
Discard the seats, O-ring, ball and screen. It is recommended that the
O-rings and backup rings be cut in half immediately after removal. This
will alleviate the possibility that the components are mistakenly reused.

CAUTION: Do not discard the Cage, #20.

4.2.11 Using the O-ring removal pick or tweezers, P/N 20005649, remove O-
ring, #11, and the remainder of the O-rings, #’s 5, 7, 9 and backup rings,
#’s 6, 8, 10 from the exterior of the body, #15. It is recommended that the
O-rings and backup rings be cut in half immediately after removal. This
will alleviate the possibility that the components are mistakenly reused.

4.2.12 Clean and inspect the following components:

 Body, #15 - Verify the unit is clean and that holes are not plugged.
 Plunger, #17 - Verify the unit is clean and the length is greater than
1.4490 inches
 Cage, #20 - Verify the unit is clean and that holes are not plugged.
 Orifice, #14 - Verify the unit is clean and that holes are not plugged.
 Armature, #18 - Verify the unit is clean, that hole is not plugged, and
the surfaces are free of scoring.
 Solenoid #19 - Verify the unit is clean and the internal diameter is
free of scoring. At this time, the solenoid can be verified electrically
using procedure A-X060683.

4.3 Assembly of DDV

NOTE: The fluid end assembly is assembled dry - DO NOT USE lubrication
of any type.

4.3.1 Place O-ring, #11, in the orifice end of the body, #15. Using the bevel
end of the O-ring installation tool, P/N 20001545, work the O-ring, #11,
down to the bottom of the counterbore in the body, #15. Insure the O-
ring is properly seated using the flat end of the O-ring installation tool.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A -X080043
any form, used, or disclosed to others for any
purpose, including manufacturing, without the ALL RIGHTS RESERVED
express written permission of Varco Shaffer, Inc.
SHAFFER 0464-2 10/05/92 Sheet 4 of 5 Rev. A
 Supercedes:
Shaffer Engineering Standards/Specifications

DIRECT DRIVE VALVE (DDV) ASSEMBLY AND REPAIR PROCEDURE NEW

NOTE: Using the bevel end of the O-ring installation tool to work
the O-ring into the body will prevent the O-ring from
being pinched from the chamfers as it is being installed.

4.3.2 Inspect the inlet seat, P/N 7401330, cage, P/N 7401336 and the vent
seat, P/N 7401331. Notice the inlet seat does not have a flange and
the vent seat can only be installed into one end of the cage. Use this
method along with 4.3.4 to verify assembly order.

4.3.3 Place the inner seat, #2 on the seat installation tool, P/N 20001544.
The flange should be positioned away from the tool. Carefully insert
the seat and the tool into the orifice end of the body, #15. Press the
seat in place. Remove the tool.

NOTE: A “Click” sound is normally heard when the seat is

properly installed. If no sound is heard the seat
installation can be verified by looking into the orifice
end of the body and observing the O-ring is radially
sandwiched between the vent seat and the body.

4.3.4 Visually inspect the cage, #20. Note the offset of the small ports on the
outside diameter. One pattern of holes is located closer to the flange
than the adjacent set. Drop the cage, with the pattern of holes closest to
the flange towards the solenoid end of the body, into the body, #15.

4.3.5 Drop the ball, #1, into the orifice end of the body, #15. Verify the ball
is centered in the cage, #20.

4.3.6 Place the O-ring, #11, in the orifice end of the body, #15. Using the
bevel end of the O-ring installation tool, work the O-ring down to seat
on the cage, #20. Insure the O-ring is properly seated using the flat
end of the O-ring installation tool.

NOTE: Using the bevel end of the O-ring installation tool to work
the O-ring into the body will prevent the O-ring from
being pinched from the chamfers as it is being installed.

4.3.7 Place the supply seat, #3, on the seat installation tool. The flange should
be positioned towards tool. Carefully insert the seat and the tool into the
orifice end of the body, #15. Press the seat in place. Remove the tool.
The seat is to be held in place by the O-ring, #11. Remove the tool.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A -X080043
any form, used, or disclosed to others for any
purpose, including manufacturing, without the ALL RIGHTS RESERVED
express written permission of Varco Shaffer, Inc.
SHAFFER 0464-2 10/05/92 Sheet 5 of 5 Rev. A
 Supercedes:
Shaffer Engineering Standards/Specifications

DIRECT DRIVE VALVE (DDV) ASSEMBLY AND REPAIR PROCEDURE NEW

4.3.8 Insert the screen, #4 into the orifice end of the body, #15. The screen
will be held in place by gravity.

4.3.9 Apply two drops of thread locker to orifice, #14. Screw the orifice into
the orifice end of the body, #15, using light torque. This will retain the
internal components in the body while preparing to torque the orifice.

4.3.10 Reattach the body, #15, to the solenoid #19 using two button head
screws #16 located 180 degrees apart.

4.3.11 Torque the orifice, #14, using the torque tool, P/N 20002953. The
torque wrench is designed to limit the torque to 25 in-lbs. Verify the
face of the orifice is located below the end of the body, #15, after
torquing.

CAUTION: Do not over torque the orifice.

4.3.12 Remove the fluid end, #15, from the solenoid, #19, and insert the
armature spring, #13, into the counterbore of the solenoid and insert
the armature into the solenoid.

4.3.13 Install the external O-rings, #’s 5, 7, 9 and backup ring, #’s 6, 8, 10 on
the fluid end body, #15.

4.3.14 Align the attachment holes of the fluid end body, #15, and the tapped
holes of the solenoid, #19. Press the fluid end body into the solenoid,
#19. Verify the body flange is flush (or slightly below) the end of the
solenoid. Insert and tighten (snug) the button head capscrews, #16.

CAUTION: Only light pressure is required.

5.0 TEST

5.1 Test the assembled valve assembly prior to installation and deployment. This
can be done with a test manifold or on the control system.

This work contains the CONFIDENTIAL AND

PROPRIETARY INFORMATION of Varco
 Varco Shaffer, Inc.
Shaffer, Inc. Neither this document nor any
information disclosed herein shall be reproduced in Copyrighted as an unpublished work A -X080043
any form, used, or disclosed to others for any
purpose, including manufacturing, without the ALL RIGHTS RESERVED
express written permission of Varco Shaffer, Inc.
SHAFFER 0464-2 10/05/92 Sheet 6 of 5 Rev. A