ABB Vetco Gray

Western Region Operations

Surface Wellheads & Production Equipment

Training Manual
APRIL 2003
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 SURFACE WELLHEADS AND PRODUCTION EQUIPMENT
TRAINING MANUAL

Table of Contents

Section 1 Modern Rotary Drilling

Section 2 Structure Of An Oil Or Gas Well

Section 3 End And Outlet Connections

Section 4 Casing Heads

Section 5 BOP Test Plugs

Section 6 Bowl Protectors And Bowl Protector Running And

Retrieving Tools

Section 7 Casing Hangers

Section 8 Casing Spools

Section 9 Casing Isolation Seals

Section 10 Tubing Heads And Spools

Section 11 Multibowl Wellhead Systems

Section 12 Single Completions

Section 13 Dual Completions

Section 14 Plugging Operations

Section 15 Gate Valves And Valve Actuators
Section 16 Production Chokes
Section 17 Mudline Suspension Systems

Section 18 Overview To API Specification 6A

 SURFACE WELLHEADS AND COMPLETIONS EQUIPMENT
TRAINING MANUAL

Forward

This manual is intended for reference purposes only.

ABB Vetco Gray has made every effort to include accurate and up
to date information; however the rapid progression of technology
will often out pace any updates.

Our many thanks go out to the field service staff for their
contributions.
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 1
Modern Rotary Drilling
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How an Oil Well Is Drilled
Through eons of time the earth’s crust has evolved such that layers of rock with
differing chemical, and physical characteristics have been formed. Sedimentary
formations typically contain varying combinations of water, gas, and oil, formed as
pressure and temperature break down organic materials deposited along with the
sediment. Tectonic and volcanic activity in certain areas cause these sedimentary
layers of rock to buckle, slip, and incline taking on geological configurations which
may trap and concentrate the fluids which are present. Areas containing
concentrations of oil and gas are known as reservoirs, and are found at depths
ranging from a few hundred feet to more than five miles deep in the earth.
To obtain oil or gas trapped in the earth it is necessary to drill a hole to the reservoir
and establish a path for the oil and gas to flow to the surface to be collected. In order
to safely and efficiently drill such a deep hole and reach the intended target
reservoir, the well must be carefully constructed using planning, knowledge of
geology, and highly sophisticated equipment.
Because of the weight of the fluids contained in geological formations these fluids
are typically under pressure. The pressure of the fluids trapped in geological
formations vary with depth, temperature, and geological configuration. Generally
formation pressures and temperatures increase with increased depth below the
earth’s surface.
In order to continue drilling it is necessary to control fluid pressures in the well to
prevent the flow of fluids to the surface under high pressure, which could damage
equipment or cause injury to the drill crew. If at any time during the drilling process
control of pressure is lost, and fluids flow from the well uncontrolled, it is referred to
as a blowout. Often gases released during a blowout are volatile, and as they
contact the hot engines or electrical connections of the drilling rig, an explosion or
fire is the inevitable result. The consequences of a blowout may include damage to
drilling equipment, environmental pollution, and loss of life. For this reason blowout
prevention is always a primary consideration for a drilling operation.
The most prevalent method of drilling at present, known as “rotary drilling,” was
introduced at the turn of the century. A drill bit is attached to steel pipe, suspended
vertically, lowered into the well, and rotated by a mechanical drive. The weight of
the pipe on the bit allows the bit to grind up the rock as it turns deepening the hole.
“Drilling mud” or “drilling fluid” is continuously pumped down the hollow drilling
assembly, (called the drill string) through the bit, and back up to the surface via the
annular space between the drill string and the borehole wall. The drilling fluid
flushes the cuttings out of the hole. The weight of the mud column creates a
hydrostatic pressure in the well preventing geological formation fluid pressure from
entering the wellbore and flowing back to the surface. The concept is simple yet the
process has evolved into a technically complex process as numerous difficulties
must be overcome for the process to work efficiently as well depths penetrate
thousands of feet of the earth’s crust.
Rig Functions
A rotary drilling rig has four systems which function together; the hoisting system,
the rotating system, the circulating system and the well control system. The
hoisting system moves the pipe in and out of the hole. The rotating system turns
the bit to make hole. The circulating system flushes the cuttings up out of the hole.
The well control system permits the shutting in of the well should a blowout
appear imminent.

January 2002 1-1

Hoisting System
The derrick, or mast, supports the hook and elevators with a traveling block,
wireline, crown block, and drawworks. The drawworks are powered by “prime
movers,” which may be from two to four diesel engines of 500 to 5000 HP ratings.
The purpose of the hoisting system is to move pipe in and out of the hole. The
maximum capacity of the hoisting system is the most significant factor determining
the depth of well a rig may be capable of drilling. The largest drilling rigs can support
up to two million pound loads.
Derrick or Mast
A conventional derrick is a structure with four supporting legs resting on a square
base and normally has to be erected piece-by-piece. The mast is portable and can
be moved without being disassembled. It is easier to lower following job completion
and easy to erect on a new site. While the derricks are being replaced by masts for
land operations, derricks are common on offshore drilling rigs.
Masts and derricks are available in various heights ranging from 95 to 180 feet, with
136 to 146 feet being the most common. Load bearing capacity ranges from 0.5 to
1.9 million pounds. They are also designed for wind resistance; some can withstand
125 mph winds without the need for external guy wires.
The purpose of these structures is to support the weight of the drill stem, whether
the stem is suspended from
the crown block or resting on
the rotary table. The height of
the derrick/mast does not
necessarily affect its load
bearing capacity, but it is a
factor in the length of the
section (stand) of drill stem to
be pulled. The drill stem must
be removed from the hole
periodically to replace the
drilling bit. The length of each
drill stem section to be pulled
is limited by the height of the
derrick/mast.
Drill pipe is usually pulled and
racked to stands. A stand
normally consists of three
joints of pipe, each about 30
feet long, and is called a
“thribble.” Such a stand,
having a 90 foot length, can
be handled in a 136 foot
derrick/mast.

1-2
Blocks and Wireline
The traveling block, crown block, and wireline connect the derrick/mast to the pipe
to be lowered or pulled from the hole. During drilling operations this load normally
consists of the drill pipe, drill collars, and drill bit. However, during the running of
casing, marine risers, or BOP stacks, the loads can be greater than those
experienced during drilling.
The crown block is fixed to the top of the mast or derrick. It consists of a number of
sheaves on a central axle. Drilling line attached to the drawworks is threaded over
the crown block down to the traveling block suspended in the mast/derrick. The
traveling block also consists a series of sheaves. The crown block and traveling
block multiply the force applied by the drawworks by adding the leverage of the
repeated wrapping of the drilling line.
As the drawworks spools the drilling line in or out, the traveling block is raised and
lowered in the mast/derrick. By attaching pipe and other objects to the traveling
block, the objects may be raised and lowered as well.
Hooks and Elevators
The hook, which may be an integral part of the traveling block, supports the
elevators, which in turn latch onto the pipe to be hoisted. Several different models of
elevators are available to handle the various types and sizes of drill pipe, tubing,
and casing.
Drawworks
The drawworks in other industries is commonly known as a hoist or winch. It may
have gained its name in the oil industry because part of its function is to draw pipe
out of the hole. The operating principle is for the wireline to be spooled on a drum
when the drawworks are engaged, reeling in wireline to raise the traveling block, or
with the brake disengaged releasing line to lower the block.
The brakes on this hoist enable the driller to control loads of thousands of pounds.
One brake is normally mechanical and can stop the load, while the other brake is
hydraulic or electrical and controls descent speed of the loaded traveling block. A
transmission system provides the driller with the choice of hoist speeds typically
ranging from four to eight speeds. Generally the drawworks also drives the rotary
table through a heavy-duty chain or drive shaft. In other cases, the rotary table is
driven by an independent diesel engine or electric motor.
Rotating System
The rotary table located in the center of the rig floor rotates the kelly, the drill stem,
and bit. The rotary, from which the rotary rig derives its name, has two primary
functions:
1. Rotation to drill stem
2. Hold slips that support the weight of the drill stem when not supported by
the hook and elevators.
The rotary, turning to the right, rotates from 40 to 250 RPM to make hole. It is
powered through a reduction gear driven by an electric motor or through the
drawworks’ diesel engines or other prime movers.

April 2003 1-3

Kelly and Swivel
The uppermost end of the drill pipe is attached to the kelly by means of a “saver” or
“kelly” sub. The kelly passes through a drive or kelly bushing located in the rotary
table, allowing the kelly to be rotated while still free to move vertically throughout
most of its length. The kelly is approximately 40 feet long and can be either square,
hexagonal, or triangular on the outside and hollow through its length to provide
drilling fluid passage.
Supporting the kelly and allowing it to rotate freely is the swivel, which in turn is
suspended from the hook. The swivel not only allows rotation, but supports the drill
stem and allows passage of fluids under high pressure to enter the drill stem. In
principle, the swivel joins the rotating system, allowing for rotation while supporting
hundreds of tons of load.
Top Drive Systems
An alternative to the Rotary Table, Kelly, and Swivel to rotate the drill pipe is the use
of a top drive system. A top drive incorporates the swivel and the kelly into the
traveling block. This is done by the use
of powerful hydraulic motor which
rotates the drill pipe. The traveling
block must be anchored to the mast
and travels on rails which extend up
the mast. Top drives usually also
include some automated pipe
handling functions and permit
pumping mud to the drill pipe or casing
as it is run.
The advantage to a top drive system is
that drilling can progress a stand of
pipe at a time rather than adding a
joint each time the length of the kelly is
drilled. This saves time and money.
Drill Stem
A drill stem is defined as all members
in the assembly used for rotary drilling
from the swivel to the bit, including the
kelly, drill pipe, drill collars, and other
ancillary equipment.
The drill pipe, available in lengths
ranging from 27 to 45 feet, is equipped
with special tool joints (threaded
fittings) to enable lengths of pipe to be screwed together to make up the drill string.
Drill collars guide, stabilize, and add weight to the bit. One hundred thousand
pounds plus of drilling weight must be employed on a large diameter bit.
All components of the drill stem must be of the highest quality and finish to
withstand the high stresses imposed by drilling. Ordinarily, several hundred horse
power may be transmitted mechanically to the bit by means of the drill string while
rotating. This string is rotated between 75 and 250 rev/min with heavy loads bearing
down on the bit.

1-4
Drilling Bit
The drill bit is the final piece of equipment in the rotating system and, in fact, is the
only piece of equipment that actually makes hole.
Three general categories of bits are used in rotary drilling: drag, roller-cone, and
diamond.
The drag bit, which evolved from the antique fish tail bit, is essentially three or four
hard metal blades welded to the body of the bit. Drag bits, in sizes up to 24 inches,
are often used for drilling soft, shallow formations prior to setting surface casing.
Replaceable blade bits are available from 1-7/8" to 16" for shot-hole, exploration,
slim-hole, blast hole, and water well drilling.
The roller-cone, known also as the rock bit, may be classified in two types: steel
tooth and tungsten carbide insert bits. The principle of offset cones is for the cone to
drill on the bottom of the hole during rotation, scraping and gouging out the
formation. The intermeshing of teeth provides a self-cleaning action which is now
supported by the drilling fluid flow. Hard formation bits do not have offset cones, and
allow cones to crack.
Diamond bits do not utilize offset cones and rely upon diamonds embedded in the
bit’s body to provide the cutting action. The diamond bits are quite expensive;
however, the fact that it generally makes more hole than any other bit over its drilling
life and that there is salvage value in the serviceable diamonds can make its use
economically feasible.
Circulating System
The circulating system, or mud system, circulates drilling fluid/mud down through
the drill stem, around the bit, and up the annulus between the drill stem and casing.
This mud circulation:
• cools the bit
• cleans the bottom of the hole
• supports the walls of the well
• acts as a blowout prevention medium by preventing formation fluids/gasses
from entering the bore hole.
The drilling fluid is pumped under high pressure from a suction tank or pit, up a
stand pipe, through the rotary hose and swivel to the hollow kelly and drill string.
After leaving the drilling bit, the fluid carrying the drill cuttings travels up the annulus
between the drill string and casing. At the wellhead, it passes over the shale shaker
(a vibrating screen) which retains the drill cuttings and allows the mud to return to
the suction tank to be recycled.
Drilling Mud
Normal drilling fluids usually consist of colloidal suspensions of clays in water, with
chemical additives to control viscosity and other properties. Under many conditions
the use of an oil-in-water emulsion, rather than water alone, is advantageous.
When drilling in low pressure oil bearing formations, a non-aqueous oil base mud
may be preferable. Air, gas, or aerated liquids can also be used in certain
circumstances and usually result in very rapid drilling.

April 2003 1-5

Well Control System
Well control equipment is defined here as pressure containing and controlling
components which are designed to contain the well pressure in case of a well kick
or blowout. The primary system of well control during the drilling or completion
phase is the hydrostatic control provided by the column of drilling mud or
completion fluid. The primary means of containment and control during the
production of either oil or gas is the christmas tree. These components will be
discussed later. The control equipment used during the drilling of the well includes
the “Diverter” and the “Blowout Preventer Stack”.
Blowout Preventer Systems
The primary function of the Blowout Preventer System (BOP stack) and its
associated components is to confine well fluids to the wellbore and allow controlled
volumes to be withdrawn at the
surface. The BOP is installed on top
of the wellhead which in turn is
installed on top of the casing. Drilling
mud pumped down the drill pipe
returns up the hole on the outside of
the drill pipe and is channeled
through the BOP and into the flow
return line back to the mud
processing equipment. Typically the
BOP system consists of a stack up of
components consisting of one or
more ram-type preventers, a drilling
spool, an annular preventer, and a
choke and kill manifold. Standard
drilling BOP bore sizes are 7-1/16”,
11”, 13-5/8”, 16-3/4”, 18-3/4”,
20-3/4”, 21-1/4” and 30”. Standard
pressure ratings are 2,000, 3,000,
5,000, 10,000, 15,000, and 20,000.
The components included in a BOP
system vary according to well
conditions and operator preference.
BOP components are hydraulically
operated. An accumulator stores
hydraulic pressure to operate the BOP even is power to the system is lost. A remote
control panel is located on the rig floor near the driller’s control station. An additional
panel is usually located near the toolpusher’s office in case the rig floor must be
abandoned.
In the event a well begins to flow during drilling operations (referred to as a kick) the
BOP system is functioned to close around any pipe which may be in the hole or to
close over the open hole if there is no pipe in the well. Once closed, mud is pumped
through the choke and kill manifold to circulate fluid into and from the well below the
closed BOP. Typically the qualities of the mud will be altered to counter the
conditions causing the well to flow. Once the well is stabilized the BOP can then be
opened up and drilling can continue.

1-6
Diverters
The diverter, or diverter system, is employed as a means of well control during the
initial phases of a drilling operation by directing well flows encountered at relatively
shallow depths away from the rig and personnel. The diverter provides a degree of
protection prior to setting the casing string and wellhead which will allow installation
of the blowout preventer stack and choke manifold. The diverter system should be
designed to packoff around the kelly, drillstring, or casing and direct flow to a safe
location. Valves in the system direct the flow when the diverter is actuated. A
diverter is not designed to shut in or halt flow, but rather permits routing of the flow to
a safe distance away from the rig. At this stage of drilling, if the well is completely
shut in, uncontrolled flow around the outside the shallow casing could result.
ABB Vetco Gray Diverter Systems
ABB Vetco Gray manufactures diverter
systems customized for use on
platforms, jackups, and floating drilling
rigs. These systems can minimize time
spent rigging up and making
connections, since they remain in place
with all connections made up at all
times. Typical diverter systems must be
removed and laid down, once the
surface casing has been installed.

KFDJ Diverter System

April 2003 1-7

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SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 2
Structure of an Oil and Gas Well
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Oilfield Tubulars
Oil and gas wells are primarily constructed of steel pipe. The types of pipe used
includes the drill pipe, drill collars, casing, and production tubing.
Drill Pipe and Drill Collars
Drill pipe is used to do the work of drilling the well. It is specially designed to take the
tensile, torsional, bending, and pressure stresses associated with rotary drilling. In
addition it is designed to be easy to handle and assemble.
Drill pipe ranges in size from 2-7/8” to 5” in diameter. It is made in sections
approximately 30‘ long, each length of which is referred to as a “joint.” The ends of
each joint of drill pipe have special thread connections referred to as “tool joints.”
The tool joint thread connection includes an external thread profile (the pin) at one
end of the joint, and a mating internal thread profile (the box) at the other end of the
joint. Drill pipe joints are made up together end to end by mating the pin and box
connections. By this means the drill pipe joints can be strung together to give the
required length of pipe to carry the drill bit to the bottom of the hole. Tool joint
connections are designed to be high strength, to contain high pressures without
leakage, to thread and unthread quickly, and to be durable.
drill collars are a specialized form of drill pipe. Several drill collars are typically used
at the bottom of the drill string to give the string weight and stability. They are larger
in diameter and very thick walled which gives them the required weight and
strength.
Casing
Casing is the structural foundation of an oil or gas well. Unlike drill pipe which is only
used during drilling, casing becomes part of the well permanently as it is cemented
into place once it is installed. It ranges from 4” to 42” in diameter and from 40 feet to
60 feet in length.
Casing keeps the wellbore from collapsing around the drill pipe. In conjunction with
the cement, it isolates formations preventing communication of fluids across
formations. And it supports the weight of all of the surface equipment used on the
well.
During drilling the action of the pipe rotating in the hole causes the walls of the hole
to break down. Fluid may enter the open hole or drain from the hole into the
surrounding formations. It is therefore necessary to line the hole with casing to
stabilize the wellbore, and isolate the penetrated formations from the well. For this
reason the well is drilled in stages. Each stage represents a bit diameter and casing
size. The bit must make a hole large enough for the casing to pass into it, with
enough space around the outside of the pipe for cement to be circulated sealing off
the space between the casing and the drilled hole. As drilling progresses casing
strings are installed at planned depths. With each new casing string installed, a
smaller drill bit is employed so that it can pass through the new casing, drill out the
bottom, and extend the hole to greater depth. When casing is installed a wet slurry
of cement is pumped down the casing and circulated up the space between the
drilled hole and the outside of the casing (casing annulus). When the cement sets it
seals the casing annulus isolating all formations through which it is installed from
the wellbore.

April 2003 2-1

The number and sizes of casing strings used on a well is a function of the depth of
the well, the geology of the well bore, expected wellbore temperatures, pressures,
and the chemical composition of the fluids in the well. The number and sizes of all of
the casing strings used in a well is referred to as a casing program.
A principle function of a wellhead system is to support, center, and seal the casing
at the surface of a well. The wellhead also provides a pressure tight connection
between the casing and the surface well control equipment. A wellhead assembly is
installed in conjunction with each casing string.
Conductor Casing
Conductor casing or drive pipe is a
short string of casing of large
diameter (16" to 48") which is
required for offshore operations,
swampy locations, and other
conditions in which extra wellhead
support is necessary. Its principal
function is to keep the top of the
wellbore open and to provide a
means of conveying the up-flowing
drilling fluids (returns) from the
wellbore to the mud pit. It may be
installed by drilling a hole and
cementing it in place like regular
casing, it may be driven in place with
a pile hammer, or washed in by
flowing fluid through the string as it is
lowered down. The depth to which it is set varies but is usually around 100 to 400
feet.
Conductor joints are attached together
to make up a conductor string. These
joints may be welded together in the
field, or specialty end connections may
provide the means for attaching them
together.
Surface Casing
External Upse t
The surface casing is the first string of (EUE)

casing run on a conventional well and

may be considered the foundation of
the wellhead. The size generally
ranges from 8-5/8" outside diameter to Plain End
(P E)

20" outside diameter and the length of

this string varies greatly in different
areas from 200 feet to several
thousand feet. It is required by law to be
set deep enough to protect all
fresh-water-bearing sands. Surface
casing must also be set deep enough Threa de d & Coupled I ntegral C onnec tor
(T & C) (Extr eme Line)

to prevent an underground blowout.

Shallow unconsolidated formations
near the surface may not be able to

2-2
contain the pressures encountered at greater depths so the surface casing must
isolate these formations before drilling can safely progress deeper.
Surface casing is lowered in the hole joint by joint. Joints are typically threaded
together using either a coupling between each joint, (T & C) or integral threaded
connections at the end of each joint. The entire length of the string is cemented all
the way back to the surface.
Intermediate Casing
Intermediate casing is any casing string installed in a well after the surface casing
and before the production casing. Its purpose is to allow for deeper drilling by
isolating geological formations which may cause difficulties while drilling through
them. The size range for intermediate casing is generally from 7-5/8" outside
diameter to 18-5/8" outside diameter and it may be set anywhere from 3000 feet to
8000 feet. A well may have one or more strings of intermediate casing or it may
have no intermediate casing.
Production Casing/Liner
The final string of casing is called the production casing. It is usually set to, or
beyond the oil bearing formation that is to be produced. In either case, this will be
the maximum penetration or total depth of the well. The production casing isolates
all the other formations from the producing zone, or zones, and is cemented back to
the previous string. In some instances, the production casing may be used to bring
the oil back to the surface. This is called an open hole or tubingless completion.
Production casing ranges in size from 9-5/8" outside diameter to 4-1/2" outside
diameter. Since the production casing cannot be easily replaced and since a
smaller string can produce the oil in a more efficient manner, tubing is usually
installed inside the production casing. The inside surface of the production casing
provides a means by which the tubing can be sealed off by using a packer or some
other form of sealing device.
A liner is a casing string which does not extend back to the surface, but is rather
suspended inside the previously installed casing. Many types of completions utilize
a liner installed through the producing formations.
Production Tubing
The final string of tubular goods that goes into the well is the production tubing.
Unlike casing, it is not cemented in the well. It is supported and sealed by hanging it
inside the wellhead, and is anchored and sealed at the bottom by a device called a
packer. The packer seals the outside diameter of the tubing string to the inside
diameter of the production casing. Tubing is used so that it can be replaced when
damaged and also, if necessary, the well can be deepened or plugged back and a
new tubing string can be used to accommodate the new depth. The annular space
between the outside diameter of the tubing and inside diameter of the production
casing can also be used to artificially lift the oil from the well or to inject chemicals
which will inhibit corrosion of the inside diameter of tubing when the well is being
produced.

April 2003 2-3

ABB Vetco Gray’s Specialty Pipe Connectors
The advantages of ABB Vetco Gray’s large diameter conductor and casing
connectors have been consistently demonstrated in a variety of offshore and land
applications since the 1960’s. These connectors are designed for the most
demanding conditions and are used extensively offshore in floating vessel, jackup
rig and platform applications. They are also used on land in operations where fast
make-up is important due to bad weather or poor hole conditions.
The connectors are manufactured in two basic configurations; automatic-lock
Squnch Joint Connectors and threaded connectors. In each case these connectors
are machined from forgings, then welded to the pipe body.
These connectors are typically used in conductor and intermediate casing
programs, and are available in a full range of sizes to suit these applications.
Squnch Joint Connectors
The Squnch Joint is a threadless automatic-lock/mechanical-release connector
that requires no rotation for make-up. It is designed to save rig time with its
extremely fast make-up characteristics.
Squnch Joints are well suited for connecting large diameter casing joints. They are
also often used to connect the last joint of casing to the subsea wellhead housing
extension. These weight-set connectors ensure that the casing joints are run
efficiently and safely, in spite of extreme casing weight and vessel movement.
The Squnch Joint is usually connected in the pin-up, box-down mode. As the box is
lowered over the pin, a lock ring on the pin is compressed by the box until it snaps
into place in the mating profile on the box. Since it engages inside the box, the lock
ring is protected from damage once made up and will successfully tolerate typical
field contamination.
The Squnch Joint features an O-ring pressure seal which is positioned to prevent
damage to the O-ring during stabbing and following make-up. An anti-rotation key
and slot prevent the connector from rotating after it is made up.
Running and connecting pipe joints with
Squnch Joint Connectors is efficiently
accomplished using conventional
handling tools. ABB Vetco Gray can
also provide pad eyes on the pipe, to
facilitate handling, as well as elevator
rings.

2-4
Connector Characteristics
• Easy Stabbing: Squnch Joints
have a tapered pin profile and
cone-shaped box profile which
permits easy stabbing and
self-aligning of the box member
onto the pin. This configuration
accommodates misalignment, and
provides fast, positive mating of
the connector.
• Automatic, Weight-Set Make-Up:
Positive locking is achieved by a
lock ring carried on the pin
member, which snaps into a
locking groove on the box member when the joint is seated. A
pressure-tight seal is established through a resilient O-ring.
• Driveable: Squnch Joints have a wide shoulder area, designed for driving.
These rugged connectors have been successfully used in a wide variety of
driving applications. Drive tests at refusal conditions have been conducted,
using a Delmag D62 diesel hammer, or equivalent.
• Jack-up rig or platform conductors connected with Squnch Joints can be
driven to the desired depth, maintaining a positive seal and a secure
connection. Energy is transmitted efficiently through the connection.
• Mechanical Release: Release screws installed radially around the outer
perimeter of the box member are used to depress the lock ring, permitting
manual release of the connector. Retrial of conductor drilling strings used
on jack-up rigs can be accomplished quickly and efficiently, and the drive
string can be disconnected below the rig when refusal is reached.
• Reusable: When properly maintained, Squnch Joints can be re-used
several times in drilling operations where
the conductor strings are recovered. This
feature is particularly valuable to the
customer because the joints can be used in
several casing programs, affording
significant economy of operation.
RL-4 Conductor Connectors
The RL-4 connector is a threaded connection
which is part of the ABB Vetco Gray Rapid Lock
family of pipe connectors. The fast make-up and
the rigidity of the RL-4 connection is especially
advantageous in jack-up and platform operations.
In these applications, the conductor pipe is not
laterally supported and a large number of
conductors and casing joints are typically required.

April 2003 2-5

The standard connector has four independent thread starts which make the
connector up fully in approximately one quarter turn. A large internal diameter will
easily pass ABB Vetco Gray 20" mudline suspension equipment. The RL-4 reduced
bore (RB) connector, with a smaller outside diameter, is available to pass through
restricted openings like platform guides, pile guides or close-clearance casing
programs. However, the RL-4RB will not
pass standard mudline equipment.
For jack-up operations, the RL-4
connector, with its anti-rotation device,
offers a means of disconnecting and
retrieving the conductor above the
mudline without the assistance of divers.
This anti-rotation device is machined in
the conductor connector to maintain a
secure connection during driving or in a
long term tieback string. Four integral
anti-rotation strips milled into the box and
four corresponding slots milled into the pin
align when the connection is made up.
One strip is then sheared into the mating
slot using a special service tool.
The RL-4 conductor connector is also an ideal choice in floating vessel conductor
strings. It offers economy, strength and superior operational characteristics. The
RL-4RB connector, with its nearly flush outside diameter, is especially
advantageous in those wells where the 30" conductor is jetted.
The RL-4 conductor and pile connector are designed and manufactured for heavy
driving. A generous flat driving shoulder on the connector efficiently transfers
driving energy through the connector.
RL-4S Casing Connector
The RL-4S casing connector has all the time saving and strength features of the
RL-4 connector. Available in sizes 16" to 26" it is used primarily for mild or
non-driving applications. The quarter turn make up, high stab angle, strength, and
anti-rotation features are similar to the larger RL-4 connector.
RL-4C
The RL-4C connector is a more compact version of the RL-4 family of connectors. It
is available only in sizes 16" and 20". The outside diameter of the 20" RL-4C
permits its use through a 21-1/4" BOP and results in a reduced cost connection for
both drilling and tieback applications.
The RL-4C maintains approximately three-quarters of the structural capacity of the
larger RL-4S. This, coupled with a similar overall connector design, provides the
same operational advantages with the exception of one. The RL-4C is not intended
for use in driving applications.
Merits Of The Rapid Lock Connector Technology
• No casing crew/no power tongs required.
• Fast, quarter-turn make-up with rig tongs.
• No cross-threading.

2-6
 • High stab angle.
• Reusability/extremely contamination resistant.
• No loose parts on anti-rotation device.
• Driveable.
• High structural rigidity.

Oil Well Cementing

Historical
The first cement jobs for oil wells were mixed by hand and placed in the hole with a
dump bailer. By 1905 oil well cementing improved to the point of using tubing to
position the cement slurry at the bottom of the casing strings. Water was used to
displace the cement, with the casing lowered to sit on the bottom and provide a
shut-off. Water pressure was maintained in the casing until the cement set.
By 1910 the two plug method had evolved, using one plug ahead of the cement
slurry and one plug behind to lessen contamination with the displacing fluid.
Cementing procedures improved rapidly and cementing of casing suspended off
bottom became the norm.
Today oil well cementing is a highly specialized operation, and many different
techniques and kinds of cements have been developed to combat the many
problems encountered in drilling and completing oil and gas wells.
Primary Cementing
The purpose of cementing casing is to:
• Provide adequate axial support for the existing casing and any casing
strings to be run later.
• Prevent casing corrosion
• Prevent pollution of fresh water zones and stop movement of fluids/ gasses
between different formations and to the surface.
The cementing of casing in an open hole is done by mixing and pumping a
calculated volume of cement slurry inside the casing to be cemented and then
forcing this cement into the annular space between the open hole and the casing.
Normally included in the casing string are two check valves to stop flowback of mud
and cement into the casing.
A casing shoe is typically made up the bottom of the casing string. The casing shoe
has a rounded bottom to facilitate running into the hole and a bore which includes a
check valve which permits flow out the bottom of the casing but inhibits flow back
into the casing.
Rubber plugs are used to separate the cement from the mud. These plugs lessen
the chance of contamination and, depending on the type used, can provide a
complete shut off when they reach the collar or shoe.

April 2003 2-7

Once the cement has been
displaced into the annulus, it is
held there by check valve devices
in the collar/shoe until it has set
firmly.
The float collar and casing shoe
are made of a drillable material and
are not difficult to drill through as
the next section of the well is
drilled.
The float collar is usually from one
to two joints above the casing shoe
and ensures that the pipe below is
always full of cement at the
completion of the cementing
operation providing a cement plug
for well control as the wellhead
assembly is installed at the
surface.
Wellhead Equipment
Wellhead housings associated
with
the various casing strings
Specific wellhead assemblies are
associated with each type of
casing. The first wellhead Wellhead housings associated
component installed, the casing with the various casing strings.
head, is installed on the surface
casing which is the first casing
string which is cemented into the
well. If conductor casing is present a fabricate base plate is usually attached to the
casing head and lands on top of the conductor. Casing Spools are installed over all
intermediate casing strings. Tubing Spools are installed over production casing.
As each casing string is installed on a well, it is suspended, and seals inside of the
previously installed wellhead component by means of a casing or tubing hanger.
Since casing strings installed on a well are exposed to progressively deeper
formations the pressure containing capacity of the casing must increase with depth,
and likewise so must the pressure containing capacity of the wellhead.
Preparing the Well for Production
Once the production casing is in place the well drilling process is complete as the
well has reached its total depth. The operations which prepare the well for
production are referred to as Completion.
Completion operations include the displacement of drilling mud with a completion
fluid, the installation of downhole equipment, the perforation of the casing, and the
installation of the production tubing. It is through the tubing that the oil will be
produced by reservoir pressure or artificial lift to the surface.

2-8
Finally, the surface production control equipment is installed. For wells which do not
flow naturally a pump of some sort must usually be installed at the surface. For
wells which flow, an assembly of valves known as the christmas tree is installed.
This assembly will control the flow of oil (and gas) from the well during production.

April 2003 2-9

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SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 3
End and Outlet Connections
This page left blank
Wellhead connection seals provide a means of connecting two wellhead
components together such that the connection is capable of containing the rated
pressure with no leakage, is easy to assemble and disassemble, and has the
structural strength to sustain the loads encountered for the drilling and production
life of a well. These seals are primary to wellbore pressure containment. The
connection seals also provide a pressure containing area for pressure testing the
various internal component seals.
API End and Outlet Connections
API Specification 6A provides detailed specifications for threaded and flanged end
and outlet connections for wellhead components.
API Line Pipe, and High Pressure threaded connections are used only for wellhead
outlets, test, injection, and gage ports.
API Flanges, or manufacturer proprietary connections are used for all wellhead end
connections, and many wellhead outlet connections.
API flanges function by trapping a metal ring
gasket in circular grooves between the faces
of two flanges, surrounding the bore through
the component. A circular bolt pattern outside
the ring groove provides a means of
preloading the connection, imposing a bearing
load between the contact areas on the gasket
and the ring groove. By applying torque to the
bolts through the flange, the ring gasket is
plastically deformed into the ring groove
creating an interference fit which prevents
passage of matter across the interface. Since
the ring gasket is plastically deformed by the
process it is only used once. If the connection
preload is released the ring gasket should be
replaced.
API flanges are designated by a nominal bore
size and a pressure rating. API nominal bore
sizes range from 1-13/16” to 21-1/4”. API
pressure ratings are 2,000, 3,000, 5,000,
10,000, 15,000, and 20,000 psi.
API flanges are grouped into two series
designated 6B and 6BX. The 6B series have
maximum pressure ratings ranging from 2,000
psi to 5,000 psi The 6BX series have pressure
ratings ranging from 5,000 psi to 20,000 psi.
6B series flanges use the “R” style ring gasket.
The 6BX series flanges use the BX style ring gasket.
There are three types of “R” style ring gaskets characterized by the cross-sectional
shape of the ring. Each of the types the oval, the octagonal, and the RX ring gaskets
can be used interchangeably in any 6B series flange. The rings have differing
sealing surfaces so may have slightly different levels of reliability. The surface of the
oval ring contacts the ring groove across a very limited area and is considered the
least reliable but is also the least expensive. The octagonal type contacts the ring

April 2003 3-1

groove across a wider surface area and is slightly more reliable. The RX type
contacts the ring groove across the widest area. In addition the higher cross-section
results in pressure in the connection increasing the bearing load between the outer
surfaces of the ring and the ring groove. This ring is the most reliable, and the most
expensive. In the 6B series of flanges the ring gasket imposes a space between the
flange faces. The type of “R” ring used will affect the final stand off. Because the RX
type ring has a higher cross-section this must be considered when using this ring in
wellhead connections as other components in the wellhead may be designed to
function with a specific stand off between the flanges, and it should be verified the
using the RX gasket will not adversely affect the functionality of other components
in the system.
Type BX rings are only available in one style. Unlike the 6B series the 6BX series
flanges make up face to face, so there is no stand off between flanges on this type
of API connection.

Type R
Oval Ring
Gasket

Type R
Octonganl
Ring
Gasket
API Series 6B Flange

TypeRX
Ring
Gasket

Type BX
Ring
Gasket

API Series 6BX Flange

API Ring Gasket Cross-Section

3-2
 API Flange Critical Dimensions
Nominal Size Maximum Outside Total Thickness Diameter of Number
of Flange Working Diameter of of Flange Bolt Circle of Bolts Bolt Size Ring Gasket Equivale
Pressure Flange nt
10,000 7-3/8 1-21/32 5-3/4 8 3/4 X 5-1/4 BX 151 B-20
1-13/16 15,000 8-3/16 1-25/32 6-5/16 8 7/8 X 5-3/4 BX 151 B-20
20,000 10-1/8 2-1/2 8 8 1 X 7-3/4 BX 151
2,000 6-1/2 1-5/16 5 8 5/8 X 5 R or RX 23 B-20
5,000 8-1/2 1-13/16 6-1/2 8 7/8 X 6-1/2 R or RX 24 B-20
2-1/16 10,000 7-7/8 1-47/64 6-1/4 8 3/4 X 5-1/2 BX 152 B-20
15,000 8-3/4 2 6-7/8 8 7/8 X 6-1/4 BX 152 B-20
20,000 11-5/16 2-13/16 9-1/16 8 1-1/8 X 8-1/2 BX 152
2,000 7-1/2 1-7/16 5-7/8 8 3/4 X 5-1/2 R or RX 26 C-25
5,000 9-5/8 1-15/16 7-1/2 8 1x7 R or RX 27 C-25
2-9/16 10,000 9-1/8 2-1/64 7-1/4 8 7/8 x 6-1/4 BX 153 C-25
15,000 10 2-1/4 7-7/8 8 1X7 BX 153 E-25
20,000 12-13/16 3-1/8 10-5/16 8 1-1/4 X 9-1/2 BX 153
2,000 8-1/4 1-9/16 6-5/8 8 3/4 X 5-3/4 R or RX 31 D-31
3-1.8 3,000 9-1/2 1-13/16 7-1/2 8 7/8 X 6-1/2 R or RX 31 D-31
5,000 10-1/2 2-3/16 8 8 1-1/8 X 7-3/4 R or RX 35 D-31
10,000 10-5/8 2-19/64 8-1/2 8 1X7 BX 154 D-31
3-1/16 15,000 11-5/16 2-17/32 9-1/16 8 1-1/8 X 7-3/4 BX 154 F-31
20,000 14-1/16 3-3/8 11-5/16 8 1-3/8 X 10-1/4 BX 154
2,000 10-3/4 1-13/16 8-1/2 8 7/8 X 6-1/2 R or RX 37 E-40
3,000 11-1/2 2-1/16 9-1/4 8 1-1/8 X 7-1/2 R or RX 37 E-40
4-1/16 5,000 12-1/4 2-7/16 9-1/2 8 1-1/4 X 8-1/2 R or RX 39 E-40
10,000 12-7/16 2-49/64 10-3/16 8 1-1/8 X 8-1/4 BX 155 F-40
15,000 14-3/16 3-3/32 11-7/16 8 1-3/8 X 9-1/2 BX 155 G-40
20,000 17-9/16 4-3/16 14-1/16 8 1-3/4 X 12-1/2 BX 155
2,000 13 2-1/16 10-1/2 8 1 X 7-1/4 R or RX 41
5-1/8 3,000 13-3/4 2-5/16 11 8 1-1/4 X 8-1/4 R or RX 41
5,000 14-3/4 3-3/16 11-1/2 8 1-1/2 X 10-1/2 R or RX 44
10,000 14-1/16 3-1/8 11-13/16 12 1-1/8 X 9 BX 169
2,000 14 2-3/16 11-1/2 12 1 X 7-1/2 R or RX 45 G-72
3,000 15 2-1/2 12-1/2 12 1-1/8 X 8-1/2 R or RX 45 G-72
7-1/16 5,000 15-1/2 3-5/8 12-1/2 12 1-3/8 X 11-1/4 R or RX 46 G-72
10,000 18-7/8 4-1/16 15-7/8 12 1-1/2 X 11-1/2 BX 156 H-72
15,000 19-7/8 4-11/16 16-7/8 16 1-1/2 X 13 BX 156 P-72
20,000 25-13/16 6-1/2 21-13/16 16 2 X 17-3/4 BX 156
2,000 16-1/2 2-1/2 13-3/4 12 1-1/8 X 8-1/2 R or RX 49 H-87
3,000 18-1/2 2-13/16 15-1/2 12 1-3/8 X 9-1/2 R or RX 49 H-87
9 5,000 19 4-1/16 15-1/2 12 1-5/8 X 12-1/2 H-87
10,000 21-3/4 4-7/8 18-3/4 16 1-1/2 X 13-1/4 BX 157 P-87
15,000 25-1/2 5-3/4 21-3/4 16 1-7/8 X 16 BX 157 S-87
20,000 31-11/16 8-1/16 27 16 2-1/2 X 22-5/8 BX 157
2,000 20 2-13/16 17 16 1-1/4 X 9-1/4 R or RX 53 M-112
3,000 21-1/2 3-1/16 18-1/2 16 1-3/8 X 10 R or RX 53 M-112
11 5,000 23 4-11/16 19 12 1-7/8 X 14-1/4 R or RX 54 M-112
10,000 25-3/4 5-9/16 22-1/4 16 1-3/4 X 15-1/4 BX 158 S-112
15,000 32 7-3/8 28 20 2 X 19-1/2 BX 158
20,000 34-3/4 8-13/16 29-1/2 16 2-3/4 X 24 BX 158
2,000 22 2-15/16 19-1/4 20 1-1/4 X 9-1/2 R or RX 57 R-137
3,000 24 3-7/16 21 20 1-3/8 X 10-3/4 R or RX 57 R-137
13-5/8 5,000 26-1/2 4-7/16 23-1/4 16 1-5/8 X 12-3/4 BX 160 S-137
10,000 30-1/4 6-5/8 26-1/2 20 1-7/8 X 17-1/2 BX 159 5V-137
15,000 34-7/8 8-1/16 30-3/8 20 2-1/4 X 21-1/2 BX 159
20,000 45-3/4 11-1/2 40 20 3 X 30-1/4 BX 159
2,000 27 3-5/16 23-3/4 20 1-1/2 X 10-3/4 R or RX 65 T-170
16-3/4 3,000 27-3/4 3-15/16 24-1/4 20 1-5/8 X 12-1/4 R or RX 66 V-170
5,000 30-3/8 5-1/8 26-5/8 16 1-7/8 X 14-3/4 BX 162 5V-170
10,000 34-5/16 6-5/8 30-9/16 24 1-7/8 X 17-3/4 BX 162
5,000 35-5/8 6-17/32 31-5/8 20 2 X 17-3/4 BX 163
18-3/4 10,000 40-15/16 8-25/32 36-7/16 24 2-1/4 X 22-3/4 BX 164
15,000 45-3/4 10-1/16 40 20 3 X 27 BX 164
20-3/4 3,000 33-3/4 4-3/4 29-1/2 20 2 X 15 R or RX 74 W-210
2,000 32 3-7/8 28-1/2 24 1-5/8 X 12-1/4 R or RX 73 V-210
21-1/4 5,000 39 7-1/8 34-7/8 24 2 X 19 BX 165
10,000 45 9-1/2 40-1/4 24 2-1/2 X 24-3/4 BX 166
* 26-3/4 2,000 41 4-31/32 37-1/2 20 1-3/4 X 14 BX 167
3,000 43-3/8 6-11/32 39-3/8 24 2 X 17-1/4 BX 168
* 30 2,000 44-3/16 5-9/32 40-15/16 32 1-5/8 X 14-1/2 BX 303
3,000 46-11/16 6-37/64 42-15/16 32 1-7/8 X 18 BX 303

*Not in API Specification 6A

API Flanges Compared To Clamp Connections

The API and ANSI ring gaskets have been used successfully for many years in a
wide range of applications. However, when compared to a flexible bore seal, the
ring joint connection has some disadvantages.

April 2003 3-3

Since the ring gasket is generally a crush type, it is not considered reusable. A
flexible seal is reusable if not loaded beyond its yield strength.
The seal diameter of the ring gasket is larger than a bore type seal. This increases
the total thrust load on the connection, thus requiring a larger flange and more
bolting. This can substantially increase space required for the connection and the
amount of material involved, as well as the time required for installation and
maintenance.
Orientation of components is determined by bolt hole alignment.
Even make-up of the flanges is critical to avoid impingement of the ring gasket
which will prevent sealing. Make up of the connection is much easier to regulate,
plus the seal ring has a positive stop which prevents impingement. This positive
stop helps to prevent the sealing surfaces of the seal ring from being loaded
beyond the yield strength.
The flange connection requires a relatively high bolting torque to achieve the seal
and maintain it. Since the relies on a clamp to exert the make-up force, the torque
required for the clamp bolting is minimal in comparison. This is due to the inherent
mechanical advantage produced by the tapered clamping surfaces.
Because the ring gasket is basically a crush type seal, it has no adaptability to
changing conditions which may affect the connection:
• Thermal Shock
• Thermal Cycling
• Extreme Vibration
•
Bending Loads
Types Of Seals
There are two basic categories of seals used in connectors for any petroleum or
industrial application:
• Face seals which seal on the mating faces of the components of the
connection and
• Bore seals which seal on the internal bore of the mating components.
Either category, face or bore, can be further broken down to include crush type and
flexible type seals. A familiar example of a crush type face seal is the API or ANSI
ring gasket, used primarily in flanged connections. An example of a flexible type
bore seal is the VG seal ring, normally used in a connection, but equally adaptable
for use with flanges.

3-4
The NT2 Connector
The “NT2" connector is made up of five (5) basic components:
• Box
• Actuating screws
• Segmented dogs
• VG Seal Ring
• Pin
The Pin
In the upper bore, of the NT2 pin is a preparation
for a seal ring. The top face has a counter bored
recess to accommodate the rib of the seal.
The outside diameter of the pin has two (2)
circumferential groove profiles which interface
with the dog segments on the “NT2" box.
The outside diameter of the pin will drift through
Rotary, Diverters, and BOP standard bore
dimensions for the most widely used sizes. The upper bore profile may, on a casing
head, have a modified stub Acme running thread for running the head through a
drilling riser or diverter system.
The Box
The box section of the “NT2" connector is
characterized by the dog segments and
actuating screws.
The dog segments, once energized, produce a
near 360° face to face contact between the
upper profile of each dog tooth and pin groove
ensuring an even distribution of load in the
connection and in the seal ring.
The number of dog segments and actuating
screws is dependent on the size and pressure
rating of the connection, the desired preload
and external bending loads on the connection.
VG-Seal Ring

April 2003 3-5

VG Seal Ring
The VG seal ring is the “heart” of the metal to metal sealing concept.
If you consider a section view through the seal, the ring resembles a “T”. The base
of the T is the rib which is held by the abutting faces of pin and box as the
connection is made up. This rib is used to limit and control the amount of load and
deformation seen by the sealing lip of the seal. The top horizontal line of the T
forms the lips that seal against the inner surfaces of the pin and box. During
connector make-up the lips of the seal ring are elastically deflected into the box and
pin seating surfaces due to the slight difference of taper which exists between them.
Internal pressure increases the effectiveness of the seal, deformation remaining
elastic throughout thereby rendering the seal ring reusable. In the make-up
position, the pre-load on the seal is approximately 30,000 psi. Coating the ring with
a baked-on lubricant, such as molybdenum disulfide, prevents galling of the
surfaces during make-up as there is a tremendous shear force in effect at this time,
and thereby enhances seal ring reusability.
The seal ring rib allows the ring to be self-aligning and ensures that maximum lip
loads are not exceeded during make-up. Also, the rib design allows the VG seal to
withstand severe bending loads. Seal ring advantages may be listed as follows:
• Unique self and pressure energizing bore seal
• Elastic deformation only
• Internal pressure improves seal
• Reusable
• Self-aligning
• Rib transfers external loads

Principles of Operation
The “NT2" connector is designed to provide
a rapid make-up, easy-to-operate, pressure
tight joint. This is achieved by employing a
self aligning pin and box type connector
which is energized with standard tools and
which employs the well established and
widely accepted sealing concept.

3-6
Alignment and Stabbing
By virtue of the pin and box design and each
components having lead-in tapers alignment and
stabbing of the connector is readily achieved.
As the box is lowered over the pin, the box is also
aligned by the VG seal ring.
Rapid Make-up and Trouble Free Disconnect
The “NT2" connector box incorporates
permanently retained segmented dogs and
actuating screws.
There are no loose component parts.
The actuating screws are used to quickly and
securely lock the pin and box into a strong rigid
pre-loaded joint. No more than six (6) turns (RH)
on each actuating screw is required to fully
make-up the connector.
Positioned in a horizontal plane, for ease of access, the actuating screws are
readily torqued, or released, by air-operated wrenches or torque wrench.
Operation
The actuating screws are used to drive the double-tooth dog segments into a
double groove profile on the pin member.
As the actuating screws are tightened, the tapered face of each dog segment
engages the double groove profile on the pin making a face-to-face contact
between the upper profile of each tooth and groove.
As the pin and box are drawn together by the segmented dogs, the seal ring lips
deflect against the inner sealing surfaces of the pin and box. This deflection
elastically loads the lips of the seal ring forming a self-energized seal.
Internal pressure enhances the sealing capability; therefore, the sealing action of
the seal ring is both self-energizing and pressure assisted.
The dogs are tightened in a criss-cross pattern until each dog segment is torqued to
the desired level. Torque requirements range from between 500 ft-lbs to 1100 ft-lbs
depending on the connector size and pressure rating. These requirements are low
enough to permit the use of a pneumatic impact wrench for make up.
Fully made-up the seal ring becomes a mechanical stop with the pin and box
butting together.
The amount of torque applied to the dog segments controls the level of preload in
the connection. Preload ensures a pressure tight rigid connection even under high
external bending loads.
The loads generated by the torque applied to the actuating screws are evenly
distributed throughout the connector due to the combination of near 360 degrees
contact made between the segmented dogs and twin-groove pin arrangement and
the preload generated in the connector. As a result stress concentrations are
minimized.

April 2003 3-7

Safety Features Of The NT2 Connector
The NT2 connector has some significant safety advantages over flange or clamp
connections.
The connector is completely self contained with no loose parts such as studs and
nuts which could be dropped on personnel working below.
The connection eliminates the need for workers to wield and hold hammer
wrenches and sledge hammers in awkward positions to make up flange
connections.
The connection is self aligning and easy to stab, minimizing the time crew members
must work below a suspended BOP.

3-8
Test Ports, Injection Ports, and Gauge Ports
API Specification 6A requires that all test, injection, and gauge ports rated 10,000
psi or less have either ½” or 3/4” NPT threads. ABB Vetco Gray has standardized on
½” NPT. (sometimes referred to as Line Pipe) Test fittings used in these ports are
standard Precision General grease injection fittings, which have a ½” NPT pin at the
inboard side and a grease injection preparation at the outboard side. The grease
injection preparation includes a thread pin and a conical seal at the outlet. The
fitting is provided with a cap which seals at the conical center outlet.
Test, injection, and gauge ports rated 15,000 psi or higher have a thread profiles
referred to as High Pressure (HP). These ports are tapped with a 1-5/8 8UN 2A
thread box and have a conical seal recess in the base of the port. The test fitting
used in these ports include a fitting with a ball type check valve which mates with the
port and seals in the conical recess by means of a conical tip on the fitting. The
fitting body is tapped 9/16” Autoclave at the outboard side and is typically plugged
with an Autoclave blind plug.

1/2” NPT Test/Injection Port Fitting 1/2” NPT Valve Stem

Packing Injector Fitting

Model D Valve Grease Port/Bleeder Fitting

High Pressure Test/Injection Fittings

April 2003 3-9

Accessing Test, Injection, and Gauge Ports
Test, injection, and gauge ports often seal wellhead cavities which may trap
pressure over the production life of a well. These fittings should only be accessed
with caution on any well which has been under production for any length of time.
Trapped pressure can not only be a well control concern, but could result in damage
to property, or injury to personnel if not correctly accessed.
Test injection fittings should never be removed until an attempt is made to bleed
them off through the check valve inside the fitting. A bleeder tool designed to
accomplish this task should be used. Once the bleeder tool has been used
however, it should never be assumed that the pressure is gone since test and
injection ports can also become plugged with mud, cement, or other debris
preventing adequate bleed down. For this reason even after bleeding off a fitting it
should only be removed with caution.
Because of the inherent risk of removing these fittings some operators require a
double check valve in the ports. This is accomplished by inserting an inner
test/injection fitting smaller in diameter (3/8” NPT) than the outer fitting. To safely
access these ports two bleeder tools are required. One to bleed the outer fitting,
and one to bleed the inner fitting.

3-10
April 2003 3-11
 Note:
Non-VG heads only

3-12
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 4
Casing Heads
This page left blank
The casing head serves as an
adapter connection between the
surface casing, or conductor pipe,
and well control equipment (blowout
preventers) or subsequent casing
and tubing spools.
Since it is the lower most section of
the wellhead assembly, the casing
head (sometimes referred to as a
starting head or braden head) is
subjected to the weight of all
subsequent casing and tubing strings
plus the weight of additional surface
equipment. The casing head must
provide a means of:
supporting the next string of casing, in
conjunction with a casing hanger,
which centers and seals the annulus
of that casing string simultaneously,
• connecting or adapting to well
control equipment and sealing
the wellbore from the
atmosphere, and
• controlling access to the
wellbore for pressure control or
fluid returns during drilling operations.
When extreme loading will be applied due to casing size and hole depth, the casing
head may be used in conjunction with a base plate for more effective weight
distribution. The base plate can be cast or forged integrally with the casing head or
fabricated and attached to the casing head with welded gussets. When either type
of base plate is used, the casing head will be connected directly to the surface
casing with the base plate positioned on the conductor or drive pipe.
Each casing head is identified by its nominal size, model type, pressure rating and
connections. The nominal size is the casing size which the casing head is intended
to fit. A casing head for 20" casing is therefore a 20" nominal casing head. The
bottom connection is the connector arrangement to attach the head to the casing,
and the top connection is the API flange or specialty connection size which is
compatible with the BOP stack. API flanges are identified by a nominal bore size
and pressure rating. Manufacturer proprietary connections may have a designation
unique to that particular manufacturer. Also included in the usual identification of
wellhead components is the manufacturer’s name, model type, special features or
options, and outlet size and type.
The upper bore of a casing head features a profile which is referred to as the top
bowl. ABB Vetco Gray designates the model of the casing head by the top bowl and
bottom bowl design. The top bowl design determines load capacities, seal design,
and compatibility with subsequently installed components.

April 2003 4-1

 API flanged top API flanged top
flanged outlets threaded outlets

Socket Weld Bottom

Casing Thread Bottom

API flanged top

studded outlets Grayloc top
Grayloc outlets

Socket Weld Bottom

VG-loc Bottom
NT-2 top
studded outlets

NT-2 top
studded outlets

Sliploc II Bottom
Sliploc III Bottom

4-2
Basic Casing Head Options
• The following casing head options are available from Vetco Gray on request,
to meet individual customer requirements:
• API flanged, NT-2, or VG top connection
• Welded, threaded, Sliploc, or VG-loc bottom connection
• Base plates - either integral or fabricated
• Outlet connections - API studded, API flanged, or API threaded
Bore Configuration Designs
The bore through the casing head includes features which provide load support and
sealing capability for subsequently installed wellhead components. The
configuration above the outlets is referred to as the “top bowl”. Casing Head top
bowl designs are characterized by a cross-sectional profile which is selected based
on the type of service for which the casing head is intended. All of the designs which
are currently available and widely accepted utilize features which include load
shoulders, tapers, threads, grooves, and smooth vertical bores. Each of these
different features provides a certain functional capability for the wellhead bowl, and
the best designs utilize combinations selected to complement each other in a
systems approach to a full function casing head top bowl design.
The load shoulder performs a primary function of supporting the load or weight of
the next casing string in conjunction with a casing hanger. The load shoulder is
usually a sharp break in the bowl profile and must be designed with a sufficient
surface area to support the various loads which may be required during drilling,
testing and hanging the next string of casing. The amount of load capacity is also a
function of the tensile strength of the material selected. For most applications, API
Spec 6A requires that materials must have tensile strengths of 60,000 psi minimum
yield for pressure ratings up to 5,000 psi and 75,000 psi minimum yield for pressure
ratings of 10,000 psi or greater.
The taper is a machined surface which has a controlled slope and in many cases
will also have a controlled surface finish. The taper provides a natural wedging
action which can be used to force slip segments or casing hangers to bite into the
wall of the casing string which is being suspended. The taper must also provide a
sufficient surface area to support the amount of weight necessary. One major
drawback to the taper is that its use alone transfers the casing weight into the wall of
the casing head as hoop stress which reduces the steel’s resistance to pressure
and subsequently requires greater wall thickness. The principal advantage of the
taper is its availability as a metal-to-metal sealing surface if the design can
incorporate some limitations on the amount of load distributed across its surface.
This is usually accomplished by using the taper in conjunction with another support
mechanism.
Threads are used to aid in the installation and handling of certain casing heads in
conjunction with running tools or cross over subs. Threads may also be used in
conjunction with retainer rings to lock casing hangers and packoffs in place.
Grooves are used in bowl profiles typically to be engaged by lock rings to lock
hangers and packoffs in position.

April 2003 4-3

The smooth vertical bore has a controlled finish, and is specifically intended to
function as a seal surface. The vertical bore can be used with metal-to-metal seals,
bore seals, and compression seals.
Typically the model designation of a casing head reflects the top bowl configuration
Abb Vetco Gray offers a variety of tubing spool top bowl profiles for various service
conditions. Top bowl nominal sizes are standard for top connection nominal sizes
but are designated based on the diameter of the hanger which is compatible. For
this reason the nominal bowl size is not the same as the top connection size.
Standard nominal top bowl sizes and their compatible top connection sizes include:

Top Bowl Top Connection

10-3/4” 11” all pressure ratings
13-3/8” 13-5/8” all pressure ratings
16” 16-3/4” 2M & 3M
16-3/4” 16-3/4” 5M & 10M
18-5/8” 18-3/4” 5M, 10M, & 15M
20” 20-3/4” 3M
21-1/4” 21-1/4” 2M, 5M, & 10M

Top Connections
The top connection of the casing head serves as a point of attachment for the BOP
during drilling and then for the casing or tubing spool once the next casing string is
installed in the well. The top connection must be compatible with the bore of the
casing upon which the casing head is installed, and it must have adequate pressure
rating for the anticipated well pressures in the surface hole.
The most widely used top connection is the API flange, however, ABB Vetco Gray
offers two specialty connectors which have certain technical and operational
advantages over the API flange.
The VG connector is a clamp type connection with a unique seal ring, which gives
the connection better sealing characteristics at extreme conditions. The connection
may also be smaller, lighter weight, and faster to make up than the API flange.
ABB Vetco Gray has developed another specialty connector the NT-2 which uses
the same sealing principal as the VG clamp, but is much faster to make up,
potentially saving an operator significant time in nipple up of BOP and wellhead
components.
Bottom Connections
The bottom connection of the casing head attaches the head to the surface casing.
The connection must be able to support the loads associated with the casing head,
BOPs, test pressures, all subsequently installed casing strings, and the production
equipment. Threaded and welded connections are the most prevalent in the
industry. Threaded casing heads are more common in the smaller sizes for lower
pressure applications. The welded connection is more prevalent in the larger sizes.

4-4
ABB Vetco Gray offers several different configurations for mechanically locking the
casing head to the casing which includes two Sliploc configurations and VG-loc.
The principal advantage to these connectors is savings of installation time.
SliplocII Casing Head Bottom Connection
Sliploc refers to a connector designed for fast reliable make up of casing heads to
casing without welding, or extensive pipe preparation. The connector stabs over a
field cut casing stub providing a mechanical lock to the casing utilizing a slip
assembly actuated by screws which
drive against the slip segment tops, and
force the slips against the pipe.
Elastomeric seals above the slip locking
mechanism provide a replaceable
pressure seal which can be tested
immediately upon installation.
The Sliploc is an assembly contained in
a recess in the lower bore of a casing
head which swallows the top of the field
cut and prepared casing stub. A 90o load
bearing shoulder in the bore of the
casing head above the Sliploc assembly
rests the casing head on top of the
casing and provides the load support for
all subsequent casing strings and
wellhead assemblies which are
required.
Below the load support shoulder in the
casing head is a recess which contains a
slip assembly consisting of a set of
casing slips which have sharp teeth on
the inside diameter and a double step
tapered back which fits into a matching
profile in the casing head. Two snap
rings fitted in grooves on the inside
diameter of the slips push the slip
segments outward radially to retain them
in the casing head lower bore. A lock
down adapter assembly consisting of
two beveled rings rests above the slip
segments to provide a bearing surface against which the actuation screws impinge
imparting a downward load against the top of the slip segments equally distributed
across the top of all of the slip segments.
The casing head is tapped radially around the circumference of the lower diameter
and actuation screws thread into the tapped holes. The actuation screws have hex
ends externally that are accessible around the connector circumference, and have
conical shaped ends internally which impinge on the lock down adapter rings when
torque is applied to actuate the connection.
Between the load shoulder and the slip assembly the bore of the casing head has a
recess for a Type BT elastomer seal. There are two sealant injection ports which
penetrate from the outside diameter of the casing head to the center of the seal

April 2003 4-5

recess. These ports are at 180o intervals and are tapped ½” NPT at the outlet.
Injection fittings with spring loaded check valves are made up into each port. These
ports permit sealant injection to energize the BT seals.
An o-ring groove is located above the BT seal recess which houses an o-ring seal
which provides a back up seal to the BT seal and permits a pressure test of the BT
seal upon installation of the casing head.
A test port penetrates the bore of the casing head between the o-ring and BT seal
which is tapped ½” NPT at the outlet. This port permits pressure testing of the seal
assembly immediately after installation.
In the running mode the connector is stabbed over the casing, the slips are driven
into the pipe by tightening the actuation screws. As soon as the connector is locked
onto the pipe an overpull is performed to verify lock down. A silicon and graphite
sealant is circulated through the BT seal and pressurized to swell the BT seal
against the casing and the casing head recess.
A pressure test is then performed to verify seal integrity.
The Sliploc connection is the result of years of experience with slip locking
mechanisms for wellhead, Diverter, and BOP adapters.
Design features resulting in considerable cost savings to the user include:
• Rapid make up, and release.
• Pressure ratings to 5,000 psi
Reusable with minimal repair and maintenance requirements.

4-6
Sliploc III Casing Head Bottom Connection
The Sliploc III bottom connection is a
Sliploc design for more extreme service
conditions. The connector has high
tensile and bending capacities than the
standard Sliploc, and provides metal to
metal seals as well as elastomer seals
between the casing and the casing head
housing.
Sliploc III is an assembly contained in a
recess in the lower bore of a casing head
which swallows the top of the field cut
and prepared casing stub. A 90o load
bearing shoulder in the bore of the casing
head above the Sliploc III assembly rests
the casing head on top of the casing and
provides the load support for all
subsequent casing strings and wellhead
assemblies which are required.
Below the load support shoulder in the
casing head is a recess which contains a
slip assembly consisting of a one piece
double tapered slip, which has sharp
teeth on the inside diameter and a double
tapered outside diameter which fits into a
matching profile in the casing head. Two
tin indium inlays at the top and bottom of
the slip provide a metal to metal seal
between the slip and the casing. The taper at the outside diameter of the slip seals
metal to metal against the lower bore of the casing head housing.
The casing head is locked to the pipe using a studded flange assembly which when
made up compresses the slip ring inward against the pipe causing the slip ring to
grip the casing.
Between the load shoulder and the slip assembly the bore of the casing head has a
recess for a Type BT elastomer seal. There are two sealant injection ports which
penetrate from the outside diameter of the casing head to the center of the seal
recess. These ports are at 180o intervals and are tapped ½” NPT at the outlet.
Injection fittings with spring loaded check valves are made up into each port. These
ports permit sealant injection to energize the BT seals.
A test port penetrates the bore of the casing head between the slip and BT seal
which is tapped ½” NPT at the outlet. This port permits pressure testing of the seal
assembly immediately after installation.
In the running mode the connector is stabbed over the casing and the slip is driven
into the pipe by tightening the stud bolts. As soon as the connector is locked onto
the pipe an overpull is performed to verify lock down. A silicon and graphite sealant
is circulated through the BT seal and pressurized to swell the BT seal against the
casing and the casing head recess.
A pressure test is then performed to verify seal integrity.

April 2003 4-7

VG-Loc Casing Head Bottom Connection
VG-loc refers to a connector designed for fast reliable make up casing heads to
casing without welding, or extensive pipe preparation. The connector stabs over a
field cut casing stub providing a mechanical lock to the stub utilizing a slip assembly
actuated by set screws which drive and hold the slips against the pipe. Elastomeric
seals above the slip locking mechanism
provide a replaceable pressure seal which
can be tested immediately upon installation.
The VG-loc consists of a recess machined
in the lower bore of a casing head which
swallows the top of the cut casing stub.
Housed in the recess is a slip assembly
consisting of a slip bowl, slips, and stop
plate. The slip bowl fits into the casing
recess and is retained in position by lock
down screws which fit radially around the
connection. The slip bowl has an internal
profile to contain the slip segments which
are retained in the slip bowl by internal snap
rings that push the slips into the slip bowl
profile. The stop plate is retained in the
bottom of the recess with a snap ring and
acts as a reaction plate to aid in slip release.

The lock down screws have hex ends

externally that are accessible around the
connector circumference, thread into the
connector, and have conical shaped ends
internally which impinge on the slips or slip bowl to actuate the connection.
In the running mode the set screws extend through a port in the slip bowl and butt
against the top of each slip segment. Once the connector is stabbed over the
casing the slips are driven into the pipe by torqueing the lock down screws. As soon
as the connector is locked onto the pipe a pressure test can be performed through a
test port located between the two seal elements located in the casing recess above
the slip area.
To release the connector the lock down screws are retracted far enough to clear the
slip bowl port. The diverter adapter or casing head is then raised until the stop plate
in the lower bore contacts the bottom of the slip bowl. The lock down screws are
then made up until they impinge on top of the slip bowl, retaining it in the lower
position. The adapter or head is then lowered back down, forcing the slips to
release from the pipe. The adapter or casing head can then be lifted free of the pipe.
Design features resulting in considerable cost savings to the user include:
• Rapid make up, and release.
• Pressure ratings to 5,000 psi
• Positive mechanical release mechanism.
Reusable with minimal repair and maintenance requirements.

4-8
Outlets
Casing Heads generally have two
outlets oriented at 180o, which
provide access to the casing head
bore through a side entry. The
outlets have a pressure rating equal
to the top connection of the casing
head, and will typically have either
one or two gate valves mounted to
them, or companion flanges if the
outlet is not in use. ABB Vetco Gray
provides Valve Removal Plug
threads in all of the outlet
configuration it offers. The Valve
Removal Plug (VR plug) permits the
bore of the casing head to be
isolated from the outlet connection
so that outlet valves can be
installed, repaired, or replaced with
or without pressure in the casing
head bore.
The API studded connection is the
ABB Vetco Gray connection for API
flanged casing heads. API flanged
outlets are sometimes provided as
well. For low pressure applications
API Line Pipe or EUE 8rd outlets are
often provided.
Landing Base/Base Plate
The landing base, or base plate, is
used to provide a greater area of
support for distribution of casing
loads over more than one string of
casing. This is especially needed
when surface soil conditions are
unstable, whether on land, offshore,
or in coastal areas. The landing base
is generally fabricated from plate
steel and welded to the casing head
housing before shipment to the
location. In some instances the
components of the landing base may
be field welded to the casing head
housing if proper material selection is
made. In special cases, the support
profile of the landing base may be
cast or forged integrally with the
casing head housing.

April 2003 4-9

Vetco Gray uses three standard designs for landing bases which could be classified
as light duty, medium duty, and heavy duty. Each standard design utilizes 4-8 or
more gussets of plate steel fabricated to the casing head housing to maximize the
total contact area of support without creating any field welding difficulties. Each
standard design also uses combinations of shear and bearing stress to increase the
overall capacity of the design.
Whenever a landing base arrangement is required, Vetco Gray uses an in-house
computer program to select the proper base plate arrangement, based on casing
program information furnished by the operator. From this information, style
selection, gusset configuration, and material strength can be optimized for the
particular application.

4-10
FC Casing Head
The FC casing head is available for 2,000 and
3,000 psi service pressures with either socket
weld or threaded bottom connections and
either 11" or 13-5/8" API flanged top
connections. Outlets may be either line pipe or
API studded connections. Valve removal plug
threads are provided with studded outlets.
The top bowl (in the upper bore of the head)
supports and seals a subsequently installed
casing string. The top bowl consists of a
primary 45o load shoulder, a vertical seal bore,
a secondary load shoulder, and a seal bore
above that at the top of the head. The primary
load shoulder supports the casing hanger and
casing. The secondary load shoulder is used
as a support mechanism for a casing bonnet when it is used. The surface finish in
the bore permits elastomeric annular seals on the casing hanger to seal against the
bore of the casing head.
CWC (Complete Well Control) Casing Heads
The Type CWC (Complete Well Control )
Casing Head for pressure ratings from
2,000 to 5,000 psi with the capability to
support medium to heavy casing loads in
both an offshore and onshore
environment.
The CWC top bowl includes a 45E
primary load support shoulder designed
to support the entire weight of a
subsequently installed casing string plus
the test pressure load applied during
installation. The vertical bore above the
primary load shoulder is the sealing
surface for the resilient annular seal on
Type W casing hangers and BOP test
plugs. A 15o shoulder above the primary
load shoulder provides a reduced
diameter sealing area for the
subsequently installed casing hangers to
protect the resilient seals of the hanger
as it is landed. The vertical bore above
the 15o shoulder provides a sealing
surface for Type WE casing hangers. A
secondary 45E load shoulder near the top of the bore provides a load bearing area
for auxiliary seals used on some installations. The straight bore above the
secondary load shoulder provides a sealing area for the auxiliary components.

April 2003 4-11

Type CWCT Casing Head
The Type CWCT (Complete Well Control
Tapered) Casing has superseded the Type
CWC and is used for similar service
applications.
The CWCT top bowl profile includes a 45E
primary load support shoulder designed to
support the entire weight of a subsequently
installed casing string plus the test pressure
load applied during installation. The vertical
bore above the primary load shoulder is the
sealing surface for the resilient annular seal
on Type W casing hangers and BOP test
plugs. A taper above the primary load
shoulder and the vertical bore provides a
sealing surface for the ABB Vetco Gray
“Controlled Taper” metal to metal seal used
with CWCT mandrel casing hangers. The
vertical bore above the tapered area
provides a sealing surface for Type WE
casing hangers. A secondary 45E load
shoulder near the top of the bore provides a
load bearing area for auxiliary seals used
on some installations. The straight bore
above the secondary load shoulder provides a sealing area for the auxiliary
components.
CWCT casing heads are available with all of the top, bottom, and outlet connection
options offered by ABB Vetco Gray.
CWCT And CWC Top Bowl Compatibility
All Type W BOP Test Plugs, and Type W Bowl Protectors fit both the CWC and the
CWCT bowls. The bowls are identical except the CWC bowl has a 15o upset in
place of the seal taper, and the inside diameter above the seal area is 1/16” smaller.
Type CWCT-F6 or CWCT-G6 Mandrel Casing Hangers will fit the CWCT top bowl
but not the CWC. Type CWC-BW Mandrel Casing Hangers fit in either CWCT or
CWC top bowl profiles.
Type W and WE Casing Hangers must have the CWCT extension to fit either CWC
or CWCT top bowl profiles. (i.e. W-CWCT, or WE-CWCT)

4-12
Type D15 Casing Heads
The Type D15 Casing Head is used for pressure ratings from 2,000 to 5,000 psi
designed to support heavier casing and pressure loads than does the CWC or
CWCT design.
The D15 top bowl is similar in configuration to the CWCT top bowl but includes a
wider primary load shoulder and smaller minimum bore than CWCT for the same
nominal bore sizes. The D-15 top
bowl configuration includes a 45E
primary load support shoulder. The
vertical bore above the primary
load shoulder is the sealing
surface for the resilient annular
seal on Type W casing hangers
and BOP test plugs. A taper above
the primary load shoulder and the
vertical bore provides a sealing
surface for the ABB Vetco Gray
“Controlled Taper” metal to metal
seal used with D15 mandrel casing
hangers. The vertical bore above
the tapered area provides a
sealing surface for Type WE
casing hangers. A secondary 45E
load shoulder near the top of the
bore provides a load bearing area
for auxiliary seals used on some
installations. The straight bore
above the secondary load
shoulder provides a sealing area
for the auxiliary components.
D15 Top Bowl Compatibility
Type W BOP Test Plugs, and Type
W Bowl Protectors sizes 10-3/4”,
and 13-3/8” will work in the
matching D15 top bowl. The
16-3/4”, 18-5/8”, 21-1/4”, and 26-3/4” D15 top bowl requires Type D15 BOP Test
Plugs and Bowl Protectors.
Only Type D15F6 or D15G6 mandrel casing hangers will function in a D15 casing
head.
Type W and WE casing hangers must have the D15 extension to fit the D15 top
bowl profile. (i.e. W-D15, and WE-D15)

April 2003 4-13

Type HL Top Bowl Profile
The HL (High Load) top bowl design has the same features as the CWCT and D15
designs, but the seal taper is moved up in the profile immediately below the
secondary load shoulder. The Type HL top bowl also has a test/monitor port which
penetrates the bore just below the seal taper.
This bowl design is used with extreme casing loads where the operator wants the
convenience and reliability of a wrap around slip type casing hanger with elastomer
seals, plus the option of metal to metal annular seals as well. By moving the taper in
the bowl above the area of the bowl covered by the slip casing hanger the taper is
accessible for seals on Casing Bonnet type isolation seals.
HL Top Bowl Compatibility
All BOP Test Plugs and Bowl Protectors for HL top bowls must be designated HL to
fit.
All mandrel casing hangers for Type HL top bowls must be designated HL to fit.
Type W and WE Casing Hangers must have the HL extension to fit the HL top bowl
profile. (i.e. W-HL or WE-HL)

4-14
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 5
BOP Test Plugs
This page left blank
The primary function of a BOP Test Plug is to provide a simple, effective means of
sealing the wellbore below the well control equipment (BOP stack). All the
connections and sealing areas from the wellhead top connection up through the
BOP stack can be pressure tested to ensure environmental integrity during drilling
operations. Because the BOP Test Plug seals in the same area of the wellhead bore
as the casing hanger, such tests are indicators of possible bowl wear.
BOP test plugs may be solid or may have a through bore depending on operator
preference. BOP test plugs with a through bore are usually designed to be used as
a storm plug for emergency location abandonment. Test plugs are typically run on
drill pipe and therefore threaded top and bottom with drillpipe threads. The
configuration of the plugs are such that they land and seal in a specific casing head,
casing spool, or tubing spool bowl type and size. There is typically a port in the test
plug extending from the top of the plug body to the root of the landing thread. This
“weep hole” is used to pressure test a lower set of pipe rams if there are no inlets to
pump fluid below the rams. The weep hole permits the fluid to be pumped down the
landing joints to pressure up below the ram to be tested.
Some BOP test plugs are also used to run and retrieve the bowl protectors. In this
case the test plug usually has drill pipe tool joint box connections top and bottom. In
one orientation the plug works as a test plug. When inverted the retrieval profile for
the bowl protector is exposed for use in running and retrieving the bowl protector.
In areas where there is a local service organization BOP Test Plugs and Bowl
Protectors for standard wellhead systems are kept in stock and usually supplied as
rental equipment. A particular set of BOP Test Plug, Bowl Protector, and Bowl
Protector Running and Retrieving Tool is only required while the rig is drilling a
particular hole section. Once casing is run and a new wellhead section is installed a
different set of BOP Test Plug, Bowl Protector, and Bowl Protector Running and
Retrieving Tool is required for the new size.
In areas that are remote, or where an extended drilling program is planned, it may
be more cost effective to for an operator to purchase these items.

April 2003 5-1

Type W Test Plug
The Type W BOP test plug is used in all CWCT and CWC casing head and casing
spool top bowls. It is also used in CWC or CWCT
tubing spools with 10-3/4" bowls because their
bowl configuration is the same as a casing spool.
It is used in D15 bowls where the diameters are
the same as CWCT. These sizes include 10-3/4”,
13-3/8”, 16”, and 20-3/4”.
The W test plug lands on the 45o primary load
bearing shoulder of the casing head or casing
spool top bowl. An o-ring housed in a dove-tailed
groove on the outside diameter of the plug seals
between the plug and the wellhead top bowl.
The Type W test plug is available with drill pipe
tool joint box top and pin bottom connections.
A weep hole port is provided penetrating from the
top surface of the test plug to the root of the drill
pipe tool joint box top connection. The weep hole
permits circulation down the landing joint 10-3/4” Type W Test Plug
assembly used to run the plug through the weep
hole to pressure up against a bottom set of pipe
rams should the rams be located below any choke and kill outlets of the BOP stack.
The weep hole is tapped 3/8” NPT at the top so a pipe plug may be used to plug the
hole when it is not used.
FC Combination BOP Test Plug and Bowl
Protector Running and Retrieving Tool
The FC Combination BOP Test Plug and Bowl
Protector Running and Retrieving Tool is used
for testing the BOP. By inverting the plug it is
used as a bowl protector running and
retrieving tool. The FC Combination BOP Test
Plug and Bowl Protector Running and
Retrieving Tool has drill pipe tool joint box top
and bottom connections. A single elastomer
seal element seals between the test plug and
the wellhead top bowl. Above the seal of the
plug is a reduced outside diameter which has
two L-slot lugs used to engage the FC Bowl
Protector for running and retrieving the bowl
protector.
10-3/4” FC Test Plug

5-2
 7” Type CWC Test Plug 7” Type AD Test Plug

CWC Test Plug

The CWC (old designation: AD) test plug is for use in tubing spool bowls and is
available only in sizes 7" and 8-5/8". CWC or CWCT tubing spools with 10-3/4" top
bowls require a Type W test plug. Test plugs for CWC tubing spools seal on the
taper in the bowl above the load shoulder. This seal is a metal to metal seal backed
up by hydraulic packing.
Type 45 Test Plug
The Type 45 test plug is used only in the Type
45 tubing spool. Type 45 equipment is
available only with 7" top bowls. Since the
Type 45 bowl design is a straight bore down
to a 45o load shoulder, the test plug seal is an
elastomer seal element activated either by
weight or by the tubing head set screws. The
load ring on the test plug compresses and
extrudes the seal as the load is applied to the
test plug.

7” Type D15 Test Plug

The 7" D15 test plug has the identical outer
profile as the 7" CWC test plug except it has a
wider 90o load shoulder for greater load
capacity.

7” Type 45 Test Plug

April 2003 5-3

 8 5/8" To 26-3/4” Type D15 Test Plugs
The Type D15 test plug in the 8 5/8" and larger size differs from the same style in
7". The D15 bowls larger than 8-5/8” have a two inch taper per foot, rather than a
four inch taper. They also have a 45o primary load shoulder rather than a 90o load
shoulder as in the 7" D15 test plug. The 8 5/8" D15 seals metal to metal on the
taper in the bowl. In sizes above 8-5/8” the D15 test plug is similar to the Type W
test plug except the diameters are different.

7” D15 Test Plug 8-5/8” D15 Test Plug

S-20 Test plugs

S-20 test plugs are high load test plugs for
extreme service completions.
S-20 test plugs are available only in the 7"
and 8 5/8" sizes since the S-20 hangers
which are run in the S-20 bowl are mandrel
hangers for either the production casing or
tubing.

7” SR-20 Test Plug

5-4
HL Test Plugs
The Type HL test plug is similar to the
Type W but it does not have the small
upset above the O-ring diameter which in
the Type W test plug, protects the seal
taper from damage. Since the seal taper
in the HL bowl is higher, it has a smaller
inside diameter in the area above the
primary load shoulder. For this reason
type W and type D-15 test plugs cannot be
used in Type HL bowls.

10-3/4” Type HL Test Plug

Multibowl Test Plugs

There are many different designs of
multibowl wellheads. Test plugs for these
designs are usually non-standard and
designed exclusively for a particular style
wellhead.

11” MB 150 Test Plug and Bowl Protector

Running and Retrieving Tool

April 2003 5-5

BOP Test Plug Adapters
The test plug adapter is
used to convert one size or
type of test plug to fit
another bowl size or bowl
design. In many cases,
one solid test plug will be
used with several bowl
adapters to accommodate
each casing bowl size
required for an entire
drilling operation. In the
illustration at the right a
10-3/4” Type W test plug is
converted to a 20” Type W
test plug using a test plug
adapter.

BOP Test Plug Adapters

Cup Testers
The cup tester was developed to provide internal testing capability of isolation seals
and outlet connections after the BOP stack has been nippled up. A standard BOP
test plug seals in the upper bowl of the
wellhead component in which it lands. For
this reason a BOP pressure test will test
only the connections above the wellhead.
On occasion it is desirable to test the
internal seals in the wellhead below the
bowl profile. In these cases a cup tester is
used. The upper portion of the cup tester
body lands in the bowl of the casing head,
casing spool or tubing spool. The extension
below the body carries a standard casing
test cup which seals inside the casing
diameter. Since the body is ported the test
cup becomes to bore seal. By this method
test pressure is applied to the casing
primary packoff, the wellhead outlets and
the BOP components.

10-3/4” x 9-5/8” Cup Tester

5-6
 Cup Tester installed in Wellhead

April 2003 5-7

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 SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 6
Bowl Protectors, Running and Retrieving Tools
This page left blank
The bowl protector (sometimes referred to as a wear sleeve or wear bushing) is
designed to protect the bore of the casing head, casing spool or tubing spool from
damage during drilling or workover operations. When positioned in the wellhead
bowl, it shields the sealing surfaces and the load bearing areas from the impact and
wear caused by rotating or tripping pipe and other tools through the wellhead.
Bowl Protectors are typically installed in the wellhead any time pipe or other tools
will be moved through the wellhead. It must be removed for BOP tests, and to run
casing or tubing. A running and retrieving tool is provided which allows the Bowl
Protector to be run into the wellhead through the BOP using drill pipe. The running
and retrieving tool makes up to drill pipe and engages the Bowl Protector with two to
four lugs on the outside diameter of the tool. These lugs slide into mating slots at the
top inside diameter of the Bowl Protector and lock on by slight right hand rotation
which moves the lugs from the vertical section of the “J” or “L” slot to the horizontal
section. The tool is released from the Bowl Protector by slight left hand rotation so
that the “J” or “L” lugs move back to the vertical section of the slot and can then be
pulled out of the Bowl Protector by direct upward pull.
In areas where there is a local service organization BOP Test Plugs and Bowl
Protectors for standard wellhead systems are kept in stock and usually supplied as
rental equipment. A particular set of BOP Test Plug, Bowl Protector, and Bowl
Protector Running and Retrieving Tool is only required while the rig is drilling a
particular hole section. Once casing is run and a new wellhead section is installed a
different set of BOP Test Plug, Bowl Protector, and Bowl Protector Running and
Retrieving Tool is required for the new size.
In areas that are remote, or where an extended drilling program is planned, it may
be more cost effective to for an operator to purchase these items.

Bowl Protector Running &

Retrieving Tool

Type W Bowl Protector

April 2003 6-1

Body Type
A bowl protector is a sleeve configured to fit a particular bore size and configuration.
Critical seal surfaces and load bearing areas in the wellhead must be protected
from the impact of the pipe run through and rotated inside of it. The bowl protector
compatible with any given casing head,
casing spool or tubing spool typically
has the same size and model
designation as the BOP Test Plug which
is compatible in the wellhead
component in question. In other words,
a CWCT casing spool takes a Type W
BOP Test Plug, and will also take a Type
W Bowl Protector.
Bit Retrievable or Full Bore
The inner configuration may be either
bit retrievable or full bore. A bowl
protector is bit retrievable if its inside
diameter is smaller than the outside
diameter of the bit and other bottom
hole equipment. The bowl protector is
run and retrieved with the drill string
bottom hole assembly. A bowl protector Bowl Protector Running and
is full bore if its inside diameter is larger Retrieving Tool
than the outside diameter of the bit. A
full bore bowl protector must be run with
a bowl protector retrieving tool. Some
bit retrievable bowl protectors are also
machined to be used with a bowl
protector retrieving tool if necessary.
J-Slot or L-Slot
At the top bore of each bowl protector is
a set of two to four slots. They are used
to attach the bowl protector to the
running and retrieving tool. There are
two kinds of slots used: the J-slot (two
grooves on the inside or through the
body, 180o apart, in the shape of a “J”,
and the L-slot (two or four vertical slots
machined on the inside of the body,
entering a groove machined in the
upper bore of the bowl protector. The
two designs are operationally the same. 13-3/8” Type W Bowl Protector

6-2
Extension Sleeve
The bowl protector may or may not have an extension sleeve. Bowl protectors for
casing sizes between 9-5/8” and 13-3/8” usually have the extension sleeve as the
bore through the casing head or spool is small enough that some wear could occur
on the top of the casing exposed in the wellhead. The extension sleeve stabs into
the top of the casing as well as the wellhead bore. The extension sleeves are
typically drilled with four holes at 90o intervals to prevent mud from sealing the
outside diameter of the bowl protector and causing it to be pumped up out of
position by circulating drilling fluid. Since the extension sleeve must fit inside the
casing each size is designated for a particular casing size and range of casing
weights.
Lock Down Screws
Lock down screws are often provided to hold the bowl protector in place and
eliminate rotation. They are located either in the top flange (hub) of the casing head
or casing spool or in an adapter flange installed directly above the spool during
drilling operations. Only four lock down screws, 90o apart are needed. The lock
down screws impinge on the side of the bowl protector body, pinning the bowl
protector in place. The shear rib on the bottom side of the groove prevents the bowl
protector from moving up. However, the lock down screws will shear through the rib
without major damage to the equipment if the bowl protector is accidentally
retrieved without retracting the lock down screws.
If lock screws in a drilling adapter above the wellhead are used then a bowl
protector with an extended top section must be used to provide a surface on which
the lock screws can impinge.
Bowl Protector Running and Retrieving Tool
The bowl protector running and retrieving tool has two or four lugs which engage
the bowl protector’s J-slot or L-slot. Some designs having two lugs also have two
stabilizing lugs which prevent the bowl protector from rocking
Type E Bowl Protector Running and Retrieving Tool
The Type E bowl protector running and retrieving tool rather than make up to the
drill pipe thread, locks onto the drill pipe body. This permits the same tool to be used
with various sizes of drill pipe and various drill pipe thread connections. The bore of
the Type E bowl protector running and retrieving tool body is significantly larger
than the drill pipe. A split sleeve configured to fit the drill pipe body diameter is used
to lock the tool to the pipe. Four hex socket screws insert through the tool body and
each split sleeve to lock the tool to the drill pipe body above the tool joint upset. The
sleeve insures that the retriever will not slip past the drill pipe upset.

April 2003 6-3

Combination BOP Test Plug and Bowl Protector Running and Retrieving
Tool
In some cases as with the FC system and many of the Multibowl Systems the BOP
Test Plug and the Bowl Protector Running and Retrieving Tool are combined into a
single tool.
The tool has drill pipe tool joint box connections at both ends. When run in one
orientation the tools BOP Test Plug seal profile is at the lower end of the tool and the
tool acts as a BOP Test Plug. When the tool is run in the inverted orientation the
J-lugs are at the bottom of the tool, and the tool functions to run and retrieve the
bowl protector.

FC Combination BOP Test Plug & Bowl

Protector Running and Retrieving Tool

FC Bowl Protector

6-4
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 7
Casing Hangers
This page left blank
A casing hanger is a retainer/packer mechanism which supports, centers, and
usually seals a string of casing in a wellhead housing. There are three primary
categories of equipment which perform the principal operation of supporting the
weight of the casing string:
• Wrap around casing slips which bite into the wall of the casing and support
the weight without providing any sealing capability.
• Wrap around casing hangers which employ slips to support the casing weight
and have a self-contained sealing mechanism.
• Mandrel style casing hangers which thread onto the casing to support the
casing weight and also have a self-contained sealing mechanism.
As the weight of the casing string is transferred through the casing hanger
assembly, the design must function with the casing head or spool top bowl to
support the weight of the string without any significant deflection or reduction of the
dimensions and mechanical properties of the casing or the hanger. The hanger
must also be designed to contain the pressure loads applied during testing of the
wellhead and BOP.
Casing Hanger Styles
The most widely used casing hangers today are the wrap around slip type hangers
with integral weight energized annular seals. These casing hangers employ sets of
slips to bite into the wall of the casing string to support it much the same as rotary
slips are used to support the drill pipe. Wrap around casing hangers may be divided
into three categories: those that do not seal the casing annulus, those that effect an
annular seal as the casing load is applied to the hanger, and those that have an
annular seal which is independently energized after the casing load is applied to the
hanger.
Many wrap around casing hangers can be installed around the casing at the rotary
floor and lowered through the BOP, or the hanger can be installed at the wellhead
by raising the BOP stack.
Wrap around casing hangers are characterized by a number of features. The
simplest styles are just machined slip segments which are hardened and then
hinged together. This style usually requires a tapered surface in the casing bowl to
effect their hanging ability by wedging the slips into the casing string. This style also
requires a separate seal assembly to seal the annulus of the string being
suspended.
The most common style of wrap around casing hanger employs an integral seal
element which is compressed and extruded by the weight of the casing. Since the
seal is located between the outside diameter of the casing and the inside diameter
of the wellhead housing, as it is extruded by the casing weight, a bearing load is
effected between the seal, the casing, and the wellhead housing. This bearing load
is sufficient to retain significant pressure of fluids applied at this interface.
It should be noted that the casing slips and compressed annular seals apply a radial
load to the wall of the casing. With sufficient tensile or pressure this radial load can
deflect the casing wall beyond its yield strength. If the design of the hanger exposes
the highly stressed slip and seal loaded areas to test or annular pressure, the
combined loads must be considered in determining the tensile and pressure
capacities of the hanger.

April 2003 7-1

FC Casing Hanger and Seal
The slips, slip bowl and a type H packoff seal ring are all combined in the FC-21
wrap-around casing hanger. The type H packoff provides a positive annulus packoff
after the casing pipe has been suspended and cut off. With the type H packoff, this
hanger is classified as a Group I (API) type hanger.

FC-21 WRAP AROUND CASING HANGER

Combined in a single the FC-22 wrap-around casing hanger incorporates packoff,

slip bowl and slips. The FC-22 casing hanger is economical and easily installed.
When the casing load is suspended, the packoff automatically seals the casing
annulus packoff before removal of the Blowout Preventer and cutting the casing
pipe. The FC-22 Hangers controlled hanger is classified as a Group III API type
hanger.

FC-22 WRAP AROUND CASING HANGER

7-2
Combined in a single unit the FC-22M wrap around casing hanger incorporates a
packoff, slip bowl and slips. The FC-22M casing hanger is economical and easily
installed at the casing head or spool with the elastomer seal mechanically activated
by cap screws. This hanger is commonly used above mudline systems. The
FC-22M hanger's controlled friction reduces casing deflection. The FC-22M is a
Group III API type hanger.

FC-22M CASING HANGER

The FC-29 wrap around casing hanger provides minimum casing deflection and a
hanging capacity that surpasses the capacity of the FC-21 and FC-22 casing
hangers. When the upper sllips move down and evergize the packoff, the
untapered lower slips engage automatically and apply controlled compression
around the pipe. The lower slips do not move down, thus they do not create a high
compressive force, as do conventional tapered slips. The FC-29 hanger is
classified as a Group III API type hanger.

FC-29 CASING HANGER ASSEMBLY

April 2003 7-3

Type W Casing Hanger
The Type W wrap around slip style casing hanger is used in casing bowls types
CWC, CWCT, D15, and HL. The type of bowl a Type W hanger fits is indicated by a
dash and the bowl type in the product description. (ie. Type W-CWCT, or W-D15).
The Type W hanger employs the
step-backed slip design which provides
maximum load support capacity and
minimum possibility of casing collapse
from tensile loading. Extrusion seals are
located below the slips and are weight
activated with positive-stop control to
prevent casing collapse across the
sealing area. The Type W hanger is
therefore able to seal the casing annulus
prior to BOP removal while
simultaneously protecting the slip-loaded
area of the casing from pressure in the
casing annulus.
The Type W hanger locks around the
TYPE W CASING HANGER
pipe using an interlocking design. The
slip bowl, seal and compression ring are
all split in half. A groove in the bottom of the slip bowl tracks onto the load pedestal
of the compression ring with the seal trapped between the two components. When
the two hanger halves are wrapped around the pipe and the slip bowl is rotated
around the compression ring 90 o the halves are locked together. This design
maintains the hanger in locked position such that it can be safely lowered through
the BOP.
The seal element of the hanger is smaller in diameter than the hanger body so that
the seal is protected by the hanger body as the hanger is installed.
WE Casing Hanger
The Type WE wrap-around slip style
casing hanger is used in casing
bowls types CWC, CWCT, D15, and
HL. The type of bowl is indicated by a
dash and the bowl designation in the
product description. (ie. Type
WE-CWCT, or WE-D15).
The Type WE wrap-around slip style
casing hanger is used in the same
bowls as the Type W casing hanger
and often in conjunction with Vetco
Gray mudline suspension
equipment. It has the same
load-carrying capacity as the W
casing hanger, but the sealing
element is located above the slips
and is mechanically activated by cap WE TYPE CASING HANGER
screws. The Type WE sealing
element does not require casing

7-4
string load to activate the seal (as does the Type
W casing hanger) therefore, it is suitable for stuck
pipe or mudline suspension applications.
Installation of the hanger requires it to be
separated into halves, wrapped around the
casing, and locked together. Two dove tailed ring
segments retained in a groove on the outside
diameter of the hanger, lock the two halves
together when they are positioned to span the
split between the hanger halves. Set screws in
the dove tailed ring segments are tightened to
hold the hanger together. When the hanger is
installed in the casing head or casing spool top
bowl, and casing is lowered through it, the slip
teeth bite into the pipe wall and the casing weight
is transferred through the slips to the slip bowl
and the casing head or casing spool load
shoulder. Tightening the cap screws in the
compression plate compresses the seal element
extruding it tightly against the casing and the bore
of the casing head or casing spool to effect an
annular seal.
Mandrel Style Casing Hangers
The mandrel style of casing hanger is a one piece hanger which is threaded onto
the end of the casing string, and is lowered into the casing bowl with a landing joint
of casing or drill pipe. The primary advantage of the mandrel style of casing hanger
is its simplicity of operation, and the reduced amount of rig time required for both
installing the hanger on the casing string and “nippling up” the next section of
wellhead. The primary disadvantage of the mandrel casing hanger is that should
the casing become stuck before it is fully landed it may be impossible to install it in
the required position.
There are two styles of mandrel casing hanger:
• Double tapered, which has integral seals
• Fluted, which provides circulation passages for mud or cement returns, but
requires a separate annular seal.

April 2003 7-5

Type CWCT, D-15, and HL, Double Tapered Mandrel Casing Hanger
The product description of this style hanger includes the designation of the type of
casing head, casing spool, or tubing spool bowl in which it is installed, and the
extension F6, or G6 depending on whether the wellhead housing has flanged or VG
end connections. (ie. CWCT-F6, or D15-G6).
The casing hanger is a single mandrel with internal upper and lower threads to
match the casing threads. The hanger is made up to the top of the casing string and
lowered through the BOP to land in the upper bore of the wellhead.
The outside diameter of the hanger conforms to the bore configuration in the casing
head or spool which receives it. The hanger configuration includes a 45o primary
load shoulder, and a two inch per foot metal to metal seal taper. The casing hanger
annular seal “controlled taper” is effected as the taper on the outside diameter of the
hanger first contacts the seal taper in the bore of the casing head or spool in which it
is landed. Enough load is transferred to this area to ensure a positive metal to metal
seal with the majority of the casing weight supported by the 45° primary load
shoulder below the taper.

Metalflex casing
isolation seal

Controlled taper
casing annulus
seal

7-6
The top of the hanger extends above the top of the casing head or spool in which it
is landed and seals in the bottom bore of the casing or tubing spool installed above
it, by means of a “Metalflex” seal. The Metalflex seal is energized by the load
initiated by the wellhead connection preload. As the casing or tubing spool to be
installed above the hanger is connected to the casing head or spool in which it is
landed, the taper on the upper casing hanger mandrel mates with a taper in the
bottom bore of the casing or tubing spool. The taper in the casing or tubing spool
has a one degree differential from the hanger mandrel seal taper so the hanger
mandrel is deflected inward as the connection preload is established and a surface
area, pressure enhanced, bore seal is effected along the mated tapers.
Both the upper and lower seals are backed up by hydraulic packing as a wiper and
to enhance reliability.
A landing assembly consisting of
casing joints is used to lower the
hanger through the BOP stack and land
it in the bore of the casing head or
spool.
The metal to metal seals maintain their
integrity under temperature extremes
and can be made relatively impervious
to corrosion or deterioration.
Fluted Mandrel Casing Hangers
One of the limitations of the double
tapered mandrel casing hanger is that
once it is landed, the annulus is sealed
and fluid will not circulate past the
hanger. For this reason the annulus is
usually cemented before the casing
hanger is fully landed. Fluted hangers
have slots through the body which
permit fluid to circulate around the Fluted Mandrel Casing Hanger
hanger. The casing annulus is sealed
by installing a separate packoff after
cementing is complete. ABB Vetco
Gray supplies many different designs
for fluted casing hangers, most of which are used in “Multibowl Wellhead
Housings”.

April 2003 7-7

 AMH-2H Adjustable Mandrel Casing Hanger, Packoff, and Running Tool

7-8
Adjustable Mandrel Casing Hangers
Wells which are drilled from Jackups and Floaters often suspend the casing
subsea, then later, it is tied back to a surface facility for production. Tieback risers
must be established from the subsea equipment to the surface production
equipment. These risers usually require tensioning from the subsea wellhead or
mudline suspension system to the surface wellhead assembly. This can be done
with a slip type casing hanger, however, that method requires the BOP to be nippled
down to cut the casing and install a casing spool or tubing spool. Adjustable
mandrel casing hangers permit the casing riser to be tensioned with the BOP in
place. The AMH-2H casing hanger is used for this purpose.
The AMH-2H casing hanger consists of a central mandrel hanger which makes up
to the top of the tieback riser. A ratcheting load ring is supported on its outside
diameter. As the riser casing is run, the subsea tieback connection is initiated, and
the riser is tensioned as desired. The running tool for the AMH-2H casing hanger is
then actuated hydraulically forcing the ratchet ring down to a load shoulder in the
wellhead housing locking the tension into the riser string.
Casing Hanger Load Capacities (Type W)
ABB Vetco Gray casing hangers employ either threaded or slip support for casing
strings. In the case of mandrel hangers, the load capacity is determined by the load
shoulder capacity or the casing thread capacity whichever is less. In the case of slip
type casing hangers the load capacity depends upon the slip design, the minimum
pipe body yield strength of the pipe, and the amount of load suspended. As casing
slips suspend pipe, the wedging action of the slips apply a radial load to the pipe,
deflecting it inward. If the load is sufficient to deflect the pipe beyond its yield
strength, the casing bore may be reduced below tolerance, or the casing hanger
may fail.
It should be noted that because of the radial load imparted by the casing hanger
slips against the casing wall, additional test pressure loads applied to that area
must be controlled to prevent deformation of the casing. If a slip casing hanger
design is such that test pressure applied at the top of the casing hanger exposes
the slip loaded area of the casing to a pressure load, the test pressure should be
calculated based on the formula below, or a Test Protector should be used.
Test Pressure = .8(CP)(MPBY-HL)/MPBY where

CP = Collapse Pressure
MPBY = Minimum Pipe Body Yield
HL = Hanging Load (load suspended on slips)

NOTE: This formula applies only to the Type W casing hanger without a test
protector.

April 2003 7-9

This page left blank
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 8
Casing Spools
This page left blank
Casing spools are installed over each
intermediate casing string in a conventional
wellhead assembly. The casing spool, in
conjunction with a casing isolation seal,
provides for increased pressure rating, and the
isolation of the casing bore from the previously
installed wellhead components and casing
strings. It also has a top bowl profile permitting
the suspension of an additional casing string,
and a top connection to adapt to the BOP for
the next section of wellbore to be drilled. The
top connector also provides a connector for the
next wellhead section once the next string of
casing is run and landed.
Casing Spool descriptions typically include the
nominal size (casing outside diameter which it
is designed to fit), model type (top and bottom
bowl design such as CWCT-CWC or D-15-BT
II), maximum service pressure rating (pressure rating of the top connection), and
the size and pressure ratings of the end and outlet connections.
Basic Casing Spool Options

Top and Bottom Connections

The top and bottom casing spool connections may be either flanged, VG
connection, or NT2. Casing spools may also be special ordered flange by VG
connection, VG connection by flange, or flange by NT2 if required.
Side Outlets
Casing spools are available with three types of
outlets: threaded, flanged, and studded. The
flanged and studded outlets will have Valve
Removal Thread profiles in the bore.
Casing Spool Top Bowl Profiles
All top bowl profiles available for ABB Vetco
Gray casing heads are identical to top bowl
profiles used in ABB Vetco Gray casing
spools, and the same components are
compatible with those profiles.
Bottom Bowl Design
The term bottom bowl in a casing spool refers
to a machined profile in the lower bore of the
spool which fits over and seals the outside
diameter of the top of the casing suspended
CWCT-CWC Casing Spool
below it. Bottom bowl profiles provide for
casing packoff retention, and/or seal surfaces
for metal to metal seals.
CWCT Casing Spool with NT2 top and
bottom connections

April 2003 8-1

ABB Vetco Gray offers a variety of bottom bowl profiles to adapt to the various
casing isolation seal arrangements offered, providing the most cost effective design
options for the well conditions on a particular well.
FC-22 Casing Spools
The FC-22 casing spools are a straight bore bowl design. Bottom preparation can
be bit guide preparation type as in the picure below or the "OO" secondary seal
type. The BG preparation allows the use of reducer bushings "4-O" and "PE"
(pressure energized). The "OO" secondary seal type contains two o-rings in the
bottom preparation.
FC-22 Casing spools provide interchangeablility of casing hangers FC-22 and
FC-21. If a bowl protector is requied during the drilling process, using an FC-22-BP
casing spool, which include lock down screws in the upper flange, would be
recommended. Alternatively, a hold down flange with lock screws can be used.
The FC-22 Casing spools are interchangeable with C-22 type commodity bowls
and will accept:
• C-21 type commodity slip hangers and primary packoffs (FC-21)
•
C-22 type commondity slip hangers (FC-22)
FC-29 Casing Spools
FC-29 casing spools are based on the same reliable design as the FC-22 with
exception that the bowl is longer, which permits the acceptance of the minimum
deflection FC-29 casing hanger with larger load capacity for deeper drilling.

8-2
CWC and CWCT Casing Spools
The CWC-CWC or CWC-CWC casing spool is for medium to heavy casing loads
and pressure ratings from 3,000 MSP to 10,000 MSP The standard top bowl is
currently the Type CWCT but some Type CWC still exist in inventory. The product
designation for a these casing spools indicate the top bowl configuration with a
hyphen then the bottom bowl configuration. Thus a CWCT-CWC casing spool has a
CWCT top bowl and a CWC bottom bowl. Type CWCT casing spools are also
available with BT bottom bowl preparations.
The casing spool is available with flanged or NT2 top and bottom connections.
Outlets may be API Line Pipe, flanged, or studded. All outlets with the exception of
Line Pipe have Valve Removal Plug thread profiles.
The CWCT top bowl is the same as a CWCT casing head top bowl in the equivalent
size. The top bowl includes a 45E primary load support shoulder designed to
support the entire weight of a subsequently installed casing string, plus the test
pressure load applied during installation. The vertical bore above the primary load
shoulder is the sealing surface for the resilient annular seal on Type W casing
hangers and BOP test plugs. A taper above the primary load shoulder and the
vertical bore provides a sealing surface for the ABB Vetco Gray “Controlled Taper”
metal to metal seal used with CWCT mandrel casing hangers. The vertical bore
above the tapered area provides a sealing surface for Type WE casing hangers. A
secondary 45E load shoulder near the top of the bore provides a load bearing area
for auxiliary seals used on some installations. The straight bore above the
secondary load shoulder provides a sealing area for the auxiliary components.
The bottom bowl profile is designated CWC, with a 45° lead in chamfer at the very
bottom, above that is a short straight bore with a snap ring groove to retain packoff
assemblies. Directly above the groove is a 2" per foot seal taper to provide a metal
to metal sealing surface to
mate with casing bonnets or
the extended neck of mandrel
casing hangers. The CWC
bottom bowl has two injection
ports with ½” NPT tapped
outlets, at a 180° interval, for
sealant injection to energize
casing packoff assemblies. A
test port also with ½” NPT
tapped outlet, located 90°
from the plastic injection
ports, permits pressure
testing of the hanger seal
assembly, the ring connection
between the flanges or
clamps, and the casing
isolation seal.

CWCT-CWC Casing Spool

April 2003 8-3

BT Bottom Bowl Design
The BT bottom bowl is characterized by a
vertical bore to fit the casing, with either one
or two rectangular recesses designed to
contain the BT seals. Two sealant injection
ports, at 180o interval for each BT seal
recess, penetrate from the outside of the
casing spool to the BT seal recesses. For
pressure ratings up 5000 psi one BT seal is
typically used. For pressure ratings up to
10,000 psi two BT seals are used. If two
seals are used there is a port entering the
casing spool bore between the two seals so
the seals may be pressure tested
independently. These injection ports are
tapped at the outlet ½” NPT. The nominal
size of the bottom bowl is the size of the
casing it is designed to fit. A test port
penetrates from the bottom of the spool
inside the wellhead end connection seal, to
the outside diameter of the casing spool
bottom connection. The test port is tapped CWCT-BII Casing Spool
at its outlet ½” NPT as well.

SP Bottom Bowl Design

The SP bottom bowl has a profile similar to
the CWC bottom bowl. The principal
difference is the shallower recess for the
packoff, the elimination of the taper, and
lower injection ports.
The SP bottom bowl was originally
designed for applications where the casing
stub was cut off shorter than the length
required by the CWC bottom bowl. This
occurs most often when a Vetco Gray
casing spool is installed to replace another
manufacturer’s casing spool after the
casing has been cut for the other
manufacturer’s packoff design.

D15 Casing Spools

The D15-CWC casing spool is for heavier
casing loads and pressure ratings from
2,000 MSP to 15,000 MSP The product CWCT-SP Casing Spool
designation for a these casing spools
indicate the top bowl configuration with a
hyphen then the bottom bowl configuration. Thus a D15-CWC casing spool has a
D15 top bowl and a CWC bottom bowl. Type D15 casing spools are also available
with BT bottom bowl preparations.

8-4
The casing spool is available with
flanged, Grayloc, or NT2 top and
bottom connections. Outlets may be
API Line Pipe, flanged, studded, or
Grayloc. All outlets with the exception
of Line Pipe have Valve Removal Plug
thread profiles.
The D15 top bowl is the same as a
D15 casing head top bowl in the
equivalent size. The top bowl includes
a 45E primary load support shoulder
designed to support the entire weight
of a subsequently installed casing
string, plus the test pressure load
applied during installation. The
vertical bore above the primary load
shoulder is the sealing surface for the
resilient annular seal on Type W D15-CWC Casing Spool
casing hangers and BOP test plugs. A
taper above the primary load shoulder
and the vertical bore provides a sealing surface for the ABB Vetco Gray “Controlled
Taper” metal to metal seal used with D15 mandrel casing hangers. The vertical bore
above the tapered area provides a sealing surface for Type WE casing hangers. A
secondary 45E load shoulder near the top of the bore provides a load bearing area
for auxiliary seals used on some
installations. The straight bore above
the secondary load shoulder provides a
sealing area for the auxiliary
components.
The CWC bottom bowl is the same as
the CWC bottom bowl configuration in
the CWCT casing spool for the
equivalent casing size.
Type HL Casing Spool
The HL Casing Spool is used for
extreme service applications. The HL
bottom bowl features a recess for
either GMW seals or CB type seals,
and a taper to seal over HL type casing
bonnets or casing hanger extended Type HL-HL Casing Spool
necks.
Two test ports, at 180o interval
penetrate from the outside of the Type HL-HL Casing Spool
casing spool to the packing recess.
The test ports are tapped ½” NPT or
1-1/8” HP thread at the outlets depending on the pressure rating. A test port
penetrates from the bottom of the spool inside the wellhead end connection seal, to
the outside diameter of the casing spool bottom connection. The test port is tapped
with the same thread as the other ports.

April 2003 8-5

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SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 9
Casing Isolation Seals
This page left blank
The term casing isolation seal includes any seal mechanism which isolates the bore
of a casing string from the wellhead connections below the seal.
The five types of isolation seals are:
• Casing Packoffs housed in the bottom bowl of a casing or tubing spool
• Casing Bonnets which seat and seal in the top bowl of a casing head or
casing spool, extend into and seal within the bottom bowl of the casing or
tubing spool installed above it.
• The seal on the upper outside diameter of a mandrel casing hanger.
• Seal profiles field machined directly onto the casing.
• Casing Packoffs installed in Multibowl Wellhead Housings.
By isolating the casing bore from the wellhead housings below it, the isolation seal
provides for the wellhead to increase in pressure containing capacity as each new
casing string is installed in the well. In the case of a kick or blowout, the isolation
seal is the first area of protection against communication between the wellhead
sections, previous casing strings and the connection seal rings which isolate the
wellbore from the environment.
Consider, for example, a 9-5/8" casing spool with a bottom connection rated for
5,000 psi and a top connection rated for 10,000 psi If at some point in the drilling
operation a kick causes BOP closure, and the pressure in the casing to build up to
7,000 psi The top connection of the casing spool would be rated in excess of shut-in
pressure, but the lower connection of the casing spool would not. The casing
packoff in the bottom bore of the casing spool isolates the lower connection of the
casing spool from exposure to the wellbore pressure. This seal assembly is also
permits a pressure test of the wellhead end connection upon installation.
Casing isolation seals are available in a wide range of styles, and materials to cost
effectively accommodate the various service conditions encountered in the field
today.

Self Energized Casing Isolation Seals

FC Reducer Bushings
FC reducer bushings are available for all
internal and external diameter sizes used
in casing head spools and tugin head
spools. The "OO" reducer bushing is to be
installed in casing or tubing head spools
with intergral "OO" lower internal
connection. The "4-O" reducer bushing is
to be installed in casing or tubing head
spools with the "BG" lower internal
connection. These bushings are available
for applications up to 5000 psi working
pressure. Reducer bushings are designed
with a reduced internal diameter to serve "OO" Reducer Bushing
as an integral bit guide.

April 2003 9-1

 "4-0" Reducer Bushing

FPE Reducer Bushing

For 10,000 psi applications, the FPE
reducer bushing can be installed in casing
head spools FC-22 and FC-29 prepared
with "BG" lower internal preparation, as
well as in FTC tubing head spools. The
FHPE reducer bushing as similar
functioning of the FPE but is is designed FPE Reducer Bushing
for 15,000 psi WP. Reducer bushings are
designed with a reduced internal diameter
to serve as an integral bit guide.

9-2
Sealant Energized Casing Isolation Seals
CWC-P Packoff
The CWC-P casing packoff assembly
is a casing bore isolation seal which is
utilized in the ABB Vetco Gray
standard CWC casing or tubing spool
bottom bore configurations when slip
type casing hangers are used. The
packoff is a sealant energized
elastomeric packing assembly which is
used for service pressures up to
15,000 psi in a variety of service
conditions.
The CWC-P casing packoff assembly
consists of four elastomer chevron
shaped pressure retaining rings, two
Kevlar non-extrusion end rings, a central metal spacer ring, a metal retainer ring,
and metal snap ring. The packoff assembly is housed in the lower bore of casing or
tubing spools which have the CWC bottom profile.
The CWC-P casing packoff seals against a field cut and prepared casing stub which
extends into the lower bore of the casing or tubing spool which contains the packing
assembly. The packing assembly seals between this casing stub and the bore of
the casing or tubing spool. Injection ports in the casing or tubing spool located 180o
apart permit sealant to be injected into the packoff after the casing or tubing spool is
installed using a hydraulically powered sealant injection gun. The chevron shaped
pressure retaining rings are installed on either side of the ported spacer ring in
opposing orientation such that sealant injected through the injection ports in the
spool migrates around the casing and through the ported spacer ring. The sealant
is trapped between the chevron pressure rings expanding them outward against
the casing and the bore of the casing or tubing spool.

CWC-P Casing Packoff installed in a CWCT Casing

Spool bottom bowl

April 2003 9-3

The advantage of sealant injection used with the CWC-P casing packoff is its
renewability. Over time, the packoff can be re-energized by circulating fresh sealant
through the packoff without any disassembly of the wellhead.
The standard sealant used is a silicon grease impregnated with graphite particles.
Other types of sealant are available which have Teflon flakes and fiber material for
tough sealing problems.

Sealant Injection Gun

Sealant Injection Gun

The ABB Vetco Gray sealant injection gun is designed to inject sealant into casing
packoffs which are sealant energized. The gun consists of a barrel with male
threads on each end and a handle in the center. The barrel has a polished bore with
a piston inserted which has swab cups attached facing both directions. On either
end, there are two caps which seal the end of the barrel via o-ring seals. These caps
are ported and tapped ½" NPT. Swivel retainers thread onto the male threads of the
barrel to hold the end caps in place, and are retained on the caps by snap rings. The
assembly makes up to the barrel with hand tight torque requirement. Threaded into
the end cap at one end is a ½" NPT nipple, which in turn has an adapter made up to
it, to fit onto a ABB Vetco Gray injection/test fitting. The entire assembly is rated to
10,000 psi service pressure.

Sealant Injection
The sealant injection gun is made up to the sealant injection port of a casing or
tubing spool. The port on the opposite side of the spool must be left open. A high
pressure hydraulic test pump is made up to the ½" NPT threads on the outer end
cap of the sealant injection gun. Pressure is applied to the sealant injection gun
utilizing the pump. The hydraulic pressure will push the swab cup in the sealant
injection gun barrel toward the opposite end, forcing the sealant out of the barrel
ahead of it, through the nipple, adapter, and test/injection fitting of the spool. The
sealant is circulated through the casing packoff until it comes out the other side of
the spool. When the sealant injection gun is empty, the swab cup in the barrel will
butt against the end cap and pressure will increase rapidly with further pumping.
Once sealant is circulated through the packoff the injection fittings are replaced in
the ports and more sealant is injected through these fittings. The check valves in
the fittings trap the pressure applied, energizing the packoff. Injection pressure is
based on the ambient temperature at the time of injection, and the temperature
class of the packoff.
See ABB Vetco Gray Engineering Specifications for details.

9-4
CWC-PMW Packoff
The CWC-PMW Packoff is identical to the
CWC-P Packoff except the Kevlar
non-extrusion rings are replaced by skive
cut split metal end rings.
The split non-extrusion rings provide a
zero clearance backup on each side of the
pressure retaining packing preventing the CWC-PMW Packoff
extrusion of the pressure rings and
extending the life of the packoff when subjected to
temperature cycles.

CWC-SP Packoff
The CWC-SP packoff (short packoff) is
designed to seal over a casing stub cut off
height which is lower than that specified by
ABB Vetco Gray for the CWC bottom bowl
profile. At times casing and tubing spools
are removed or replaced, in which case the
casing is already cut off at a specific height
above the top of the previously installed
casing head or casing spool. Because the
CWC bottom bowl profile has a seal taper CWC-SP Packoff
included, it is deeper than the other bottom
bowls in the industry. For this reason if a competitor spool is removed to be replaced
by an ABB Vetco Gray spool, and the chevron style packoff is desired, the SP
bottom bowl profile is used. A spool with an SP bottom bowl is not as deep as the
CWC bottom bowl since it eliminates the seal taper in the lower bore. The injection
ports are consequently lower as well. The CWC-SP Packoff is identical to the
CWC-P except the metal retainer ring is shorter in height.

April 2003 9-5

PS-PMW Packoff
The PS-PMW Packoff (pocket short
packoff) based on the field-proven
CWC-PMW packoff. It is retained in a
“pocket” in the bore of a crossover
connector, or a casing bonnet. The packoff
is identical to the CWC-PMW Packoff
except the metal retainer ring, and snap
ring are eliminated. Instead the packoff is
retained in a recess integrally machined
into the component which houses it. The
metal spacer ring is cut into three
segments to facilitate installation into the appropriate recess.

CWC Reducing Bushing Packoffs

The CWC Reducing Bushing Packoffs are used to adapt a casing spool down to a
smaller casing size. This permits a more effective use of inventory and provides for
an easy way to adapt to odd casing sizes.
The CWC Reducing Busing is a metal
bushing which fits into the CWC bottom
bowl profile and is retained by a snap ring.
Two o-rings with par-bak ring back up seal
between the bushing and the casing or
tubing spool bottom bowl. The bushing is
ported so sealant can be circulated
throughout. A standard CWC-P or
CWC-PMW packoff is retained in the bore.
The top of the bushing is chamfered to
provide a bit guide so tools run through the
packoff will not hang up at the top.

BT Seal
The BT Seal is a molded elastomeric seal element with self-contained
non-extrusion rings suitable for both sweet and sour service in a temperature range
of -20EF to 250EF. Single or multiple seal elements can be combined for service
applications up to 15,000 psi
BT seals are available in a variety of compounds for special applications.
The BT Seal is shaped like a hollow ring. It has an opening in the outside diameter, a
hollow recess in the center, and two seal pedestals on the inside diameter. Two
Inconel non-extrusion springs are
molded into the seal at the top and
bottom. Ports between the seal
pedestals permit circulation of
sealant in the hollow recess and
between the load pedestals in the
inside diameter.

9-6
The seal is housed in a recess in the inside diameter of a component which will slip
over a cylindrical body against which the BT ring is to seal.
Upon installation the seal is energized by circulating sealant around and through
the seal through ports in the component which houses the seal. The sealant is
pressurized to swell the seal in its recess, and create a surface load between the
seal element the component housing the seal, and the pipe against which the seal
is effected.
The BT Seal has been reliably used for many years. It is performance tested to
meet requirements such as corrosive/sour well fluids, conditions such as eccentric
casing, vertical casing movement, and thermal cycling.

Compression Energized Casing Isolation Seals

It is wide spread industry practice to utilize the energy applied as two wellhead end
connections are drawn together to also compress a set of seals and store energy
which initiates an isolation seal.
In many cases the seals are elastomeric, however ABB Vetco Gray has developed
some compression set seals for extreme service which are non-elastomeric.

Two BT seals installed in the bottom bowl of a

D15-BTII Casing Spool

April 2003 9-7

Type GMW (Flexible Graphite Seal)
In today’s drilling environments casing isolation seals in wellhead assemblies are
exposed to wide temperature variations, ranging from -70o F to in excess of +350o
F. If a packoff is installed in a normal ambient
temperature range of about 0o F. to 100o F,
significant temperature variation will cause a
sealing problem because the thermal
coefficient of expansion of the packoff material
is greater than that of the metal wellhead
housings. Temperatures significantly above
the installation temperature cause excessive
pressure in the seal, leading to extrusion or
deformation of the seal components.
Temperatures significantly below the
installation temperature cause the packoff
(either compression or interference fit) to lose
stored energy and sealing effectiveness.
ABB Vetco Gray has solved the problem by incorporating a packoff material with a
thermal coefficient of expansion close to that of steel. The design uses molded
flexible graphite which has significantly reduced thermal expansion.
Examinations of casing packoffs under both test and field applications confirm that
unsupported seal extrusion paths can be as much as 1/8" to the side, and that
casing may not be centered in the packoff. This condition, coupled with the lack of
mechanical strength of the graphite seal, requires a packoff design that will fully
contain the sealing materials. Metal non-extrusion rings with zero clearance
between both the casing and the housing profile are placed on each side of the
flexible graphite seal.
The “GMW” seals against casing that is prepared in the field by hand. The
energization of the seal is accomplished through compression. The compressing
force is generated by normal flange make up. In cases where there is not enough
stroke in non-flanged connections to compress the “GMW” seal, a torque set
version is available. The “GMW” can also be arranged to fit into other profiles as a
single seal element, or as multiple seals where redundancy is required. Each
“GMW” seal consists of metal end rings with specially tapered profiles and a shaped
flexible graphite seal member which is positioned between the end rings. This
design has been thoroughly tested and field proven for service conditions up to
20,000 psi and temperature ranges from -75o F to 400o F.

Type CB Seal
The “CB” seal assembly is a weldless casing
isolation seal developed to provide a
metal-to-metal seal against the outside
diameter of casing when a wrap around,
slip-type casing hanger is required or
preferred. The “CB” assembly features a
specially designed metal seal which conforms
radially to the outside diameter of the casing
string (within API tolerance ranges) to provide CB Seal Ring
a metal seal. Preparation of the casing stub is

9-8
similar to that required for standard elastomer packoffs and eliminates the time
needed for field machining operations
Installed over a normally prepared casing stub the “CB” is housed in a casing
bonnet or hanger. On top of the “CB” seal is a compression driver. As the wellhead
end connections are drawn together by the bolting, the compression driver forces
the “CB” seal into the casing. The “CB” seal is made from a softer metal and
conforms to the casing forming a seal around the casing. The compression driver
seals against the “CB” seal and against the wellhead housing which is installed over
it.
When the wellhead is not conventional flanged (i.e., Grayloc, or “NT2"), there is not
enough stroke in the connection makeup to activate the ”CB" seal. For these
situations a torque set assembly is available.
The “CB” seal is a high performance seal rated to 20,000 psi and temperature
ranges from -75o F to 400o F.

Metal To Metal Casing Isolation Seals

In assemblies which utilize an extended neck, mandrel style casing hanger , the
extended neck provides the casing isolation seal which meets the requirements for
area restriction necessary to increase the pressure rating. The guidelines for seal
diameters on extended neck hangers are the same as those for bottom casing
packoffs. If the design exceeds these limits, finite element analysis is required to
prove that the design meets the allowable stress levels.
The ABB Vetco Gray metal flex seal used for decades provides a field proven metal
to metal casing isolation seal for the most extreme service conditions existent in the
industry. This type of seal has been used on the world’s only 30,000 psi rated
completions, as well as with extreme temperatures, and highly corrosive wellbore
environments.

Casing Bonnet Type Casing Isolation Seals

In cases where the cross sectional area of a packoff exceeds the capacity of a snap
ring to retain it in the bottom bowl of a casing or tubing spool, or where extreme
service seals are required to be used in conjunction with a wrap around slip type
casing hanger casing bonnet assemblies are used.
Casing bonnets seat in the upper bowl of a casing head or spool on the secondary
load shoulder, and extend above the top of the spool into the bottom bowl of the
casing or tubing spool installed above it. Casing bonnets may have a wide variety of
seal designs including self energized elastomer seals as in the VG100 Casing
Bonnet, sealant injected type seals as in the D15-PSPMW Casing Bonnet, graphite
seals as in the HL-GMW-2 Casing Bonnet, or metal to metal seals as in the HL-CB
or SMT Casing Bonnets.

April 2003 9-9

Type SMT Weldless Casing Bonnet
The Type SMT Casing Bonnet offers metal to
metal annular seals in conjunction with wrap
around slip type casing hangers.
The “SMT” Casing Bonnet provides a metal to
metal sealing interface between a field
machined casing stub, and the tapered sealing
surface in the bottom bowl of a casing or tubing
spool. The SMT Casing Bonnet has a tapered
metal sealing surface on the inside diameter to SMT Casing Bonnet
match the profile as required on the casing,
and an outside diameter taper which extends
into the next spool to effect the metal to metal
seal. The SMT Casing Bonnet is available in sizes to match the customer’s casing
program and has been field tested for pressures up to 15,000 and temperatures up
to 400o F.
The SMT Casing Bonnet is installed on the casing after it has been suspended by
the slip type casing hanger. The casing must be machine cut with a sealing taper.
This taper is machined directly
on to the casing in the field by
an ABB Vetco Gray technician.
Once the casing is tapered the
SMT Casing Bonnet is fitted
over the casing stub and effects
a seal between the casing and
the next wellhead member.
Instead of having the next
wellhead member seal directly
on the machined casing stub
the SMT Casing Bonnet is
used. If a mistake is made when
machining the taper it is much
easier to manufacture a bonnet
to match the mistake than a
new wellhead.

SMT Casing Bonnet installed in a HL

wellhead assembly

9-10
Type HL-GMWII Casing Bonnet
The HL-GMW II Casing Bonnet is an extreme service casing bore isolation seal
which offers metal to metal seals used in conjunction with the convenience and
reliability of a wrap around slip type casing hanger
and field cut and prepared casing termination.
The HL-GMW II casing bonnet assembly isolates
the casing, and casing or tubing spool bore from
the lower connection of the casing or tubing spool
and the casing hanger annular seal below the
casing bonnet.
The HL-GMW II Casing Bonnet Assembly
consists of the casing bonnet body, two molded
GMW seals, a energizing ring, and a selection of HL-GMW II Casing Bonnet
shims to adjust the compression of the seals.
The HL-GMW II Casing Bonnet Assembly is installed and supported by the
secondary 45o load shoulder in the Type HL casing head or spool top bowl. The
HL-GMW II Casing Bonnet seals metal to metal against a seal taper below the
secondary load shoulder in the HL top bowl. It extends above the top of the casing
head or spool, and seals similarly metal to metal against a taper in the lower bore of
the casing or tubing spool installed above it. The HL-GMW II Casing Bonnet uses
two compression set GMW seals to seal against the field cut and prepared casing
which extends through it into the lower bore of the casing or tubing spool.
Metal to metal
seals

GMW Seals

HL-GMWII Casing Bonnet installed in a

HL wellhead assembly

April 2003 9-11

Type HL-CB Casing Bonnets
The HL-CB Casing Bonnet is an
extreme service casing bore isolation
seal which offers metal to metal seals
used in conjunction with the
convenience and reliability of a wrap
around slip type casing hanger and
field cut and prepared casing
termination.
The HL-CB casing bonnet assembly is
installed and supported by the
secondary 45o load shoulder in the
Type HL casing head or spool top bowl. HL-CB CasingBonnet
HL-CB Casing Bonnet
The HL-CB casing bonnet seals metal
to metal against a seal taper below the
secondary load shoulder in the HL tp bowl. It extends above the top of the casing
head or spool and seals similarly metal to metal against a taper in the lower bore of
the casing or tubing spool installed above it. The HL-CB casing bonnet uses the
compression set CB seal ring to seal against the field cut and prepared casing
which extends through it into the lower bore of the casing or tubing spool.
The “CB” seal is a metal seal ring which conforms radially to the OD of the casing
string (within API tolerance ranges) to provide a metal seal against rough casing.
Preparation of the casing stub is similar to that required for standard elastomer
packoffs and eliminates the time needed for field machining operations. The seal is
housed in a recess in the bore of the HL-CB Casing Bonnet. On top of the “CB” seal
is a compression driver. As the spool is brought down by the studs in the wellhead
connection, the compression driver forces the “CB” seal into the casing. The “CB”
seal ring is made from a softer metal and conforms to the casing forming a seal
around the casing. The compression driver seals on the two inch per foot taper in
the bore of the HL-CB Casing Bonnet, and against the “CB” seal. The inside
diameter of the CB seal has four pedestals extending inward toward the center. A
tin-indium compound is inlaid between these pedestals. As the ring is driven
against the casing the pedestals impinge into the casing forming metal to metal
seals. The soft tin-indium fills and conforms to the surface irregularities of the
casing insuring a reliable seal.
The “CB” seal is a high performance seal which is fully qualified to PR2 in
accordance with API Specification 6A, 16th Edition for temperatures from -75o F to
375o F and pressures to 20,000 psi

9-12
 Metal to metal
seal

CB Seal and
drive ring

HL-CB Casing Bonnet installed in a HL

wellhead assembly

April 2003 9-13

D15-PSPMW Casing Bonnet
The D15-PSPMW Casing Bonnet seats on the
secondary load shoulder of a casing head or
spool above a slip type casing hanger. The
bonnet extends above the top connection into
the CWC bottom bowl of the casing or tubing
spool installed above it. There is an o-ring seal
near the bottom of the bonnet on the outside
diameter to seal in the bore above the
secondary load shoulder in the casing head or
spool which supports the casing bonnet. A taper D15-PSPMW Casing Bonnet
on the outside diameter of the bonnet near the
top seals against the taper in the CWC bottom
bowl of the casing or tubing spool installed above it. An o-ring with par-bak rings is
located on the outside diameter of the bonnet above the sealant port to trap the
sealant between the o-ring and the metal seal taper as it is circulated around the
outside diameter of the casing bonnet. A PSPMW packoff is retained in a pocket in
the bore of the bonnet to seal against the casing stub above the slip casing hanger.
A port through the bonnet permits sealant injection of the packoff. An additional port
through the bonnet body permits venting of air from below the bonnet during
installation. This port has a 1/8” NPT tap at the upper end and is sealed off with a
pipe plug after the bonnet is installed.
The D15-PSPMW Casing Bonnet is usually used as a casing isolation seal when
the cross-sectional area of a packoff is to great for a snap ring to retain the packoff
in the lower bore of the casing or tubing spool. This occurs when the casing
diameter is smaller than the nominal size of the casing or tubing spool installed
above it.

D15-PSPMW Casing
Bonnet installed

9-14
Test Protectors, Primary Packoffs
The Test Protector or Primary Packoff
is a metal bushing with o-ring seals on
the inside diameter and the outside
diameter.
The Primary Packoff is the seal
assembly which goes into the
wellhead assembly above the casing
slips if the casing hanger has no
self-contained seal element to seal the
annulus between the casing bowl and
the casing string.
A Test Protector is the same as a primary packoff except its purpose is to isolate the
slip-loaded area of the casing string from possible hydraulic overload when the
seals and wellhead connection are pressure tested.
CWC-O Test Protector installed above a Type W Casing Hanger on the secondary
load shoulder in a Type CWCT Casing Head
The CWC-O Test Protector is an optional unit. If an operator desires a field pressure
test which approaches the yield strength of the pipe in the area where the slips are
wedged against the casing the test protector is recommended, otherwise the test
pressure must be limited. The Test Protector is installed on the 45o secondary load
shoulder of the casing head or casing spool prior to installation of the next spool.

CWC-O Test Protector installed above a Type W

Casing Hanger on the secondary load shoulder in
a Type CWCT Casing Head

April 2003 9-15

Casing Isolation Seals For Multibowl Wellheads
A variety of casing isolation seal designs are available for use with Multibowl
Wellhead Systems. These seals must be run through the BOP since the BOP is
typically not nippled down after the casing is landed in a Multibowl System. These
seals are covered in more detail in Section 11, Multibowl Wellhead Systems.

MB 154 Casing Hanger and Packoff

9-16
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 10
Tubing Heads and Spools
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There is often confusion regarding the terms tubing head, and tubing spool. These
terms are frequently used interchangeably
however, a head is a wellhead housing
which is mounted directly on the pipe, and
a spool is a wellhead housing mounted on
top of a previously installed wellhead
housing assembly. By this definition the
only true tubing heads are those used on
wells which have only one casing string.
(usually shallow low pressure wells)
Tubing spools are installed over the
production casing string in a conventional
wellhead assembly. The tubing spool, in
conjunction with a casing isolation seal,
provide for increased pressure rating, and
the isolation of the casing bore from the
previously installed wellhead components
and casing strings. It also has a top bowl
profile permitting the suspension, and
mechanical lockdown of the production
tubing string. The top connection provides
a means to attach the BOP used for the
completion operation. The top connector
also provides a connector for the
Christmas tree or pump equipment once
the production tubing has been installed in the well.
Tubing Spool designations typically
include the nominal size (casing outside
diameter which it is designed to fit),
model type (top and bottom bowl design
such as CWCT-CWC or D-15-BT II),
maximum service pressure rating,
(pressure rating of the top connection),
and the size and pressure ratings of the
bottom and outlet connections.
Top and Bottom Connections
The top and bottom tubing spool
connections may be either flanged or
NT2. Tubing spools may also be special
ordered NT2 by flange, or flange by NT2
if required.

CWC Tubing Spool

April 2003 10-1

Side Outlets
Tubing spools are available with three types of outlets; threaded, flanged, and
studded. The flanged and studded outlets have Valve Removal Thread profiles in
the bore.
Tubing Spool Top Bowl Profiles
ABB Vetco Gray offers a variety of tubing spool top bowl profiles for various service
conditions. Top bowl nominal sizes are standard for top connection nominal sizes,
but are designated based on the diameter of the hanger which is landed inside
them. For this reason the nominal bowl size is not the same as the top connection
size. Standard nominal top bowl sizes and their compatible top connection sizes
include:

Top Bowl Top Connection

7” 7-1/16”
8-5/8” 9”
10-3/4” 11”

Tubing spool top bowl profiles are the same as casing spool top bowl profiles with
the same designation when the nominal size is 10-3/4” or greater. In the smaller
sizes the bowl configurations are different since the load and seal requirements
differ.
A tubing spool top bowl must provide a means of mechanical lockdown of the
production tubing since the tubing is not cemented in place and may experience
heat expansion during production. This is accomplished most often by an array of
lockdown screws which extend through the tubing spool body, (usually the top
connection) and once tightened, impinge on top of the tubing hanger landed in the
tubing spool top bowl.
Many tubing spools also include Multi-completion Guide Screws. These screws
extend through the tubing spool body similar to the lockdown screws except there
are typically only two of them. Located 90o from the tubing spool outlets the
Multi-completion Guide Screws enter the tubing spool bore just below the primary
load shoulder. Their function is to provide positive orientation of the tubing hanger
when it is landed.
Lockdown screws and Multi-completion Guide Screws will be covered in greater
detail later in this chapter.
When a tubing spool has an NT2 top connection the top bowl is typically different
from the flanged equipment of the equivalent type and size since the NT2 box
overlap the top of the tubing spool and preclude the placement of the lockdown
screws in the connection, as is the case with the flanged tubing spool. Tubing
spools with NT2 top connections typically have internal lockdown devices to
eliminate the lockdown screws. For this reason tubing hangers for NT2 are not
interchangeable with tubing hangers for flanged assemblies.

10-2
Tubing Spool Bottom Bowl Designs
Tubing spools are offered with the same designs used in the bottom bowls of casing
spools. The nominal size of the tubing spool bottom bowl is also the same as the
production casing outside diameter.
Since the isolation seal used with the
production casing could be exposed to
the full shut-in pressure of the well, this
annular seal should be selected to offer
full protection against both pressure
and corrosion in the production casing.
The production tubing annulus will also
be affected by temperature increases
from the produced fluids, and this
“thermal effect” must be taken into
consideration when selecting the
tubing spool bottom bowl and
production casing isolation seal.
FTC Tubing Spools
FTCM tubing heads are a straight bore
bowl design which avoids damage to
sealing areas by drilling tools, and
prevents wedging of the tubing FTCM Tubing Spool
hangers, bowl protectors and test
plugs. The secondary seal for the last
casing pipe can be an integrated "OO" seal type (FTCM-OO) or the plastic injection
type (FTCM-PI) , but also accepts reducer bushings "OO", "4-O" and FPE sizes.
The upper flange is supplied with lockdown screws for packoff re-inergization and
tubing hanger retantion. Side outlets are LP or studded type prepared with internal
threads to install a valve removal plug when desired. The lower flange includes a
grease fitting and orifice for testing of the secondary seal.
FTC-60 Tubing Head
The FTC tubing heads for mulitple completions offer the same features as teh
FTCM, with the addition of an aligning pin to be used as a guide and for orientation
of the miltiple completion tubing hangers. FTC-60-BG tubing heads are desined
with a maximum straight bore on single and mutiple completions, thus allowing
access to 7-5/8" casing through a 7-16" upper falnge, eliminating the necessity of
changing the flange to larger size when the well condition requires the casing
diameter as mentioned. FTC-60 tubing heads are manufactured with forged steel
and include two retractable heavy-duty pins for safety support of pipe in deep wells.
FTC-60 tubing heads are also available with integrated "OO" seal tyep bottom
(FTC-60-OO) or plastic injection (FTC-60-PI) or with reducer bushings.

April 2003 10-3

Type CWC Tubing Spools (4" - 8-5/8" Nominal)
This tubing spool top bowl is
characterized by a straight bore down to
a tapered load and seal area, with a 90o
load shoulder below it, for positive tubing
hanger support. The load shoulder is
engaged when the tubing hanger is
landed and the tubing weight is applied,
or as the lockdown screws are engaged
(single completion). In multi-completion
settings, the lockdown screws also
activate the annulus seal assembly.
Type CWC Tubing Spools (9-5/8” -
10-3/4”)
This tubing spool top bowl is the same as
the CWC casing head top bowl, but has
lockdown screws in the top connection.
This bowl may be used to suspend
tubing or casing which permits the user
to change the casing program, drill
deeper, and hang off an additional
casing string if desired. Another tubing
spool would be installed on top of the
first one to suspend the tubing string. CWC Tubing Spool 7" top bowl
This type of tubing spool is sometimes
identified as a “combination” spool.
Combination spools are available with
either flanged or Grayloc end
connections.
Type CWCT Tubing Spools (9-5/8” -
10-3/4” Nominal)
This tubing spool top bowl is the same as
the CWCT casing bowl but has lockdown
screws in the flange to hold the tubing
hanger in place or activate the. This size
tubing spool is also considered a
combination spool as either casing or
tubing can be suspended in it.
Combination spools are available with
either flanged or Grayloc end
connections.

CWCT Tubing Spool 10-3/4” top bowl

10-4
Type 45 Tubing Spools (7-5/8" Nominal)
This tubing spool top bowl has a straight bore down to a 45o load shoulder.
Extrusion-type seals activated by the lockdown screws are used on both single and
multi-completion type hangers. The Type 45
tubing spool is designed for use over 7-5/8"
casing in conjunction with a 7-1/16” top
connection. The taper in the bowl of the
Type CWC tubing spool in the 7” nominal
size requires that the minimum bore of the
spool be no more than 6-3/8”. This is not a
large enough bore to install over 7-5/8”
casing. The alternative is to use a CWC
spool with a 9” top connection or use the
Type 45. The Type 45 spool has a bore of
6-25/32”. For higher tubing loads there is a
Type 45M bowl which is identical to the Type
45 except the minimum bore below the load
shoulder is 6-21/32”. The tubing hangers for
Type 45 and Type 45M are not
interchangeable because the diameter of
the hanger below the load shoulder in a
Type 45 hanger is to great to fit in a Type
45M bowl.

Type 45 Tubing Spool

Type D-15 Tubing Spools (7” Nominal)

Just as the D-15 casing head bowl is
designed to support heavier casing strings
at higher working pressures, the D-15
tubing spool is designed to accommodate
similar requirements for tubing strings.
The top bowl of the D-15 tubing spool for
7” or smaller casing, has the same design
features as the CWC tubing spool 7” top
bowl when used with a top connection of
7-1/16". A 4" taper per foot metal to metal
sealing surface and a 90o load shoulder.
The bowl however, is deeper and the bore
is smaller than the 7” CWC. The smaller
minimum bore permits the primary load
shoulder to be wider for more load carrying
capacity.
D15 Tubing Spool
7" top bowl

April 2003 10-5

Type D-15 (7-5/8” - 10-3/4” Nominal)
The D-15 Tubing Head top bowl for
sizes 8-5/8" and 10-3/4” has the same
design features as the D-15 casing
head top bowl. These features include a
2" taper per foot and a 45E primary load
shoulder, with a 45E secondary load
shoulder near the top of the bowl. The
D-15 bowl is deeper and has a smaller
bore than the CWC or CWCT of similar
size. This provides for more load
capacity.

D15 Tubing Spool

10-3/4" top bowl

Type S-20 Tubing Spool

The S-20 Tubing spool was originally
designed for 20,000 psi completions
and evolved into the design of choice for
30,000 psi applications.
Starting from the top of the S-20 bowl, a
straight bore leads down to a 4" taper
per foot seal area. Just below the seal
taper is the primary load shoulder.
Below the primary load shoulder is the
minimum bore of the spool. Only the
S-20 mandrel tubing hanger is used in
the S-20 tubing spool top bowl. This
hanger provides a metal to metal
controlled taper annular seal.

S-20 Tubing Spool

7" top bowl

10-6
Tubing Hanger Lockdown Mechanisms
The tubing hanger must be mechanically locked in place in the tubing spool since
the production tubing is not cemented and well control must be maintained when no
BOP or tree is in place. The standard method of lockdown is lockdown screws.
Standard lockdown screws thread into ports drilled and tapped through the body of
the tubing spool. The inboard end of the screw extends into the bore of the spool
where the tubing hanger lands. The conical nose on the screw, when tightened,
impinges on the tubing hanger body, locking it in position. The outboard end of the
screw has a square shank so that wrenches can be used to rotate the screw and
engage or release the hanger. The lockdown screw assembly also includes a seal,
for pressure integrity around the outside diameter of the screw, a set of junk rings to
retain the seal, and a gland nut to retain and energize the seal assembly. The
lockdown screw may also be used to energize elastomer seals on the tubing
hanger assembly, as in the Type 45, or dual segmented tubing hanger designs.
API Specification 6A requires that the lockdown mechanism retain the hanger, and
seal with full rated service pressure applied across the annular seal area. This
requirement results in a number of lockdown screws arrayed around the top
connection of a standard tubing spool.

Seal Gland Nut

Pin Junk rings

Type HLS Lockdown Screws

Because the standard lockdown screw has a conical tip, and only a small surface
area on the tip of the screw contacts the tubing hanger, the standard screw does not
have the load bearing capacity for extreme pressure and temperature applications.
The type HLS lockdown screw is used in this case. The HLS screw has a flat
surface on the bottom of the screw which provides more surface area contact with
the tubing hanger and therefore more load capacity.

Type HLS lockdown screw for high pressure loads

April 2003 10-7

The HLS lockdown screw is made in two pieces. The nose piece swivels on the
screw so that the flat surface is always oriented on the bottom of the screw. The
HLS lock screw threads into the gland nut of the assembly rather than the tubing
spool body as is the case with the conventional lockdown screw.
Internal Lockdown Tubing Hanger and Bowl
The Internal Lockdown (IL) tubing hanger and bowl is designed for applications in
which it is undesirable to have external penetrations into the tubing spool for
lockdown screws. The tubing hanger bowl
has three grooves near the upper bore
which are matched to the configuration of
the locking ring on the tubing hanger. Once
the hanger is landed, the lockdown feature
is engaged by actuating the running tool Internal lock
which drives the actuating ring down behind down profile
the lock ring expanding it into the mating
groove profile of the tubing spool top bowl.
This type of lockdown mechanism was
developed in conjunction with the
“Multibowl” wellhead housings which
include the tubing hanger suspension in the
“Mulitbowl” arrangement, and an NT2 top
connection.
The advantage of internal lockdown is that it
eliminates all the penetrations to the
wellhead housing which are included with
lockdown screws, and does not interfere
with the wellhead top connection
configuration. The disadvantage is the
running tool for an internal lockdown tubing
hanger is expensive. And unnecessary with
lockdown screws.
Multi-Completion (MC) Guide Screws
Multi-completion Guide Screws are similar in design to lockdown screws. They are
located in the tubing spool body and penetrate the tubing spool top bowl just below
the primary load shoulder. There are typically two screws 180o apart. The MC Guide
Screw has a recess just behind the screw threads. A split ring is installed in this
recess, and has the function of limiting the extent to which the screw can be
threaded into the tubing spool bore to a maximum of ½". These screws provide

Multi-Completion (MC) Guide Screw Assembly

10-8
guides to align dual and single tubing hangers in the tubing spool bowl when
landed. The tubing hangers mating guide slots on the outside diameter which
engage the end of the guide screw and rotate the hanger into position as it lands in
the bowl.

MC Guide Screw

Lockdown Screws

April 2003 10-9

This page left blank
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 11
Multibowl Wellhead Systems
This page left blank
ABB Vetco Gray was a pioneer in introducing the multibowl concept to the oil and
gas industry in the 1950’s. Also known in the industry as “compact” or “unitized”
wellheads, the multibowl concept of suspending multiple strings of casing or tubing
within one wellhead housing was developed initially to reduce rig time spent
removing the blowout preventer stack after running each casing string and then
re-installing it. This time-saving feature becomes more significant the higher the
day rate for operating at a specific location. Other cost savings associated with
multibowl wellhead systems include height and weight reduction, which minimize
cost of construction for offshore platforms.
ABB Vetco Gray designed and introduced many features for multibowl systems,
including:
• Full bore multibowls with field installed load shoulders
• Split multibowls
• Metal-to metal seals
• NT2 wellhead connectors for rapid make-up
• Through the rotary landing operations
• Fire Resistant Multibowls
• Reduced height, weight, and close proximity designs
• ABB Vetco Gray now has available a catalog of multibowl experience in all of
the world’s oil fields, both onshore and offshore. This record of field-proven
successes has proven the cost saving advantages of these systems.

Definition of a Multibowl
A multibowl can be defined as a single wellhead housing assembly with the
capability of suspending and sealing two or more strings of casing/tubing. It is
important to recognize there are many ways to achieve the objective of suspending
and sealing multiple casing strings in a single housing, which is why there have
been many designs offered over the years.
Since the principal aim of the multibowl system is a reduction of rig time and costs, it
is important to consider the relationship of the multibowl design to the casing
program and blowout preventer system used on a specific location. The ideal use of
a multibowl system is to have it custom designed for the parameters of a particular
drilling program. Development projects which use the same BOP arrangement and
casing program consistently over a number of wells will realize the greatest savings
since the emergency stuck casing contingency components required for the project
is minimized. Operational practice, on many wells also leads to improved running
times, and less error.

April 2003 11-1

 MB 150 Split Multibowl Wellhead Housing

MB 150 System Drawing

11-2
Multibowl Wellhead Housings
Several variables govern the configuration of a Multibowl wellhead housing. The
casing program will determine factors such as the overall height and diameter of the
assembly, the type of top and bottom
connection, the number and type of outlets
required, the minimum bore and diameter of
individual casing hangers, and the type of seal
and lockdown profiles required in the bore.
Since each casing/tubing string to be suspended
requires space in the housing for a casing/tubing
hanger and annular seal, as well as casing
outlets, the total number and diameter of strings
to be suspended affects the overall height and
diameter of the housing. Other factors which
affect the envelope dimensions of the wellhead
housing include space requirements of the
location, and bit sizes to be run through the
housing. If the casing/tubing hangers are
stacked on top of one another the overall height
and diameter of the system can be minimized.
However, in many cases tensile and pressure
load factors preclude stacking of the casing
hangers. In these cases individual load support
and seal profiles for each string are designed
into the housing. In all cases the height and MB 160 30” and 20” Housings
diameter of the housing is less than the
equivalent conventional stacked wellhead
system.
The bottom connection options for multibowl housings are no different than for
conventional casing heads or spools. If the housing is to be mounted on pipe, the
options include; casing threads, squnch joint connectors, socket weld, and Sliploc
designs. If the housing is to be installed on top of a previously installed housing,
then a bottom connector to make up to the previously installed wellhead is required.
A bottom bowl and packoff to seal over the casing suspended in the housing below
is included as well. The wellhead housing may have an integral annular seal on its
outside diameter, and a lockdown device, if it is to be run through the rotary and
landed along with the casing.
The top connection of the housing is sized to match that of the BOP which will be
installed on it during drilling. The top connection may be API flanged, VGloc, or
NT2. VGloc connectors are often used for close proximity systems, as the total
diameter of the connection can be minimized. The NT2 connector offers additional
time savings during nipple up and nipple down of the BOP. The diameter of the NT2
pin, which is the connector profile on the housing, is small enough to drift through a
diverter or BOP in many cases, which allows the wellhead housing to be run
through the rotary and landed along with the casing. If a diverter, or more than one
BOP is to be used, the multibowl arrangement must adapt. In some cases where a
single BOP is to be used, the multibowl must accommodate many strings of pipe
internally. In other cases where more than one BOP or a diverter is to be used, the
multibowl housings may be stacked on top of one another.

April 2003 11-3

 MB-154 13-5/8” 10M Two Stack System
30” x 26” x 20” x 13-3/8” x 9-5/8” x 3-1/2”

11-4
Multibowl Casing Hangers
There are typically two complete casing hanger
systems for each multibowl system; a primary
mandrel casing hanger, and an emergency slip
type casing hanger for each casing string to be
suspended. Because the BOP is not nippled
down when casing is run with a multibowl
system, mandrel casing hangers are preferred
since they can be run from the rotary and do not
require the casing to be cut in the field.
However, if the casing gets stuck as it is run, it
may be impossible to land the mandrel hanger
as required. For this reason emergency wrap
around slip casing hangers are provided to back
up each mandrel hanger in the system.
The emergency slip casing hangers require the
casing to be cut after it is suspended. Multibowl
systems include a means to make this cut MB 160 Fluted Mandrel Casing
accurately should the slip hanger be run. In tall Hanger
multibowl wellhead housings this can be a
problem, as the cut must be made several feet
down inside the housing. Split multibowl
housings provide a connector between housing
sections which can be parted to gain direct
access to the casing. In one piece housings
special pipe cutting tools must be supplied
along with the system.
Emergency slip casing hangers must also
provide for casing annulus isolation.
Emergency slip hangers with integral annulus
seals, and with separate packoff assemblies
are available. In most cases the slip hangers
are not run through the BOP. The BOP is parted
and raised so the hanger can be installed at the
MB 160 Emergency Slip Casing
wellhead, however, slip hangers are available Hanger
which can be run through the BOP and over
casing collars if necessary.
Casing Annulus Isolation Seals
Along with each casing hanger, a casing
annulus isolation seal is provided. Some
mandrel hanger designs include an integral
annulus seal. This is the most cost effective
method of sealing the casing annulus, but fluid
returns during cementing operations cannot be
brought back through the normal fluid handling
path once the hanger is landed and the
annulus sealed. This type of hanger must be
held out of the seal profile during cementing of
the casing, then landed after cement MS-CB Casing Packoff
circulation is ended. For this reason fluted
mandrel casing hangers with flow by slots

April 2003 11-5

 Fluted Mandrel Casing Hanger with Emergency Slip Casing Hanger with
elastomer style packoff elastomer style packoff

Emergency Slip Casing Hanger with

Fluted Mandrel Casing Hanger with MS-CBT metal to metal style packoff
MS-T metal to metal seals

11-6
through the hanger body are generally preferred. Fluted hangers require a separate
packoff to be installed after cementing. This type of packoff is typically run, and set
through the BOP using a specialized running tool. ABB Vetco Gray offers both
metal to metal and resilient seal options for casing packoffs used with the fluted
mandrel casing hangers, and the emergency slip casing hangers for multibowl
systems.
Multibowl Packoffs With Elastomer Seals
Many types of casing packoffs with elastomer seals are offered, as pressure rating,
wellhead housing design, and cost are factors influencing the design. The simplest
style packoff consists of o-ring seals on the inside and outside diameters. Another
type consists of a pair of metal bushings bolted together above and below
compression type elastomer seals. This type of seal is energized by lockdown
screws in the wellhead housing which are tightened after the packoff is landed on
top of the hanger.
The standard packoff is a one piece metal bushing which has a BT seal in the bore
and o-rings or poly-bipak seals on the outside diameter. The BT seal seals against
the casing hanger upper mandrel and the o-rings or poly-bipak seals seal against
the wellhead bore. The packoff threads onto the external Left hand Acme landing
threads of the casing hanger. The packoff expands a metal lock ring located on the
casing hanger body, locking the hanger down as well as sealing the annulus. These
packoffs are typically run on drill pipe using a J-slot engagement to the running tool.
Multibowl Packoffs With Metal To Metal Seals
The standard metal to metal multibowl packoff seal is the MS-T seal. This seal is
landed with a hydraulic powered running tool as it requires about 300,000 pounds
of downward load to energize. The MS-T Casing Packoff Assembly consists of a
soft low alloy seal ring, a high strength energizing ring, and a retaining nut. The “U”
shaped seal is carried on the bottom of the energizing ring held by the retaining nut.
A square thread on top of the retaining nut makes up to the adapter for the running
tool.
After the cementing operation is complete the packoff is made up to the running tool
and run into the hole on drill pipe. When the seal is positioned on top of the casing
hanger the running tool is actuated. Hydraulic force pushes the energizing ring
down into the recess of the “U” shaped seal ring which expands the seal ring out
laterally in both directions. The softer material of the seal plastically deforms into
the wicker profiles on the wellhead housing inside diameter, and the outside
diameter of the fluted mandrel casing hanger. This locks the casing hanger in
position and provides redundant metal to metal seals at each wicker peak.
The metal to metal seal for the emergency slip casing hanger is the MS-CB seal
which is run and actuated the same as the MS-T seal except it must seal against
casing on the inside diameter rather than the casing hanger. For this reason the
inside diameter of the packoff has the CB type seal profile which is capable of
sealing against casing when driven into the casing outside diameter by the
hydraulic setting tool.
Service Tools For Multibowl Systems
Most multibowl wellhead systems include a set of specialized service tools to
facilitate the installation of the equipment. BOP test plugs, bowl protectors, and
bowl protector running tools are usually unique to an individual multibowl project.
Crossover landing subs may be required to run the wellhead housings, and

April 2003 11-7

mandrel casing hangers. Most multibowl housings and hangers which are run
through the rotary utilize Left Hand Acme landing threads so that right hand rotation
of the landing string and low torque requirements make release of the tools simple
and reliable. Casing packoff running tools are required if the packoff is separate
from the hanger. L-slot or J-slot engagement is often used to run these packoffs.
Some types of casing packoff such as the MS series require special hydraulically
powered installation tools. Tubing hangers typically require a crossover landing
sub. The internal lockdown style tubing hanger requires a hydraulically powered
tool to set the lockdown mechanism.
Other service tools which may be required for a multibowl system may include
specialty pipe cutting tools, cup testers, Valve Removal Plugging Tools, and
through the BOP load shoulder installation tools.
Multibowl Standardization
Because of the unique nature of multibowl designs for specific projects each
multibowl design receives a unique designation. This designation includes the
prefix MB and a number assigned sequentially as each new design is developed.
Therefore, if a design is designated MB-160 then all the components included in the
system receive the MB 160 designation. Despite the tremendous variation between
multibowl system certain standard profiles, and dimensions have been established
to afford as much interchangeability as possible, especially for the service tools.
Cost effective multibowl system options are available for any drilling program.

11-8
 MB 160 18-3/4” 10M Single Stack System
30” x 20” x 13-3/8” x 9-5/8” x 5-1/2”

April 2003 11-9

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SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 12
Single Completions
This page left blank
A single completion produces from one formation through a single string of tubing.
The principle wellhead components related to single completions include the tubing
spool, the single tubing hanger, and the tubing head adapter or tubing bonnet. The
tubing hanger and the tubing head adapter
provide a transition from the relatively large
bores of the BOP and the casing strings, to
the smaller bores of the production tubing,
and christmas tree valves. There are many
different methods of single completion and
the wellhead components must be designed
for compatibility with these methods. The
surface wellhead system must contain and
control the well under full production
pressures. Each component must therefore
be designed to safely contain the pressure
expected at the surface. If the well produces
at an elevated temperature or is subjected to
wide temperature changes, this thermal
cycling must also be considered. In addition,
if corrosive or erosive contaminants are
present, a material selection which satisfies
all of the requirements of the well becomes a
matter of equal importance. In lower
pressure completions, these are the
minimum considerations. When a
combination of pressure, temperature,
tubing weight, or contaminants require
corrosion resistant alloys, the design considerations and quality assurance become
much more complex.
Completion Operations
A single completion is the procedure which prepares a drilled well for production.
The cement plug left from cementing the production casing must be drilled out. The
drilling mud must be circulated out, and replaced with a completion fluid, usually a
brine solution. The casing may be perforated. A liner, screens, or gravel may be
installed. A packer is usually installed. There are many different ways the hole is
prepared for production.
Finally the production tubing is run down to the reservoir and suspended at the
surface in the wellhead.
A pump system, or flow control equipment is then installed at the surface to control
the flow of produced fluids from the well, and a flowline is attached to carry the
production to the field processing equipment.
Surface Flow Control Equipment
For wells which do not have sufficient reservoir pressure to flow an artificial lift
system must be installed at the surface. The most widely used method is the beam
pumping unit which uses a swab at the bottom of the hole to lift oil as it reciprocates
up and down. Sucker rods extending from the swab are attached to the
reciprocating beam which is in turn driven by a power unit of some sort.
Other artificial lift methods include Electrical submersible pump systems and
electrical rotating surface pump systems.

April 2003 12-1

12-2
Gas lift is used rather widely where formation pressures will flow a well but require
assistance for maximum production. The production tubing annulus is pressured
with gas which passes into the tubing flow stream through gas lift valves installed
along the tubing string at various intervals. The gas lightens the oil and assists its
flow.
Christmas Trees
Wells which have sufficient formation pressure to flow unassisted have a Christmas
tree assembly installed at the surface to control flow. The trees are a series of
valves, flow fittings such as the tubing head adapter, tees, crosses, fluid sampling
devices, instrument fittings, lubricator adapters and production chokes. The trees
typically have a vertical section and a horizontal section. The vertical section is
referred to as the run of the tree, and has a bore diameter consistent with the
production tubing below it. This permits tools the be run through the tree into the
well on wireline to maintain down hole devices, and clean the tubing. The horizontal
section of the tree is referred to as the wing and may be of a smaller bore diameter
than the run. The run usually includes one or two master valves, a flow tee or cross,
a crown (swab) valve and a tree top flange or lubricator adapter. The wing section
typically includes one or two gate valves, and a production choke. The choke is
used to control the rate of flow from the well. All other devices are typically full
opening.
Christmas trees have redundancy built into them since the consequences of failure
of the tree can lead to serious environmental pollution, fires, injury, and loss of life.
The more extreme the pressures and flow conditions of a well the more elaborate
the tree. In addition to manually operated valves many trees may have one or more
remotely operated valves so the tree can be controlled from a remote location. This
is particularly important offshore where there may be personnel living on the
platform where the producing wells are located, and where the consequences of
tree failure are more severe.
Most government regulatory agencies require “Production Safety Systems” to be
installed on all offshore installations. These systems provide for emergency
shutdown of all components of a production facility offshore in the event of a failure
or accident. Part of this system is the emergency shutdown of all flowing wells on
the structure. As part of that system a remotely actuated valve referred to as a
Surface Safety Valve is typically installed at the secondary master valve position.
This valve is tied into the emergency shutdown system permitting shutting off the
well flow at the surface of all wells on a structure with a single switch or signal.
The Surface Safety Valve (SSV) as part of the “Production Safety System” must be
manufactured to a higher standard of quality than other valves in the tree. API
Specification 14D sets the worldwide industry standard for manufacture of SSVs.
Currently the Specification 14D is being incorporated into API Specification 6A the
specification for surface wellhead and Christmas tree equipment, as that
specification also covers all gate valves manufactured for oil and gas production
control.

April 2003 12-3

Stacked and Composite Trees
Historically Christmas trees have been assemblies of individual components
configured for whatever the existing flow conditions of a well. Stacked trees are still
the industry standard, however, they have some limitations, especially for offshore
installation. The risk of fire on an offshore platform is significant, and the industry
has experienced many tragic accidents involving explosions and fires on offshore
installations. Fire resistant equipment is
therefore a desirable commodity. For this
reason composite trees began to
increase in use for offshore operations. A
composite tree has all of the critical flow
control components assembled into a
single or two housings. By eliminating the
connections between components the
potential for leaks in a fire condition is
greatly reduced as these connection tend
to fail in a fire. Fire resistant valves and
other fittings have also been developed.
These feature have an additional cost
associated with them so they are not
universally used. In areas where
environmental concerns are extreme, Stacked Christmas Tree in Alaska
and/or well flow conditions are extreme
the added cost is just prudent production
planning for safety. Composite trees are also more compact, so when space is a
considerations these trees are an advantage. The disadvantage to a composite
tree is that if a single valve in the tree becomes damaged the whole tree must be
removed to send it in for repair.

Composite Block tree for the North Sea

12-4
Horizontal Trees
With more prolific use of electrical
submersible pump lift systems a tree
configuration known as a Horizontal
tree gained more industry use.
Electrical submersible pumps tend to
fail and wells with these systems are
typically subject to frequent workover
operations to repair the pumps. A
horizontal tree facilitates workover
operations since the tree need not be
removed to recover the production
tubing and the pump.
Mandrel Tubing Hanger
Completions
The mandrel tubing hanger is the
simplest and most frequently used
method of suspending the production
tubing in the wellhead.
The mandrel hanger threads onto the
top of the production tubing and lands
in the upper bowl of the tubing spool
where it is locked in place. An extended neck or separate seal sub on the hanger
protrudes above the tubing spool top, so the tubing head adapter (tubing bonnet on
the tree, seals over the top of this mandrel and mates with the top of the tubing
spool simultaneously.
Service Tools Associated With Single Mandrel Hanger Completions
Back Pressure Valves
A Back Pressure Valve (BPV) is a one way check valve which is installed in the
tubing hanger bore and is designed to contain pressure from below. The BPV can
be installed through a BOP or through a christmas tree using a running tool and
extensions. The BPV provides positive well control
during a completion by plugging the bore of the
tubing hanger in the interim time between BOP
stack is removal, and the tree installation and test.
On well workovers the BPV provides positive well
control in the interim time between the tree removal
and the BOP system installation and test.
BPV Adapter
The BPV adapter is used to install the BPV through
a tree or BOP stack. The BPV adapter makes up to
the BPV running threads. The other end has a
polish rod hex connection to adapt the tool to polish
rod extensions or tubing joints.

Type H BPV (below)

and H BPV adapter (above)

April 2003 12-5

Two-way Check Valve
The two-way check is used to plug the bore of the tubing hanger similar to a BPV,
but hold pressure from the top as well as the bottom. It is used to pressure test a
tree upon installation. For wells with the Type F plug socket a Solid Test Plug is
used.

Type H
BPV
Adapter

Two Way
Check
Valve

EUE 8rd x polish rod hex adapter

The EUE 8rd x Polish Rod Hex Adapter (bi-hex) is used to adapt the BPV or BOP
test plug to tubing joints to set or retrieve plugs through a BOP stack.

12-6
Modified Centralized Acme Landing Sub
The Modified Centralized Acme Landing Sub is used to thread into the top of the
tubing hanger to lower it through the BOP stack on a completion using a tubing
hanger which has this type of thread as a landing thread. This thread is used in
most tubing hangers because it has excellent load capacity, does not require much
torque to make up, and has a low potential to gall.

Modified Centralized Acme Landing Sub

Crossover Landing Subs

In most cases a crossover sub will be used to land the tubing hanger, and adapt the
service tools to the type of tubing being utilized.
Full Bore (Wireline) Subs
Some landing subs are not full bore for the tubing string. This is especially true of
Modified Centralized Acme landing subs, which in some cases must be below drift
diameter in order to support the full tubing string weight. In cases where the landing
subs are not full bore, subs which are full bore should be supplied, to permit wireline
work through the tubing before the tree is installed.

Full Bore (Wireline) Subs

April 2003 12-7

Polish Rod Extensions
Polish Rod Extensions enable the installation of various types of plugging devices
through the bore of valves on a casing outlet or tree. The Polish Rods are available
in various lengths to achieve the proper space out for these operations. Polish Rods
have a proprietary end connection called a Polish Rod Hex connection, which when
made up permits torque to be transmitted through the Polish Rods to a plugging
device, in either direction without possibility of the Polish Rod Connection
disengaging.
Tubing Spool Lockdown Screw Wrench
The Tubing Spool Lockdown Screw Wrench is used to turn the tubing spool lock
down screws without damage to the square end.

Lockdown Screw Wrench

Polish Rod

12-8
Surface Controlled Subsurface Safety Valve (SCSSV)
Completions offshore require additional safety devices since personnel live and
work on the structures which also support the production equipment. The high
pressure and volatility of the produced fluids make the risk of fire or explosion
significant. Contingencies for escape and evacuation are always a part of the
systems. The overall system to protect the safety of personnel and equipment
offshore is referred to as the “Production Safety System” which includes safety
devices to shutdown flow of wells in an emergency. One of these devices is the
Surface Controlled Subsurface Safety Valve.
The Surface Controlled Subsurface Safety Valve is installed in the tubing string
usually about 500 feet below the mudline. This valve is capable of shutting off the
flow from the well if the “Emergency Shutdown System” is actuated. ESD actuation
switches are located at every escape point on an offshore platform. In most cases
government regulatory agencies require that these valves be installed on every
well.
The SCSSVs are “Fail-safe Closed”
valves. Hydraulic pressure to the valve
is required to maintain them in the open
position. If hydraulic pressure is lost a
spring in the valve shuts the valve. To
maintain pressure on the valve a
hydraulic line is attached to the valve
hydraulic control port and then strapped
to the tubing back to the surface flow
control equipment. The tubing hanger
and tree must be arranged to provide
hydraulic porting so that the hydraulic
control can transition to the exterior of
the tree. From there a hydraulic control
line is routed to the central control panel
of the platform, and the ESD system.
Various methods are used to terminate
the downhole control line to the SCSSV
at the tubing hanger or tree, but all
methods must maintain well control
integrity. During the completion
operation this line is installed once the
SCSSV is installed and pressure
tested.
The tubing hanger and control line for
the SCSSV is made up at the rig floor
when the last joint is suspended in the
rotary table.

Surface Controlled Subsurface Safety Valve

(at left valve is shown open, at right it is shown
closed)

April 2003 12-9

 SCSSV control line

Tubing hanger

Rig floor

BOP

The tubing hanger and control line for the SCSSV is made up at the rig floor when the last joint
is suspended in the rotary table.

12-10
Additional Service Tools Used For Well Reentry During Workover
Operations
All wells occasionally require workover operations to repair problems that arise
from producing the well. The well may get clogged with sand, or the tubing may
become corroded and part, or begin leaking. Many causes lead to well workovers.
In most cases workovers require using a rig capable of circulating kill and
completion fluids, handling the production tubing string, and a BOP.
The reentry of a well for purposes of a workover which will require pulling the
production tubing out of the well, involves killing all well pressure by filling the tubing
and the production casing with fluid. Once there is no pressure or vacuum at the
surface, the tree bore may be opened, and a Back Pressure Valve set in the tubing
hanger. With the Back Pressure Valve in place, positive well control is effected so
the tree can be safely removed, and a BOP installed. The BOP must be fully tested
before any tubing is pulled from the well. This requires applying pressure against
the top of the tubing hanger. Because the Back Pressure Valve will not contain
pressure from above, an additional plug called a Blanking Plug is installed in the
tubing hanger landing threads to permit a blind ram pressure test. This Blanking
Plug is retrieved through the BOP after the blind rams are tested. A tubing joint is
then made up to the top of the tubing hanger and the remaining BOP components
are tested. After a successful BOP test, the Back Pressure Valve is retrieved
through the BOP, the tubing is tied into the tubing hanger, and the tubing is pulled
from the well.
Blanking Plugs
There are two types of Blanking Plugs. Both make up to the tubing hanger landing
threads so the bottom thread of the Blanking Plug must be compatible with the
tubing hanger landing threads. The top thread may be either 1.285 Left Hand 6 Stub
Acme box threads, or Left Hand 8rd pin threads equivalent to the tubing thread size.
Some older tubing hangers have PE 10rd landing threads which require a Blanking
Plug with similar threads. The Blanking Plugs with the Left Hand 8rd threads permit
testing of pipe rams with the Blanking Plug Adapter latched to the plug. The 1.285
Left Hand 6 Stub Acme box retrieval threads require a Blanking Plug Adapter which
has a Polish Rod Hex connection at the top. This type of Blanking Plug must be
retrieved before any pipe rams testing takes place, as the Polish Rod Hex
connection does not have sufficient strength to retain a landing joint tied to it with
the BOP test pressure applied. The result may be that the test joint is blown from
the BOP as pressure is applied.
The left hand retrieval threads on the Blanking Plug Adapter permit the tool to
engage the Blanking Plug using left hand rotation. Once the Blanking Plug Adapter
is made up to the Blanking Plug continued left hand rotation of the retrieval joint
backs the Blanking Plug out of the tubing hanger and it is then retrieved back to the
rig floor.

April 2003 12-11

 Blanking Plug Adapter with 1.285
left hand 6 stub acme pin bottom
and Polish Rod Hex box top

Blanking Plug with MCA pin

bottom and 1.285 left hand 6
stub acme box top

Blanking Plug Adapter with 8rd

thread box top and left hand 8rd
thread bottom

Blanking Plug with left hand 8rd

thread pin top and 8rd thread pin
bottom

12-12
 Blanking Plug installed after tree is removed
If a control line nipple is present it must be plugged using a 1/8” NPT pipe plug

The Blanking Plug is retrieved using the Blanking Plug Adapter made up on tubing

April 2003 12-13

Slick Joint Completions
The Slick Joint completion is a variation of the single completion which has been
used for many years in a number of different applications. The slick joint completion
uses three components to support and seal the tubing string. The hookwall or wrap
around packoff, which resembles the boll weevil hanger body, contains an
elastomer seal element to seal the outside diameter of the tubing string. The
hookwall or wrap around packoff also seals the annulus at the tubing spool top
bowl. The tubing string is threaded into a Canfield Bushing (plug bushing or seal
nipple) and this in turn is threaded into the bottom of the tubing bonnet. In this
manner, the tubing weight is actually supported from the tree and not landed in the
tubing spool top bowl. The last joint of tubing is called the slick joint, and before the
use of coated tubing, was actually a polished joint.
The principal advantage of the slick joint completion is the ease with which the well
can be cleaned up and brought on line. Since the tubing weight is suspended from
the bottom of the tree, a landing joint can be screwed into the top of the tree, and the
tubing string lifted out of the downhole seals. Control of the well is maintained by the
hookwall or wrap around packoff which is locked down by the tubing spool lock
down screws and initially by the drilling or completion fluid column. After the tubing
string is clear of the packer seals, the tubing string is displaced with a fluid which is
light enough to allow the well to flow. The tubing is lowered back into the seals and
the connection is made up at the tubing spool. The control of the well is now through
the christmas tree and the well can be flowed as soon as the flowline is connected.

12-14
Additional Service Tools Required For Slick Joint Completions
Support Couplings
Support Couplings are placed between the plug bushing and the tubing hanger
packoff on slick joint completions to support the tubing string, and elevate the plug
bushing for easier make up of the tree. It also protects the tubing hanger packoff
gland nuts from the weight of the
tubing.
Gland Wrench
A Gland Wrench is used to tighten
the tubing hanger packoff gland nuts
on HW and CBHW tubing hanger
assemblies.
The Gland Wrench wraps around
the tubing and the lugs on the end
engage slots in the gland nuts which
are recessed in the hanger packing
bore.

Combination 2-3/8” x 2-7/8” Gland Wrench for HW

and CBHW Tubing Hangers

Outside Landing Device

Combination 2-3/8” X 2-7/8” Gland
Wrench for HW and CBHW Tubing
Hangers
Some types of Plug Bushings used on
slick joint completions do not have a
landing thread in the top inside
diameter. The Acme outside diameter
threads which make up to the tree are
used as a landing thread with this
type of plug bushing. In such cases it
is necessary to have a crossover sub
from the tubing, to the plug bushing,
to land the tubing. These subs are
called Outside Landing Devices since
they make up to the outside threads
of the plug bushing. They have a
tubing thread box top connection, and
a Plug Bushing thread box bottom
connection, including a Plug Bushing
Seal Ring to seal to the top of the Plug
Bushing. Outside Landing Device

April 2003 12-15

FC Tubing Hangers With Seal Sub
The FC Mandrel hanger is used with the low pressure standard service VG 100
wellhead system. In nominal sizes 8-5/8” and 7” the hanger features a 90o load
support shoulder and an o-ring annular seal above it to seal on a 4" per foot taper in
the FC Tubing Spool. In the 10-3/4” nominal size the hanger has a 45o load
shoulder. There is a Type H Back Pressure Valve profile in the bore and an EUE 8rd
landing thread with a bore equivalent to the tubing bore. If a flow bore isolation seal
is desired, a separate seal sub may be added to seal between the tubing bonnet
lower bore and the tubing hanger upper bowl.

FC Mandrel Tubing Hanger, Seal Sub and Tubing Bonnet

FTC-1A-EN is an extended neck and threaded single completion tubing hanger,

sealing the annular space. It is supplied with a Back Pressure Valve thread
preparation. The upper part of the extended neck has
sealing rings to pack against the internal diameter of
the tubing bonnet, providing a reliable way to confine
the well pressure. The FTC-1A-EN tubing hanger is
also available with plastic packing on the upper
sealing area for 10 and 15,000 psi WP.
The FTC-1A-EN-DHCL is also an extended neck but
includes a down hole control line preparation. The
upper part of the extended neck is designed with
three sealing rings, two of them providing a gallery
seal to transmit the external pressure signal through
the control line to the bottom where the storm valve is
located.

FTC-1A-EN Tubing Hanger

12-16
FTC-1W Tubing Hanger
The FTC-1W is a slick-joint wrap around tubing
hanger which does not require a polished joint to
slip over the tubing pipe inset. The seal between
the pipe and the hanger is obtained by
energizing the lockdown screws in the flange
head.

FTC-1W Tubing Hanger

Type CWC
Type CWC tubing hangers are used in the
7", 8-5/8", and 10-3/4” CWC tubing spool
top bowls. The hanger features an
extended neck with a tapered nose for a
Metal-Flex metal-to-metal seal. This seal
is an elastically deformed metal seal which
is self-energized during installation and
enhanced by internal pressure during
service.
For the 7” and 8-5/8” nominal sizes the
CWC tubing hanger also features a 4"
taper per foot external seal surface on the
body of the hanger. This seal mates with
the seal surface in the CWC tubing spool
top bowl to form a controlled interference
metal-to-metal seal for the annulus. Both
metal-to-metal seals also feature a groove
for hydraulic packing which prevents
surface galling during installation, and 7” X 2-7/8” CWC-F6H Tubing Hanger
assists low pressure sealing capability if
the surfaces become scratched during
drilling operations. Each 7” or 8-5/8” CWC
tubing hanger also has a 90E load shoulder on the body below the tapered sealing
surface. This shoulder acts as a positive stop to prevent any wedging of the hanger
into the tubing spool top bowl during the installation and life of the equipment. It also
insures a fixed location of the tubing hanger when the seal is made up between the
extended neck of the hanger and the seal pocket at the bottom of the christmas
tree.
For the 10-3/4” nominal bowl size CWC tubing hangers have an o-ring annular seal
on the body which is housed in a dove-tailed groove on the lower outside diameter
of the hanger.
CWC tubing hangers also feature an internal profile to accept a back pressure valve
or tubing plug. A landing thread box in the top bore of the hanger is used to lower the
hanger through the BOP with the tubing suspended below it. The standard landing
thread is Modified Centralized Acme. All CWC style tubing hangers have a thread
box bottom to match the tubing string threads selected by the operator. The CWC
tubing hanger is used for completions requiring a flow bore isolation seal at working
pressures from 2,000 psi to 10,000 psi, for NACE or non-NACE service. and are
available with control line nipples, jumpers, or continuous control line
arrangements.

January 2002 12-17

CWC style tubing hangers are used with both flanged and tubing heads but they are
not interchangeable. The positioning of the tubing head lock down screws below
the clamp hub and clamp require a deeper bowl and therefore a longer hanger neck
on the CWC tubing hangers.
The family of CWC style tubing hangers includes the CWC-F6 (for flanged tubing
spool and tubing bonnet), CWC-G6 (for tubing spool and tubing bonnet),
CWC-F6CN (for flanged tubing spool and tubing bonnet with a control line nipple)
and CWC-G6CN (for tubing spool and tubing bonnet with a control line nipple). In
addition there are many special designs to meet a variety of customer-preferred
completion programs.
Type 45 Tubing Hanger
The Type 45 tubing hanger is designed to be
used only in the Type 45 tubing spool. This
tubing hanger also features the Metal-Flex
metal seal on the extended neck of the
hanger but the annular seal is an
elastomeric seal which is energized
mechanically by the tubing head lock down
screws when they are run in after the tubing
hanger is landed. Type 45 tubing hangers
have a 45E load shoulder below the
compression seal which lands on the
corresponding shoulder of the tubing spool
top bowl. Type 45 tubing hangers also
feature the internal profile for a back
pressure valve or tubing plug, Modified
Centralized Acme box top landing threads,
and box bottom tubing threads to match the
tubing string selected by the operator.
Type 45 tubing hangers are available only in
the 7" size for use over 7-5/8" casing when
the operator prefers to use a 7-1/16" BOP
stack for completion and workover
operations. These hangers are used with 7” X 2-7/8” Type 45-F6H Tubing Hanger
both flanged and connections but they are
not interchangeable. Usually the Type 45
hanger is selected for 5,000 psi or 10,000 psi applications only, either NACE or
non-NACE.
The Type 45 tubing hangers include the 45-F6, the 45-G6, the 45-F6CN and the
45-G6CN.
CWCT Tubing Hangers
The standard CWCT tubing hangers are generally used in the 11"(10-3/4" nominal
bowl) and the 13-5/8"(13-3/8" nominal bowl) CWCT tubing spool top bowls. CWCT
tubing hangers feature the Metal-Flex metal-to-metal seal on the extended neck of
the hanger and a controlled interference metal-to-metal seal on the body of the
hanger. CWCT tubing hangers also use the hydraulic packing groove across the
area of the metal seals for protection during installation. The CWCT tubing hanger
has a 45o load shoulder to transfer the tubing weight to the tubing bowl after the
annular metal seal is engaged.

12-18
CWCT tubing hangers also feature the internal
profile to accept a back pressure valve or tubing
plug, box top landing threads (Modified Centralized
Acme) and box bottom threads to match the tubing
string selected by the operator. CWCT tubing
hangers are generally used for completions over
9-5/8" and larger production casing for working
pressures from 3,000 to 10,000 psi They are
available for NACE and non-NACE service
conditions, and with control line nipples or
continuous control line arrangements.
CWCT tubing hangers are available for both flanged
and CWCT tubing heads but again, because of the
position of the tubing head lock down screws, they
are not interchangeable.
The CWCT family of tubing hangers includes the
CWCT-F6, the CWCT-G6, the CWCT-F6CN and the CWCT-F6 Tubing Hanger
CWCT-G6CN.
D-15 Tubing Hangers
Type D-15 Tubing Hangers for single completions are double-tapered, metal
sealing, extended neck, mandrel style hangers like the CWC and CWCT tubing
hangers. The D-15 tubing hangers are characterized by a larger load shoulder to
support the heavier bearing loads associated with 15,000 psi completions and
some deep 10,000 psi completions.

7” X 2-7/8 D-15-F6H Tubing Hanger 8-5/8” X 4-1/2 D-15-F6H Tubing Hanger

April 2003 12-19

D-15 tubing hangers for the 7-1/16" nominal bowl size feature a 4" taper per foot
controlled interference, metal-to-metal annular seal and a 90o load shoulder. D-15
tubing hangers for 8-5/8" nominal bowl size have a 2" per foot seal taper annular
seal with a 45o load shoulder. All D-15 tubing hangers have the Metal-Flex
metal-to-metal seal on the extended neck of the hanger.
Additional features include a special modified centralizing (MCA) landing thread,
back pressure valve profile, optional arrangement for one or more control lines, and
tong space for easy field installation.

S-20 Tubing Hangers

The S-20 Tubing Hanger is designed for completions rated at pressures of 20,000
psi and 30,000 psi The S-20 Tubing Hanger may also be selected for 15,000 psi
completions if the tubing loads are extreme. The S-20 hanger is also the choice for
those wells which produce hazardous fluids at high pressure. Since this tubing
hanger is designed for such severe service conditions, the primary sealing systems
are pure metal-to-metal seals.
The S-20 tubing hanger features a 45E load shoulder, a 4" taper per foot controlled
interference annular seal, and a Metal-Flex seal of the extended neck of the hanger.
The S-20 tubing hanger also features a special landing thread, back pressure valve
profile and is available with an arrangement for control line.

S-20 Tubing Hanger, Seal Nipple and Packoff

12-20
Control Line Connections
ABB Vetco Gray offers high integrity control
line systems with all wellhead assemblies
which use downhole safety valves.
The control line seal nipple is installed in
threaded ports provided in Vetco Gray’s
standard control line tubing hangers.
Metal-to-metal seals between the nipple and
the tubing bonnet maintain control line
connection pressure. Hydraulic packing is
combined with these seals, which are
common to all control line nipples.
The seal between the ¼" control line and
seal nipple uses a tapered ferrule cone
which, when engaged by the threaded
gland, forms a metal-to-metal seal between
the tubing and the top of the seal nipple.
While the tubing hanger is being run and set,
test pressure can be applied to the entire
control line system and downhole safety
valve.
Since the tubing bonnet must align with both Style III Control Line nipple
the tubing hanger neck and the control line
nipple the tubing hanger is aligned in the
tubing spool top bowl by using a single Multi-completion Guide Screw. A key slot on
the hanger body engages the Multi-completion Guide Screw as it lands in the bowl
rotating it into final orientation.

Metal Flex Seals

Controlled Taper Seal

April 2003 12-21

Continuous Control Line Arrangements
A continuous control line arrangement refers to a
design which does not terminate the control line
until it exits the pressure containing envelope well.
The control line is passed completely through the
tubing hanger and is fished through an exit port
either in the tubing spool or tubing bonnet.
Swagelock fittings are used to anchor and seal the
control line in the tubing hanger. A termination
fitting seals over the end of the line where it exits
the tubing spool/bonnet and provides a thread
connection to attach the hydraulic line leading back
to the platform control panel and ESD system.
Control Line Termination Fittings
Where continuous control line arrangements are
used a fitting is required to seal over the exit port of
the control line, anchor and seal the line itself, and
provide a connecting port for the surface control
system. A selection of control line termination
fittings is available for a variety of service
conditions.
D15-FCCH Tubing Hanger

C-94 Control Line Fitting

The C-94 control line fitting is used in pressure ratings below 10,000 psi where an
integral needle valve is not required. The
C-94 fitting has ½” NPT pin thread on the
inboard side and ½” NPT box on the
outboard side. The end of the control line is
locked into this fitting when it is installed.

C-94 Control Line Fitting

12-22
C-20
The C-20 control line fitting is used
in pressure ratings 15,000 psi and
above where an integral needle
valve is not required. The C-20
fitting has 9/16” Autoclave pin
thread on the inboard side and
9/16” Autoclave box on the
outboard side. The end of the
control line is locked into this fitting
when it is installed.
C-77 Control Line Needle Valve
The C-77 control line fitting is used
in pressure ratings up to 15,000 psi
where an integral needle valve is
required. The C-77 control line
block is connected to the tree via a
four bolt stud connection utilizing a
seal ring to seal between the
control line valve block and the
tree. The end of the control line is
locked into the C-77 Block when it
is installed. C-77 control Line Needle Valve

Style T Control line

April 2003 12-23

Style T Control Line Arrangement
The Style T Control Line arrangement is used for 20,000 psi rated completions. This
arrangement utilizes a modified Seal Ring to seal between the tubing hanger top
and the Block Master Valve bottom profile and provide a hydraulic fluid path from a
port in the Block Master Valve through the tubing hanger to a port at the bottom of
the tubing hanger into which the control line is locked and sealed by a Swagelock
fitting.
The tubing hanger does not require orientation when landed with this type of
arrangement.

D15-D20-FCCH Tubing Hanger with Style T Control line Seal Ring

12-24
Style TA Control Line Arrangement
The most widely used control line seal arrangement in the industry is to port the
tubing hanger such that a port exits the tubing hanger upper outside diameter
between to elastomer seals which seal into the tubing head adapter. A port on the
tubing head adapter penetrates
from the outside of the tubing
head adapter to the plane
aligned with the port on the
tubing hanger. The two
elastomer seals isolate the flow
bore of the hanger and the
control line port from one
another. This design does not
require alignment of the tubing
hanger when landed, but if the
upper seal fails the tubing
pressure will be applied to the
control line. ABB Vetco Gray
refers to this design as a TA
arrangement.
Control Line Jumper
Arrangement
A control line jumper is a
precoiled length of control line CWC-TA-1C Tubing Hanger
which bridges the connection
between the tubing hanger and
the tubing bonnet. Swagelock
penetrator fittings anchor the
jumper at the top of the tubing
hanger and the bottom of the
tubing bonnet. The control line
jumper provides a reliable
termination for the control line and
does not require that the tubing
hanger be oriented in the tubing
spool bowl when landed.
The control line jumper is installed
as the tree is installed by
stretching the coil enough to allow
attachment to the tubing bonnet.
As the tree is landed the slack in
the coil is taken up by the natural
bend of the tubing.

Type CWCT-FJH Tubing Hanger with control line

jumper

April 2003 12-25

Slick Joint Tubing Hangers
Slick Joint Tubing Hangers are in actuality only a suspension device during the
completion operation. The production tubing is ultimately suspended from the
tubing bonnet. Its primarily functions as an annular seal for the tubing while allowing
reciprocation of one joint of tubing through its center.
Stripper Rubbers
Stripper rubbers are annular seals installed in the tubing spool bowl which allow the
pulling of production tubing while maintaining an annular seal. These seals are
designed for low pressure usually wells on which rod pumping units are installed.
Wrap Around Packoffs
The “WA” wrap around packoffs may be manufactured to use in most ABB Vetco
Gray tubing spool top bowls. Unlike the “HW” this packoff is saw cut in half so it may
be parted to wrap around the tubing. The packoff has a hinge on one side and a
socket head screw on the other to tie the two halves together. A slab elastomer seal
element, also cut in two provides the annular seal. The compressive load of the
tubing spool lock down screws energize the seal, extruding it tightly against the
inside of the tubing spool bowl and the outside of the tubing.

FC Adjustable Tension Tubing Bonnet and

Stripper Rubber

12-26
 Type A-CBHW Completion

April 2003 12-27

Hookwall Packoffs - Chevron-Type Packing
The HW tubing hanger is used for packing off around tubing that is screwed directly
into the tubing bonnet, when used with flanged tubing spools. This tubing hanger
was initially designed for use in the type A tubing spool top bowl.
The type A bowl is now inactive; however, the A bowl was modified to have 1/16"
smaller inside diameter and an overload shoulder to accommodate
multi-completion tubing hangers. The modification added a square overload
shoulder which reduced the length and area of the tapered seating surface of the
Type A bowl. This modified bowl is known as CWC for 7" and 8-5/8" only.
The hookwall (HW) hanger is used for
flanged settings without plug bushings or
settings with plug bushings.
Flanged settings with plug bushings require
a CB(PB)-HW packoff, which has a recessed
internal sealing element to accommodate the
plug bushing without damage to the sealing
element from the tubing string weight.
Plug Bushings
The plug bushing supports and seals the
tubing with threads, and makes up into the
tubing bonnet to seal and support the tubing
string. The Plug Bushing also provides a
profile in the bore to accept a BPV.
The plug bushing seal ring provides
metal-to-metal sealing technology between
the plug bushing and the tubing bonnet.
The tubing bonnet supports the tubing via the 7” X 2-7/8” Type A-HW Tubing Hanger
with Type F-1 Tubing Bonnet
plug bushing and seals the tubing string.
The hookwall tubing hanger does not
support tubing string weight once the tree is installed but provides a dynamic
annular seal which allows the tubing string to be raised after the tree is installed,
thus allowing the tubing to be displaced through the tree.
The hookwall single tubing hanger supports and seals the tubing string with four
primary components:
• The packoff body houses the chevron packing assembly and provides a
metal to metal annular seal.
• The hookwall packoff composed of a stack of split chevron elastomer seals,
seals between the tubing bowl inside diameter and the tubing string outside
diameter.
• A gland nut retains the packoff in the bore of the hanger body on the top side.
• A snap ring retains the packoff in the bore of the hanger body on the bottom
side.

12-28
7” X 2-7/8” Type A-CBHW Tubing Hanger with Plug Bushing, Plug Bushing Seal Ring and Type F
Tubing Bonnet

Electrical Feed through Tubing Hangers

In many cases oil is discovered in reservoirs which do not have sufficient natural
pressure to flow unaided or the pressure decreases before the well is depleted. The
entire field of enhanced recovery is devoted to assisting in the production of these
remaining reserves. In many cases, such as gas lift injection, no changes are
required when used with a single completion. However, when a downhole electrical
pump is used, the tubing hanger must be modified to contain and seal the electrical
cable which is connected to the downhole pump. This cable must also pass through
the tubing head adapter for connection to the surface power source and it must be
sealed at this connection also. Since this is generally a low pressure application,
compression elastomer seals will be sufficient. For other applications involving high
injection pressures, high temperatures, or high levels of H2S, special materials or
metal-to-metal seals may be required.

April 2003 12-29

The electrical penetrator mandrel is provided by a company specializing in
electrical connectors, and the tubing hanger is adapted to accept the penetrator
used.

Type CWC-EF Tubing Hanger with electric feedthrough penetrator

12-30
Tubing Head Adapters (Tubing Bonnets)

Type SH and MH Tubing Bonnets

Type SH and MH tubing bonnets are threaded onto the top of the production tubing
and support the full weight of the string upon the tubing spool. There is no provision
for a back pressure valve so these assemblies are generally used on wells which
will require artificial lift.
Type K Tubing Bonnet
The Type K tubing bonnet is designed to
be used with double-tapered mandrel
tubing hangers. The bore that seals
against the neck of the extended portion of
the hanger has a taper on a 1E differential
from the taper of the hanger. The hanger’s
seal taper flexes within the elastic
limitations of the metal, creating a
metal-to-metal seal backed up by
hydraulic packing. As the internal pressure
within the tubing string increases, the seal
is further enhanced.
Type KC Tubing Bonnet
Tubing bonnets with a seal pocket for a
control line nipple are referred to as Type
KC Tubing Bonnets.
Type F Tubing Bonnet
The Type F Plug Bushing Tubing Bonnet is used in those completions where it is
necessary to reciprocate the tubing for displacement of well control fluid. The Plug
Bushing combines features of an ordinary hookwall hanger and a double-tapered
mandrel hanger. The combination is provided by the Plug Bushing which has three
primary functions:
• to support and seal the tubing with threads
• to provide for a tubing plug
• to make up into and seal the tubing bonnet

Type FD and FDC Tubing Bonnets

April 2003 12-31

The Plug Bushing seal ring is threaded on the outer diameter of its rib. It is screwed
into the tubing bonnet until it passes through the bonnet’s threads and into a
recessed socket area. The plug bushing seal ring provides a metal-to-metal seal
between the plug bushing and the tubing bonnet. The tubing bonnet supports the
entire weight of the tubing string via the plug bushing and seals the tubing string.
The Type F Tubing Bonnets support the weight of the tubing with Plug Bushing
threads, have a flanged bottom connection, studded top connection, and are for
use in 5,000 through 15,000 psi applications.
Lubricator Adapters
The Type “L” flanged hammer lug nut Lubricator Adapter is Vetco Gray’s standard
for pressure to 10,000 psi. It contains metal-to-metal seals and has quick make-up
and break-down connectors. The metal-to-metal seal and the seal are
mechanically, as well as pressure, energized. Either seal may be assembled and
disassembled repeatedly without seal damage. Internal top threads are included
for lifting the production tree.

Type L Lubricator Adapter

12-32
GENERAL RUNNING PROCEDURES

April 2003 12-33

Single Completion Procedure With Mandrel Hanger
Step 1 Check the Equipment
Equipment to be carried by ABB Vetco Gray Service Technician:
2 Appropriate sized BPVs
1 Correct BPV adapter
1 Solid test plug with adapter or two-way check if type H socket
3 36" Polish rod extensions
1 EUE 8rd box x polish rod adapter
1 EUE 8rd pin x (whatever the particular pipe thread being used; box)landing
sub. If hanger has MCA landing threads an additional landing sub back to
tubing thread is needed.
1 Full bore subs if the landing subs are not full bore.
1 Plugging tool with adapter to tree connection (if required)
1 Spare ring gasket for bonnet to tubing head connection
1 Spare tubing hanger annular seal
1 If hanger has control line nipple, spare ferrules, spacers, and 1/8" pipe plug
is necessary
Equipment to be on location:
1 Seal ring for the appropriate flange or connection between the tubing spool
and tree.
1 Mandrel tubing hanger threaded back to the tubing thread
1 Set of studs and nuts for the appropriate flange (w/weather seal)
1 Christmas tree
1 Double pin sub of the appropriate threads (if necessary)

Step 2 Verify the Equipment

1. Make sure the flange on the tubing bonnet corresponds to the flange at the
top of the tubing spool. Use the ring gasket to gauge the tubing bonnet
bottom connection.
2. Inspect the seal pocket of the tubing bonnet. It should be clean and free of
gouges or scars. The test port and control line ports should be free of
debris. Insert the hanger mandrel into the bonnet to check for spacing of
mandrels, proper stand off, and orientation.
3. Drift the tree with the proper BPV.
4. If using a landing sub, make it up on a joint of tubing to check the threads.
Use a thread lubricant.
5. Rabbit the tubing hanger and any sub to be used.

12-34
 Tubing Hanger landed in the tubing spool

April 2003 12-35

 6. Make sure the hanger is threaded correctly for the tubing being run.
7. Set a BPV in the hanger to check the socket
8. Make sure the control line drifts the control line nipple. Be sure all the
necessary Swage-lock fittings and spacers are present.
9. Carefully make up the landing sub into the hanger to check the threads. Use
thread lubricant.
10. Make sure that all the lock down screws and MC guide screws on the tubing
spool are fully retracted.
Step 3 Hanging Off
1. After the tubing has been run, tested and spaced out, it will be necessary to
have a pin up on the last joint of tubing. This may be done either by backing
off a collar, or by inverting the last joint by means of a double pin sub. The
hanger should be placed on this joint. Be sure to protect all seal surfaces
from damage during handling of the hanger. Never use a landing joint to
torque up the hanger to tubing connection. If the hanger has a control line
nipple, an MC guide screw on the tubing spool should be used to align the
hanger correctly. Be sure that the position of the hanger as it is fully made
up, orients the guide slot on the hanger over one of the tubing spool MC
guide screws.
2. If a control line is run, make up the tubing hanger control line seal assembly.
Have the subsurface safety valve tested. It is desirable to leave the control
line attached to the hanger during hang off to maintain the valve in open
position, and to insure the line is not damaged.
3. Make up the landing joint (If a crossover landing sub is used be sure to
torque it onto the landing joint to full rated torque for the tubing threads so it
will not inadvertently back off of the landing joint). Torque the landing joint
into the hanger - one man 24” pipe wrench tight.
4. Drain and wash the BOP down to the tubing spool outlet. If alignment is
necessary, run in one MC guide screw all the way, and back it out a turn.
5. Slack off tubing until the entire weight of the string is resting on the hanger.
Observe it as it lands to check for proper engagement of the tubing hanger
guide slot to the tubing spool MC guide pin.
6. Run in all the lock down pins making sure they go in 3 to 4 turns before
contacting the hanger.
7. Back out the landing joint.
8. Set the BPV through the rotary using a joint(s) of tubing. With the Company
representative’s approval, it may be convenient to set the BPV at the rotary
before hanging off.
9. Nipple down the BOP stack.

12-36
Step 4 Install the Tree
1. Clean off the hanger mandrel, change out the seal ring. Disconnect the
excess control line from the top of the nipple or remove the pipe plug
whichever was used. Fill the tubing spool bowl with the test medium (oil).
2. Thoroughly clean the tubing bonnet and pick up the tree in as straight a
position as possible. Install all the studs into the tubing bonnet with a nut on
the top end only. Install the weather seal onto the studs.
Step 5.Nipple Up the Tree
1. Stab the tree onto the tubing hanger carefully. Make up the studs fully.
Alternate from one side of the flange to the next to pull the bonnet down
straight.
2. Remove the BPV and install a solid test plug or two way check.
3. With all the valves in the open position, and the tubing bonnet test port
open, pressure test the tree to full working pressure, or the rated pressure
of the solid test plug which ever is less.
4. Leaving test pressure on the tree, attach a test pump to the tubing bonnet
test port, and test between the bonnet, hanger, and tubing spool to full
working pressure of the connection.
5. Bleed all pressure from the test port and tree. Reinstall the port plugs.
6. Remove the two way check or test plug. Reset the BPV if required.
7. Shut in the tree as required by the operator.

April 2003 12-37

 Crossover sub from
tubing to EUE 8rd

EUE 8rd by Polish

Rod Hex Adapter

Back Pressure
Valve

Back Pressure Valve

BPV installed in tubing hanger bore for well control prior to BOP nipple down

12-38
 Install the tree and pressure test

April 2003 12-39

Step 1 Check the Equipment
Equipment to be carried by Vetco Gray Service Technician:
2 Appropriate sized BPVs
1 Correct BPV adapter and stinger
1 Tubing hanger BOP test plug and adapter (this must be either EUE 8rd or
MCA threads depending on the tubing hanger landing threads)
3 36” Polish Rod extensions
1 EUE 8rd box x polish rod adapter
1 EUE 8rd pin x (whatever the pipe thread being used box) landing sub. If the
hanger has MCA landing threads an addition landing sub back to tubing
thread is needed.
1 Full bore subs if the landing subs are not full bore.
1 Plugging tool with adapter to tree connection (if required)
1 Spare ring gasket for bonnet to tubing head connection.
1 If hanger has control line nipple, a 1/8” NPT pipe ;plug is necessary to plug
the control line nipple for BOP tests.
Step 2 Verify the Equipment
1. Make sure the correct BOP to tubing head adapter is present.
2. Verify that the correct BPV and lift subs for the tubing in the hole are
present.
Step 3 Nippling Down The Tree
1. After the well has been killed, set a BPV in the tubing hanger by direct
method.
2. Open the tubing bonnet test port to bleed off any trapped pressure. A test
port bleeder tool should be used for this operation.
3. Nipple down the tree and set it aside out of the way.
4. Screw the BOP test plug into the tubing hanger landing threads over top the
BPV. Do not torque this connection more than one man with a 18" pipe
wrench tight. Use an anti-galling thread lubricant on the landing threads. If a
control line nipple is present the 1/8" pipe plug must be used to plug the top
of the nipple.
5. Install a new ring gasket on the tubing spool.
6. Nipple up the BOP stack.

Step 4 Testing the BOP Stack

1. Once the BOP is fully made up the blind rams must be tested first.

12-40
 2. Upon successfully testing the blind rams, use a stand of tubing, the 8rd x
polish rod hex adapter, and the BOP test plug adapter, to retrieve the BOP
test plug through the BOP. Be sure to make up any crossover subs and the
8rd x hex adapter significantly tighter than the BOP test plug is made up into
the hanger. This will prevent backing off the adapter connections
inadvertently as the BOP test plug is backed off.
3. Make up the tubing stand to the top of the hanger, and complete the BOP
tests. Under no circumstances should BOP tests be conducted with the
tubing tied into the BOP test plug with the 8rd x hex adapter. The polish rod
hex connection will fail and the tubing will be blown out of the BOP. Some
BOP Test Plugs have a left hand EUE 8rd running and retrieval thread
instead of the 6 stub acme. In this case the running and retrieving tool is an
EUE 8rd collar with one side left hand and the other right hand. This type of
BOP Test Plug can be left in place during pipe rams tests.
Step 5 Pulling The Tubing Hanger
1. Using the tubing stand, the 8rd x hex adapter and a BPV adapter retrieve
the BPV through the BOP stack. Beware of pressure build up below the
BPV. Excessive torque required to make up on the BPV is an indication of
pressure below it. Be sure to count the turns as the BPV adapter is made up
to the plug so as to be sure when the plug has been fully opened. If pressure
has built up below the BPV under no circumstances release the plug. Either
bleed it down to 0, or pump through it to re-kill the well.
2. Make the tubing stand up to the tubing hanger once more.
3. Loosen the tubing spool lock down screw gland nuts slightly, and back out
all the lock down screws. Measure the distance they are backed out to
insure they are fully retracted. Also back out any MC guide screws which
are run in. Then re-tighten all the lock down screw glands once more.
4. Pull the tubing hanger to the rig floor
5. Remove the hanger from the tubing. Be sure not to damage any seal areas
on the hanger. If a control line is present it must be cut below the hanger to
remove it. If the hanger is not being sent in for repair it

April 2003 12-41

Running Procedure For Slick Joint Single Completions
Step 1 Check the Equipment
Equipment to be carried by Vetco Gray Service Technician:
2 Appropriate sized BPVs
1 Correct BPV adapter and stinger
1 Solid test plug with adapter
3 36” Polish rod extensions
1 EUE 8rd box x polish rod adapter
1 EUE 8rd pin x (whatever the particular pipe thread bring used
2 Appropriate sized BPV’s
1 Correct BPV adapter and stinger
1 Solid test plug with adapter
3 36” Polish rod extensions
1 EUE 8rd box x polish rod adapter
1 EUE 8rd pin x (whatever the particular pipe thread being used; box) landing
sub. If the plug bushing has no internal landing thread an outside landing
device is required.
1 Plugging tool with adapter to tree connection (if required)
1 EUE 8rd box x (the particular connection)
1 Gland wrench
1 Support coupling
1 Plug bushing seal ring
1 Set of hanger packoff seals for the type hanger being run
1 If a flush type plug bushing is being run, a spanner wrench and an outside
landing device for the plug bushing will also be necessary.
Equipment to be on location:
1 Seal ring for the appropriate flange or connection
1 Plug bushing threaded on bottom to match the appropriate pipe
1 Set of studs and nuts for the appropriate flange (w/weather seal)
1 Slick joint hanger packoff
1 Christmas tree
1 Double pin sub of the appropriate threads (if necessary)

12-42
Step 2 Verify the Equipment
1. Make sure the flange on the tubing bonnet corresponds to the flange at the
top of the tubing spool. Use the ring gasket to gauge the tubing bonnet
bottom connection.

Landing the FC Slick Joint Tubing Hanger Assembly

April 2003 12-43

Landing the FC Slick Joint Tubing Hanger Assembly
1. Check to see that there is a plug bushing seal ring in the tubing bonnet.
Make up the plug bushing to the bonnet carefully using thread lubricant to
insure the threads are viable. Make the plug bushing loosely up onto a joint
of tubing in the pipe rack to check the bottom threads.
2. Drift the tree with the proper BPV.
3. If using a landing sub make it up on a joint of tubing to check the threads.
Use a thread lubricant.
4. Rabbit the plug bushing and any sub to be used.
5. Make sure the hanger packoff is the correct one for the tubing being run. If
possible it is a good idea to prepare a slick joint and install the hanger
packoff, plug bushing and support coupling on the pipe rack while the
tubing is being run.
6. Make sure that all the lock down screws and MC guide screws on the tubing
spool are fully retracted.
Step 3 Hanging Off
1. After the tubing has been run, tested and spaced out, it will be necessary to
have a pin up on the last joint of tubing. This may be done either by backing
off a collar or by inverting the last joint by means of a double pin sub. The
hanger packoff and plug bushing should be placed on this joint if it has not
already been done.
2. Make up the plug bushing onto the top of this joint (test if necessary) and
install the support coupling between the hanger and plug bushing.
3. Make up the landing joint (If a crossover landing sub is used be sure to
torque it onto the landing joint to full rated torque for the tubing threads so it
will not inadvertently back off of the landing joint). Torque the landing joint
into the plug bushing - one man 24” pipe wrench tight.
4. Drain and wash the BOP down to the tubing spool outlet.
5. Slack off tubing until the entire weight of the string is resting on the hanger.
6. Run in all the lock down pins making sure they go in 3 to 4 turns before
contacting the hanger.
7. Back out the landing joint.
8. Set the BPV through the rotary with a joint of tubing. With the Company
representative’s approval, it may be convenient to set the BPV at the rotary
before hanging off.
9. Nipple down the BOP stack.

12-44
 Set the BPV for Well Control

April 2003 12-45

Set the BPV for well control
Step 4 Install the Tree
1. Clean off the plug bushing, change out the seal ring.
2. Thoroughly clean the tubing bonnet and pick up the tree in as straight a
position as possible. Install all the studs into the tubing bonnet with a nut on
the top end only. Install the weather seal onto the studs.
3. Count the rounds on the plug bushing to determine how much to make the
tree up onto the plug bushing.
4. Then, lower the tree very carefully onto the plug bushing. Holding a back-up
on the plug bushing, make up the tree to the right by hand, very carefully. If
you encounter drag on the threads, do not try to force the tree to make up.
5. When the tree bumps up at the proper number of rounds, it should be
cheated an additional ¼ round.
Step 5 Nipple Up the Tree
1. Install pick-up hub onto top of tree, if necessary, and screw in joint of tubing.
Pick up the tree. (At this point, the tubing may be displaced.)
2. Remove support coupling. At this point if it is a CBHW hanger the gland nut
should be tightened one last time.
3. Lower tree into position.
4. Tighten studs and nuts on flange or connection.

Step 6 Test the Tree

1. Pull the BPV and install the solid test plug in the plug bushing.
2. Test the tree with rig pumps or a testing unit. (The plug bushing may be
installed, plug set, and tree tested prior to nipple-up.)
NOTE: Certain pipe threads prohibit landing threads in the plug bushing and the
completion is accomplished through the use of an outside landing device.

12-46
 Nipple down the BOP

April 2003 12-47

 Tree threaded onto Plug Bushing and pressure tested

12-48
 Tubing made up to tree top connection- support couple in removed

April 2003 12-49

Single Well Reentry Operations Procedure With Slick Joint Hanger
Step 1 Check the Equipment
Equipment to be carried by Vetco Gray Service Technician:
1 Correct BPV adapter and stinger
1 Tubing hanger BOP text plug and adapter (this must be either EUE 8rd or
MCA threads depending on the tubing hanger landing threads)
3 36” Polish rod extensions
1 EUE 8rd box x polish rod adapter
1 EUE 8rd pin x (whatever the pipe thread being used box) landing sub. IF the
plug bushing does not have integral landing threads an outside landing
device back to tubing thread is needed.
1 Plugging tool with adapter to tree connection (if required)
1 Spare ring gasket for bonnet to tubing head connection
1 For HW and CBHW hangers the correct support coupling will be necessary.
1 For HW and CBHW hangers a gland wrench will be necessary.
1 For flush type plug bushings a spanner wrench to back the tree off will be
needed.
1 If the tree does not have one already, a treetop adapter back to tubing
thread is needed.
If the hanger is an HW or CBHW some Tefseal 104 will be necessary to
pack around the top of the chevron packing to aid the BOP test. Tests
against this style hanger should not exceed 5,000 psi.
1 For flush type plug bushings a spanner wrench to back the tree off will be
needed.
1 If the hanger is the HW type a plug bushing will have to be carried.

Step 2 Verify the Equipment

1. Make sure the correct BOP to tubing head adapter is present.
2. Verify that the correct BPV and lift subs for the tubing in the hole are
present.
Step 3 Nippling Down The Tree
1. After the well has been killed, set a BPV in the tubing hanger by direct
method.
2. Open the tubing bonnet test port to bleed off any trapped pressure. A test
port bleeder tool should be used for this operation.
3. Nipple down the tree and set it aside out of the way.
4. Screw the BOP test plug into the tubing hanger landing threads over top the
BPV. Do not torque this connection more than one man with a 18" pipe
wrench tight. Use an anti-galling thread lubricant on the landing threads.

12-50
 5. Install a new ring gasket on the tubing spool.
6. Nipple up the BOP stack.

STEP 4 Testing the BOP Stack

1. Once the BOP is fully made up the blind rams must be tested first.
2. Upon successfully testing the blind rams, use a stand of tubing, the 8rd x
polish rod hex adapter, and the BOP test plug adapter, to retrieve the BOP
test plug through the BOP. Be sure to make up any crossover subs and the
8rd x hex adapter significantly tighter than the BOP test plug is made up into
the hanger. This will prevent backing off the adapter connections
inadvertently as the BOP test plug is backed off.
3. Make up the tubing stand to the top of the hanger, and complete the BOP
tests. Under no circumstances should BOP tests be conducted with the
tubing tied into the BOP test plug with the 8rd x hex adapter. The polish rod
hex connection will fail and the tubing will be blown out of the BOP.
Step 5 Pulling The Tubing Hanger
1. Using the tubing stand, the 8rd x hex adapter and a BPV adapter retrieve
the BPV through the BOP stack. Beware of pressure build up below the
BPV. Excessive torque required to make up on the BPV is an indication of
pressure below it. Be sure to count the turns as the BPV adapter is made up
to the plug so as to be sure when the plug has been fully opened. If pressure
has built up below the BPV under no circumstances release the plug. Either
bleed it down to 0, or pump through it to re-kill the well.
2. Make the tubing stand up to the tubing hanger once more.
3. Loosen the tubing spool set screw gland nuts slightly and back out all the
set screws. Measure the distance they are backed out to insure they are
fully retracted. Also back out any MC guide screws which are run in. Then
re-tighten all the set screw glands once more.
4. Pull the tubing hanger to the rig floor
5. Remove the hanger from the tubing. Be sure not to damage any seal areas
on the hanger.

April 2003 12-51

This page left blank
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 13
Dual Completions
This page left blank
 A dual completion is one in which two
individual tubing strings are run into one
wellbore to control production from two
different pay zones without allowing any
pressure communication or commingling of
fluids. This same concept is also used for a
“parallel single” completion in which two
strings of tubing are run in the wellbore but
only one pay zone is to be produced. The
“parallel” string will be used as a kill string or to
circulate a special production fluid while the
well is on line. The equipment used at the
wellhead for either of these types of
completions will be the same.
The differences in the wellhead system
between a single and a dual completion
include:
• A tubing spool with Multi-completion
(MC) guide screws to align the dual
strings in the wellbore.
• A dual tubing hanger which suspends
two production tubing strings and seals the annuluses.
• A dual tree with independent flow bores isolated from one another.

Dual Tubing Hangers

Parent Hanger-Mandrel Style Dual Tubing Hanger
The earliest types of dual tubing hangers were very simple “iron donut” designs with
two ports machined through them rather than one port. At Vetco Gray, the first dual
tubing hangers were the Type D hangers. The principal components of this type of
dual tubing hanger is the parent hanger, and the individual tubing hanger mandrels
for supporting each tubing string. Even though this design was introduced in the
mid-1950’s, it is important to note that all of the seals are metal to metal. The
annular seal on the outside diameter of the parent hanger and those on the outside
diameter of each mandrel are interference fit metal to metal seals. The upper seals
on the extended necks of the hanger mandrels are the Metal-Flex metal to metal
seals.
The parent hanger-mandrel design has proven to be a reliable and efficient design
for many years. This principal advantage of this design is the availability of full metal
to metal sealing. However, the lack of wellbore clearance after the parent hanger is
installed with the first or long tubing string, severely limits the application of this
design. This quickly became apparent during the 1960’s when widespread need
developed for equipment compatible with gas lift mandrels. Some parent
hanger-mandrel designs were developed for gas lift applications. These include the
EDG (eccentric dual gaslift) and the WDG version for tubing heads.

April 2003 13-1

FTC-60 Tubing Hanger
The FTC-60 tubing hanger is a split hanger with integral packoff which allows
selective and independent running and pulling of tubing strings. Once both strings
are landed in the tubing head, the annular packoff seal is activated by the lockdown
screws. No plastic injection nor addition of other packoff element is requrired to
produce the annular seal.
The FTC-60 is supplied with preparation to receive a back pressure valve, and it is
available with a downhole line.

Tubing Bonnet

Dual Tubing Hangers

13-2
D-15 Dual Tubing Hangers
The D-15 Dual Tubing Hanger is designed for
wells with a rated working pressure of 15,000
psi This same design is also available as a
D-20 for 20,000 psi completions. The D-15 is
a parent hanger design based on the “D” style
completions, and features individual tubing
hanger mandrels which land and seal in the
dual ported parent hanger. This design
features controlled interference metal to
metal seals on all annular sealing areas.
Each hanger mandrel also utilizes the
Metal-Flex metal seal on the extended neck
which seals into the tubing bonnet.
D-15 Dual hangers also feature the MCA
landing thread, a back pressure valve profile
and the option of one or more control lines.
Note that the outside profile of the D-15
parent hanger changes with the bowl size
from 7-1/16" to 9" and larger just like the D-15
single hangers. 8-5/8 x 2-3/8” x 2-3/8”
D15 Dual Tubing Hanger
It should be noted that the parent
hanger/mandrel hanger design cannot be
API monogrammed. The parent hanger is the only part of the hanger which is
locked down by the tubing spool lock down screws. Since each individual hanger
mandrel which support the tubing strings is not locked down independent of any
subsequently installed component, it does not meet the API Specification 6A tubing
hanger lock down requirements. For this reason this design is rarely used.

Segmented Dual Tubing Hanger Design

To facilitate the completion of wells requiring gas lift, particularly those using “side
pocket” design gas lift mandrels, the tubing hangers were eventually re-designed.
The clearances required by the various gas lift mandrels mandated the removal of
much of the material from the center of the parent hanger. This resulted in the
parent hanger having a reduced load capacity when combined with the taper-only
designs of the current “A” style tubing heads. As tubing spool bowl designs evolved
a different dual tubing hanger design evolved. Initially a matching 90o load shoulder
was added to the re-designed parent hanger and it was then identified as a support
ring. The support ring carries the weight of the tubing strings but does not provide
any seals. At this time an alignment pin was also added to the tubing head to assist
in the orientation of the support ring and tubing hanger assembly. This new type of
dual completion was called an AD(Alignment Dual) and the gas lift version was
called the ADG. The tubing heads produced for these dual completions were also
called Type AD tubing heads. In fact, the AD tubing spool bowl is essentially the
same as the CWC tubing spool bowl and is identified specifically by its one
alignment pin.
This new design required a separate method of sealing the tubing annulus. This
was accomplished with the introduction of the seal assembly. This separate seal
assembly is one of the primary characteristics of most segmented hanger designs
and is an important feature in the installation of these types of completions. There

April 2003 13-3

are many different types of seal assemblies
which have been used. All of them generally fall
into two categories except for some special
applications. The majority of seal assemblies
consist of two steel plates compressing a
rubber-type seal element when the tubing head
lock down screws are tightened. Some early seal
assemblies were made with O-ring seals.
The segmented hanger design was widely
accepted during the 1960’s and it was also
widely modified for many applications. The
single most important identifying feature of these
hangers remains presence of the independent
seal assembly. This design evolved into
CWC-FS or CWC-GS dual completions, and
then to FSCN and GSCN for adaptation to
settings arranged for control lines.
The current style of dual hangers, the CWC,
CWCT, D-15, and Type 45 segmented duals,
have incorporated the support ring and hanger
mandrel into one piece with annular seals
achieved by the extrusion seal element of the
seal assembly. These hangers are available in
sizes to meet any requirement, and control line
arrangements compatible with subsurface CWC-GSCN Dual Tubing Hanger
safety equipment throughout the industry are
available.

CWC-FS Split Segmented Dual Tubing Hangers (7” and 8-5/8” Nominal)
The CWC-FS dual tubing hanger lands and seals in the Type CWC Tubing Spool
top bowl profile for nominal bowl sizes of 7”, 8-5/8”. The annular seal is provided by
a separate seal assembly positioned directly over the segments and energized by
the lock down screws in the tubing spool. Key slots on both sides of each hanger
mandrel engage the MC Guide Screws in the tubing spool to orient the tubing
hanger to the proper position for the installation of the tree.
The top of the extended neck of the CWC dual segments employs the Metal-Flex
seal to form a metal-to-metal seal in the tubing bonnet.
Type H Back Pressure Valve profiles are provided in each hanger mandrel.
If control lines are required the hangers have control line nipples. The letters CN
added to the product description indicate control line nipple arrangement.
(CWC-FSCN, CWC-GSCN, Type 45-FSCN)

13-4
CWCT-FS Dual Tubing Hanger
(10-3/4" and Larger)
The CWCT segmented dual tubing
hanger employs the same support
and seal design found in the CWC
segmented dual tubing hangers,
except that the primary load
shoulder is 45E instead of 90E. The
top of the extended neck seals
metal-to-metal in the tubing bonnet.
This hanger is available in 10-3/4"
and larger sizes for use in CWC
bowls and in CWCT bowls. The
annular seal assembly for the CWC
bowls is the CWC-FS seal
assembly. For the CWCT bowls the
CWCT-FS seal assembly is used.
Dual Segmented Tubing Hanger Seal Assembly
Type 45-FS Dual Tubing Hanger
10-3/4” x 2-7/8”x 2-7/8” CWCT-FS Dual Tubing
The Type 45-FS dual tubing hanger Hanger shown in tubing spool bowl
lands and seals in the Type 45
tubing spool top bowl profile.
Functionally these hangers are the same as the Type CWC and D15 segmented
tubing hangers.

Dual Christmas Trees

Dual Christmas Trees differ from single bore trees in that they require two
independent flow control paths. Dual trees may be of the stacked valve type or they
may be composite design. The stacked tree design utilizes dual valves which
incorporate to valves into one body. These valves must have special end
connections because each bore must seal independently.

Double Tapered Seal

Instead of an API ring gasket, and seal sleeves ABB Vetco Gray uses the Type D
double-tapered seal ring to ensure a reliable,
positive seal between components in the
tree assembly of multiple completions.
The “D” seal employs the “Metal Flex” metal
to metal seal, with the seal occurring close to
the inside diameter of the bore. This reduces
the area subjected to pressure, thus
increasing the pressure rating of the
connection.
The efficiency of this type of seal permits an
overall reduction of the connection size,
reducing the size and cost of multiple bore Type D Dual end connections
stacked Christmas trees.
with Double Tapered Seal Ring

April 2003 13-5

Dual Tubing Bonnets
The Dual Tubing Bonnet or tubing head adapter
serves the same purpose as the single
completion tubing bonnet. The principal
difference is that two ports are required, one for
each string of tubing, and the top connection will
adapt to a dual flange or clamp hub top
connection. Dual bonnets will use the Type D
double tapered seal pockets as a connection
seal. Flanged dual bonnets are usually furnished
with Type D seal pockets but can be supplied
with API ring joint profiles and API seal rings.
Refer to the API 6A, latest edition for complete
information on the proper selection of dual flange
sizes and seal ring information.

Dual Treetop Connections.

Type FD Tubing Bonnet
There are essentially two types of standard dual
treetop connections used by Vetco Gray. There is
a bull plug style using Acme threads with either a seal ring or a taper on the bottom
of the bull plug as a sealing mechanism. This type is
used for trees rated up to 10,000 psi . The
nomenclature for these connections is as follows
• For 2 1/16" bore trees to connection is 2 7/8"
Type A
• For 2 9/16" bore trees the connection is 3"
Type B
• For 3 1/8" bore trees the connection is 4"
Type A
The other style
treetop connection
for trees rated Dual Top Flange with Acme
10,000 and 15,000 threaded bull plugs
is the D-5 flange
connection. These
are dual five bolt segmented flanges which contain
a tapered bottom connection or use a double
tapered seal ring as the connection seal.
Dual Top Flange with D-5 top connections
These connections are available for 2 1/16" and 2
9/16" 10,000 and 15,000 psi rated trees. The bolt
size and pattern differs from 10,000 to 15,000 psi
rated service pressure.

Dual top flange with D-5 top

connections

13-6
GENERAL RUNNING PROCEDURES

April 2003 13-7

Dual Completion Procedure With Parent Hanger and Mandrels
Step 1 Check the Equipment
Equipment to be carried by Vetco Gray Service Technician:
3 Appropriate BPVs
2 Correct BPV adapters and stingers
2 Solid test plugs with adapter or two way checks
4 36" Polish rod extensions
1 1EUE 8rd box x polish rod adapter
1 ½" NPT pin x polish rod hex adapter
2 EUE 8rd pin x (whatever the particular pipe thread being used; box)landing
sub. If hanger has MCA landing threads two additional landing subs back to
tubing thread are needed.
2 Full bore subs if the landing subs are not full bore.
1 Tubing hanger protector, if strings are to be run consecutively
1 Plugging tool with adapter to tree connection (if required)
1 Spare ring gasket for bonnet to tubing head connection
1 Spare tubing hanger annular seal

Equipment to be on location:
1 Seal ring for the appropriate flange or connection
2 Tubing hanger mandrels threaded back to the tubing thread, and a parent
hanger
1 Set of studs and nuts for the appropriate flange (w/weather seal)
1 Christmas tree
2 Double pin subs of the appropriate threads (if necessary)

Step 2 Verify the Equipment

1. Make sure the flange on the tubing bonnet corresponds to the flange at the
top of the tubing head spool. Use the ring gasket to gauge the tubing bonnet
bottom connection.
2. Inspect the seal pockets of the tubing bonnet. They should be clean and
free of gouges or scars. The test port and control line ports should be free of
debris. Insert the hanger mandrels into the bonnet to check for spacing of
mandrels, proper stand off, and orientation.
3. Drift the tree with the proper BPV.
4. If using landing subs, make them up on a joint of tubing to check the
threads. Use a thread lubricant.

13-8
 5. Rabbit the tubing hanger mandrels and any subs to be used. Be sure all the
tools in the tubing will drift the parent hanger.
6. Make sure the hangers are threaded correctly for the tubing being run.
7. Set a BPV in the hanger mandrels to check the socket
8. Carefully make up the landing subs into the hanger mandrels with the BPV
in place, to check the threads. Use thread lubricant.
9. Make sure that all the lock down screws and MC guide screws on the tubing
head are fully retracted.
Step 3 Hanging Off
Note: The production tubing may be run simultaneously using dual slips and
elevators or it may be run consecutively. The procedure for hanging off
tubing must be adapted to these differing situations. Separate
procedures are described for each method.
Landing The Strings Individually
1. The long string will be run first. After the tubing has been run, tested and
spaced out, it will be necessary to have a pin up on the last joint of tubing.
This may be done either by backing off a collar or by inverting the last joint
using a double pin sub below the last joint. The hanger should be placed on
this joint. Be sure to protect all seal surfaces from damage during handling
of the hanger. Never use a landing joint to torque up the hanger to tubing
connection. Slip the parent hanger over the tubing string allow it to rest on
top of the slips before making up the hanger mandrel.
2. Make up the tubing hanger mandrel to the tubing.
3. Make up the landing joint (If a crossover landing sub is used be sure to
torque it onto the landing joint to full rated torque for the tubing threads so it
will not inadvertently back off of the landing joint). Torque the landing joint
into the hanger - one man 24” pipe wrench tight.
4. Drain and wash the BOP down to the tubing spool outlet. Run in the MC
guide screws all the way, and back them out a turn.
5. Make up the ½" NPT x polish rod hex to the EUE 8rd x polish rod adapter,
and make that up to a joint of tubing. Thread this assembly into the parent
hanger landing threads. Pick up on the tubing and remove the rotary slips.
Using an air hoist or cat line lower the parent hanger into the tubing spool
bowl making sure the guide slots of the hanger engage the MC guide
screws of the tubing spool. Run in some lock down screws to verify that it is
in position, then back off the landing joint. Slack off tubing until the entire
weight of the string is resting on the hanger.
6. Run in all the tubing spool lock down screws making sure they go in 3 to 4
turns before contacting the hanger.
7. Back out the landing joint.
8. Set the BPV through the rotary with a joint of tubing. With the Company
representative’s approval, it may be convenient to set the BPV at the rotary
before hanging off.
9. Install the tubing hanger protector.

April 2003 13-9

 10. Run the short string.
11. Make up the short string hanger mandrel to the last joint of tubing. Make up
a landing joint to the hanger mandrel using the same procedure as before.
Pick up the tubing and remove the rotary slips. Using a landing joint on an
air hoist or cat line retrieve the hanger protector. Lower the mandrel into the
parent hanger until the full weight of the string is supported.
12. Set a BPV in the short string.
13. Nipple down the Blowout Preventers.

Landing The Strings Simultaneously

1. After the tubing has been run, tested and spaced out, it will be necessary to
have a pin up on the last joints of tubing. This may be done either by backing
off a collar or by inverting the last joints by means of double pin subs. The
hangers should be placed on these joints. Be sure to protect all seal
surfaces from damage during handling of the hangers. Never use a landing
joint to torque up the hanger to tubing connection. The dual slips and
elevators hold the tubing strings too far apart to easily install the parent
hanger. It will be necessary to set the rotary slips so that about 10’ of tubing
extends above the floor to give the flexibility to push them close enough
together to slip the parent hanger over the tubing strings.
2. Make up the tubing hanger mandrels to the tubing.
3, Make up the landing joints (If crossover landing subs are used be sure to
torque them onto the landing joint to full rated torque for the tubing threads
so one will not inadvertently back off of the landing joint). Torque the landing
joints into the hanger - one man 24” pipe wrench tight.
4. Drain and wash the BOP down to the tubing spool outlet. Run in the MC
guide screws all the way and back out a turn.
5. Make up the ½" NPT x polish rod hex to the EUE 8rd x polish rod adapter
and make that up to a joint of tubing. Thread this assembly into the parent
hanger landing threads. A service tool can be made which will suspend the
parent hanger from the two hanger mandrels. Using this tool is the best
method to land this type hanger as a unit. Otherwise it must be landed with a
separate landing joint. Pick up on the tubing and remove the rotary slips.
Using an air hoist or cat line lower the parent hanger into the tubing spool
bowl making sure the guide slots engage the MC guide screws of the tubing
spool. Run in some lock down screws to verify that it is in position. They
should make up 3 to 4 turns. Slack off tubing until the entire weight of the
string is resting on the hanger.
6. Run in all the hold-down screws making sure they go in 3 to 4 turns before
contacting the hanger.
7. Back out the landing joints.
8. Set the BPVs through the rotary with a joint of tubing. With the Company
representative’s approval, it may be convenient to set the BPV at the rotary
before hanging off.

13-10
Step 4 Install the Tree
1. Clean off the hanger mandrels, change out the seal ring. remove the
hanger protector. Fill the tubing spool bowl with the test medium. (oil)
2. Thoroughly clean the tubing bonnet and pick up the tree in as straight a
position as possible. Install all the studs into the tubing bonnet with a nut on
the top end only. Install the weather seal onto the studs.
Step 5 Nipple Up the Tree
1. Stab the tree onto the tubing hanger carefully. Make up the studs fully.
Alternate from one side of the flange to the next to pull the bonnet down
straight. Be sure the side of the tree with the lower valves in the dual valve
blocks is placed over the long string of tubing.
2. Remove the BPVs and install solid test plugs or two way checks.
3. With all the valves in the open position pressure test the tree to full working
pressure, or the rated pressure of the solid test plugs which ever is less.
4. Leaving test pressure on the tree, attach a test pump the bonnet test port
and test the void between the bonnet, hanger, and tubing spool to full
working pressure of the connection.
5. Bleed all pressure from the test port and tree. Reinstall the port plugs.
6. Remove the two way check or test plug. Reset the BPV if required.
7. Shut in the tree as required by the operator.

Dual Decompletion Procedure With Parent Hanger And Mandrels

Step 1 Check the Equipment
Equipment to be carried by Vetco Gray Service Technician:
3 Appropriate BPVs
2 Correct BPV adapters and stingers
2 Tubing hanger BOP test plug and adapter (this must be either EUE 8rd or
MCA threads depending on the tubing hanger landing threads)
4 36" Polish rod extensions
1 EUE 8rd box x polish rod adapter
1 ½" NPT pin x polish rod hex adapter
2 EUE 8rd pin x (whatever the particular pipe thread being used; box)landing
sub. If hanger has MCA landing threads two additional landing subs back to
tubing thread are needed.
2 Full bore subs if the landing subs are not full bore
1 Plugging tool with adapter to tree connection (if required)
1 Spare ring gasket for bonnet to tubing head connection

April 2003 13-11

 1 Spare tubing hanger annular seal
2 If hanger has control line nipples, two 1/8” NPT pipe plugs are necessary to
plug the control line nipples for BOP tests.
Step 2- Verify the Equipment
1. Make sure the correct BOP to tubing head adapter is present.
2. Verify that the correct BPVs and lift subs for the tubing in the hole are
present. Include wireline subs if the landing subs are not full bore.
3. Make a written note as to which side of the hanger is the long string and
which is the short string.
4. Verify that all the tools in the short string will drift the parent hanger. If not
dual slips and elevators will be needed to pull the tubing, so the parent
hanger can be pulled with the first joints of tubing.
Step 3 - Nippling Down The Tree
1. After the well has been killed, set BPVs in the tubing hanger by direct
method.
2. Open the tubing bonnet test port to bleed off any trapped pressure. A test
port bleeder tool should be used for this operation.
3. Nipple down the tree and set it aside out of the way.
4. Screw the BOP test plugs into the tubing hanger landing threads over top
the BPVs. Do not torque this connection more than one man with a 18" pipe
wrench tight. Use an anti-galling thread lubricant on the landing threads. If a
control line nipples are present the 1/8" pipe plugs must be used to plug the
top of the nipples. If there is a lot of elevation from the wellhead to the rig
floor it is good to place a sub under the short string BOP test plug so it will
stand up higher than the long string test plug. This will make it possible to
tell which plug one is latched onto. It is sometimes difficult to determine
which side of the hanger the landing joint is stabbed into, as after the BOP
test, the stack will be full of fluid with no safe way to drain it. If this is done be
sure to tighten the connection between the sub and the test plug to a greater
torque than it is made up into the hanger.
5. Install a new ring gasket on the tubing spool.
6. Nipple up the BOP stack.

Step 4 - Testing the BOP Stack

1. Once the BOP is fully made up the blind rams must be tested first.
2. Upon successfully testing the blind rams, use a stand of tubing, the 8rd x
polish rod hex adapter, and the BOP test plug adapter, to retrieve the BOP
test plugs through the BOP. Be sure to make up any crossover subs and the
8rd x hex adapter significantly tighter than the BOP test plug is made up into
the hanger. This will prevent backing off the adapter connections
inadvertently as the BOP test plug is backed off. It is sometimes difficult to
determine which side of the hanger the landing joint is stabbed into as after
the BOP test the stack will be full of fluid with no safe way to drain it.

13-12
 3. Make up the tubing stand to the top of the hanger, and complete the BOP
tests. Under no circumstances should BOP tests be conducted with the
tubing tied into the BOP test plug with the 8rd x hex adapter. The polish rod
hex connection will fail and the tubing will be blown out of the BOP.
Step 5 - Pulling The Tubing Hanger
1. Using the tubing stand, the 8rd x hex adapter and a BPV adapter retrieve
the short string BPV through the BOP stack. Beware of pressure build up
below the BPV. Excessive torque required to make up on the BPV is an
indication of pressure below it. Be sure to count the turns as the BPV
adapter is made up to the plug so as to be sure when the plug has been fully
opened. If pressure has built up below the BPV under no circumstances
release the plug. Either bleed it down to 0, or pump through it to re-kill the
well.
2. Make the tubing stand up to the tubing hanger once more.
3. Loosen the tubing spool set screw gland nuts slightly and back out all the
set screws. Measure the distance they are backed out to insure they are
fully retracted. Also back out any MC guide screws which are run in. Then
retighten all the set screw glands once more.
4. Pull the short string tubing hanger to the rig floor. If pulling both strings at
once the parent hanger must be left in the hole to either ride up with the first
tubing string component which will not drift it, or to be retrieved after the
tubing is out of the hole. The ½" landing threads on the parent hanger do not
have enough capacity to pull the parent hanger as it is usually wedged
tightly in the bowl. A taper tap is the best tool for this purpose, but since it
must tie into one of the parent hanger mandrel bowls the tubing must be
removed to use it.
5. Remove the hanger from the tubing. Be sure not to damage any seal areas
on the hanger. If a control line is present it must be cut below the hanger to
remove it. If the hanger is not being sent in for repair it should be coated with
grease and placed in a safe place.
6. If the tubing strings were not pulled simultaneously, then once the short
string is out of the hole it will be necessary to retrieve the BPV from the long
string and pull that hanger to the floor. Once the long string is out of the hole
the parent hanger can be pulled with a taper tap. If a tool in the long string
will not drift the parent hanger then it can be used to pull the parent hanger
as it is pulled through the wellhead.

April 2003 13-13

Dual Completion Procedure Using Segmented Dual Tubing Hangers
Step 1 - Check the Equipment
Equipment to be carried by Vetco Gray Service Technician:
3 Appropriate BPVs
2 Correct BPV adapters and stingers
2 Solid test plugs with adapter or two way checks
4 36" Polish rod extensions
1 EUE 8rd box x polish rod adapter
1 ½" NPT pin x polish rod hex adapter
2 EUE 8rd pin x (whatever the particular pipe thread being used; box)landing
sub. If hanger has MCA landing threads two additional landing subs back to
tubing thread are needed.
2 Full bore subs if the landing subs are not full bore.
1 Tubing hanger protector, if strings are to be run consecutively
1 Plugging tool with adapter to tree connection (if required)
1 Spare ring gasket for bonnet to tubing head connection
1 Spare tubing hanger annular seal
1 Set of spare ferrules and spacer for control line nipple if required.

Equipment to be on location:
1 Seal ring for the appropriate flange or connection
2 Tubing hanger mandrels threaded back to the tubing thread, and a parent
hanger
1 Set of studs and nuts for the appropriate flange (w/weather seal)
1 Christmas tree
2 Double pin subs of the appropriate threads (if necessary)

Step 2 - Verify the Equipment

1. Make sure the flange on the tubing bonnet corresponds to the flange at the
top of the tubing head spool. Use the ring gasket to gauge the tubing bonnet
bottom connection.
2. Inspect the seal pockets of the tubing bonnet. They should be clean and
free of gouges or scars. The test port and control line ports should be free of
debris. Insert the hanger mandrels into the bonnet to check for spacing of
mandrels, proper stand off, and orientation.
3. Drift the tree with the proper BPV.

13-14
 4. If using a landing subs make them up on a joint of tubing to check the
threads. Use a thread lubricant.
5. Rabbit the tubing hanger segments and any subs to be used. Be sure the
seal assembly fits the hanger segments.
6. Make sure the hangers are threaded correctly for the tubing being run.
7. Set a BPV in the hanger mandrels to check the socket
8. Make sure the control line nipples drift the control line. Be sure all the
necessary Swagelock fittings and spacers are present.
9. Carefully make up the landing sub into the hanger mandrels with the BPV in
place to check the threads. Use thread lubricant.
10. Make sure that all the set screws and MC guide screws on the tubing head
are fully retracted.
Step 3 - Hanging Off
Note: The two production tubing strings may be run simultaneously using
dual slips and elevators or they may be run consecutively. The
procedure for hanging off tubing must be adapted to these differing
situations. Separate procedures will be described for each situation.
Landing The Strings Individually
1. The long string will be run first. After the tubing has been run, tested and
spaced out, it will be necessary to have a pin up on the last joint of tubing.
This may be done either by backing off a collar or by inverting the last joint
by means of a double pin sub. The hanger should be placed on this joint. Be
sure to protect all seal surfaces from damage during handling of the hanger.
Never use a landing joint to torque up the hanger to tubing connection.
2. Make up the tubing hanger segment to the tubing. When it is fully made up
turn the tubing string until the hangers flat side is in line with the two MC
guide screws on the tubing spool. If present the control line nipple must be
installed at this time. Procedure for installing a control line nipple for dual
hangers is the same as for single. However care must be taken not to place
a pipe wrench on the nipple in the area where the seal assembly seals
around the nipple.
3. Make up the landing joint (If a crossover landing sub is used, be sure to
torque it onto the landing joint to full rated torque for the tubing threads so it
will not inadvertently back off of the landing joint). Torque the landing joint
into the hanger - one man 24” pipe wrench tight.
4. Drain and wash the BOP down to the tubing spool outlet. Run in the MC
guide screws all the way, and back out a turn.
5. Land the long string hanger making sure that it is fully behind the two MC
guide screws in the tubing spool. If it is in position there should not be weight
on the MC guide screws and it should be possible to rotate them slightly to
check this.
6. Back out the landing joint.
7. Install BPV in the long string.

April 2003 13-15

 8. Install the hanger protector.
9. Run the short string.
10. Make up and land the short string hanger segment as with the long string.
11. Set a BPV in the short string.
12. Retrieve the hanger protector.
13. Make up the EUE 8rd x hex adapter to a landing joint. Make up the ½" NPT x
hex adapter to the hanger seal assembly, and then to the landing joint with
the hex adapter attached. Using an air hoist or cat line land the seal
assembly through the BOP, stabbing it over the hanger mandrels.
14. Run the tubing spool set screws in making sure they only go in about 3 or 4
turns before they contact the seal assembly. The torque on these pins
effect the seal by extruding the seal rubber on the seal assembly so they
must be torqued up to their full recommended torque. Several rounds of
tightening each screw is usually required as the top plate on the seal
assembly is drawn down a little more with each pass.
15. Nipple down the Blowout Preventers

Landing The Strings Simultaneously

1. After the tubing has been run, tested and spaced out, it will be necessary to
have a pin up on the last joints of tubing. This may be done either by backing
off a collar or by inverting the last joints by means of double pin subs. The
hangers should be placed on these joints. Be sure to protect all seal
surfaces from damage during handling of the hanger. Never use a landing
joint to torque up the hanger to tubing connection. The dual slips and
elevators hold the tubing strings too far apart to easily install the seal
assembly. It will be necessary to set the slips so that 10’ of tubing extends
above the floor to give the flexibility to push them close enough to slip the
seal assembly over the tubing hanger segments.
2. Make up the tubing hanger segments to the tubing. If control lines are used
the control line nipples must be made up and tested at this time.
3. Slip the seal assembly up over the two landing joints then make up the
landing joints to the tubing hanger segments. Lower the seal assembly so it
rests on top of the hanger segments. Use a landing sub with a seal retainer
skirt attached to hold the seal assembly in position on top of the hanger
segments. (If crossover landing subs are used be sure to torque them onto
the landing joint to full rated torque for the tubing threads so it will not
inadvertently back off of the landing joint). Torque the landing joints into the
hanger - one man 24” pipe wrench tight.
4. Drain and wash the BOP down to the tubing spool outlet. Run in the MC
guide screws of the tubing spool all the way, and back out a turn.
5. Pick up the tubing strings and align the hanger so the guide slots are over
the MC guide screws on the tubing spool.
6. Land the hangers and seal assembly simultaneously.

13-16
 7. Run in all the hold-down screws making sure they go in 3 to 4 turns before
contacting the hanger seal assembly. The set screws effect the annular
seal by extruding the seal rubber on the seal assembly so they must be
made up to full recommended torque.
8. Back out the landing joints.
9. Set the BPVs through the rotary with a joint of tubing. With the Company
representative’s approval, it may be convenient to set the BPV at the rotary
before hanging off.
10. Nipple down the BOP.

Step 4 Install the Tree

1. Clean off the hanger mandrels, change out the seal ring. remove the
hanger protector. Fill the tubing spool bowl with the test medium. (oil)
2. Thoroughly clean the tubing bonnet and pick up the tree in as straight a
position as possible. Install all the studs into the tubing bonnet with a nut on
the top end only. Install the weather seal onto the studs.
Step 5 Nipple Up the Tree
1. Stab the tree onto the tubing hanger carefully. Make up the studs fully.
Alternate from one side of the flange to the next to pull the bonnet down
straight. Be sure the side of the tree with the lower valves in the dual valve
blocks is placed over the long string of tubing.
2. Remove the BPVs and install solid test plugs or two way checks.
3. With all the valves in the open position pressure test the tree to full working
pressure, or the rated pressure of the solid test plugs which ever is less.
4. Leaving test pressure on the tree attach a test pump the bonnet test port
and test the void between the bonnet, hanger, and tubing spool to full
working pressure of the connection.
5. Bleed all pressure from the test port and tree. Reinstall the port plugs.
6. Remove the two way check or test plug. Reset the BPV if required.
7. Shut in the tree as required by the operator.

Dual Decompletion Procedure With Segmented Hangers

Step 1.Check the Equipment
Equipment to be carried by the ABB Vetco Gray Service Technician
3 Appropriate BPVs
2 Correct BPV adapters and stingers
2 Tubing hanger BOP test plug and adapter (this must be either EUE 8rd or
MCA threads depending on the tubing hanger landing threads)
4 36" Polish rod extensions
1 EUE 8rd box x polish rod adapter

April 2003 13-17

 1 ½" NPT pin x polish rod hex adapter
2 EUE 8rd pin x (whatever the particular pipe thread being used; box)landing
sub. If hanger has MCA landing threads two additional landing subs back to
tubing thread are needed.
2 Full bore subs if the landing subs are not full bore.
1 Plugging tool with adapter to tree connection (if required)
1 Spare ring gasket for bonnet to tubing head connection
1 Spare tubing hanger annular seal
2 If hanger has control line nipples, two 1/8" NPT pipe plug are necessary to
plug the control line nipples for BOP tests.
Step 2 Verify the Equipment
1. Make sure the correct BOP to tubing head adapter is present.
2. Verify that the correct BPVs and lift subs for the tubing in the hole are
present.
3. Make a written note as to which side of the hanger is the long string and
which is the short string.
Step 3 Nippling Down The Tree
1. After the well has been killed, set BPVs in the tubing hanger by direct
method.
2. Open the tubing bonnet test port to bleed off any trapped pressure. A test
port bleeder tool should be used for this operation.
3. Nipple down the tree and set it aside out of the way.
4. Screw the BOP test plugs into the tubing hanger landing threads over top
the BPVs. Do not torque this connection more than one man with a 18" pipe
wrench tight. Use an anti-galling thread lubricant on the landing threads. If a
control line nipples are present the 1/8" pipe plugs must be used to plug the
top of the nipples. If there is a lot of elevation from the wellhead to the rig
floor it is good to place a sub under the short string BOP test plug so it will
stand up higher than the long string test plug. This will make it possible to
tell which plug one is latched onto. It is sometimes difficult to determine
which side of the hanger the landing joint is stabbed into, as after the BOP
test, the stack will be full of fluid with no safe way to drain it. If this is done be
sure to tighten the connection between the sub and the test plug to a greater
torque than it is made up into the hanger.
5. Install a new ring gasket on the tubing spool.
6. Nipple up the BOP stack.

Step 4 Testing the BOP Stack

1. Once the BOP is fully made up the blind rams must be tested first.

13-18
 2. Upon successfully testing the blind rams, use a stand of tubing, the 8rd x
polish rod hex adapter, and the BOP test plug adapter, to retrieve the BOP
test plugs through the BOP. Be sure to make up any crossover subs and the
8rd x hex adapter significantly tighter than the BOP test plug is made up into
the hanger. This will prevent backing off the adapter connections
inadvertently as the BOP test plug is backed off.
3. Make up the tubing stand to the top of the hanger, and complete the BOP
tests. Under no circumstances should BOP tests be conducted with the
tubing tied into the BOP test plug with the 8rd x hex adapter. The polish rod
hex connection will fail and the tubing will be blown out of the BOP.
Step 5 Pulling The Tubing Hanger
1. Using the tubing stand, the 8rd x hex adapter and a BPV adapter retrieve
the short string BPV through the BOP stack. Beware of pressure build up
below the BPV. Excessive torque required to make up on the BPV is an
indication of pressure below it. Be sure to count the turns as the BPV
adapter is made up to the plug so as to be sure when the plug has been fully
opened. If pressure has built up below the BPV under no circumstances
release the plug. Either bleed it down to 0, or pump through it to re-kill the
well.
2. Make the tubing stand up to the tubing hanger once more.
3. Loosen the tubing spool lock down screw gland nuts slightly, and back out
all the set screws. Measure the distance they are backed out to insure they
are fully retracted. If the tubing will be pulled one string at a time the MC
guide screws must be left extended to hold the other hanger segment in
place as the short string is pulled. Be sure to retighten the set screw glands
once the screws are retracted.
4. Pull the short string tubing hanger to the rig floor. The hanger seal assembly
will ride up on top of this segment.
5. Remove the hanger from the tubing. Be sure not to damage any seal areas
on the hanger. If a control line is present it must be cut below the hanger to
remove it. If the hanger is not being sent in for repair it should be coated with
grease and placed in a safe place.
6. If the tubing strings were not pulled simultaneously, then once the short
string is out of the hole it will be necessary to retrieve the BPV from the long
string and pull that hanger to the floor. Once the long string hanger has
been pulled retract both the MC guide screws in the tubing head.

April 2003 13-19

This page left blank
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 14
Plugging Operations
This page left blank
The function of ABB Vetco Gray Plugging
Systems is to provide a means for positive well
control during all phases of the drilling and
production of a well.
The device used to plug and control the tubing
bore of a well at the tubing hanger is a Tubing
Plug or Back Pressure Valve. The device used
to plug a casing head, casing spool, or tubing
spool outlet is a Valve Removal Plug. These
may be installed and removed directly when
no significant pressure exists; or they may be
installed or removed under pressure using B
Vetco Gray Plugging Tools (Lubricators).
These devices make possible safe exchange
or repair of valves attached to wellhead outlets
or tree without eliminating well pressure by
lengthy and costly kill operations. They also provide well control during certain
stages of completion and decompletion operations, as well as provide an extra level
of safety when the potential exists for damage to the tree or wellhead, such as when
heavy equipment is moved near a live well, or when hot work is done near an
existing well.

Tubing Plugs (Back Pressure Valves)

A tubing plug (back pressure valve) is a one way check valve which is installed into
a specially machined profile in the bore of a tubing hanger or plug bushing. Once
installed it prevents the passage of well fluids or gases through the tubing hanger,
thus securing the tubing bore from leakage to the environment. If necessary it
allows pumping down through the tubing to kill any undesired flow or pressure.
Tubing plugs are installed during completion and decompletion operations to seal
the tubing bore while the BOP is being removed and the christmas tree installed or
vice versa. In this way the unexpected flow of a well is controlled. Tubing plugs are
also used to seal off live wells at the tubing hanger for safety purposes whenever
any possibility exists of damage to the tree such as when heavy equipment is
operating in the vicinity of the well.
Tubing plugs may be set or pulled through a christmas tree with no pressure, by
means of adapting the running tool to extension rods. It may be set or pulled
through a tree under pressure by utilizing a plugging tool which mounts to the top of
the tree and is designed to contain the well pressure during the setting or pulling
operation. Tubing plugs may be set or pulled through a BOP stack by adapting the
running tool to a tubing joint, but only while the well is dead.
Since a tubing plug is designed to contain high pressure it is essential that it be
utilized only by individuals trained in their proper function. The inadvertent release
of a tubing plug under pressure, or the improper installation of a tubing plug leading
to a subsequent blow out could be injurious if not fatal to any one working in the
vicinity, not to mention the potential for fire and damage to property. For this reason
Vetco Gray typically rents tubing plugs rather than selling them, and recommends
that only trained Vetco Gray service technicians install or remove them.

April 2003 14-1

Type H Back Pressure Valves
The Type H back pressure valve is a left hand threaded check valve which screws
into a profile in the inside diameter of the tubing hanger. The Type H BPV has an
elastomeric annular seal with a separate spring loaded seal in the bore of the back
pressure valve to allow pump through if necessary. The bore seal is pressure
energized by well pressure from below. The top of the Type H back pressure valve
features a box running tool thread and two slots for torque transfer. The thread/slot
combination allows installation or retrieval to be accomplished with either a right
hand threaded running tool or with a spring-loaded ST. type adapter. The Type H
back pressure valve has been used extensively throughout the oil and gas industry
and is the standard tubing plug for Vetco Gray completions from 2"-4" nominal. The
Type H BPV is available in a variety of materials to meet standard and non-standard
well conditions.

Ty pe H B PV A da p ter

Type H Type H
Back Pressue Valve Two Way C heck Valve

14-2
Type K FUL-FLO Tubing Plugs
The Vetco Gray Type K Tubing Plug is a unique design “Full Flo” tubing plug with
back pressure valve for large bore completions. The
Type K plug is designed for extreme service
conditions and can be installed either manually or
with a single stroke of the setting tool. The Type K
plug can be set under pressure using the Vetco Gray
Model HO lubricator or plugging tool.
The Type K tubing plug features a compression set
annular seal, a heavy duty dart-style back pressure
check valve, and twin locking dogs which engage the
plug socket profile in the tubing hanger. A special
floating locator ring is also provided to accommodate
possible physical damage to the tubing hanger. Major
parts of the tubing plug assembly are spline locked
together to eliminate any unnecessary adjustment.
During installation, the running tool uses a stinger to
hold the dart in the open position so pressure is
equalized at all times. The Type K plug and running
tool assembly have been designed to eliminate any
unplanned disconnection of the tool from the plug.
When the tubing plug lands in the plug socket, a
shoulder stops the K plug body in position. Further downward movement of the
setting tool forces the locking wedges or “dogs” outward into matching grooves in
the tubing hanger and sets the compression seal. The setting tool is then rotated
clockwise to retract the locking nut into position to secure the wedges in place and
maintain compression on the seal assembly. This rotation also disengages the
locking nut from the running tool J-slot attachment and allows the running tool to be
retrieved. Removal of the Type K plug essentially follows the reverse of the setting
procedure.
The Type K Tubing Plug was originally designed for Mobil’s requirements in the
Arun field and the North Sea and has been extensively field proven under these
operating conditions for many years.

April 2003 14-3

 Type K Tubing Plug with Stinger and Adapter

14-4
Type F Tubing Plug
These plugs mechanically lock into a groove machined into the tubing hanger or
plug bushing by means of a wedge which snaps into the groove and is expanded by
rotation of the plug body which is then drawn up a screw thread in behind the wedge
fingers forcing them out into the
groove of the plug socket. An
adapter running tool and stinger
maintain the check valve within the
plug in the open position until it is
fully locked in place. Further rotation
of the running tool will then back the
adapter off of the plug allowing it to
seal off the tubing bore. A lip seal
backed by an O-ring provides the
seal around the diameter of the plug.
The top of the Type F tubing plug has
a screw with two matching left hand
six pitch acme threads. The plug
adapter for setting the plug makes up
onto the upper thread. The wedge is
made up on the lower thread. When
the plug is snapped into the plug
socket a knurled stop shoulder on
the wedge positions it automatically.
As the adapter is rotated clockwise
the wedge is held stationary by the
friction of the wedge fingers and the
knurled shoulder. The threads of the
screw back up the wedge and draw
the plug body up behind the wedge
fingers expanding them into the plug Type F Tubing Plug with Stinger and Adapter
socket groove.
The Valve Removal Plug
The Valve Removal Plug (VR plug) is a threaded device which may be installed
through an outlet valve on a casing head, casing spool or tubing spool, into a female
thread machined into the outlet. This isolates the outlet valve from well pressure to
facilitate its repair or replacement. Once the valve has been repaired or replaced
the plug is retrieved to allow access to the outlet again.
There are three styles of valve removal plugs made by Vetco Gray.

April 2003 14-5

Valve Reinstallation Nipple and Plug
For casing outlets which are
threaded, the Valve
Reinstallation Nipple and Plug
are available. To remove a
threaded outlet valve with well
control, it is necessary to set
the VR plug in the threaded
nipple which is installed
between the casing outlet and
the valve. This nipple is
threaded with the male outlet
threads on either end. At one
end it is threaded internally
with a right hand acme thread profile for the VR plug. The nipple is threaded into the
casing outlet and the valve is threaded onto it. The Valve Reinstallation Plug has the
male acme thread profile which seals metal to metal in the nipple on its tapered
nose. It has a spring loaded dart type check valve in it to seal off back pressure but
allow pressure equalization with a plug adapter stinger. It also has a VR hex
connection on one end for the VR plug adapter.

Standard Valve Removal Plug

For flanged casing outlets the standard VR plug is used. The outlet is threaded
internally with a right hand sharp tapered
thread to receive the VR plug. The VR
plug has a male thread to match the outlet.
At the other end the plug has the hex
connection for the plug adapter. Internally
the plug has a ball type check valve which
has both a low pressure and high pressure
seat. the low pressure seat is a PEEK
seal. At out 1000 psi the ball check is
pushed through the PEEK seal to seat on
a metal to metal seat.

High Pressure Valve Removal Plug

For casing outlets rated to 15000 psi MSP and over the High Pressure VR thread is
used. This thread is a very long right hand acme thread with a tapered seal at the
end. The HP VR allows for high pressure loads with low torque make up, and
reduced galling potential. The HP VR has the male acme thread profile, the VR hex
connection, and a spring loaded dart type
check valve.

14-6
Plugging Tools
Model 62 Plugging Tools
The Model 62 Plugging tool is a mechanically operated manual device designed to
install and retrieve tubing and valve removal plugs from live wells at high pressure.
The tool is made in varying lengths which correspond to the length of reach the tool
may obtain. Generally the tool lengths used to set and retrieve tubing plugs are 60",
80", and 100" inch. The 100" tool is a 15,000 psi NACE rated tool. The 60", and 80",
may be either NACE or Non-NACE and are rated to 10,000 psi service pressure.

Tool kit for installation or retrieval of a BPV with the Model 62 Plugging tool

April 2003 14-7

The tool lengths that are used to set and retrieve Valve removal plugs are the 16"
and 24".
The Model 62 Plugging tool consists of a high pressure tong stem which rotates
within a stuffing box assembly located at the bottom of the tool. The stuffing box is a
two piece housing made up together with acme threads and a locking ring. The
bottom piece has a B-20 hub and male acme thread. The top piece slips over the
tong stem and rests on a bearing shoulder machined onto the tong stem. It has
female acme threads to make up to the lower piece. Internally the stuffing box
contains a set of chevron packing which seals around the base of the tong stem
which has a shoulder and seal surface for the housing. above the packing is a
bearing retainer which threads into the stuffing box housing on the internal acme
threads. above it is the thrust bearing.
The tong stem houses a screw stem which consists of a cylinder machined with left
hand 6 pitch acme threads internally. Attached to the top of the screw cylinder is a
bearing assembly which passes through a packing head assembly. The bearing
assembly rotates within the packing head thus rotating the screw cylinder. Attached
to the top of the bearing assembly is a crank handle by which the operator manually
rotates the screw stem.
The traveling stem of the tool is a solid rod, threaded its full length with the left hand
acme threads. It passes in and out of the tong stem assembly by threading into and
out of the screw stem as the operator rotates the crank handle. Slots along the
length of the traveling stem slide along keepers in the tong stem and tie them
together so that rotating the tong stem also rotates the traveling stem. The keepers
also act as a positive stop so the traveling stem will not thread out of the tool
inadvertently. There is a polish rod hex at the bottom of the tool for the attachment of
polish rod extensions.
The plugging tool is mounted to the top of a christmas tree or to the end of a casing
valve by means of an adapter which mates with the connection on the tool and with
the treetop connection or the valve connection on the other end.
The combined action of the tool is such that as the operator rotates the crank
handle he extends and retracts the traveling stem of the tool to which is attached
the running tool and plug. When the traveling stem is extended into position to
operate a plug, rotation of the tong stem with a pipe wrench which rotates the
traveling stem with the tools attached. Clockwise rotation of the crank handle
extends the tool at the rate of 1" per 6 turns. Counterclockwise rotation retracts it. If
the tool is mounted vertically on a christmas tree there is a work platform attached
to the tong stem of the tool which allows the operator the work the crank handle.

14-8
The “R” Type Plugging Tools
The R-120 and R-80 plugging tools are 15,000 psi maximum service pressure rated
NACE tools. They are designed to set and retrieve either locking or Threaded type
tubing plugs through most christmas trees without need for polish rod extension.
The tool is hydraulically operated with either a 120 inch or an 80 inch reach. Either
well pressure or a remote pressure source can be used to operate the tool.
The tools consist of a barrel housing and a polish rod and piston assembly. The
barrel cap consisting of a padeye, for handling, and a 9/16 inch autoclave outlet, is
threaded to the top of the plugging tool barrel. At the bottom of the barrel a yoke
assembly is installed with a window allowing access to the polish rod with a
parmalee wrench provides for rotation of the rod to set or release plugs. The bottom
of the yoke assembly has a B-20 connection. The tool comes equipped with a 1/4
inch autoclave manifold mounted on the tool. Pressures in the tool may be
manipulated to operate the travel of the polish rod and piston assembly. All of the
outlets for the pressure control are 9/16" inch autoclave.

R-80 Plugging Tool

April 2003 14-9

Type HO Plugging Tools
The HO plugging tool was designed to set and retrieve the large diameter Type K
tubing plugs.
The HO style plugging tools operate by a closed high pressure hydraulic system. A
hydraulic pump, reservoir, and control manifold are hooked to the plugging tool
barrel to operate a polish rod attached to a piston. The polish rod is graduated, and
passes out of the cylinder through a yoke assembly which seals it off both from the
well pressure side, and from the hydraulic pressure side. In this yoke assembly is a
window which exposes the polish rod so a parmalee wrench may be attached to
rotate the polish rod. The bottom of the polish rod has the spline connection to
attach the Type K plug adapter. The yoke assembly has a connection on the bottom
end for adaptation to a treetop connection. The HO tools in the short versions were
developed for special applications to set and pull valve removal plugs in cramped
areas.

14-10
GENERAL RUNNING PROCEDURES

April 2003 14-11

Running Procedure For Type H Tubing Plugs
Pre-Operational Checklist
1. Thoroughly clean the back pressure valve with solvent.
2. Inspect the outer seal. If it is worn or cut replace it.
3. Inspect the adapter threads in the top of
the plug for damage.
4. Check the plug adapter. Make sure the
polish rod hex connection is in good
condition.
5. Make up the adapter and plug. They
should thread all the way freely.
6. Check the valve. Verify that it is free of
obstructions and the seats are in good
condition.
7. Make sure that the necessary polish rod
extensions are available.
8. If a tubing thread to polish rod adapter is
to be used be sure it will make up onto
the polish rod hex of the plug adapter or
polish rods. Be sure the adapter tubing Type H BPV in tubing hanger
thread is the correct for the tubing, or bore with BPV Adapter
and polish rod made up
that the necessary crossover sub to
adapt it to the tubing is available.

Type H Plug Installation, Direct Method

1. Determine the amount of reach necessary to extend the tubing plug into the
plug socket. Assemble the required amount of polish rod extensions or
tubing joints to accomplish this task. If tubing joints are to be used the tubing
thread by polish rod hex adapter must be made up on the bottom of the
assembly. The torque used to make up this adapter to the tubing should be
considerably greater than that used to make up the plug to the plug adapter
to prevent inadvertently backing off the tubing from the tubing adapter. If
polish rod extensions are to be used it is a good idea to attach a tubing
thread by polish rod hex adapter to the top of the assembly so that the polish
rods can in no way be mistakenly dropped down the tubing.
2. Check to make sure the exact number of turns of the plug adapter
necessary for it to unseat the check valve, and to fully make up on the plug.
3. Make up the proper plug adapter to the tubing plug. Torque this connection
to approximately 50 ft-lbs. Twelve inch pipe wrenches are sufficient for this
purpose.
4. Make up the plug adapter and plug on the bottom of the extension
assembly.
5. Lubricate the tubing plug threads with liquid thread lubricant.

14-12
 6. Insert the tubing plug straight into the plug socket checking to verify that the
amount of travel through the tree or BOP equals the approximate distance
to the plug socket.
7. Make a vertical mark on the extension in order to accurately count the
number of rotations being made.
8. Rotate the extension clockwise until the threads jump and the starting
threads of the plug socket and the plug are aligned.
9. Rotate the plug extension counterclockwise out 5 turns. The extension
should drop slightly as the plug is made up into the plug socket. Once the
plug is made up all the way the torque will increase until the plug adapter
breaks loose from the plug. Once the torque required to overcome the
preloaded torque of the plug adapter and plug is achieved, the extension
should turn freely. Continued counterclockwise rotation will back the
adapter off of the plug in out 12 more turns allowing the valve to seat.
10. Retrieve the extension and plug adapter from the tree or BOP.

CAUTION If at any point in the setting operation the required number of turns
to achieve each step varies by more than a couple of turns
something is wrong. If this occurs the setting operation should be
reversed back to the starting point, the plug retrieved, and the
necessary pre-operational checks repeated until the problem is
found. This is necessary to insure that the plug is being set
properly, and safely.
Type H Plug Removal, Direct Method
CAUTION Removal of the tubing plug by the direct method is extremely
dangerous unless great care is taken. Even if a plug is set with no
pressure, it may build up during the time the plug is set. For this
reason if pulling a plug through a tree it is recommended the a
plugging tool be used.
If pulling a plug through a BOP strict adherence to proper procedure as described in
this procedure is mandatory. If at any point in the procedure normal torque at
inappropriate numbers of turns occurs, the procedure should be reversed, and the
plug adapter and extension recovered. It is then possible to attempt to pump
through the plug to determine what pressure is under it and to rebalance the fluid
column to kill that pressure.
1. Determine the amount of reach necessary to extend the tubing plug
adapter into the plug. Assemble the required amount of polish rod
extensions or tubing joints to accomplish this task. If tubing joints are to be
used the tubing thread by polish rod hex adapter must be made up on the
bottom of the assembly. The torque used to make up this adapter to the
tubing should be considerably greater than that used to make up the plug to
the plug adapter to prevent inadvertently backing off the tubing from the
tubing adapter. If polish rod extensions are to be used it is a good idea to
attach a tubing thread by polish rod hex adapter to the top of the assembly
so that the polish rods can in no way be mistakenly dropped down the
tubing.
2. Make up the plug adapter on the bottom of the extension assembly.

April 2003 14-13

 3. Stab the plug adapter straight into the plug checking to verify that the
amount of travel through the tree or BOP equals the approximate distance
to the plug socket.
4. Rotate the extension clockwise until the starting threads on the plug
adapter and plug jump.
5. Make a vertical mark on the extension in order to accurately count the
number of rotations being made.
6. Rotate the extension clockwise counting the number of rotations being
made. This action threads the tubing plug adapter into the plug. A few turns
before the adapter is fully made up the nose of the adapter will unseat the
check valve in the plug releasing any pressure which may have built up
before the plug is unset. If normal torque develops before the 13 turns to
make up the adapter has been achieved then reverse the procedure and
retrieve the adapter. Check for pressure under the plug. If there is a small
amount of pressure bleeding through the plug do not continue until this
pressure bleeds off. If it does not bleed off rekill the well or use a plugging
tool to pull the plug. Never release a plug which has pressure under it when
using the direct removal technique.
7. If there is no pressure under the plug, place a pipe wrench on the extension
and continue to rotate clockwise still counting the rotations. A distinct
breakfree point should be noticed within one rotation, as the amount of
torque required to overcome the preloaded torque of the plug is achieved.
The extension should turn freely once this sudden break occurs. At this
point the plug is beginning to back out of the plug socket. Within 5 more
rotations the plug should be fully backed out and the threads will jump.
8. Retrieve the extension, plug adapter, and plug from the tree or BOP.

14-14
Running Procedure For The Type K Tubing Plug
There are two methods for setting or retrieving the Type K tubing plug. The direct
method may be used when there is no pressure on the tubing. The plugging tool
method is used when there is pressure on the tubing.
Pre-operational Checklist
1. Check to be sure the precise size of the tubing plug socket
2. Insure that the proper tubing plug, plug adapter, and stinger are being used.
3. Inspect the tubing plug. Be sure all threads are undamaged. Be sure all
seals are in good condition. All threads and moving parts should be
lubricated. The lock nut should be threaded fully into the actuator sleeve.
The actuator sleeve must be fully retracted and the lock down wedges
should also be free to retract into the hold down wedge housing.
4. Be sure the stinger is made up tightly into the tubing plug adapter.
5. Make sure that the necessary extensions are available.
6. If a tubing thread to spline adapter is to be used be sure it will make up onto
the spline connection of the plug adapter. Be sure the adapter tubing thread
is the correct for the tubing, or that the necessary crossover sub to adapt it
to the tubing is available.

Type K Plug Installation, Direct Method

1. Determine the amount of reach necessary to extend the tubing plug into the
plug socket. Assemble the required amount of extensions or tubing joints to
accomplish this task. If tubing joints are to be used the tubing thread by
spline adapter must be made up on the bottom of the assembly. The torque
used to make up this adapter to the tubing should be considerably greater
than that used to make up the plug to the plug adapter to prevent
inadvertently backing off the tubing from the tubing adapter.
2. Make up the proper plug adapter to the tubing plug. The adapter has two
positions: the set position when the reset spring is in the detent groove in
the adapter body, and the unset position when the adapter piston is in the
up position. The adapter must be unset the make up to the plug. It must be
set to install the plug.
3. Rotate the tubing plug lock nut clockwise until it is in contact with the
retainer nut and locking the actuating sleeve in behind the tubing plug
wedges.
4. Slip the plug adapter over the top of the tubing plug inserting the stinger into
the plug bore.
5. Engage the J-slot lugs of the adapter into the J-slots on the tubing plug lock
nut.
6. Rotate the adapter counterclockwise to engage it fully into the J-slots. If the
adapter is not in the unset position it will require approximately 3000 lbs. of
axial force to unset the adapter as the reset spring is forced out of the detent
groove in the adapter body. Continue to rotate counterclockwise until the

April 2003 14-15

 lock nut is fully retracted into the actuator sleeve and the adapter lugs are
locked at the top of the J-slot.
7. Before installing the plug verify that the actuator sleeve is fully retracted and
that the tubing plug wedges are free the retract into the wedge housing.
8. Check the compression on the seal element. To adjust the compression
back out the set screws in the seal retainer nut, tighten the nut hand tight,
and retighten the set screws.
9. Make up the plug adapter and plug on the bottom of the extension
assembly. Remove the retainer nut and reset ring from the adapter and slip
them over the extension adapter. Position the spline nut in the recess of the
adapter body cap. Install the adapter onto the extension adapter. Install the
split ring in the groove in the extension adapter and make up the reset ring
and retainer nut once more. Lock the retainer nut by tightening the set
screw.

10. Insert the tubing plug straight into the plug socket checking to verify that the
amount of travel through the tree or BOP equals the approximate distance
to the plug socket. The locating ring at the top of the plug cage will bottom
out on the plug socket load shoulder.
11. Slide the extension assembly up and down to properly seat the actuator
sleeve behind the tubing plug lockdown wedges, forcing them into the plug
socket groove.
12. Make a vertical mark on the extension in order to accurately count the
number of rotations being made. Rotate the extension clockwise
approximately 8 turns. This action threads the tubing plug lock nut up the
actuator sleeve and against the retainer nut which pulls the body up through
the wedge housing and compresses the seal simultaneously as it is locked
in the socket.
13. Around the eighth rotation there will be a sudden 30 turn of free rotation as
the plug adapter unsets and the lugs drop down in the J-slot.
14. Make an additional half turn clockwise to set the lock nut fully.
15. Retrieve the extension and plug adapter from the tree or BOP by pulling
directly up on the extension assembly.
CAUTION If at any point in the setting operation the required number of turns
to achieve each step varies by more than a couple of turns
something is wrong. If this occurs the setting operation should be
reversed back to the starting point, the plug retrieved, and the
necessary pre-operational checks repeated until the problem is
found. This is necessary to insure that the plug is being set
properly, and safely.
Type K Plug Removal, Direct Method
CAUTION: Removal of the tubing plug by the direct method is extremely
dangerous unless great care is taken. Even if a plug is set with no
pressure, it may build up during the time the plug is set. For this
reason if pulling a plug through a tree it is recommended the a
plugging tool be used.

14-16
If pulling a plug through a BOP strict adherence to proper procedure as described in
this procedure is mandatory. If at any point in the procedure normal torque at
inappropriate numbers of turns occurs, the procedure should be reversed, and the
plug adapter and extension recovered. It is then possible to attempt to pump
through the plug to determine what pressure is under it and to rebalance the fluid
column to kill that pressure.
1. Determine the amount of reach necessary to extend the tubing plug
adapter into the plug. Assemble the required amount of extensions or
tubing joints to accomplish this task. If tubing joints are to be used the tubing
thread by spline connection adapter must be made up on the bottom of the
assembly. The torque used to make up this adapter to the tubing should be
considerably greater than that used to set the lock nut of the tubing plug to
prevent inadvertently backing off the tubing from the tubing adapter.
2. Verify that the plug adapter is in the unset position.
3. Make up the plug adapter on the bottom of the extension assembly.
4. ST. the plug adapter straight into the plug checking to verify that the amount
of travel through the tree or BOP equals the approximate distance to the
plug socket.
5. Rotate the extension clockwise until the plug adapter J-slot lugs drop into
the J-slot grooves in the tubing plug lock nut. Any pressure on the plug will
be released at this point. If the adapter will not engage the J-slots properly
do not release the plug. Rig up a plugging tool to pull the plug. Rotate the
extension further until free rotation ceases. Check to see if the J-slots are
engaged by pulling gently up on the extension to see if it is locked onto the
plug. Never release a plug with pressure below it using the direct method.
6. Make a vertical mark on the extension in order to accurately count the
number of rotations being made.
7. Rotate the extension counterclockwise 8 ½ turns, to a positive stop. This
action threads the tubing plug lock nut down into the plug body trapping the
adapter lugs onto the plug and releasing the plug wedges from the plug
socket.
8. A direct upward pull will now retrieve the extension, plug adapter, and plug
from the tree or BOP.

April 2003 14-17

Running Procedure For The Type F Tubing Plug
There are two methods for setting or retrieving the Type F tubing plug. The direct
method may be used when there is no pressure on the tubing. The plugging tool
method is used when there is pressure on the tubing.
Pre-operational Checklist
1. Check to be sure the precise size of the tubing plug socket
2. Insure that the proper tubing plug, plug adapter, and stinger are being used.
3. Inspect the tubing plug. Be sure all threads are undamaged. Make sure the
wedge is in good condition. The wedge fingers should not be bent and the
knurled stop shoulder should be undamaged. The wedge should thread
freely up and down the
tubing plug screw. The
plug adapter should
likewise make up freely
onto the plug. The
outside diameter seal
should be free of cuts or
holes. Inspect the tubing
plug check valve. The
seat should be
undamaged. The ball or
dart should travel freely
in the tubing plug cage.
4. Be sure the stinger is
made up tightly into the
tubing plug adapter.
5. Make sure that the
necessary polish rod
extensions are available.
6. If a tubing thread to polish
rod adapter is to be used
be sure it will make up
onto the polish rod hex of
Type F Tubing Plug Installed in tubing hanger bore
the plug adapter or polish
rods. Be sure the adapter
tubing thread is the
correct for the tubing, or that the necessary crossover sub to adapt it to the
tubing is available.

14-18
Type F Plug Installation, Direct Method
1. Determine the amount of reach necessary to extend the tubing plug into the
plug socket. Assemble the required amount of polish rod extensions or
tubing joints to accomplish this task. If tubing joints are to be used the tubing
thread by polish rod hex adapter must be made up on the bottom of the
assembly. The torque used to make up this adapter to the tubing should be
considerably greater than that used to make up the plug to the plug adapter
to prevent inadvertently backing off the tubing from the tubing adapter. If
polish rod extensions are to be used it is a good idea to attach a tubing
thread by polish rod hex adapter to the top of the assembly so that the polish
rods can in no way be mistakenly dropped down the tubing.
2. Check to make sure the exact number of turns of the plug adapter
necessary for the stinger to unseat the check valve, and to fully make up on
the plug.
3. Make up the proper plug adapter to the tubing plug. Torque this connection
to approximately 50 ft. lbs. Twelve inch pipe wrenches are sufficient for this
purpose.
4. Make up the plug adapter and plug on the bottom of the extension
assembly.
5. Adjust the plug wedge by threading it up the tubing plug screw thread until
the top of the wedge is out 1/16" from the screw shoulder.
6. Insert the tubing plug straight into the plug socket checking to verify that the
amount of travel through the tree or BOP equals the approximate distance
to the plug socket. The last two inches of travel should meet with some
resistance as the tubing plug wedge fingers snap into the plug socket and
the positive stop on the wedged shoulders up on the plug socket shoulder.
Pull up and reset the plug to feel if the plug is snapping into the plug socket.
7. Make a vertical mark on the extension in order to accurately count the
number of rotations being made.
8. Rotate the extension clockwise counting the number of rotations being
made. This action threads the tubing plug body up through the wedge until
the taper of the body seats behind the wedge fingers forcing them out into
the plug socket groove and locking the plug into the plug socket. At this
point the torque necessary to rotate the extension will begin to increase,
and a pipe wrench will be necessary to continue the rotation. Check the
chart in this procedure for the required number of turns this should take for
the size plug being set.
9. Pipe wrench on the extension and continue to rotate clockwise still counting
the rotations. A distinct breakfree point should be noticed within one
rotation as the amount of torque required to overcome the preloaded torque
between the plug adapter and plug is achieved. The extension should turn
freely once this sudden break occurs. At this point the plug is locked into the
plug socket and the plug adapter is backing off the top of the plug. As the
adapter backs off of the plug it rises up the threads and the stinger allows
the check valve to seat and seal off the tubing bore. Check the chart in this
procedure for the required number of turns to completely back off the plug
for the size tubing plug being set. When the adapter is completely backed
off the plug one should feel the thread starts jump.

April 2003 14-19

 10. Retrieve the extension and plug adapter from the tree or BOP.

CAUTION If at any point in the setting operation the required number of turns
to achieve each step varies by more than a couple of turns
something is wrong. If this occurs the setting operation should be
reversed back to the starting point, the plug retrieved, and the
necessary pre-operational checks repeated until the problem is
found. This is necessary to insure that the plug is being set
properly, and safely.
Type F Plug Removal, Direct Method
CAUTION Removal of the tubing plug by the direct method is extremely
dangerous unless great care is taken. Even if a plug is set with no
pressure, it may build up during the time the plug is set. For this
reason if pulling a plug through a tree it is recommended the a
plugging tool be used.
If pulling a plug through a BOP strict adherence to proper procedure as described in
this procedure is mandatory. If at any point in the procedure normal torque at
inappropriate numbers of turns occurs, the procedure should be reversed, and the
plug adapter and extension recovered. It is then possible to attempt to pump
through the plug to determine what pressure is under it and to rebalance the fluid
column to kill that pressure.
1. Determine the amount of reach necessary to extend the tubing plug
adapter into the plug. Assemble the required amount of polish rod
extensions or tubing joints to accomplish this task. If tubing joints are to be
used the tubing thread by polish rod hex adapter must be made up on the
bottom of the assembly. The torque used to make up this adapter to the
tubing should be considerably greater than that used to make up the plug to
the plug adapter to prevent inadvertently backing off the tubing from the
tubing adapter. If polish rod extensions are to be used it is a good idea to
attach a tubing thread by polish rod hex adapter to the top of the assembly
so that the polish rods can in no way be mistakenly dropped down the
tubing.
2. Check to make sure of the exact number of turns of the plug adapter
necessary for the stinger to unseat the check valve, and to fully make up on
the plug.
3. Make up the plug adapter on the bottom of the extension assembly.
4. Stab the plug adapter straight into the plug checking to verify that the
amount of travel through the tree or BOP equals the approximate distance
to the plug socket.
5. Rotate the extension clockwise until the starting threads on the plug
adapter and plug jump.
6. Make a vertical mark on the extension in order to accurately count the
number of rotations being made.
7. Rotate the extension counterclockwise counting the number of rotations
being made. This action threads the tubing plug adapter onto the plug. A
few turns before the adapter is fully made up the stinger on the adapter will
unseat the check valve in the plug releasing any pressure which may have
built up before the plug is unset. Check the chart for the required number of

14-20
 turns to fully make up the tubing plug.(See caution at the beginning of this
procedure)It is possible that if there is a lot of pressure under the plug the
torque required to unseat the check valve exceeds the torque required to
begin releasing the plug, so it is critical that the correct number of turns are
achieved for each step of the procedure with no normal torque encountered
to prevent releasing the plug with pressure under it and blowing it out of the
hole. If there is a small amount of pressure bleeding through the plug do not
continue until this pressure bleeds off. If it does not bleed off rekill the well or
use a plugging tool to pull the plug. Never release a plug which has
pressure under it when using the direct removal technique.
8. If there is no pressure under the plug, place a pipe wrench on the extension
and continue to rotate counterclockwise still counting the rotations. A
distinct breakfree point should be noticed within one rotation as the amount
of torque required to overcome the preloaded torque between the plug
wedge and plug body is achieved. The extension should turn freely once
this sudden break occurs. At this point the plug is beginning to release from
the plug socket. As it releases the plug screw threads down through the
wedge and the plug body drops out from behind the wedge fingers. Check
the chart in this procedure for the required number of turns to completely
release the plug from the plug socket for the size plug being retrieved.
When the plug is completely unset it is usually possible to feel the wedge
begin to rotate in the plug socket as it shoulders up on the plug screw.
9. Retrieve the extension, plug adapter, and plug from the tree or BOP.

Running Procedure Valve Removal Plugs

Pre-operational Checks
1. Provided the casing outlet has no pressure on it, the VR plugs may be set
directly through the outlet valve. All three style VR plugs are set and
retrieved by the same plug adapter for each size casing outlet.
2. Verify that the VR plug is the correct plug for the outlet into which it will be
set.
3. Verify that the correct VR adapter is available
4. Make sure the adapter polish rod hex will make up on the extension
5. Make sure the VR adapter has a fresh o-ring.
6. Snap the adapter onto the plug, it should hold it securely.

Installation of a Valve Removal Plug, Direct Method

1. Snap the VR adapter onto the VR plug.
2. Attach the VR adapter and plug to a polish rod extension long enough to
reach through the valve.
3. Open outlet valve or valves and bleed all pressure from the casing.
4. Insert the plug into the outlet.
5. Rotate the extension clockwise until the threads snug up.

April 2003 14-21

 6. Place a 24" pipe wrench on the extension and tighten with one man.
7. Retrieve the extension and adapter with a hard tug on at the extension.
8. Valve Removal Plug Retrieval, Direct Method
9. The plug may be retrieved by reversing the above operation, however
extreme caution should be used to insure no pressure has built up behind
the plug while it was installed. If it is impossible to force the VR adapter all
the way onto the plug to equalize pressure, a plugging tool should be used
to retrieve the plug.

Operating The Model 62 Plugging Tool

The Model 62 plugging tool may be used to install and retrieve the Type H tubing
plugs as well as the valve removal plugs, however, the operations vary for each
style plug. For this reason separate running procedures have been written for
setting each style plug with the Model 62 tool.
Pre-operational checks
1. Insure that the plugging tool is rated to an adequate service pressure for the
amount of pressure expected in the well.
2. Verify that the tool has sufficient reach to extend from the tree or casing
valve gate to the plug receptacle.
3. Check that the necessary hub adapter, clamp, and seal rings for the
adapter are available.
4. Make sure that all the mechanical functions of the tool work freely without
excessive torque.
5. Inspect the seal surface for the connection of the tool for damage. There
should be no scratches or gouges.
6. The hub adapter should also be free of damage.
7. The appropriate wrenches to make up the plugging tool connections and to
operate the plugging tool should be available. (36” pipe wrench to rotate the
plugging tool tong stem, 2 12"-18" pipe wrenches, one may be a crescent
wrench, hammer wrenches to fit the treetop flange and B-clamp)
8. An appropriate hoist to install the plugging tool on the tree should be
available.
9. There should be enough clearance above the tree, or next to the wellhead,
to install the plugging tool.
10. Check the plug and plug adapter as specified in their pre-operational
checklist.

Type H Plug Installation, Model 62 Plugging Tool

1. Assemble the hub adapter onto the plugging tool.
2. Measure from the estimated top of the master valve gate to the top of the
treetop. Record this dimension.
3. Measure from the estimated top of the master valve gate to the estimated
location of the tubing plug socket. Record this dimension.

14-22
 4. Measure the length of the tubing plug and plug adapter when they are fully
made up together. Record this dimension.
5. Measure from the bottom of the tubing plug threads to the bottom of the
tubing plug. Record this dimension.
6. Calculate the amount of polish rod extension which may be added to the
plugging tool traveling stem so that the total length of the tubing plug and
adapter plus polish rod extensions will clear the master valve gate when
they are attached to the bottom of the traveling stem, the entire assembly is
stabbed into the tree, and the treetop connection made up. Be aware that if
the traveling stem has been extended beyond the hub adapter it may be
retracted into the adapter. If the traveling stem is left partially extended be
sure that enough reach is left to travel the distance from the starting point to
the plug socket.
7. Assemble this amount of polish rod extension onto the plugging tool
traveling stem. Snug up each polish rod connection with a pipe wrench.
8. Make up the proper plug adapter to the tubing plug. Torque this connection
to approximately 50 ft. lbs. Twelve inch pipe wrenches are sufficient for this
purpose.
9. Make up the plug adapter and plug on the bottom of the extension
assembly.
10. Measure from the bottom of the hub adapter to the bottom of the tubing plug
threads. Record this dimension.
11. Calculate the amount of travel that will be necessary to extend the tubing
plug from the starting point into the plug socket. This distance will be the
total distance from the treetop to the master valve gate plus the distance
from the master valve gate to the plug socket, minus the distance from the
bottom of the hub adapter to the tubing plug threads. (Step 2 + Step 3 - Step
11)
12. Calculate the number of turns of the plugging tool crank handle necessary
to extend the plug from the starting point into the plug socket. The tool will
extend the traveling stem 1" for every six turns of the crank handle. (Step 12
x 6) Record this total.
13. Close the outer wing valve on the tree.
14. Close the master valve.
15. Open all other valves in the run of the tree.
16. Bleed all pressure from the tree.
17. Open the treetop connection.
18. Fill the tree with antifreeze or other appropriate liquid.
19. Assemble the plugging tool, extension rods, tubing plug adapter and plug
onto the top of the tree. Be sure to tighten all polish rod connections with the
12" pipe wrench. Make up flange and clamp studs to the torque specified by
API for that size. Torque up threaded adapters as required for the type of
thread.
20. Close the needle valve on the plugging tool.

April 2003 14-23

 Plugging Tool rigged up on tree with plug extended into plug socket

14-24
 21. Gradually open the master valve.
22. Climb onto the work platform of the plugging tool.
23. Turn the plugging tool crank handle clockwise keeping count of the
rotations.
24. Within approximately 20 turns of the number of turns previously estimated
in Step 12 the plug should bottom out in the plug socket and it will be
impossible to turn the crank handle further.
25. Turn the crank handle back counterclockwise to retract the plug from the
socket counting the number of rotations. (4 or 5 turns is adequate)
26. Reseat the plug making sure the same number of turns is required to
bottom out once more.
27. Holding the crank handle stationary have a helper rotate the tong stem of
the plugging tool counterclockwise. Count the number of rotations. The
crank handle should stay free and not bind up or begin to turn with the tong
stem. As the tong stem is rotated two actions take place simultaneously.
The tubing plug is threading into the plug socket. The traveling stem is
extending because it is rotating clockwise in relation the screw stem and
tong stem. Since the traveling stem thread has a different pitch than the
plug it will be necessary to gradually feed the traveling stem down as the
plug makes up by rotating the crank handle gradually in the clockwise
direction. Keep all functions of the tool operating freely.
28. When approximately 5 turns have been made on the tong stem the plug will
be fully made up in the plug socket. When this takes place the torque
required to turn the tong stem will increase then break free suddenly. This
occurs when the preloaded torque imparted between the plug adapter and
plug is overcome as the plug is tightened into the plug socket.
29. Continue to rotate the tong stem counterclockwise. Now the plug adapter is
backing off of the tubing plug. Since the plug adapter will rise as it backs off
of the plug it is now necessary to reverse the action of the crank handle of
the tool. It will be necessary to gradually rotate the crank handle
counterclockwise at a slightly faster rate than the tong stem is being turned.
This keeps the tool from binding up as the plug adapter rises out of the plug.
30. When the required number of turns to set the plug and be fully released
from it has been achieved stop rotating the tong stem, and attempt to rotate
the crank handle counterclockwise. If the plug adapter is free of the plug it
will be possible to rotate the crank handle freely, if it isn’t the handle will bind
up within a turn. If the plug does not set in the required number of turns Do
not continue to turn the tong stem. Recover the plug and inspect it for
damage. Repeat the setting process. Use a another plug if necessary.
31. Continue to rotate the crank handle counterclockwise out 12 turns.
32. Crack open the needle valve on the plugging tool and bleed all pressure
from the tree to insure that the plug is holding pressure.
33. Rotate the crank handle counterclockwise the same number of total turns
that were used to extend the plug into the socket.
34. Close the master valve.

April 2003 14-25

 35. Rig down the plugging tool.
36. Secure the tree as required by the operator

Type H Tubing Plug Retrieval Plugging Tool Method Model 62 Tool

1. Assemble the treetop adapter onto the plugging tool.
2. Measure from the estimated top of the master valve gate to the top of the
treetop. Record this dimension.
3. Measure from the estimated top of the master valve gate to the estimated
location of the tubing plug socket. Record this dimension. The tubing head
set screws are not a bad guide.
4. Measure the length of the correct size tubing plug and plug adapter when
they are fully made up together. Record this dimension.
5. Measure from the nose of the plug adapter to the stop shoulder at the top of
the retrieval threads. Record this dimension.
6. Calculate the amount of polish rod extension which may be added to the
plugging tool traveling stem so that the total length of the tubing plug and
adapter plus polish rod extensions will clear the master valve gate when
they are attached to the bottom of the traveling stem, the entire assembly is
stabbed into the tree, and the treetop connection made up. Be aware that if
the traveling stem has been extended beyond the hub adapter it may be
retracted into the adapter. If the traveling stem is left partially extended be
sure that enough reach is left to travel the distance from the starting position
to the plug socket.
7. Assemble this amount of polish rod extension plus the appropriate plug
adapter onto the plugging tool traveling stem. Snug up each polish rod
connection with a pipe wrench.
8. Measure from the bottom of the hub adapter on the plugging tool to the
bottom of the plug adapter. Record this dimension. The traveling stem of
the tool must be le to retract far enough that the plug adapter plus the plug
will clear the master valve gate when the tool is mounted on the tree.
9. Calculate the amount of travel that will be necessary to extend the tubing
plug adapter from the starting point onto the top of the plug. This distance
will be the total distance from the treetop to the master valve gate plus the
distance from the master valve gate to the plug socket, minus the distance
from the bottom of the hub adapter on the plugging tool to the bottom of the
tubing plug adapter at the starting position, plus the distance from the nose
of the plug adapter to the stop shoulder of the plug adapter. (Step 2 + Step 3
- Step 9 + Step 5)
10. Calculate the number of turns of the plugging tool crank handle necessary
to extend the plug from the starting point onto the plug. The tool will extend
the traveling stem 1" for every six turns of the crank handle. (Step 10 x 6)
Record this total.
11. Close the outer wing valve on the tree.
12. Close the master valve.
13. Open all other valves in the run of the tree.

14-26
 14. Bleed all pressure from the tree.
15. Open the treetop connection.
16. Fill the tree with antifreeze or other appropriate liquid.
17. Assemble the plugging tool, extension rods, and tubing plug adapter, onto
the top of the tree. Make up flange and clamp studs to the torque specified
by API for that size. Torque up threaded adapters as required for the type of
thread.
18. Close the needle valve on the plugging tool.
19. Gradually open the master valve.
20. Attach a remote pressure source to the wing of the tree or the needle valve
of the plugging tool and pressure up on the tree and lubricator until the
pressure equalizes above and below the plug. When gauge pressure
ceases to rise steadily the pressure is passing through the tubing plug
check valve and pressure is equalized. If this is not feasible the pressure
may be equalized by tagging into the plug but this is a riskier operation as
the tool is extended through all the valves at that point and the only well
control is the plug itself.
21. Climb onto the work platform of the plugging tool.
22. Turn the plugging tool crank handle clockwise keeping count of the
rotations.
23. Within approximately 20 turns of the number of turns previously estimated
in Step 11 the plug adapter should bottom out on top of the plug and it will be
impossible to turn the crank handle further.
24. Have a helper rotate the tong stem of the plugging tool clockwise using a
pipe wrench. Count the number of rotations. The crank handle should be
rotated along with the tong stem. It should stay free and not bind up. As the
tong stem is rotated, and the crank handle, two actions take place
simultaneously. The tubing plug adapter is being threaded into the tubing
plug, and the traveling stem must thread out of the plugging tool. For this
reason it will be necessary to feed the crank handle in the clockwise
direction slightly faster than the tong stem is rotated, to compensate for the
downward travel of the plug adapter as it makes up into the tubing plug
retrieval threads.
25. In approximately 13 turns the plug adapter will be fully made up. The plug
adapter nose will tag the tubing plug check valve and offseat it 4 or 5 turns
before full make up of the adapter. At this point the pressure above and
below the plug will equalize if it is not already.
26. Continue to rotate the tong stem clockwise while counting the rotations.
The torque required to rotate the tong stem will increase, then suddenly
break free again. This indicates the plug adapter is fully made up into the
plug, and that the preloaded torque imparted to the left hand plug threads at
the plug’s installation, has been overcome. At this point the plug will begin
to back out of the plug socket.

April 2003 14-27

 27. As the plug backs out of the plug socket it will also travel upward. For this
reason it is necessary that when the plug breaks loose, the action of the
crank handle must be changed, it must be rotated at a slightly slower rate
than the tong stem to compensate for the upward travel of the plug. The
crank handle should stay free and not bind up. After 5 more turns of the tong
stem the plug should be free of the plug socket.
28. Rotate the crank handle counterclockwise until the total number of turns
required to extend down to the plug has been achieved.
29. Gradually close the master valve on the tree.
30. Crack open the needle valve on the plugging tool and bleed all pressure
from the tree.
31. Rig down the plugging tool from the tree. Make sure the plug is on the
adapter.
32. Secure the tree as required by the operator.

Type F Plug Installation and Retrieval Plugging Tool Method, Model 62

1. Assemble the treetop adapter onto the plugging tool.
2. Measure from the estimated top of the master valve gate to the top of the
treetop. Record this dimension.
3. Measure from the estimated top of the master valve gate to the estimated
location of the tubing plug socket. Record this dimension.
4. Measure the length of the tubing plug and plug adapter when they are fully
made up together. Record this dimension.
5. Measure from the bottom of the tubing plug wedge to the bottom of the
tubing plug. Record this dimension.
6. Calculate the amount of polish rod extension which may be added to the
plugging tool traveling stem so that the total length of the tubing plug and
adapter plus polish rod extensions will clear the master valve gate when
they are attached to the bottom of the traveling stem, the entire assembly is
stabbed into the tree, and the treetop connection made up. Be aware that if
the traveling stem has been extended beyond the treetop adapter it may be
retracted into the adapter. If the traveling stem is left partially extended be
sure that enough reach is left to travel the distance from the master valve
gate to the plug socket.
7. Assemble this amount of polish rod extension onto the plugging tool
traveling stem. Snug up each polish rod connection with a pipe wrench.
8. Make up the proper plug adapter to the tubing plug. Torque this connection
to approximately 50 ft. lbs. Twelve inch pipe wrenches are sufficient for this
purpose.
9. Make up the plug adapter and plug on the bottom of the extension
assembly.
10. Adjust the plug wedge by threading it up the tubing plug screw thread until
the top of the wedge is out 1/16" from the screw shoulder.
11. Measure from the bottom of the treetop adapter to the bottom of the tubing
plug wedge. Record this dimension.

14-28
 12. Calculate the amount of travel that will be necessary to extend the tubing
plug from the starting point into the plug socket. This distance will be the
total distance from the treetop to the master valve gate plus the distance
from the master valve gate to the plug socket, minus the distance from the
bottom of the treetop adapter to the tubing plug wedge. (Step 2 + Step 3 -
Step 11)
13. Calculate the number of turns of the plugging tool crank handle necessary
to extend the plug from the starting point into the plug socket. The tool will
extend the traveling stem 1" for every six turns of the crank handle. (Step 12
x 6) Record this total.
14. Close the outer wing valve on the tree.
15. Close the master valve.
16. Open all other valves in the run of the tree.
17. Bleed all pressure from the tree.
18. Open the treetop connection.
19. Fill the tree with antifreeze or other appropriate liquid.
20. Assemble the plugging tool, extension rods, tubing plug adapter and plug
onto the top of the tree. Be sure to tighten all polish rod connections with the
12" pipe wrench. Make up flange and clamp studs to the torque specified by
API for that size. Torque up threaded adapters as required for the type of
thread.
21. Close the needle valve on the plugging tool.
22. Gradually open the master valve.
23. Climb onto the work platform of the plugging tool.
24. Turn the plugging tool crank handle clockwise keeping count of the
rotations.
25. Within approximately 20 turns of the number of turns previously estimated
in Step 14 the plug should bottom out in the plug socket and it will be
impossible to turn the crank handle further. A slight thump may be heard as
the wedge snaps into the plug socket.
26. Turn the crank handle back counterclockwise to retract the plug from the
socket counting the number of rotations. (4 or 5 turns is adequate)
27. Reseat the plug making sure the same number of turns is required to
bottom out once
more. This may be
repeated a couple
of times.

Valve Removal Plug and VR Adapter

April 2003 14-29

 28. Holding the crank handle stationary have a helper rotate the tong stem of
the plugging tool clockwise. Count the number of rotations. The crank
handle should stay free and not bind up or begin to turn with the tong stem.
As the tong stem is rotated two actions take place simultaneously. The
tubing plug body is being threaded up through the tubing plug wedge
locking it in the socket. The traveling stem is rotating counterclockwise in
relation the screw stem and tong stem, because the crank handle is
stationary and the tong stem is rotating clockwise, so the traveling stem is
being retracted at the same rate the plug is being drawn up. This is because
the thread on the tubing plug screw match those on the traveling and screw
stems.
29. The break free point is reached as the plug body is fully wedged behind the
wedge fingers. At this point the torque required to rotate the tong stem will
increase then suddenly release as preloaded torque between the plug
adapter and the plug is overcome. Check the chart to see how many turns
of the tong stem are required to achieve this.
30. Continue to rotate the tong stem clockwise and holding the crank handle
stationary. Now the plug adapter is backing off of the tubing plug.
31. When the required number of turns to set the plug has been achieved
(check chart for plug size) stop rotating the tong stem, and attempt to rotate
the crank handle counterclockwise. If the plug adapter is free of the plug it
will be possible to rotate the crank handle freely, if it isn’t the handle will bind
up within a turn. If the plug does not set in the required number of turns Do
Not continue to turn the tong stem. Recover the plug and inspect it for
damage. Repeat the setting process. Use a another plug if necessary.
32. Continue to rotate the crank handle counterclockwise out 12 turns.
33. Crack open the needle valve on the plugging tool and bleed all pressure
from the tree to insure that the plug is holding pressure.
34. Rotate the crank handle counter clockwise the same number of total turns
that were used to set the plug in the socket.
35. Close the master valve.
36. Rig down the plugging tool.
37. Secure the tree as required by the operator.

Type F Tubing Plug Retrieval Plugging Tool Method, Model 62

1. Assemble the treetop adapter onto the plugging tool.
2. Measure from the estimated top of the master valve gate to the top of the
treetop. Record this dimension.
3. Measure from the estimated top of the master valve gate to the estimated
location of the tubing plug socket. Record this dimension.
4. Measure the length of the correct size tubing plug and plug adapter when
they are fully made up together. Record this dimension.
5. Measure from the bottom of the tubing plug wedge to the bottom of the
correct size plug adapter when made up to the tubing plug. Record this
dimension.

14-30
 6. Calculate the amount of polish rod extension which may be added to the
plugging tool traveling stem so that the total length of the tubing plug and
adapter plus polish rod extensions will clear the master valve gate when
they are attached to the bottom of the traveling stem, the entire assembly is
stabbed into the tree, and the treetop connection made up. Be aware that if
the traveling stem has been extended beyond the treetop adapter it may be
retracted into the adapter. If the traveling stem is left partially extended be
sure that enough reach is left to travel the distance from the starting point to
the plug socket.
7. Assemble this amount of polish rod extension plus the appropriate plug
adapter onto the plugging tool traveling stem. Snug up each polish rod
connection with a pipe wrench.
8. Measure from the bottom of the treetop adapter on the plugging tool to the
bottom of the plug adapter. Record this dimension. The traveling stem of
the tool must be retracted far enough that the plug adapter plus the plug will
clear the master valve gate when the tool is mounted on the tree.
9. Calculate the amount of travel that will be necessary to extend the tubing
plug adapter from the starting point onto the top of the plug. This distance
will be the total distance from the treetop to the master valve gate plus the
distance from the master valve gate to the plug socket, minus the distance
from the bottom of the treetop adapter on the plugging tool to the bottom of
the tubing plug adapter at the starting position, plus the distance from the
bottom of the plug wedge to the bottom of the plug adapter when made up to
the plug. (Step 2 + Step 3 - Step 9 + Step 5)
10. Calculate the number of turns of the plugging tool crank handle necessary
to extend the plug from the starting point onto the plug. The tool will extend
the traveling stem 1" for every six turns of the crank handle. (Step 10 x 6)
Record this total.
11. Close the outer wing valve on the tree.
12. Close the master valve.
13. Open all other valves in the run of the tree.
14. Bleed all pressure from the tree.
15. Open the treetop connection.
16. Fill the tree with antifreeze or other appropriate liquid.
17. Assemble the plugging tool, extension rods, and tubing plug adapter, onto
the top of the tree. Make up flange and clamp studs to the torque specified
by API for that size. Torque up threaded adapters as required for the type of
thread.
18. Close the needle valve on the plugging tool.
19. Gradually open the master valve.
20. Attach a remote pressure source to the wing of the tree or the needle valve
of the plugging tool and pressure up on the tree and lubricator until the
pressure equalizes above and below the plug. When gauge pressure

April 2003 14-31

 ceases to rise steadily the pressure is passing through the tubing plug
check valve and pressure is equalized. If this is not feasible the pressure
may be equalized by tagging into the plug but this is a riskier operation as
the tool is extended through all the valves at that point and the only well
control is the plug itself.
21. Climb onto the work platform of the plugging tool.
22. Turn the plugging tool crank handle clockwise keeping count of the
rotations.
23. Within approximately 20 turns of the number of turns previously estimated
in Step 11 the plug adapter should bottom out on top of the plug and it will be
impossible to turn the crank handle further.
24. Holding the crank handle stationary have a helper rotate the tong stem of
the plugging tool counterclockwise using a pipe wrench. Count the number
of rotations. The crank handle should stay free and not bind up or begin to
turn with the tong stem. As the tong stem is rotated and the crank handle
held stationary, two actions take place simultaneously. The tubing plug
adapter is being threaded onto the tubing plug, and the traveling stem is
threading out of the plugging tool at an equal rate since the screw stem is
rotating clockwise in relation to the traveling stem and tong stem. This is
because the thread on the tubing plug screw matches those on the traveling
and screw stems.
25. In the required number of turns for the size plug being retrieved, the plug
adapter stinger will tag the tubing plug check valve and offseat it. At this
point the pressure above and below the plug will equalize if it is not already.
26. Continue to rotate the tong stem counterclockwise while holding the crank
handle stationary and counting the rotations. Now the plug screw is
threading into the plug wedge allowing the plug body to drop from behind
the wedge fingers. This releases the plug from the plug socket.
27. When the required number of turns to release the plug has been achieved
(check chart for plug size) stop rotating the tong stem, and attempt to rotate
the crank handle counterclockwise. If the plug is free of the plug socket it will
be possible to rotate the crank handle freely, if it isn’t the handle will bind up
within a turn.
28. Continue to rotate the crank handle counterclockwise until the total number
of turns required to extend down to the plug has been achieved.
29. Gradually close the master valve on the tree.
30. Crack open the needle valve on the plugging tool and bleed all pressure
from the tree.
31. Rig down the plugging tool from the tree. Make sure the plug is on the
adapter.
32. Secure the tree as required by the operator.

14-32
Valve Removal Plug Installation and Retrieval Model 62 Plugging Tool
1. Assemble the hub adapter onto the plugging tool.
2. Measure from the estimated location of the outer side of the valve gate to
the outside of the outer valve.
Record this dimension.
3. Measure from the estimated
location of the outer side of the
valve gate to the estimated
location of the Valve Removal
thread socket. Record this
dimension.
4. Measure the length of the VR Valve Removal Plug and VR Adapter
plug and plug adapter when they
are fully made up together.
Record this dimension.
5. Measure from the top of the VR plug threads to the top of the plug hex
connection. Record this dimension.
6. Calculate the amount of polish rod extension which may be added to the
plugging tool traveling stem so that the total length of the VR plug and
adapter plus polish rod extensions will clear the outer valve gate when they
are attached to the traveling stem, the entire assembly is stabbed into the
casing outlet, and the valve to hub adapter connection made up. Be aware
that if the traveling stem has been extended beyond the hub adapter it may
be retracted into the adapter. If the traveling stem is left partially extended.
Be sure that enough reach is left to travel the distance from the starting
point to the plug socket.

Valve Removal Plugging tool rigged up on a tubing spool outlet with VR plug extended

April 2003 14-33

 7. Assemble this amount of polish rod extension onto the plugging tool
traveling stem. Snug up each polish rod connection with a pipe wrench.
8. Mate the plug adapter to the VR plug.
9. Make up the plug adapter and plug on the extension assembly.
10. Measure from the bottom of the hub adapter to the end of the VR plug
threads. Record this dimension.
11. Calculate the amount of travel that will be necessary to extend the VR plug
from the starting point into the plug socket. This distance will be the total
distance from the outer side of the valve gate to the outside connection of
the outer casing valve plus the distance from the outer side of the valve gate
to the plug socket, minus the distance from the bottom of the hub adapter to
the end of the VR plug threads. (Step 2 + Step 3 - Step 10)
12. Calculate the number of turns of the plugging tool crank handle necessary
to extend the plug from the starting point into the plug socket. The tool will
extend the traveling stem 1" for every six turns of the crank handle. (Step 11
x 6) Record this total.
13. Close the outer casing valve on the outlet to be plugged.
14. Bleed all pressure from the outlet.
15. Remove the companion flange from the valve end connection.
16. Assemble the plugging tool, extension rods, VR plug adapter and plug onto
the end of the casing valve. Be sure to tighten all polish rod connections
with the 12" pipe wrench. Make up flange and clamp studs to the torque
specified by API for that size. Torque up threaded adapters as required for
the type of thread.
17. Close the needle valve on the plugging tool.
18. Gradually open the casing valve.
19. Turn the plugging tool crank handle clockwise keeping count of the
rotations.
20. Within approximately 20 turns of the number of turns previously estimated
in Step 12 the plug should run into the plug socket and it will be impossible
to turn the crank handle further.
21. Turn the crank handle back counterclockwise to retract the plug from the
socket counting the number of rotations. (4 or 5 turns is adequate)
22. Reseat the plug making sure the same number of turns is required stop
once more.
23. Rotate the crank handle as a helper rotates the tong stem of the plugging
tool clockwise. Count the number of rotations. The crank handle should
stay free and not bind up or begin to turn with the tong stem. As the tong
stem is rotated with the crank handle two actions take place
simultaneously. The VR plug is threading into the plug socket. The traveling
stem must extend to compensate for the inward travel of the plug as it
threads into the socket. For this reason it will be necessary to feed the crank

14-34
 handle of the tool at a slightly greater rate than the tong stem is turning.
Keep all functions of the tool operating freely.
24. When an adequate number of turns have been made on the tong stem the
plug will begin to tighten into the VR socket. When this takes place the
torque required to turn the tong stem will increase. One man with a 24" pipe
wrench is adequate torque. Excessive torque will make it difficult to
retrieve.
25. Rotate the crank handle counterclockwise out 12 turns.
26. Crack open the needle valve on the plugging tool and bleed all pressure
from the outlet to insure that the plug is holding pressure.
27. Rotate the crank handle counterclockwise the same number of total turns
that were used to extend the plug into the socket.
28. Close the casing valve.
29. Rig down the plugging tool.
30. Secure the well as required by the operator

VR Plug Retrieval Plugging Tool Method Model 62 Tool

1. Assemble the hub adapter onto the plugging tool.
2. Measure from the estimated outer side of the outer casing valve. Record
this dimension.
3. Measure from the estimated outer side of the outer valve gate to the
estimated location of the VR plug socket. Record this dimension.
4. Measure the length of the correct size VR plug and plug adapter when they
are fully made up together. Record this dimension.
5. Measure from the hex of the VR plug to the base of the VR plug threads.
Record this dimension.
6. Calculate the amount of polish rod extension which may be added to the
plugging tool traveling stem so that the total length of the VR plug and
adapter plus polish rod extensions will clear the outer valve gate when they
are attached to the bottom of the traveling stem, the entire assembly is
stabbed into the outlet, and the hub adapter to valve connection made up.
Be aware that if the traveling stem has been extended beyond the hub
adapter it may be retracted into the adapter. If the traveling stem is left
partially extended be sure that enough reach is left to travel the distance
from the starting position to the plug socket.
7. Assemble this amount of polish rod extension plus the appropriate plug
adapter onto the plugging tool traveling stem. Snug up each polish rod
connection with a pipe wrench.
8. Measure from the bottom of the hub adapter on the plugging tool to the end
of the plug adapter. Record this dimension. The traveling stem of the tool
must be le to retract far enough that the plug adapter plus the plug will clear
the outer valve gate when the tool is mounted on the outlet.
9. Calculate the amount of travel that will be necessary to extend the VR plug
adapter from the starting point into the end of the plug. This distance will be

April 2003 14-35

 the total distance from the end connection of the outer valve to the outer
side of the gate plus the distance from the outer side of gate to the plug
socket, minus the distance from the bottom of the hub adapter on the
plugging tool to the end of the VR plug adapter at the starting position, plus
the distance from the plug hex to the base of the plug threads. (Step 2 +
Step 3 - Step 8 + Step 5)
10. Calculate the number of turns of the plugging tool crank handle necessary
to extend the plug from the starting point onto the plug. The tool will extend
the traveling stem 1" for every six turns of the crank handle. (Step 9 x 6)
Record this total.
11. Close the outer casing valve on the outlet to be plugged.
12. Bleed all pressure from the outlet.
13. Remove the companion flange from the casing valve end connection.
14. Assemble the plugging tool, extension rods, and VR plug adapter, onto the
casing valve end connection. Make up flange and clamp studs to the torque
specified by API for that size. Torque up threaded adapters as required for
the type of thread.
15. Close the needle valve on the plugging tool.
16. Gradually open the casing valve.
17. Attach a remote pressure source to the needle valve of the plugging tool
and pressure up on the casing outlet and lubricator until the pressure
equalizes through the plug. When gauge pressure ceases to rise steadily
the pressure is passing through the VR plug check valve and pressure is
equalized. If this is not feasible the pressure may be equalized by tagging
into the plug, but this is a riskier operation as the tool is extended through all
the valves at that point and the only well control is the plug itself.
18 Turn the plugging tool crank handle clockwise keeping count of the
rotations.
19. Within approximately 20 turns of the number of turns previously estimated
in Step 10 the plug adapter should bottom out on top of the plug and it will be
impossible to turn the crank handle further.
20. Have a helper rotate the tong stem of the plugging tool clockwise using a
pipe wrench as pressure is applied in the clockwise direction to the crank
handle. As the hex on the plug adapter aligns with the hex on the plug the
crank handle will free up and the traveling stem will be extended out 6 more
turns. Pressure will equalize at this point if it has not already, as the stinger
of the plug adapter offseats the check valve in the VR plug.
21. Rotate the tong stem back counterclockwise along with the crank handle.
The preloaded torque imparted to the plug upon installation must be
overcome to begin backing out the plug.
22. Continue to rotate the tong stem counterclockwise while counting the
rotations. As the VR plug backs out of the socket it will travel out toward the
tool. For this reason it will be necessary to feed the crank handle in the
counterclockwise direction at a slightly greater rate than the tong stem is
turning. The crank handle should remain free to turn.

14-36
 23. Once the plug is free of the socket rotate the crank handle counterclockwise
until the total number of turns required to extend out to the plug has been
achieved.
24. Gradually close the casing valve.
25. Crack open the needle valve on the plugging tool and bleed all pressure
from the outlet.
26. Rig down the plugging tool from the outlet. Make sure the plug is on the
adapter.
27. Secure the well as required by the operator.

Operating The “R” Type Plugging Tools

Pre-operational Checklist
The following items are needed to set a tubing plug with the R Type tool:
1. R Type plugging tool
2. Correct size and type tubing plug and corresponding running tool
3. Correct B-20 to treetop adapter
4. B-Clamp
5. Size 20 seal ring
6. New ring gasket for the treetop connection if applicable.
7. For the purposes of brevity, the space in the plugging tool barrel above the
polish rod piston will be referred to as the upper barrel, the space below the
piston as the lower barrel. Refer to the drawing for the position of the
various valves.
Installation Running Procedure
1. Install the B-20 by treetop adapter onto the tool utilizing the B clamp and
size 20 seal ring.
2. Loosen the polish rod packing glands and push the polish rod hex adapter
through the tree top adapter far enough to expose the hex swivel at the
bottom of the polish rod.
3. Make up the tubing plug and running tool using standard procedure for that
assembly.
4. Make up the tubing plug and running tool assembly to the polish rod hex
adapter.
5. Retighten the polish rod glands (18” pipe wrench).
6. Measure the distance from the bottom of the hub adapter to the bottom of
the tubing plug collet or threads whichever applies. Record this dimension.
7. Measure the distance form the treetop to the approximate location of the
plug socket in the tubing hanger. Record this dimension.

April 2003 14-37

 Parmalee wrench used to
turn polish rod and set
plug

R-80 Plugging tool rigged up on tree with the BPV extended into plug socket

14-38
 8. The difference between the two measurements is the approximate travel of
the polish rod to land the tubing plug in the plug socket. Make a note of this
estimate.
9. Open all the valves in the plugging tool manifold.
10. Close a wing valve on the tree and the master valve.
11. Bleed off all pressure from the run of the tree above the master valve.
12. Remove the treetop connection.
13. Install the plugging tool on top of the tree and test if required.
14. Close the two vent valves in the tool manifold.
15. Gradually open the master valve allowing well pressure to equalize
throughout the tool and manifold. Check for leaks.
16. Close the lower barrel isolation valve.
17. Open the lower barrel vent valve and bleed pressure gradually until the
polish rod begins to stroke downward. Keep track of the graduation marks
on the polish rod so you will know how far the tool has extended. Observe
the pressure difference between the upper barrel and the lower barrel
required to move the polish rod initially. Try to keep this pressure difference
constant as the rod extends through the tree (see caution at the end of
procedure).
18. As soon as the plug lands in the plug socket close the lower barrel vent
valve immediately.
19. Close the well pressure isolation valve. To neutralize upward or downward
force at the tubing plug the pressure in the upper barrel must be 3/4 of the
pressure in the lower barrel. To do this open the upper barrel vent valve and
bleed off until the pressure in the upper barrel is 3/4 of that in the lower
barrel, then close the valve.
20. Latch the parmalee wrench onto the polish rod in the window of the yoke
assembly. Parmalee wrench can be used to apply downward force on the
plug.
21. Rotate the polish rod as necessary to set the tubing plug using
recommended procedures for setting that type of plug.
22. Once the plug is set and the running tool is backed off and released from the
plug, close the well pressure isolation valve.
23. Open the upper barrel vent valve and bleed pressure slowly allowing the
polish rod to retract. Note the pressure difference between the upper and
lower barrel required to start the rod moving and attempt to keep that
difference constant (see caution at the end of the procedure). Warning:
The polish rod should be retracted slowly.
24. When the polish rod has been fully retracted close the master valve or
working valve of the tree.
25. Open all valves in the tool manifold and bleed all pressure from the tool.

April 2003 14-39

 26. Open the master valve and bleed all pressure from the tree to verify the plug
is set and holding pressure.
27. Close the master valve. and rig down the plugging tool.

Retrieval Running Procedure

1. Close a wing valve. Close the master valve.
2. Bleed all pressure from the run of the tree above the master valve or
working valve.
3. Install the correct tree top adapter and tubing plug adapter on the plugging
tool.
4. Measure from the top of the tree to the estimated position at the top tubing
plug.
5. Measure from the bottom of the treetop adapter to the bottom of the running
tool. The difference between the two measurements is the necessary travel
to land the tubing plug adapter on the plug.
6. Remove the tree top adapter and fill the tree with fluid. Use antifreeze if
conditions warrant.
7. Mount the plugging tool onto the treetop.
8. All valves in the tool manifold should be open.
9. Attach a pump or other remote pressure source to the upper barrel vent
valve.
10. Close the lower barrel isolation valve and open the master valve of the tree.
11. Pressure up on the tree and tool until pressure equalizes through the tubing
plug (see note at the end of the procedure).
12. Close the lower barrel vent valve.
13. Open the lower barrel isolation valve and bleed slowly allowing the polish
rod to extend downward. Apply pressure through the upper barrel vent
valve to lower the polish rod.
14. Keep track of the polish rod travel by observing the graduation marks on the
polish rod.
15. Once the tubing plug adapter lands atop the tubing plug close the lower
barrel vent valve immediately.
16. Open the lower barrel isolation valve.
17. Latch the parmalee wrench onto the polish rod and rotate the rod as
necessary to make up on, and release, the tubing plug. Keep track of the
rotations. Follow the recommended procedure for releasing the type of plug
that is in the hole.
18. Close the well pressure isolation valve.
19. Open the upper barrel vent valve and bleed slowly allowing the polish rod to
retract. Observe the difference between upper barrel and lower barrel
pressure required to start the rod moving. By opening and closing the upper

14-40
 barrel vent valve attempt to keep this pressure differential constant (see
caution at the end of the procedure).
20. When the polish rod is fully retracted close the master valve.
21. Open all the tool manifold valves and bleed all pressure form the tree and
tool.
22. Rig down the plugging tool.

CAUTION This tool relies on the balance of pressure above and below the
piston of the polish rod to control the extension and retraction of
the tool as well as the force applied to the plug’s downward or
upward motion. It is critical not to allow these pressures to become
greatly imbalanced. The operator must closely monitor these two
pressures. If the tubing plug attached to the polish rod becomes
hindered in the bore of the tree preventing the extension or
retraction of the polish rod as the operator is bleeding pressure
form the barrel, to continue to bleed pressure could result in
damage to the plug, the tree, or cause a sudden thrust of the polish
rod. In addition when the travel of the polish rod becomes hindered
the tool in effect becomes a hydraulic jack attempting to force apart
the connections in the tool or the tree.
While retracting the polish rod if the pressure below the piston exceeds the
pressure above the piston by more than 5000 psi, the bolt attaching the piston to the
polish rod will fail and the piston will part from the polish rod.

Operating The HO Style Plugging Tools

The HO style tool is primarily designed to install and retrieve the Type K tubing plug
. For this reason this is the procedure which will be described.
Pre-operational Checks
1. Insure that the plugging tool is rated to an adequate service pressure for the
amount of pressure expected in the well and that it is complete with control
panel and hoses.
2. Verify that the tool has sufficient reach to extend from the tree or casing
valve gate to the plug receptacle.
3. Check that the necessary hub adapter, clamp, and seal rings for the
adapter are available.
4. Make sure that all the mechanical functions of the tool work freely without
excessive torque.
5. Inspect the seal surface for the connection of the tool for damage. There
should be no scratches or gouges.
6. The hub adapter should also be free of damage.
7. The appropriate wrenches to make up the plugging tool connections and to
operate the plugging tool should be available. (Parmalee wrench to rotate
the plugging tool shaft, 2 12"-18" pipe wrenches, hammer wrenches to fit
the treetop flange and B-clamp)
8. An appropriate hoist to install the plugging tool on the tree should be
available.

April 2003 14-41

 Spanner wrench
for polish rod

HO-100 Plugging Tool

9. There should be enough clearance above the tree, or next to the wellhead,
to install the plugging tool.
10 Check the plug and plug adapter as specified in their pre-operational
checklist.
Running Procedure
1. Install the tubing plug on the adapter as previously described in the setting
procedure for the K plug.
2. Install the spline nut in the recess of the plug adapter stem.

14-42
 3. Remove the retainer nut and reset ring from the adapter and slip them over
the plugging tool stem.
4. Mate the plugging tool stem to the adapter and plug locking them together
with the split ring and retaining wire.
5. Make up the reset ring and retainer nut on the adapter, locking the retainer
nut in place with the set screw.
6. Retract the plugging tool stem by opening the “Raise Tool” valve on the
control panel until the reset spring bottoms out on the plugging tool, latching
the reset spring in the detonate groove.
7. At this point it is necessary to estimate the amount of travel necessary for
the shaft to extend the plug to the plug socket. Measure from the plug’s
locating ring to the bottom of the hub adapter. Measure from the top of the
tree to the approximate location of the tubing hanger plug socket. The
necessary amount of travel will be the difference between these two
measurements.
8. Assemble the plugging tool, plug, and adapter onto the treetop.
9. Pressure test the tool to tree connection against the sw valve.
10. Open all the valves in the tree starting with the uppermost.
11. Lower the tubing plug by opening the “Lower Tool” valve on the control
manifold. The setting of this valve will control the rate of movement. Keep
the motion steady but gradual. The stem is graduated in 3" increments to
keep track of the extension.
12. When the full extension is approached slow the rate of extension further.
When the plug is in place motion of the stem will cease.
13. Additional hydraulic pressure must be applied to unset the reset spring in
the plug adapter, allowing the actuator sleeve of the plug to seat behind the
plug hold down wedges. Watch for the 2" of downward travel this will
require.
14. Once the plug is set bleed off as much hydraulic pressure as possible
without the stem retracting. This will reduce the friction evident as the plug
is locked. Close the “Lower Tool” valve.
15. Make a vertical mark on the stem for reference. Rotate the stem clockwise
approximately 8 ½ turns, until it stops. Do not overtighten.
16. Retrieve the adapter by engaging the “Raise Tool” valve on the control
panel.
17. Close the sw valve on the tree.
18. Bleed off all pressure from the tool and control manifold.
19. Secure the tree as required by the operator.

April 2003 14-43

Type K Plug Retrieval, Plugging Tool Method, Type HO
1. Connect the plug adapter to the stem. The adapter must be in the unset
position.
2. Estimate the travel necessary to latch the plug. This is the distance from the
adapter lugs to the bottom of the hub adapter at the starting position minus
the distance from the treetop to the plug lock nut.
3. Make up the plugging tool and the adapter to the treetop.
4. Open all valves in the run of the tree.
5. Pressure up on the tree and tool until pressure equalizes through the tubing
plug.
6. Engage the “Lower Tool” valve in the control panel to lower the tool stem.
Observe the amount of extension.
7. When the stem travel stops the plug adapter lugs should be atop the plug
lock nut. Raise the stem slightly. Mark the stem with a horizontal mark.
Rotate the stem 1/3 of a turn and lower. When the plug adapter lugs drop
into the J-slots on the plug lock nut the stem will travel down an additional
distance.
8. Once the adapter lugs are engaged in the J-slot rotate the stem
counterclockwise as far as possible. Raise the tool. If the tool is latched to
the plug it will only rise the length of the J-slot.
9. If the plug is latched rotate the stem counterclockwise an additional 8 ½
turns to release the plug from the socket.
10. Engage the “Raise Tool” valve on the control panel. This will pull the
actuating sleeve of the plug from behind the wedges releasing the plug to
allow full retraction of the tool.
11. Close a tree valve.
12. Bleed all pressure from the tree and tool.
13. Rig down the tool. Make sure the plug is on the adapter.
14. Secure the tree as required by the operator.

14-44
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 15
Gate Valves and Valve Actuators
This page left blank
ABB Vetco Gray Valve Development and Technology
The ABB Vetco Gray Graygate valve was introduced in the mid-1960’s when ABB
Vetco Gray (then Gray Tool Co.) realized that existing gate valve designs did not
meet the requirements of a fast changing
oil and gas industry. A research and
development program was initiated with
two important criteria as the guiding
principles: (1) Develop a valve to provide
the maximum dependable service and (2)
Provide this valve with a maximum cost
effectiveness for the operator over the life
of the valve. The result of that program
and over twenty years of experience is a
superior valve line with advanced design
features and an outstanding performance record in the field.
• ABB Vetco Gray has designed and successfully installed gate valves to meet
many requirements. Among these are:
• A full line of standard sizes and pressure ranges from 1-13/16" to 12" and
from 2,000 psi to 30,000 psi.
• A complete selection of valve trims for any service including H2S, CO2, high
temperature, low temperature, and corrosion resistant cladding.
• A complete selection of end connections including API and ANSI flanges,
threaded, weld-prep, and VGloc.
• Special configurations for applications involving reduced height, reduced
weight, in-a-leg completions for mud slide areas, and Fire Resistant
requirements.
• Remote or automatic operation by ABB Vetco Gray and other manufacturers’
hydraulic or pneumatic actuators including actuators for 20,000 and 30,000
psi extreme service and the Reduced Height RHA actuator for increased
working space.
• In addition to our leading position as a supplier of subsea trees and
completion equipment, ABB Vetco Gray is proud of our record as a supplier
of valves for surface wells. To date, ABB Vetco Gray is the only manufacturer
to actually install a 30,000 psi Christmas Tree on a well. All of the 30,000 psi
completions in the world have ABB Vetco Gray valves controlling their
production, including the first completion, which has been in service since
1974. The determination to supply our customers with the valves which meet
their requirements today is still evident. Recent developmental work includes
the competitively priced VG 200 valve for lower pressure applications and
corrosion resistant overlays for longer service at lower cost.

April 2003 15-1

 Handwheel

Bonnet Cap

Grease Injection
Fitting

Bearing Mount
Valve Bonnet

Bonnet Seal Packing

Retainer

Gate Expander
Stem Packing

Gates
Seat Retainer

Stem

Drive Bushing

Seats

Body

Model D Valve - Non-rising stem, fixed seats, segmented gate

15-2
What Is A Gate Valve ?
API Spec 6A is the source reference for technical guidelines applicable to the
design and manufacture of gate valves. In the new seventeeth edition, a gate valve
is defined as a valve assembly with a gate operating within the body, 90 degrees to
the conduit, to effect a closure. API Spec 6A also provides detailed instructions on
the design, manufacture, and performance verification of gate valves with API
flanged, threaded or other end connections. This definition is deliberately intended
to encourage individual engineering and design effort relative to the internal
components of gate valves.
Essentially there are two different classes of gate valves available on the market
today. These two classes are through-conduit and solid wedge gate. While solid
wedge gate valves are inexpensive to build and require no drift adjustment, their
application for oil and gas production is limited by a design which exposes the
sealing surfaces to continuous erosion during flow and allows constant deposition
of contaminants in the cavity of the valve. This will eventually cause problems with
the closure mechanism of the valve.
The through-conduit design is generally accepted as necessary and desirable for
the long term, trouble free operation required for oil and gas production.
Although closer tolerances must be maintained during manufacturing to “drift” a
through-conduit design, this design concept offers significant advantages which
promote reliable, long term service with reduced maintenance costs and
operational problems. A through-conduit design should incorporate features which
promote the smoothest flow of fluids through the valve while protecting the sealing
mechanism against erosion. The design should also seek to eliminate the build-up
of contaminants in the valve cavity while promoting the retention of lubricants to
ensure a longer life span.
The through-conduit design applies specifically to the configuration of the valve
bore sealing mechanism. To complete the optimum design for maximum service
dependability and cost effectiveness other characteristics such as stem packing
design, power train design, and material selection must be chosen to complement
the operation of the valve bore sealing mechanism.
Through-Conduit Gate Valve Designs
The through-conduit gate valve design is now widely accepted in the petroleum
industry and has been used successfully for years to control the flow of oil and gas.
However, there are markedly different design concepts which have been developed
and refined and which represent various commitments to applied engineering,
material technology, and manufacturing capabilities. Key among these concepts
are the relative merits of slab gates vs. segmented gates, rising stems vs.
non-rising stems and floating seats vs. fixed seats. The selection of materials for
both metallic and non-metallic components has expanded with the demands of the
petroleum industry and includes a wide variety of alloys and compounds to meet
each specific application. Material selections, or valve trims, will be addressed in a
separate document.
On the following pages, the advantages and disadvantages of each of these key
concepts will be reviewed from the standpoint of both maximum service
dependability and cost effectiveness.

April 2003 15-3

Slab Gate versus Segmented Gate Design
The through-conduit valve bore sealing mechanism consists of a gate or gates
which move back and forth across fixed seats to start or stop the flow of fluid
through the valve bore. The “gate” is not generally intended to throttle the flow of
fluid. The slab gate design employs a one-piece, or single gate, valve bore sealing
mechanism and the segmented gate design uses a two-piece split or “segmented”
valve bore sealing mechanism. The advantages and disadvantages of each design
are as follows:
One-piece slab gate advantages
• Fewer parts
• Usually will not pressure lock unless designed with close fitting floating seats.
This could result in lower operating torque for some designs.
• May be less expensive to manufacture, although some designs require very
close tolerances.
One-piece slab gate disadvantages
• Difficult to maintain constant contact with both seats on each side of the valve
cavity.
• Some designs seal best from one direction.
• Relies solely on well pressure to establish a seal.
•Requires a floating seat with elastomer seals to establish gate/seat and
seat/body contacts.
Segmented gate advantages
• Easier to maintain contact with seats on both sides of valve cavity. This
prevents contaminants from intefering with the gate/seat sealing interface.
• The design does not rely on well pressure to establish an initial seal.
•Better overall sealing characteristics for both low and high pressure
applications.
Segmented gate disadvantages
• More parts.
• Pressure can become trapped between gate segments if the pressure is bled
down from both the upstream and downstream sides of the valve which
increases the opening torque.
• More expensive to manufacture.

15-4
Rising Stem versus Non-Rising Stem Design
The stem of the through-conduit gate valve is the device which converts the
rotational movement of the handwheel external to the valve to the horizontal
movement of the valve bore sealing mechanism, the gate(s), past the seats. In a
rising stem design, the stem is attached to a fixed drive mechanism which pulls and
pushes the stem and the gate(s) across the seats. In a non-rising stem design, the
stem is fixed in placed and attached to the gate(s) which traverse up and down the
stem to move them across the seats. The advantages and disadvantages of the
rising stem and the non-rising stem design are as follows:
Rising Stem Advantages
• Lower operating torque results from pressure equalization across the gate
assembly.
• Easily adaptable to operation by actuators.
• Stem offers a visual indicator of open or closed position of the valve.
• Drive bushing threads are not directly exposed to well fluids.
Rising Stem Disadvantages
• Stem packing is exposed to the full stroke of the stem, including portions
which travel in the cavity. This reduces the packing life.
• High pressure designs require a second stem to balance pressure due to
pressure piston effects.
• A second stem requires separate stem packing and additional parts, as well
as additional penetrations in the valve body.
• Not readily adaptable to backseating capability without requiring full stroking
capability.
• Not suitable for critical service applications such as fire resistant.
Non-Rising Stem Advantages
• Stem does not stroke through packing set, ensuring seal integrity for long
maintenance-free life.
• Stem does not require a secondary stem to balance the piston effect from
high pressure.
• Stem can be selectively backseated to isolate well pressure from stem
packing with the valve in the open or closed position.
• Allows design of valve body without penetrations.
• Preferred design for critical service applications, including fire resistant.
Non-Rising Stem Disadvantages
• Drive mechanism is indirectly exposed to well fluids, but not well flow.
• Slightly higher operating torque.

April 2003 15-5

 • Stem is not a visual indicator of whether the valve is in the open or closed
position
Floating Seats versus Fixed Seats
The seats of a gate valve are a replaceable component of the valve bore sealing
mechanism which remain on a fixed axis in the flow bore of the valve body. The
seats remain in the seat pockets of the valve body during the horizontal movement
of the gates as the valve is opened and closed. To accommodate the different gate
designs and specific operating conditions, the seats may be “fixed” into the seat
pockets or allowed to “float” in the seat pockets. The advantages and
disadvantages of floating seats and fixed seats are as follows:
Floating seat advantages
• Maintains constant contact with the gate(s) during the operation of the valve.
• Provides wiping action to protect the gate/seat interface sealing surface.
• Floating seat disadvantages
• Requires an elastomer seal to maintain a constant seal with the seat pocket
in the valve body.
• Allows deposition of contaminants between the seat/body seal area during
flow and may prevent sealing in this area.
• Produces increased drag on the gate/seat interface during operation.
Fixed seat advantages
• Maintains constant contact seal with the valve body during the operation of
the valve.
• No movement of the seat to interfere with the operation of the gates during
opening and closing.
• Prevents trash from interfering with the seat/body seal.
Fixed seat disadvantages
• Requires gates designed with an expander or springs to effect a low pressure
seal and maintain a clean gate/seat interface.
• Requires close tolerance fit to hold the seat in the fixed position.
Gate Valve Components and their Functions
The gate valve is an assembly of many parts, each designed to perform a specific
function and each operating in conjunction with the others to provide a flow
passage for line fluid under control or to shut off totally that flow.
The main component in the valve assembly is the valve body. The body is a
pressure vessel which means that it is designed to contain the fluid under maximum
service pressure. The body is provided with a bore or conduit through which the
fluid passes when the valve is in the open position. At each end of the bore are the
end connections which provide for attachment to other valves, fittings or pressure
vessels. Gate Valves are offered with a variety of connections including flanges,
threads, clamped hubs, and weld ends.

15-6
Midway between the end connections is the valve cavity which runs at 90 to the
conduit and which houses the gates, seats, and expander.
The cavity is closed off by the valve bonnet which bolts to the studded connection at
the open end of the cavity. The seal between the body and the bonnet is
accomplished by the bonnet seal ring which provides a metal-to-metal,
pressure-energized seal. The bonnet also provides a housing for the stem, stem
packing and bearing assembly.
In order to shut off the flow of fluid through the valve, the valve is equipped with a
pair of gates and seats. The gate is solid at one end and has a bore through the
other end. When the gate bore is aligned with the body bore the valve is open and
fluid can pass from through the valve. When the gate is moved so as to block the
body bore, then the passage of fluid is stopped.
When the gate is moving between the open and closed position, there is often a
turbulent flow condition set up which can cause erosion of the interface surfaces of
the gates and seats. The sliding motion of the gate on the seat face while under load
also causes wear. Because of these two factors, as well as others, the seats are
designed as separate replaceable components.
The sealing action between the gate and the seat and between the seat and the
valve body is caused primarily by the pressure of the fluid itself. The pressure
difference from the back side of the gate to the front side results in a high load which
forces the gate against the seat with enough bearing contact load to effect a seal.
To aid in starting the sealing action, the gate valve is provided with an expander
which has two wedge-shaped legs which mate with tapered tracks on either side of
the gate. Closing the valve drives the wedge and track together forcing the gate
face against the seat face to establish an initial low pressure seal. The expander
provides a positive stop in the closed position and also acts as a guide for the gates
to provide side-to-side alignment.
This gate valve is a downstream sealing valve. This means that the gate opposite
the source of pressure (the downstream gate) is the one that seals. As pressure
increases the gate is pushed against the seat with increasing force and the
metal-to-metal seal capacity is increased. Both gates and seats are identical and,
therefore, the Valve will seal with the same reliability from either direction.
In order to move the gates between the open and closed position the Graygate
valve makes use of a non-rising stem and a drive bushing. Two drive pins (one in
top of each gate segment) keep the drive bushing from rotating. As the stem is
rotated, the stem thread converts the stem rotation into linear motion of the drive
bushing. The drive bushing is engaged into the two gate segments and so, as the
stem rotates, the gates move across the bore of the valve between the open and
closed position. The stem is held in place by two thrust bearings which permit
rotation but keep the stem from moving up or down. These bearings are housed in
the bonnet and are retained by a bonnet gland. The rotation of the stem in a
clockwise direction closes the valve while counterclockwise rotation opens the
valve.

April 2003 15-7

Gate Valve Operation
In operating any valve, it is necessary to overcome the torque required to rotate the
stem. The torque or resistance to rotation comes from the friction of moving parts
under load. The three main sources of friction are the gate-seat interface, the
stem-drive bushing thread and the stem packing.
When the gates are in the closed position with pressure on one side of the valve,
the difference of pressure from one side to the other creates a high load between
the gate and seat. the force required to slide the gate, which we call gate-draw is
directly proportional to the force pushing the gate against the seat. The higher the
pressure difference, the higher the gate drag. As the gates move by turning the
stem, the gate drag causes a high load to be placed on the stem thread and this
high load causes friction in the thread. The combination of friction between the gate
and seat and friction in stem threads causes resistance to rotation of the stem which
is called torque. The other source of friction is the stem packing. Internal pressure
pushing against the stem packing causes a high load between the packing and the
stem. This load is seen as an additional resistance to rotation or torque.
As pressure increases, so does friction and the torque that results from friction.
Other factors also increase friction. Abrasive materials such as sand will cause
higher friction in the stem thread. Loss of lubrication, wear, corrosion and
mechanical damage can all increase friction and result in higher torque to operate.
A split gate design such as used in the ABB Vetco Gray gate valve as well as some
others can sometimes become double blocked. Sometimes, this is referred to as
“pressure locked”. This term is really not correct because the valve is not actually
locked. What occurs is that the pressure has been trapped between the gate
segments and both the upstream and downstream sides of the valve have been
bled down. When this happens, both gates contribute gate drag and the torque
required to open the valve is nearly doubled when compared to normal opening
torque. Once the gates are moved far enough to break the seal, the pressure
bleeds off and the torque drops. Valve operation can then return to normal. This
condition is usually the result of some operation such as pressure testing the tree.
Definition of terms
Body
The body of a valve is a tee shaped steel casting or forging with two outlets and a
large opening to the central cavity. End connections are flanged or threaded. The
opening to the central cavity (bonnet face) is studded and provides a means to seal
against the bonnet.
Bonnet
The bonnet is the top cap that seals against the body and provides a packing bore
and bearing cap for the stem.
Seats
Seats provide the seal faces between the body and gate segments. Teflon rings
inside the seats seal at low pressure to gain an initial seal and help to reduce gate
friction or drag.
Gates Segments
Gate segments are rectangular plates with a conduit or gate bore on one end. In the
open position, the hole in the gate is in alignment with the bore in the seat. Moving
the gate to the closed position, the solid surface covers the seat completely thereby
blocking the flow.

15-8
Expander
An expander sits on a ledge inside the body and when a manual valve is closed this
devise will wedge the gate segment against the seats.
Stem/Bearing Flange
The manual valve has a non-rising stem. The manual stem’s bearing flange (either
integral or separate) permits axial rotation but not axial movement.
Bearings/Bearing Cap
As the stem rotates, any axial thrust is contained by the bearing cap (bonnet gland)
and friction is alleviated by two roller bearings, one on each side of the bearing
flange.
Stem Packing
Stem packing, located in a pocket below the bearing flange, isolates the cavity
pressure from the bearing area in the bonnet.
Stem/Drive Bushing
The end of the stem is normally threaded with a modified 6 pitch left hand acme
thread and the gate segments are connected to the stem via a drive bushing. The
drive bushing is basically a nut trapped between the gate segments. When the stem
is rotated inside the drive bushing the bushing rides up or down on the threads, thus
moving the gate segments up or down.
Backseat
In newer designs the bearing cap may be loosened to allow a small amount of axial
movement of the stem. When this is done the stem packing is isolated from the
cavity pressure by the internal metal-to-metal seal between the stem and the
bonnet and in doing so the valve becomes backseated. This enables the removal
and replacement of stem packing while the valve is under pressure.
Packing and Fittings
The stem packing works to isolate cavity pressure from the atmosphere between
the valve stem and the packing bore in the bonnet. Packing is generally of the
chevron or “W” cross sectional type composed of fabric and elastomer compounds.
When the stem packing leaks the seal may be renewed by pumping heavy grease
or sealant onto the packing area. This temporary measure allows time for planned
maintenance or replacement.
Other injection fittings may be used to inject lubricants into the body cavity.

April 2003 15-9

Graygate Model B Valve
The Model B Graygate is an updated version
of the Model A. The changes that were made
were minor because the configuration
remained that of an expanding gate, fixed
seat, non-rising stem valve. The Model B is
the most simple and the most heavily
manufactured Graygate to date. For these
reasons, we can use the Model B as a
standard in comparing the other Graygate
valve models. the Model B is used with 2,000,
3,000, and 5,000 service pressures, and bore
sizes ranging from 2 inches to 6 inches
nominal.
The Model B body is made from API Type II
cast steel rated to 2,000, 3,000, and 5,000 psi
MSP.
Model B valves come with threaded, API
flanged, and VGloc end connections for oilfield service. The end connection size is
specified by the bore size and the connection pressure rating. An example
specification would be the 2-1/16, 5M, meaning 2-1/16 inch bore, and 5000 psi
Maximum Service Pressure rating. The same size and pressure rating with VGloc
ends would be designated 2-1/16 5M, B-20 ends. “B” stands for clamp size, and 20
for the ring size.
A VGloc seal ring is used to seal the valve bonnet to the body.
All model B valves use the flanged bonnet design.
The Model B valve has a stem packing sealant injector fitting located on the bonnet
neck. It is the only fitting on the bonnet and the only Graygate model that has a
fitting in this location. The fitting consists of a solid dart threaded into a 1/2 inch NPT
fitting which has a ball check valve inside it. The stem packing can be reenergized
at full working pressure.
The Model B uses a split, parallel, expanding gate assembly to effect closure of the
valve. A square pocket machined into the top of the gate segments traps the gate
drive bushing and prevents it from rotating with the stem.
The Model B drive bushing is a one piece internally threaded lift nut. It rides up and
down the stem drive threads as the stem is rotated pulling the gates with it as they
are hooked to its square bottom. The drive bushing is also the drift control stop as it
contacts the bottom of the bonnet when the valve is fully open.
The seat pocket machined into the valve body accepts the seats and provides a
sealing surface for the back side of the seats.
Fixed seats are pressed into the seat pockets to seal face to face. It forms metal to
metal seals both at the gate-seat and the seat-body interface. The seats have been
retained in the body three different ways over the years. At first it utilized a heavily
knurled finish on the O.D. of the seat. A rolled tubular ring was also used. And last
the corrugated ring is now used as in the Model D valve. The seats have teflon rings
imbedded in the face on both sides to provided effective low pressure sealing.

15-10
The expander centralizes the gates, guides them, and prevents lateral or twisting
motion of the gates. Tapered ramps on the bottom of the expander contact
matching tapers on the sides of the gates forcing them apart as the gates are drawn
into closed position. This gives the valve a double block capacity (both gates and
seats seal simultaneously). A ledge in the valve body supports the expander and
prevents the gates from contacting the bottom of the body cavity.
The Model B stem is a rotating non-rising stem. It has a 6 pitch,left hand, stub acme
thread on which the drive bushing travels. The stem has an integral bearing flange
which prevents any axial movement of the stem. For this reason the stem is
installed from the front of the valve bonnet.
The stem packing consists of a multiple ring stack. the unique feature of the stack is
a sealant slug ring which is positioned between chevron packing rings in line with
the packing injection port. This allows the packing to be energized by sealant
injection.
A packing gland retains the packing in the packing bore of the bonnet is in turn
retained by the bonnet cap.
Two bearing sets are located just behind the bonnet cap on either side of the stem
integral flange. The bearings reduce frictional forces developed by the piston effect
of pressure on the stem, and thrust forces generated by gate motion. This
minimizes torque required to open and close the valve.
The bonnet cap is threaded into the front of the bonnet. It centralizes the stem and
retains the bearings and packing assembly. A hex socket set screw threaded
through the bonnet neck contacts and locks the bonnet cap in place. A zert grease
fitting in the bonnet cap allows for grease injection to the bearings. There is a rubber
grommet which seals between the stem and the bonnet cap to keep water out of the
bearing assembly.
The Model B valve uses either one or two standard grease injection fittings in the
valve body on the same side. These fittings are 1/2 inch NPT. They provide access
to the valve body for grease injection to ease friction
and protect moving parts for longer valve life.
Graygate Model C Valve
The Model C Graygate was developed for service
pressure ratings of 5M, 10M, and 15M. Some
extreme service valves made for secondary service
in the 20M pressure class strongly resemble this
valve design. Although the Model C has many
additional features, when compared to the Model B, it
is still an expanding gate, fixed seat, non-rising stem
valve. Most notable of additional features to the valve
is the stem backseat. The backseating feature is a
safety feature allowing the isolation of the stem
packing from pressure in case a leak developes. A
metal to metal seal is effected between the stem and
the bonnet by allowing the stem to slide outward a
fraction of an inch. The stem packing can then be
changed without removing the valve from service.

April 2003 15-11

Model C valve bodies may be either cast or forged from either type II or type III
material. Sizes range from 1-13/16 inch to 6-3/8 inch nominal bore. Service
pressure ratings range from 5M to 15M.
Model C valves come with either API flanged or VG end connections.
The Model C valve has a VGloc seal ring as the bonnet to body seal.
Model C valves have a flanged type bonnet configuration. There are two injection
fittings in the bonnet one is angled and is ported to the stem packing area. The other
is perpendicular to the bonnet and is ported below the stem packing but above the
backseat. This is the easiest identifying feature of the valve. Some of the later
designs had both injection fittings perpendicular to the bonnet neck.
Model C gates are split expanding gate assemblies. A semi-circular groove in the
top of the gates trap the drive bushing attaching it to the gate assembly. A torque
plate attached to the drive bushing is pinned to the end of each gate to prevent
rotation of the drive bushing. The gates are counter bored in the inside conduit to
accept a silt barrier ring which fits between the gates in this counter bore. This
prevents solids from building up in the cavity. For Model C valves rated to 10M and
15M there are coiled springs between the gates to maintain gate seat contact at all
times. The 5M model does not have the springs.
The Model C drive bushing consists of three parts, the internally threaded drive
bushing, the torque plate, and the retainer clip. The torque plate is attached to the
drive bushing in a splined arrangement. Two holes in the torque plate fit over drive
pins in the gates while a spiral lock clip ring locks the torque plate to the drive
bushing. The drive bushing travels on the stem threads pulling the gate back and
forth as the valve is operated. The drive bushing also acts as the drift stop as it
contacts the back of the stem backseat upset when the valve is fully opened.
Seat pockets are machined into the valve body to retain the seats and seal metal to
metal.
The Model C seats are fixed in the seat pockets and retained by either a rolled
tubular ring or a corrugated ring. The primary seal both gate to seat and seat to
body is metal to metal, however there are teflon rings in the seat faces to aid in low
pressure sealing. Seat skirts are welded to the seats in the Model C valve or they
may clip onto the seat. These skirts face the bottom of the valve and cover the
conduit during opening and closing to prevent the loss of lubricant caused by
turbulence.
The gate expander centralizes the gates, guides them, and prevents lateral or
twisting motion of the gates. Tapered ramps on the bottom of the expander contacts
matching tapers on the sides of the gates forcing them apart as the gates are drawn
into closed position. This gives the valve a double block capacity (both gates and
seats seal simultaneously). A ledge in the valve body supports the expander and
prevents the gates from contacting the bottom of the body cavity.
The Model C stem rotates but does not travel. It has a 6 pitch left hand stub acme
thread to drive the gates. An integral backseat flange is machined on the stem and
seats against the valve bonnet when the valve is backseated. This metal to metal
seal isolates the stem packing from valve cavity pressure. A recess is machined on
the stem to retain a split bearing flange.

15-12
A split bearing flange is installed on the stem between the bearings to retain thrust
forces generated by pressure and mechanical action.
The packing consists of a multiple chevron ring stack with a metal lantern ring in
between for sealant distribution. The 15M Model C valves have a double packing
stack backed by metal packing cartridges.
The packing gland retains the stem packing and is in turn retained by the bonnet
cap.
Two bearing sets are located just behind the bonnet cap on either side of the stem
integral flange. The bearings reduce frictional forces developed by the piston effect
of pressure on the stem, and thrust forces generated by gate motion. This
minimizes torque required to open and close the valve.
The bonnet cap is threaded into the front of the bonnet. It centralizes the stem and
retains the bearings, the split bearing flange, the packing gland, and the packing. A
hex socket set screw threaded through the bonnet neck contacts and locks the
bonnet cap in place. In normal operating position the bonnet cap is tightened snug
against the packing gland. To back seat the valve the set screw must be released
and the bonnet cap backed off a couple of turns. This allows the stem to move
outward and the backseat seal is effected. There is a retaining snap ring in the
bonnet which prevents the bonnet cap from being backed all the way out during the
backseating procedure. A zert grease injection fitting allows lubrication of the
bearing assembly. Weather seals are installed between the bonnet cap and stem
and between the bonnet cap and bonnet to keep water out ot the bearing assembly.
An identifying feature of the Model C bonnet cap is that it has two wrench flats milled
on the O.D. of the cap. It is the only model which
has this feature.
Model D Valve
The Model D Graygate has a two-piece
expanding gate that seals equally as well from
either direction. It has a fixed seat arrangement
with face-to-face sealing and a rotating
non-rising stem. Perhaps the most unique
feature of the Model D is the single
lubricant/sealant injection fitting which can be
isolated from well pressure by backseating.
Design Features:
Rated for 2,000, 3,000, 5,000, 10,000, and
15,000 psi service in sizes from 1-1/16 to 6-3/8
inches.
Available in threaded (screwed ends), API
flange, studded block, or VGloc end
connections for oilfield service.
VGloc Bonnet Seal Ring creates the seal
between the bonnet and the body. This patented seal ring provides a proven, safe,
reusable, metal-to-metal seal.
The injection fitting in the bonnet flange is used to inject lubricant or sealant. The
injection port leads into the valve above the backseat and below the stem packing.

April 2003 15-13

Alignment of the gate conduit with the run through the valve is achieved by the
square bottom stem pocket on each gate half contacting the end of the valve stem
when the gates assume the full open position.
Rotation of the non-rising stem in the drive bushing will raise or lower the gate
assembly.
Fixed seats are installed with a press fit into the seat pocket to ensure a face-to-face
seal.
In the closed position, the tapered ramps of the gate segments contact the
expander, mechanically forcing the gate segments against the seats. This positive
contact initiates the seal without relying on well pressure.
The stem backseat and the bonnet backseat can be selectively set to seal the stem
and the bonnet through metal-to-metal sealing technology. Backseating isolates
the stem packing in emergency situations and allows the packing to be removed
and replaced while the valve is under pressure.
Bearings on each side of the split bearing flange absorb friction thrust exerted by
well pressure and thrust forces exerted during gate movement.
The Model D Graygate body features one piece construction of forged or
cast-equivalent steels selected to meet or exceed the requirements of API 60K
(Type II) or 75K (Type III) materials, no penetrations in the pressure containment
section, CAD design for optimum distribution of allowable stresses, VGloc ring seat
for body to bonnet sealing, studded bonnet connection, recessed seat pockets with
metal-to-metal sealing surfaces.
Graygate Model D valves are available with threaded ends, API ring joint flanged
ends, ANSI ring joint flanged ends, VGloc clamp hub ends for API and ANSI service
and can be supplied in a variety of custom end connections by customer request.
Graygate composite block bodies with multiple valve cavities for special
applications are also available with the same selection of end connections.
Bolting for the Model D body to bonnet connection is selected for the service
application requested and meets or exceeds the requirements of all applicable
specifications and codes including, but not limited to API Spec 6A, Sixteenth
Edition. Custom bolting or materials are available upon request for special
applications.
The Graygate Model D valve bonnet features one piece construction from forged or
cast equivalent steels selected to meet or exceed the requirements of 60K or 75K
API Spec 6A materials. Model D bonnets are available only in a flanged style with
the VGloc ring seat for the body to bonnet seal, a selective metal-to-metal backseat
seal surface, a polished bore receptacle for the stem packing only, internal profile
for the stem bearings and internal threading for the bonnet cap. The Model D
bonnet also features an injection port above the backseat seal for injection of valve
lubricant and a weephole above the stem packing receptacle to prevent pressure
from becoming trapped above the stem packing.
The Model D bonnet seal ring is a VGloc ring which provides an elastically
deformed metal-to-metal seal between the valve body and the valve bonnet. This
bonnet seal design is in continuous service today under a wide variety of service
conditions from vacuum to 105,000 psi at temperatures from -423°F to over 1000°F.
VGloc seals are available in many materials with a broad selection of coatings to

15-14
meet the specifications of NACE, API Spec 6A (Sixteenth Edition), API 14D, ASME
and other applicable industry standards.
The only injection fitting in the Model D valve is located in the bonnet flange. This
single fitting is used to inject lubricant during routine valve maintenance. The
injection port leads into the valve cavity above the backseat and below the stem
packing and also serves to clear the backseat seal area when lubricant is injected.
The injection fitting is threaded directly into the valve bonnet and can be isolated by
the selective backseat seal for replacement, if ever required. The injection fitting is
a solid, one piece fitting with a metal-to-metal seal on the tapered nose. Any
possible damage to the fitting would leave the seal intact until replaced under
control. An O-Ring seal of a suitable material is located on the injection fitting O.D.
to control pressure from the valve cavity during injection. The hollow stem design
permits pressure equalization of the lubricant prior to opening the injection port.
The Model D features seats which are of a fixed design and are press fit into the
seat pockets of the valve body (See Seat Retainer). The back face of the seat is
fitted with a Teflon ring to provide a face to body low pressure initial seal. When well
pressure is introduced, the face to body seal becomes a metal-to-metal seal. The
front face of the seat is also provided with a Teflon ring. In addition to providing an
initial low pressure seal, the Teflon ring reduces operating friction and acts to wipe
the gates clean during opening and closing. The front face of the seat, which forms
part of the gate/seat sealing interface, is also designed to use well pressure to
achieve a metal-to-metal seal. This metal seal is specifically designed to balance
the bearing load which occurs during high pressure sealing and prevent
unnecessary friction from developing during the initial movement of the gates from
the closed position. The Teflon rings are pressed into a specially developed groove
to prevent any travel or dislocation during normal service. Special coatings are
used to replace the Teflon rings for applications of 10,000 psi and above and are
available for unusual conditions which require a gate/seat interface with no Teflon
or elastomeric inserts.
The press fit required for the Model D fixed seat design is accomplished with a
corrugated seat retainer ring. This ring was developed specifically to maintain the
position of the seat during the working life of the components and to facilitate the
replacement process when the seats are replaced in the field while the valve is still
in-line.
The Model D valve uses two expanding gate segments to complete the valve bore
sealing mechanism with the fixed seats. Close tolerance manufacturing capabilities
allow the Model D gates to function very smoothly along the gate/seat interface and
prevent the build-up of contaminants either in the valve cavity or across the
gate/seat sealing surface. The external sides of each gate segment in a manually
operated valve are machined with a tapered ramp. This tapered ramp is fitted with a
gate expander which orients the gates during opening and closing and provides a
bearing surface when the gates are expanded mechanically to initiate the low
pressure seal. The gates also feature drive pin holes on the top end of each
segment for drive pins which prevent the drive bushing from rotating during the
opening and closing cycles of the valve. Each gate half has a semi-circular groove
to trap the driving bushing in place and a square bottom stem pocket for drift
control.
The segmented gates of the Model D valve are made in a variety of materials with
appropriate coatings and hardfacings for the particular service conditions the valve
is intended for.

April 2003 15-15

The gate expander wraps around the segmented gate assembly and centralizes it
during opening and closing. As the gate assembly moves into the closed position,
the tapered ramp on each manual gate moves up the matching taper of the
expander to mechanically force the gates against the seats.
The gate expander lands on a separate machined shoulder in the valve body. This
shoulder is designed in harmony with the valve body and the valve bore sealing
mechanism to absorb the downward force of the gates in the closed position. The
gate expander and the gate expander shoulder prevent the gates from contacting
the bottom of the valve cavity.
The Model D drive bushing is a one piece, internally threaded lift nut. The circular
bottom end is trapped between the gate segments in corresponding semi-circular
grooves in each segment. The oval shape on the top of the drive bushing has open
slots on each end to work with the gate drive pin. This prevents rotation of the drive
bushing. rotation of the non-rising stem in the drive bushing will raise or lower the
gate assembly.
The Model D stem is a rotating, non-rising type stem. The stem rotates to open and
close the gates and does not move up and down. The threaded portion of the stem
area that is connected to the drive bushing is six threads per inch, left hand modified
stub acme. Materials and coatings are selected for the service conditions specified.
The stem backseat and the bonnet backseat can be selectively set to seal the stem
and the bonnet through metal-to-metal sealing technology. Backseating isolates
the stem packing in emergency situations and allows the packing to be removed
and replaced while the valve is under pressure. Backseating can be performed with
the valve in either the open or closed position.
The Model D also features a recess for the split bearing flange (see split bearing
flange) and a tapered/threaded end connection for positive attachment of the
handwheel.
ABB Vetco Gray’s ‘AMI’ Amine Inhibitor Packing for valves was developed in
response to the need for high performance seals to resist high temperatures (up to
350°/175°C), pressures in excess of 10,000 psi, and the presence of H2S, CO 2,
water, steam, amine inhibitors, or hydrocarbon corrosion inhibitor.
Because of the complex balance of seal design and compound selection, it is
important that the proper material and design be recommended for each
application.
The packing set consists of four components:
Item 1 is a beige-colored NON-EXTRUSION RING. Made of PEEK material, the
ring bridges the gaps between the metal parts and reduces the extrusion of the
pressure seals.
Item 2 is a purple-colored, TFE-filled PRESSURE RING developed for high
pressure (up to 20,000 psi) at high temperatures (up to 350°F).
Item 3 is also a PRESSURE RING. Black in color, it is much softer than the other
pressure ring (Item 2). This component ensures low pressure gas-tight sealing
capability.

15-16
Item 4 is a beige-colored CAP SEAL. Made of PEEK material, it performs three
functions: a) acts as back-up ring for Item 3; 3) maintains the pressure in the
packing area and slowly bleeds it off without damaging the elastomers; c) supports
Item 3 at the energizer quad ring and reduces the possibility of pressure being
trapped between the two pressure rings (Items 2 and 3).
The CT Stem Packing design was specifically developed to replace the existing
stem packing arrangements in the
Model D and Model ETP gate valves
for pressure ranges up to 15,000 psi
and temperatures from -20°F to 375°F.
The CT stem packing is highly resistant
to the presence of H2S, CO2, water,
steam, and amine based inhibitors,
and is qualified to Material Class HH in
accordance with API Spec 6A, 16th
Edition. The CT stem packing is a high
performance, non-elastomeric
configuration suitable for both oil or gas CT Valve Stem Packing
service and is capable of long term
service without any deteriation from
the extreme conditions imposed by critical service operations.
The CT stem packing consists of a number of individual components designed to
function as a unit during the temperature and pressure cycles encountered in oil
and gas production. The packing set consists of five components:
The upper NON-EXTRUSION RING is made of PEEK material. This component
bridges the clearances between the stem and packing bore and eliminates
extrusion of the pressure containing seals.
The PRESSURE SEALS are special Carbon-filled Teflon rings which are designed
to provide both mechanically energized low pressure and low temperature sealing
as well as maintain their structural integrrity and sealing capability at high pressures
and high temperatures.
The CAP SEAL is another PEEK ring with special design to provide structural
support for the packing set, assist with initially energizing the lower pressure rings,
and maintain the structural integrity of the lower pressure rings during bleed down.
The Model D packing gland is threaded to screw into the bonnet to hold the stem
packing down in the packing bore. A pin face spanner wrench is used for removal
and installation. The threaded type packing gland prevents movement of the stem
packing during backseating and provides a bearing surface for pressure contained
by the stem packing.
The backseat on the valve stem necessitates this type bearing flange because the
stem must be installed through the bottom of the bonnet. The matched set split ring
fits into a corresponding groove in the valve stem and maintains the relative
position of the stem during opening, closing, and backseating the stem.
The Model D valve stem bearings are located on each side of the split bearing
flange. Each bearing assembly is a heavy duty ball bearing set retained in a steel
case for maximum operating life. These bearings absorb friction thrust exerted by
well pressure and thrust forces exerted during gate movement.

April 2003 15-17

The bonnet cap is connected to the top of the valve bonnet by threads. It centralizes
the valve stem and contains the bearings and split bearing flange. it holds the stem
off the backseat during normal operation. With sufficient well pressure the Model D
valve can be backseated in any position.
Two weather seals are used to keep water out of the stem bearings and bonnet cap.
One seal fits into the top of the bonnet cap while the second seal is an O-Ring on the
OD of the bonnet cap directly above the threaded portion.
Model ETP Valve
The Model ETP (Extreme Temperature and Pressure) gate valve is a critical
service valve with a cartridge design packing stack based on the SR packing
assembly. The ETP design is a simplified
modification which eliminates the threaded
cartridge housings for sections which fit together.
The sealing mechanism of Teflon rings backed up
by flexible metal rings to create a zero clearance
stem seal remains the same. Two Autoclave
injection ports are used to inject sealant and create
a pressure energized redundant stem seal. The
Model ETP valve is available in sizes from
1-13/16" to 4" for pressure ranges of 15,000 and
20,000 psi. Major design features include
non-rising stem, no body penetrations, selective
backseating and VGloc bonnet seal ring. The
15,000 psi ETP valve features fixed seats and
tapered ramp gates to create a low pressure seal
with the mechanical force exerted by the
handwheel of the manual valve during closing. The
20,000 psi ETP valve uses the floating seats and
split gates with coil spring design from the SR
valve. Both designs ensure a positive gate-to-seat
contact during initial sealing. The 15,000 psi ETP
valve is similar to a Model D gate valve in the
components used in the valve body. The 20,000
psi ETP uses the valve body and components from the SR valve. Both are available
in a number of trims suitable for critical service applications including those
requiring Grayclad corrosion resistant cladding of all wetted surfaces.
The Graygate Model ETP valve bonnet features one piece construction from forged
steels selected to meet or exceed the requirements of 60K or 75K API Spec 6A
materials. Model ETP bonnets are forged with a flanged connection which features
the VGloc ring seat for the body to bonnet seal, a selective metal-to-metal backseat
seal surface, a polished bore receptacle for the ETP stem packing only, internal
profile for the stem bearings and internal threading for the stem packing retainer
and bonnet cap. The Model ETP bonnet also features three injection ports above
the backseat seal for injection of the ETP cartridge stem packing seals and valve
lubricant. A weephole is included above the stem packing receptacle to prevent
pressure from becoming trapped above the stem packing.
The Model ETP bonnet seal ring is a VGloc ring which provides an elastically
deformed metal-to-metal seal between the valve body and the valve bonnet. This
bonnet seal design is in continuous service today under a wide variety of service
conditions from vacuum to 105,000 psi at temperatures from -423°F to over 1000°F.

15-18
VGloc seals are available in many materials with a broad selection of coatings to
meet the specifications of NACE, API Spec 6A (Seventeenth Edition), API, 14D,
ASME and other applicable industry standards.
The Model ETP valve uses a redundant sealing, “zero clearance” stem packing
cartridge which is a direct application of the technology developed for the Extreme
Service 30,000 psi SR valve. The ETP stem packing cartridge uses separately
energized sealing assemblies consisting of Teflon seal elements and special helical
non-extrusion rings. Each section of the cartridge provides complete sealing
integrity field proven under the most extreme conditions in the oil and gas industry.
The ETP cartridge differs from the SR cartridge by eliminating the threaded
cartridge seal retainers. Each ETP cartridge segment fits together in the bonnet
packing bore and rests on a shoulder in the lower portion of the ETP bonnet. After
all the cartridge segments are in place, a packing retainer is threaded into the
bonnet to retain the packing set. This modification of the cartridge elements
provides improved performance at elevated temperatures and pressures.
The Model ETP valve features three injection assemblies located in the bonnet.
These assemblies are used to energize the redundant sealing compartments of the
ETP cartridge and inject lubricant during routine valve maintenance. The lowest
injection assembly, which is angled, leads into the valve cavity above the backseat
and below the ETP stem packing. This injection assembly is used for lubricant
injection and also serves to clear the backseat seal area when lubricant is injected.
The two upper injection assemblies are used only for energizing the ETP stem
packing cartridge. All injection assemblies are connected directly into the valve
bonnet with Autoclave fittings and can be isolated by the selective backseat seal for
replacement, if ever required. The injection assembly consists of an Autoclave
fitting in the ETP valve bonnet, high pressure nipple and Autoclave block needle
valve for control of the injection pressure in each sealing compartment. All of the
seals used in the injection assemblies are metal-to-metal seals.
Model SR Valve
Model SR Graygates are used in extreme service
applications and are made from API Type III steel
rated for 20,000 and 30,000 psi. They are available
in API flange and VGloc end connections in sizes
from 1-13/16" to 4". The basic Graygate design
consisting of two-piece gates, seats that seal
face-to-face, and a non-rising stem is the same as
for other Graygate models. The major design
features are described below:
A VGloc bonnet seal ring seals the flanged bonnet
to the body.
The valve stem is a rotating, non-rising type stem
with integral bearing flange. The stem is contained
in a manner to allow rotation but not axial
movement as it opens and closes the valve.
Flat roller bearings on each side of the integral
bearing flange absorb frictional thrust exerted by
the combination of well pressure and thrust forces
during gate movement.

April 2003 15-19

Three autoclave sealant injection ports are provided through which the cartridge
style stem packing is injected.
Stem packing is contained in a metal cartridge packing assembly which is threaded
into the bonnet to prevent movement. Multiple Teflon rings backed up by flexible
metal rings are injected with sealant at increasingly greater pressures toward the
lower cartridge segment to seal tightly at extreme pressures.
Secondary stem packing isolates the upper end of the valve stem so that lower
stem packing leakage can be monitored and prevents water from entering the
bearing area.
Because the gate conduit is located in the upper portion of the gate, the valve can
be converted to an actuator valve by removing the bonnet cap, the stem, bearings,
etc., and installing an actuator stem and actuator.
Non-expanding gates have eight coil springs between the segments to ensure a
positive gate and seat contact in all gate positions. Since the seats are not press
fitted, the springs also ensure positive seat/seat pocket face contact.
Skirts fitted around the seats act as body fillers and gate guides for lateral drift
alignment.
The seats slip into the seat pockets and are held in constant contact with the seat
pocket face by coil springs and the gate segments. The seats seal metal-to-metal
on the surface inside the Teflon ring grooves transmitting the seal from the gate to
the seat pocket face.
The backseat taper is located on the OD of the drive bushing, which is a pressure
containing component when the backseat is engaged. The drive bushing backseat
and the bonnet backseat can be selectively set to seal the drive bushing to the
bonnet with metal-to-metal sealing technology. Backseating isolates the stem
packing in emergency situations and allows
the stem packing cartridge to be removed and
replaced while the valve is under pressure.
The Model SR valve can be backseated only
when the gates are in the closed position.
Backseating is performed by removing the
backseat lock segments and rotating the
backseat nut to the left with the gates in the
closed position. Well pressure acting on the
cross-sectional area of the valve stem sets the
seal between the OD of the solid drive bushing
and the backside of the bonnet.
The original SR valve design has evolved into
the SR-CT2 valve. The principle difference is
the CT cartridge type stem packing which has
replaced the sealant injected packing
assembly used in the original SR valve. The
CT2 stem packing is composed of Carbon
Filled Teflon pressure rings expanded by inconel springs with PEEK non-extrusion
end rings housed in a cartridge assembly which minimizes the wear on any single
set of packing, and provides redundancy for reliability.

15-20
 SR-CT2Valve

April 2003 15-21

VG 200 Series Gate Valve
The VG 200 series gate valve is a slab gate valve
design with floating seats and non-rising stem.
VG-200 series valves are certified to API
Specification 6A, Appendix F, PR2 for -20o to 250o
F service and API 14D Class I for SSV service.
The VG-200 series valve is available in all
standard trims to meet the requirements of PSL 1
and PSL 2. VG 200 series valves are available in
sizes from 2-1/16” to 4-1/16” at 5,000 psi pressure
rating.
Turning the operating lever on the end of the stem
rotates the stem inside the drive bushing which
travels on the threaded lower end of the stem
carrying the gate between the open and closed
positions. The drive bushing is connected to the
gate by a insertion into a T-slot in the top of the
gate. This allows the gate to float freely and provides optimum gate to seat contact.
Wave springs behind the seats maintain the gate-to-seat interface and keep the
valve body free of contaminants. The gate, seats, stem and drive bushing have a
xlylan coating to reduce friction. This design makes the operating torque of the
valve exceptionally low.
The seal between the gate and seats is a pressed in Viton. Resilient seals are used
between the seats and valve body seat pockets. An o-ring with a back up ring is
used for PR 1 rated valves. An o-ring with two back up rings are used for PR 2 rated
valves. Engineered plastic packing rings are used for cold weather temperatue
classes below -20o F.
The VG 200 Valve stem packing is the PR 2 rated engineered plastic CT packing.
The valve bonnet is made up to the valve body by a studded connection utilizing a
flat metal gasket seal between the two components.
The VG 200 series valve has no penetrations into the body below the backseat.
There is a single standard lubrication port in the valve bonnet located above the
backseat profile. The valve bonnet has a seal profile which mates with a profile on
the stem to isolate the stem packing and bearings from well bore pressure with a
metal seal when backseated.
A threaded on bonnet cap retains the stem packing, packing retainer, needle roller
bearing sets, and bearing spacer in position in the valve bonnet bore. When the
bonnet cap is backed off two or three turns the valve stem can shift toward the front
of the valve permitting the stem to backseat against the valve bonnet isolating the
stem packing from the valve pressure cavity.
The upper and lower bearing sets are positioned in the valve bonnet bore outboard
of the stem packing, and stem packing retainer. A bearing spacer held in position by
a thrust pin through the stem is located between the two bearing sets. The needle
roller thrust bearings can easily be replaced without disturbing any of the seal
mechanisms.

15-22
 Closed Position Open Position

VG 200 Series Valve

April 2003 15-23

The stem has a shear pin below the operating lever which drives the stem as the
operating lever is turned. The shear pin protects the valve from damage which
could be caused by applying excessive torque to the operating lever.
The operating lever is retained on the end of the stem by a klick pin inserted through
the stem outboard of the operating lever.
An instruction plate is located on the outside of the operating lever. The instruction
plate indicates how many turns of the stem are required to open or close the valve,
and instructs the operator to rotate the valve back a quarter turn from its extreme
open and closed positions so the gate is free to shift toward the downstream seat to
maintain a seal.
Variations available for the VG 200 series valves include options for a cast or forged
body. The cast body valve is designated by the third digit of the 200 series. Cast
bodies are designated VG 200, forged bodies are designated VG 201.
The valve gate, seats, stem, and drive bushing are available with surface hardening
rather than xylan coating in this case the valve is designated VG 220.
The valve gate, seats, stem, and drive bushing may also be weld overlaid with
stellite in which case the valve is designated VG 230.
A VG 200 series valve with a forged body and weld overlaid gate, seats, stem, and
drive bushing is designated VG 231.
VG 230SE
The VG 230SE valve is a through conduit
gate valve for high temperature steam
service. The VG 230SE is suited for steam
injection wells, fireflood, or thermal
secondary recovery as well as industrial
plant applications. The non-rising stem
offers a more cost effective valve for this
temperature range. (To 650o F.) The valve
is available in sizes including 2-1/16”,
2-9/16”, 3-1/8”, and 4-1/8” for both ANSI
and API steam service requirements.
The VG 230SE valve features metal to
metal seals at the bonnet to body, gate to
seat, seat to body, and backseat seal
interfaces. The spring energized gate to
seat to body seal does not depend on line
pressure to effect a seal.
The valve is completely symetrical in
configuration and therefore bi-directional. A
smooth continuous flow conduit eliminates
turbulence with no pressure drop through
the valve other than that of an equal length
of pipe with the same bore diameter. The
seat faces are outside the flow stream, and
in full contact with the gates at all times
whether open or closed.

15-24
The CT stem packing is made of engineered plastic rings which are reinforced by
carbon fiber. The valve bonnet configuration spaces the stem packing away from
the bore and therefore from the heat source to further protect it from heat. The
added surface area of the bonnet neck provides for convective heat disipation to
the environment.
A single bonnet grease fitting is located in the bonnet flange and can be isolated
from the pressure cavity when the valve is backseated.
VG-300 Gate Valve
The VG 300 Gate Valve is an API
monogrammed, premium construction, oilfield
gate valve.
The valve body and bonnet are forged steel
construction with a bolted bonnet connection.
A VGloc seal ring seals metal-to-metal
between the valve body and the valve bonnet.
The bonnet has a single injection fitting that
can be isolated by the stem metal-to-metal
backseat seal.
The free floating one piece gate offers
bi-directional metal-to-metal sealing. The
seats are positioned in machined recesses in
the valve body. The seats seal metal-to-metal
at the seat to body interface and at the
gate-to-seat interface. Wave springs located
between the seats and the valve body hold the
seats against the gate to maintain continuous
gate to seat contact. Engineered Plastic seals on the outside diameter of the seats
enhance low pressure seat to body sealing.
The gate is driven by a single piece stem. The stem is threaded at its inboard end
with left-hand stub acme threads. A drive bushing threads onto the stem and mates
with the gate by a “T” shaped slot arrangement which allows the gate to float
between the seats. As the stem is rotated by the handwheel, the drive bushing
travels on the stem thread moving the gate between the opened and closed
positions.
The valve stem has an integral metal-to-metal backseat flange to isolate the stem
packing and the injection port from cavity well pressure. The valve bonnet has a
seal profile on its inner bore which mates with the backseat flange on the stem to
isolate the stem packing and bearings from wellbore pressure when backseated.
The valve backseats when the bonnet cap is backed off approximately three turns.
This allows the stem to shift towards the valve bonnet and the backseat flange seals
against the bonnet taper to seal metal-to-metal. Backseating also allows for field
replacement of the stem packing. The grease injection port can be used to verify
the backseat seal integrity.
The stem packing used in the valve is the type CT. This stem packing has been
qualified to API Specification PR2 for service pressures up to 20,000 psi and
temperatures from -75°F to 450°F. The stem packing is suitable for service to API
Material Class HH, including amine based inhibitors. A weep hole in the bonnet
neck is used to monitor stem packing integrity.

April 2003 15-25

 Open Position Closed Position

VG 300 Series Valve

15-26
The stem packing stack is fixed in position with a threaded packing gland which
cannot be backed out when the bonnet cap is removed. This arrangement
eliminates stem packing pressure loads from the stem bearings.
The handwheel is safely contained by a retention pin which allows for convenient
removal and replacement.
Beneath the handwheel is a corrosion resistant shear pin which drives the stem as
the handwheel is rotated. The shear pin protects the valve drive assembly from
excess torque should the operation of the valve be impeaded.
Variations available for the VG 300 series valves include options for a cast or forged
body. The forged body valve is designated by the third digit of the 300 series.
Forged bodies are designated VG 300, cast bodies are designated VG 301.
The valve gate, seats, stem, and drive bushing are available with surface hardening
rather than weld overlay with stellite, in this case the valve is designated VG 320.
A cast body VG 300 series valve with surface hardened gate, seats, stem, and drive
busing is designated VG 321.
VG 600 Geothermal Valve
The VG 600 Geothermal Valve is manufactured for high temperature service (550o
F.) with special geothermal trims for ease of field opeation
and well safety. The valve is particularly well suited for
applications where corrosive and/or abrasive fluids or
hydrate build up may damage stem drive threads if
exposed to the flow media. A rising stem design isolates
the stem drive threads for pressure and the fluids in the
valve bore. The VG 600 valve is available in ANSI 600#
Class 6”, 8”, 10”, and 12” sizes and API 7-1/16”, 9”, 11”,
and 13-5/8” sizes.
The VG 600 valve features metal to metal seals at the
bonnet to body, gate to seat, seat to body, and backseat
seal interfaces. The spring energized gate to seat to body
seal does not depend on line pressure to effect a seal.
The valve is completely symetrical in configuration and
therefore bi-directional. A smooth continuous flow conduit
eliminates turbulence with no pressure drop through the
valve other than that of an equal length of pipe with the
same bore diameter. The seat faces are outside the flow
stream, and in full contact with the gates at all times
whether open or closed.
The valve includes a fitting on the body for lubrication and/or draining and flushing
the valve body cavity.
The gate to seat and stem threads are coated with a baked on solid film lubricant.
A stem scraper (wire mesh impregnated with graphite) reduces hydrate build up
and extends the stem packing life.
The CT stem packing is made of engineered plastic rings which are reinforced by
carbon fiber. The valve bonnet configuration spaces the stem packing away from

April 2003 15-27

the bore and therefore from the heat source to further protect it from heat. The
added surface area of the bonnet neck provides for convective heat disipation to
the environment.
VGM Valve
The VG-M series gate valve is designed with a split wedge style expanding gate,
replaceable press-fitted seats and a rotating, non-rising stem. The expanding gates
obtains an extraordinarily high seating force simultaneously against both the
upstream and downstream seats. This seating force which is created is entirely
mechanical and unaffected by line pressure fluctuations or vibrations.
In the fully open position full flow is obtained through the valve, with the seat faces
protected from the flow stream. This full-bore-through conduit design minimizes
pressure drop and turbulence. In the fully closed position, the upper matching
surfaces of the male and female gate segments are in solid contact with each other.
The female segment wedges against the male segment, thus expanding the gate
assembly outward against the seat faces. Expansion of the gate is controlled by the
downward movement of the gate, so that extremely high seating pressure is
obtained. The seat inserts give an initial “Teflon”-to-Metal seal in addition to the
Metal-to-Metal seal obtained when the gate assembly is fully expanded. The seats
are fully protected from flow in both open and closed positions, allowing for
exceptionally long service life.
The VG-M series gate valve is designed for low operating torque. Providing lower
initial breakout torque means less wear on the valve bearings, stem and gate
assembly.
The VG-M series gate valve is equipped with two safety capped grease fittings so
that the valve body cavity can be filled with grease. The valve bonnet is fitted with
one packing injection fitting such that the stuffing box can be re-packed while the
valve assembly is in service. Additionally, the valve bonnet is also equipped with
one single standard Alemite grease fitting to lubricate the thrust bearings. All these
standard features can be performed while the valve assembly is in service.

15-28
 13

12 19

10
9
8
16
2
11
3
18 15
17

1 7

14

April 2003 15-29

 VG-M VALVE

ITEM # QTY DESCRIPTION

1 1 VALVE PART, BODY, API FLG, VG-M, FLANGE ENDS, 60K NACE

2 1 VALVE PART, BONNET, MANUAL, VG-M, 60K NACE

3 1 VALVE PART, STEM, MANUAL, VG-M, M ACME LEFT HAND THREAD

4 2 VALVE PART, SEAT ASSEMBLY, VG-M, 60K NACE

5 1 VALVE PART, GATE MANUAL, ASSEMBLY,VG-M

6 2 VALVE PART, GATE-GUIDE, VG-M

7 1 VALVE PART, BONNET CRUSH RING, VG-M,

8 1 VALVE PART, SPACER SLEEVE, VG-M,

9 1 VALVE PART, BEARING RETAINER NUT, VG-M,

10 1 VALVE PART, BEARING RETAINER LOCK NUT,VG-M,

11 1 VALVE PART, PACKING RETAINER BUSHING, VG-M

12 1 VALVE PART, HANDLE, VG-M,

13 2 BEARING,THRUST, 1.890 OD X .885 ID X .594 THK, W/OUTSIDE RETAINER AND CAGE

14 2 GREASE FITTING,GSP, 1/2 LP,FOR TEST/BLEEDER,PLASTIC/GREASE INJECTION

15 1 INJECTION FITTING,PLASTIC, 1/2 LP, 10M MODEL B

16 1 GREASE FITTING,STANDARD, .125 PTF,SPECIAL EXTRA SHORT,

17 8 STUD/ONE NUT, 7/8- 9UNC-2 X 3-1/2 LG,L-7/2H, PLT STUD & NUT

18 1 PACKING SET,PRESSURE RING,CHEVRON S, SET TO BE A 1-3-1 CONFIG

19 1 PIN,KLICK,.250 OD 1.750 LG WITH 1.375 REF RING ID

20 1 NAMEPLATE,VALVE ASSEMBLY,API 6A SSV OR USV 1.750 X 4.500,304SS (NOT SHOWN)

Remotely Actuated Valves

The API uses the term Actuator to describe the devise that opens or closes on
oilfield gate valve. In the field, however, the term operator is also quite common.
These terms are actually outgrowths of the efforts to market the Axelson “Actuator”
and the Otis “Operator”, two pioneers in the field of pneumatic or hydraulic
actuators. An actuator or operator is fitted atop a valve to open or close by using
compressed air (Pneumatic Actuator - PA) or pressurized hydraulic fluid (Hydraulic
Actuator - HA or Reduced Height Hydraulic Actuator - RHA). These actuators are
arranged to fit any model type by installing a special valve bonnet which adapts the
actuator to the valve.
The type of valve most common to this useage is the rising stem type and the
principle of operation is quite simple. A piston in a cylinder (the actuator) forces the
valve stem down into the valve whereby the holes in the gates are aligned with the
bore of the valve. The point to remember is the stem is being forced into the cavity
of the valve body and the pressure in the valve body will exert a constant piston
effect on the valve stem. This piston effect is used to close the valve when the
pressure in the cylinder of the actuator is released. To close a valve without
pressure, a spring is placed under the cylinder piston in the actuator.
Actuated gate valves can be backseated, but only with the valve in the closed
position. This is accomplished by loosening the cap on top of the actuator.
The valve just described is known as a fail-close valve because if for any reason,
emergency or otherwise, the pressure is bled off the actuator the valve will
automatically close.

15-30
Differences Between Manual and Remotely Actuated Valves
The body for an actuator valve is identical to that for a manual valve.
The bonnet design for an actuator valve is different from a manual valve in two
respects. First the bonnet must provide a means by which the actuator is attached
to the bonnet. Secondly the packing bore and gland will be different because this
valve is a rising stem valve instead of a rotating stem valve. No bearings are
necessary which simplifies the design.
The seats used in an actuator would normally not be any different from those used
in a manual valve although there may be some differences in the way they are
installed.
Gates for a fail-close actuator valve usually differ from a set of manual gates in that:
• Gate bores or conduits are located in the top of the gate rather than at the
bottom and are some times called reverse acting gates.
• A rising stem valve does not require a stem pocket, drive bushing pocket or
torque plate pins.
• Most actuator gates have straight edges where expander ramp tapers would
exist on manual valves. Early designs featured a curved ramp for a split type
ball end expander.
In most cases the expander in an actuator valve does not expand the gates but
merely acts as a guide mechanism and on some valves the part description may
call it a gate guide. Most actuated ABB Vetco Gray valves use the same expander
that goes into a manual valve.
The stem for an actuator valve is a long shaft with an extremely smooth surface to
move up and down in the stem packing. One end has a flange which is trapped
between the gate segments and on Model D valves, will have a tapered upset for
backseating purposes. The other end has a smaller extension with a threaded end
for connecting the piston of the actuator. Pneumatic actuator stems may have a
grooved recess for a dash pot mechanism which affords a smooth operation during
closing. The stem may also be threaded for a drift (or stop) ring which serves as an
adjustment for aligning the gate bore with the bore of the valve. Other models have
a two piece design consisting of an upper and lower stem with a spacer ring to
control the drift for proper alignment.
Packing and injector fittings are basically the same types used in manual valves.
Some large bore actuator valves have the cartridge type stem packing
arrangement.
Valve Actuators
ABB Vetco Gray valve actuators are unique in that most of the actuators in the
market are built into the valve bonnet. This means that to replace the actuator the
gates must be removed from the valve body. ABB Vetco Gray actuators can be
removed from the valve without removing the valve assembly from the service
location.

April 2003 15-31

Three types of actuators are available for surface applications:
• The Pneumatic Actuator (PA),
• The Hydraulic Actuator (HA) and
• The Reduced Height Hydraulic Actuator (RHA)
• The compact height Hydraulic Actuator (CH)
In most installations these four lines are interchangeable.
Actuator components can be divided into two main groups - the base and stationary
parts which connect to the bonnet and contain the pressure and the moving internal
parts which actuate the gates.
The central part of the first group is the cylinder housing which contains the actuator
mechanism. The lower end of the cylinder housing is attached to a lower housing
which provides the base for connecting the actuator to the valve bonnet. Newer
types use a large nut with an internal tapered thread (box end) which makes up on a
pin connection of the same type on the bonnet. The base will contact the face of the
bonnet flange between the studs and nuts on the bonnet to lock the actuator to the
valve. The outer portion of this large hold down nut is cut with gear teeth because a
rack gear tool was to be used to install them. A large screwdriver or crowbar is
easier to use and much faster.
The top end of the cylinder is prepared to attach a cylinder head. This item seals off
the top of the cylinder, provides an internal bore and seal for the piston rod sleeve,
and is threaded on top so that the cap can be installed. The cylinder head and blind
cap also make provision for a magnetic position indicator.
Internal moving parts consist of the piston, piston rod sleeve and spring(s).
The piston moves down in the cylinder
when pressure is introduced from above.
O-rings are used to seal the pressurized
areas inside the cylinder. The top of the
piston is fitted with a replaceable piston
rod sleeve that seals in top of the piston
and also seals in the center of the cylinder
head. The upper portion of the valve stem
is connected to the piston rod sleeve with
a large nut. This nut will contact the cap to
prevent backseating in normal operation.
Pneumatic Actuators (PA)
The ABB Vetco Gray Pneumatic Actuator
(PA) is a remotely operated valve actuator
which is designed to open or close a gate
valve using compressed air or gasses.
The pneumatic medium is compressed on
top of a sealed piston in a cylinder housing
which in turn strokes the valve stem into
the open or closed position. Actuated
valves are normally fail-safe closed
designs and OCS certified Surface Safety

15-32
Valves (SSV) must be fail-safe closed. The force to close the PA actuator is
supplied by the coil springs positioned beneath the piston. The spring force is
assisted by well pressure in the valve, but each actuator is designed to close
without any pressure assist. The PA-WLS series will close and shear standard
sizes of wireline.
ABB Vetco Gray pneumatic actuators can be adapted to any manual valve body
with the proper valve bonnet. A single nut mounting allows fast, easy installation.
Because the actuator does not have to be rotated during removal or installation, it
may be easily aligned with pressure control lines. A breather disc allows air to be
expelled from or inhaled into the cylinder beneath the piston by piston movement.
This disc allows thermal breathing, but protects against contaminants. A burst disc
protects against accidental damage due to excessive operating pressure.
ABB Vetco Gray pneumatic actuators are available in four standard sizes to
accommodate standard valve sizes and pressure ranges. The PA actuator is
available as a PA-11, PA-16, PA-17, and the PA-23, Operating pressures range
form 80 to 375 psi pressure in the cylinder. A rupture disc is provided in the piston to
prevent possible damage from excessive pressure in the cylinder housing.
Hydraulic Actuators (HA)
Hydraulic actuators are designed to operate at control pressures of 1500 psi or
2500 psi. To close a pneumatic actuator valve the compressed air is simply vented
to the atmosphere by control valve mechanisms.
Operation of the hydraulic becomes more
involved because the operating fluid must be
contained in a closed system. When the valve is
closed the fluid on top of the piston must be
dumped and returned to the reservoir of the
hydraulic pump. A most simple approach is to
have one line ported to the upper cylinder to be
used for both pressure (opening) and return
(closing ). In large valves this presents a problem
because it may take a long time for the fluid to be
pushed out of the actuator. A through conduit
valve is most vulnerable in the opening and
closing operation because the sealing surfaces
are exposed to the abrading turbulence in the
flow of the well. If the valves are to have a long life
they must be opened and closed quickly. This is
true for any type or make of oilfield valve.
To allow quick closure of a hydraulic valve we
equip the actuator with a devise called a quick
close control valve (QCCV). Instead of dumping
all the fluid back in the return line at once we can
transfer the fluid to the lower side of the actuator
for temporary storage allowing more time for the
fluid to return to the reservoir after the valve has
been closed. Closing times of less than 2 seconds are not uncommon for large bore
high pressure valves operated at full cavity pressure.
Overrides and lockouts can be attached to most actuators so that wireline and other
well operations can be performed in complete safety. Some lockout caps feature a

April 2003 15-33

fuseable strip of eutectic material which would close a locked open valve in the
event of a fire.
Hydraulic Actuators (RHA)
In addition to our standard line of hydraulic actuators, ABB Vetco Gray is proud to
present our latest innovation in actuators — the Reduced Height Actuator (RHA).
This new design is as powerful as conventional piston-type hydraulic actuators but
7 to 11" shorter than traditional valve/actuator assemblies.
The RHA actuators fit on API gate valves rated to
15,000 psi and can be easily converted from a
simple hydraulic configuration to a manual
override version. Operating pressures for the
RHA series are 3,000 to 6,000 psi.
Traditional piston-type actuators depend on wire
helical coil springs for the additional force
required to open or close the valve. ABB Vetco
Gray is the first manufacturer to use volute
springs, a conical structure of rectangular blades
which nest within one another concentrically, so
that the solid height of the spring equals the
height of the blade when compressed.
Conventional helical coil springs require a much
larger operating area because coils rest on top of
one another. The volute spring uses a smaller,
non-pressurized housing, which can be built of
lightweight materials. Additional height savings
are achieved with the indicator shaft positioned
on the side (rather than on the top) and the low
handwheel profile for the override. On offshore
platforms the RHA allows greater flexibility in the
arrangement of the wellhead deck, since less
distance is required between units.
The very high initial force provided by the volute spring results in a more rapid
closing time because it quickly overcomes the fluid inertia in the hydraulic control
lines. The actuator can easily adapt to wireline shearing and retain its small size
because of the high force induced by the volute springs. High pressure operation (3
to 6 ksi) also requires very little fluid displacement. Repair and maintenance have
been simplified with a union connection that allows the lower mounting ring to be
unclamped (while the valve is on backseat) to reach the bolting. Piston seal
replacement, a common maintenance procedure, is easily effected by removal of
the hydraulic power supply connection

15-34
Type CH Hydraulic Actuator
The CH hydraulic valve actuator is used both for surface and subsea applications.
The CH valve actuator is designed and performance test -verified to API 6A,
Appendix F, PR2 Specification and meets or exceeds the requirements of API 17D
and API 14D for safety valve actuators, and can be readily supplied to NAS 1638
cleanliness levels upon request. The actuator has a slim design to reduce space
needed for block valve installations. Actuation pressure rating is 4500 psi
maximum. The actuator can be fitted to shear either 7/32” braided wireline or 1-3/4”
coiled tubing. The CH actuator has a selective backseat, failsafe eutectic lockout
cap. Position indicators to fit customer specifications can be provided including
proximity switch, limit switch, and visual.

CH-CTS 48 Hydraulic Actuator

Capable of shearing 7/32” braided wireline or 1-1/2” coiled tubing

April 2003 15-35

SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 16
Production Chokes
This page left blank
A production choke restricts the flow of oil
or gas to a level which promotes the
highest recovery efficiency without
formation damage or unnecessary erosion
throughout the production equipment and
flow lines. A choke, unlike a valve, does not
necessarily stop the flow completely but
does control the flow rate. There are some
new designs which claim to offer complete
shut-off capability but the seals are not
located in the area of the choke itself. There
is a wide variety of choke designs available
which use different philosophies to achieve
the same result - variation of the flow orifice
to control the flow volume. Chokes are
available in either positive or adjustable
style for flow control with a variety of sizes,
connections, and pressure ranges to meet
any know industry requirements. The
positive choke is one which requires that
the flow be stopped to change the orifice or choke “bean.” An adjustable choke can
vary the orifice area and volume of flow without shutting in the well.
All Vetco Gray positive chokes come with a one-piece bean which is easily changed
out without removing the choke from the line. After shutting in the well, pressure is
bled from the choke body, the bonnet is removed, and a bean wrench used to
remove and replace the bean. The choke bean for a positive choke is usually a
stainless steel, ceramic, or tungsten carbide insert with a fixed diameter measured
in 64ths of an inch. The various sizes of positive beans allows the flow of production
to be set as needed. For an adjustable choke this is accomplished by removing the
bonnet/stem assembly and, using a similar bean wrench, remove the old “orifice”
bean and replace it with a new one. The flow area between the stem tip and the
orifice may also be adjusted in 64ths of an inch with a gauge ring to show equivalent
flow diameter. In addition to the tapered stem and orifice bean assembly for
adjustable chokes, there is also the sliding sleeve assembly. The sliding sleeve
design uses computer designed flow ports or
venturis in a metering tip which slides in and
out of a straight bore orifice bean. Once again
the flow volume is adjusted by opening
(increasing) or closing (decreasing) the flow
area. This type of assembly is featured in the
FBS choke designs.
VG 400 Line of Production Chokes
The VG 400 line of production chokes was
first marketed in 1994 and consists of a
variety of positive and adjustable chokes
which are value engineered for the optimum
reliability and performance at the lowest cost.
This line of chokes was developed to allow
production choke users options to utilize all of
the choke bean and spare parts inventory that VG 400T1 Positive Choke
they already possess by permitting the

April 2003 16-1

purchase of a choke from the supplier of
the tree which may use any of the most
commonly used choke bean designs in the
industry. The VG 400 family of chokes
include the H2, T1, PC, JWA, N60, N62,
FT108, and FT 116F. The differences
between these choke designations relates
to the type of inlet and outlet connection,
pressure rating, type of bean and required.
VG 400 chokes have choke bodies which
can be used for either positive or
adjustable arrangements depending and
the ancillary parts used. The choke
VG 400H2 Adjustable Choke
bonnets are threaded hammer union
connections with a safety plate. The safety
plate assembly mandates removal of a bleeder plug before the bonnet can be
removed thereby requiring that the choke be devoid of pressure before it can be
opened.
Standard series 400 chokes are API monogrammed to API Specification 6A. They
are available in Temperature classes P through U, to PR2, Material Classes AA
through FF, and PSL 1 or 2.
Materials for series 400 chokes meet the NACE MR-01-75 standard for H2S
service.
VG 400 series chokes are available in sizes from 1-13/16” to 4-1/16” and pressure
rating from 2,000 to 10,000 psi
The VG 400 family of chokes have a 1” maximum flow orifice although some beans
are only offered up to 3/4” orifice.
VG 400 chokes are offered with Line Pipe inlet and outlet, API flange inlet and
outlet, or a combination of flange by Line Pipe inlet and outlet.
Two types of beans are provided to fit all of the above choke models. The FC-140 is
used in the FT 108, FT 116F, T1, and PC. The Big John (BJ) is used in the H2. For
large flow orifice requirements the choke beans may be provided in the form of a
master bean and an adapter as with the H2 BJ
and the H2 HJ, or the FC-141 and the FC-140.
Choke beans are provided in stainless steel
with either ceramic or Tungsten Carbide
inserts.
Type 8746 Positive Choke
The 8746 is the workhorse of the Vetco Gray
choke line. Available in pressures from 2,000 to
10,000 psi, the 8746 is an economical choke
for standard oil or gas service and has a history
of over forty years of field service. The 8746
choke is available with flanged, Grayloc, or
threaded end connections and a studded
bonnet for easy replacement of the choke Type 8746 Positive Choke

16-2
bean. The threaded end 8746 is usually called an 8727 choke. All of the 8746 and
later chokes use the Type 80 choke bean. The Type 80 choke bean replaces the
Type 60 choke bean. The Type 80 bean has a maximum flow orifice of 3/4” and is
available with either ceramic or tungsten carbide inserts for increased operational
life. The Type 80 bean threads into the body of the choke via acme threads and
seals metal to metal by means of an integral taper located below the threads.
The bonnet of the choke seal metal to meat via an integral tapered metal to metal
seal retained by two studs in the body of the choke. An S-shaped bonnet is also
available which allows removal of the bonnet without completely removing the
bonnet bolting. This bonnet is called the quarter turn bonnet.
8746 Adjustable Choke
Most chokes manufactured by Vetco Gray, including the Type 8746, can be easily
and quickly converted from positive to adjustable, or vice versa, by changing the
bonnet assembly. The 8746 positive choke is converted to an adjustable assembly
by exchanging the positive or quarter-turn
bonnet for the 8711 Adjustable Assembly and
by changing out the Type 80 positive choke
bean for a Type 80 tapered orifice bean.
The 8746 adjustable choke provides
metal-to-metal sealing integrity in both the
bonnet and bean-to-body seals. Stem packing
is of the chevron cross- sectional type
composed of fabric and elastomer compounds
to suit service conditions. The 8746 adjustable
choke comes standard with a maximum
equivalent flow orifice of 3/4" and is available
with standard flange or Grayloc end
connections in pressure ranges up to 10,000
psi The 8746 is also available in a number of
standard trims and can be Grayclad upon
request.
Type T-80 Chokes
The T-80 is designed for intermediate pressure
ranges (10,000-15,000 psi). The body/bonnet
connector on this type of choke is either a
studded bolt and bonnet design similar to the
8746 or a Grayloc connection for quick change
of the Type 80 choke bean. The T-80 positive
choke is available with either flanged or Type 8746 Adjustable Choke
Grayloc end connections in a variety of
materials and trims, including Grayclad, for all
service conditions in the oil and gas industry.
The Type T-80 positive choke body is easily converted to an adjustable model by
changing out the positive bonnet and choke bean for an orifice bean and tapered
stem bonnet assembly.

April 2003 16-3

VG 1000, 2000, and 3000 Chokes
VG 1000, 2000, and 3000 Chokes are designed for service in the 5,000 to 10,000
psi pressure ranges. They are available with outlet
sizes from 1-13/16” to 3-1/16”. The VG 1000, 2000,
and 3000 provide a larger maximum flow orifice than
the Type 8746 which has a maximum of 3/4”. The
difference between the VG 1000, 2,000, and 3,000
chokes is the end and outlet connection sizes and
the maximum orifice size of the choke. The 1000
indicates a 1” maximum orifice, the 2,000 indicates a
2” maximum orifice and the 3000 indicates a 3”
maximum orifice.
These chokes are offered in cases where the large
maximum orifice is required. Both positive and
adjustable bonnet assemblies are available. This
family of chokes uses the VG 1 type choke bean
which has a metal to metal seal between the bean
and the choke body which is above the threads so
as to isolate the threads for exposure to the
production flow.
The bonnet of the choke seal metal to meat via an VG 1000 Positive Choke
integral tapered metal to metal seal retained by two
studs in the body of the choke.
Type FBS Chokes
The FBS (Flow Balanced Stem) choke is designed for operating pressures of 5,000
to 15,000 psi and is used for high volume
situations requiring a full opening (2" and
larger) orifice. The FBS choke uses a rotating
non-rising stem and drive bushing to operate
the choke stem. This strokes the sliding
sleeve tip assembly in and out of the choke
bean to adjust the flow. This design uses the
downstream pressure to equalize the
effective piston area of the choke stem to
reduce operating torque at the high
pressures and flow rates the FBS was
designed for. The stem packing assembly is
independently retained in the adjustable
bonnet assembly. When the Grayloc bonnet
connection is disassembled, the stem can be
removed from the bottom of the bonnet
assembly and the stem packing changed.
This design also allows the use of a selective
backseat on the PBS choke stem. If a leak
should occur, an injection port is provided to
re-energize the packing and temporarily
renew the seal. FSB Choke

The FBS choke line also offers three

different, interchangeable metering tips
which connect to the choke stem with a tool joint type of thread:

16-4
The Sliding Sleeve tip is a ported venturi tip for production of gas or light crudes and
condensate.
The Full Bore tip for lower flow volumes of oil or heavier crudes, and
The Clean Out tip for initial well production which may include drilling fluids,
completion fluids, proppants or frac material.
Type PBS Chokes
The PBS choke was designed for low torque operation with flow in the 3,000 to
10,000 psi range where large bore (2” to 4”) service is needed. As with all ABB
Vetco Gray chokes it can be supplied with
either a positive or adjustable bonnet
assembly.
In the adjustable assembly to balance forces
exerted on the metering tip, the PBS choke
equalizes the effective piston areas in the
upstream and downstream pressure cavities.
This system produces low operating torque
characteristics over a broad flow range. This
pressure balanced design minimizes the load
on the stem tip, and exposes the stem
packing only to the lower downstream
pressure rather than the upstream pressure.
A tapered metal to metal seal with hydraulic
packing backup between the body and
bonnet is provided by the lower housing. All
PBS chokes are supplied with a Grayloc
clamp to maintain this seal interface.
The choke features a stem backseat to
isolate the stem packing from the pressure
cavity in case of stem packing failure. This is
provided by a integral flange on the stem which seats and seals against the choke
bonnet when the stem is backseated by rotating the bonnet cap to the left.
The PBS choke line also offers three different, interchangeable metering tips which
connect to the choke stem with a tool joint type of thread:
The Sliding Sleeve tip is a ported venturi tip for production of gas or light crudes and
condensate.
The Full Bore tip for lower flow volumes of oil or heavier crudes, and
The Clean Out tip for initial well production which may include drilling fluids,
completion fluids, proppants or frac material.

April 2003 16-5

Extreme Service Chokes
The Vetco Gray SM-10 and SM-15 chokes meet extreme service requirements for
very high pressure (20,000 and 30,000
psi) applications. As with all ABB Vetco
Gray chokes it can be supplied with
either a positive or adjustable bonnet
assembly.
The adjustable assembly provides easy
operation with minimum torque because
a small orifice equalizes pressure above
and below the metering tip.
A parabolic metering tip minimizes the
amount of travel required to move the
stem to various orifice positions as well
as equalizing the increments of travel
between orifice sizes. This facilitates
adaptation of the choke to a remotely
operated stepping actuator. A blast
sleeve protects the metering tip from the
impact of high velocity flow.
The stem packing is the high integrity
CT2 engineered plastic cartridge type
packing.
Choke beans can be supplied in a variety
of trims including ceramic and tungsten
carbide inserts.

The following 2 pages contain pictures of SM 15 - CT2 Adjustable Choke for 20,000 psi
Positive and Adjustable chokes available service and sour gas
through ABB Vetco Gray.

16-6
Positive Chokes

VG-400H2 FPC

FFT-116-F FFT-108

FT-1 FPC-R

April 2003 16-7

Adjustable Chokes

VG-400H2 FN-60 FO-60

FN-62 FJW-A

16-8
SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 17
Mudline Suspension Systems
This page left blank
In 1958, the oil and gas exploration industry entered
a new era when offshore drilling from a mobile
drilling rig was first accomplished. The earliest
mobile rigs were submersible rigs drilling individual
wells in shallow water and the equipment was
identical to that used on land wells. As the drilling
moved into open waters, the need for producing well
protection, and treating facilities resulted in the
installation of platforms or well jackets when a well or
wells were to be produced. The jackup rig evolved
as the need arose for a mobile offshore rig which
could be used for the purpose of exploratory drilling
since the investment in a platform was not desirable
until a commercially viable reservoir was
discovered. Since the necessary protection and
treating facilities were not present as these
exploratory wells were drilled it was necessary to
temporarily abandon the wells after drilling until a
platform or well jacket could be constructed and
installed over the well. To facilitate re-entry into
these wells, mudline suspension systems were
developed. The mudline suspension system provides a base of support for the
weight of the casing strings and a disconnect/tieback interface for easy
abandonment and re-entry. Mudline suspension systems are now universally
utilized for exploration drilling from jackup and other submersible drilling rigs.
As offshore drilling moved into deeper waters, the free standing column of a
conductor string in 300’ to 400’ water depths could not support the weight of
subsequent casing strings at rig level. Mudline suspension move the load support
interface to the conductor stabilized by the surface strata of the ocean floor.
ABB Vetco Gray has developed a new mudline casing suspension system that
provides the load bearing capacities for deep, high pressure wells and incorporates
metal-to-metal sealing technology for working pressures up through 15,000 psi.
The ML mudline suspension systems also include the ML-H hanger only system for
applications which do not require any disconnect/tieback interface (usually run from
platforms which cannot support additional casing loads.
The ML-L, ML-H, and ML-C systems all provide the operator with the ability to
complete the well by:
• tieback to a fixed platform,
• or installation of a subsea tree.

April 2003 17-1

ML Mudline Suspension Systems Ratings
The Pressure and load capacities of system components varies with the type of ML
system used as well as the sizes, grade, and weights of the casing programs
utilized. The MLC system, rated at 10,000 psi maximum, has sufficient capacities
for nearly all wells drilled by jackups. Since it is the lowest cost system the MLC
system is now used in most cases. The MLL system has more load support
capability, deeper stack down, and 15,000 psi pressure capacity in the 9-5/8” and
smaller suspension assemblies. This system is used on deep, extreme service
wells. The MLS system is no longer actively marketed.

Typical Mudline system joints made up - 30” x 20” x 13-3/8” x 9-5/8” x 7”

17-2
Mudline Systems Assemblies
Mudline Suspension Systems utilize various components to provide for the
suspension, abandonment, and tieback of exploration and/or development wells.
These components are typically assembled into casing joints prior to shipment to
the rig, permitting each assembly to be handled easily on the rig, and minimizing
the potential for delay during assembly in the field.

Conductor Landing Rings

The first component installed in a
mudline system is the Conductor
Landing Ring which is a one piece
ring with an internal load shoulder of a
smaller inside diameter than the pipe
in which it is installed. The Conductor
Landing Ring has butt weld end Landing Ring
preparations, and is typically welded
into one of the conductor landing
joints. In the field the landing ring joint is run such that the Conductor Landing Ring
is positioned at or just below the mudline.

Conductor Release Connector

A remote release connector is sometimes
supplied for the conductor string to permit a
fast reliable way of disconnecting the
conductor just above the mudline and to
facilitate tieback to the connector once the
platform or jacket is installed. Some
operators don’t tieback the conductor to the
platform in which case the conductor is
typically cut off.
ABB Vetco Gray offers several specialty
conductor connectors which are easily
released and can tolerate pile driving loads
which the most common way of installing the
conductor string.

DMR Conductor Connector

The DMR Driveable mudline releasable
connector is a remote method of releasing Diverless Remote Release - DMR
the drive pipe/conductor string at the Conductor Connector
mudline when drilling form a jackup rig.
When the DMR connector is remotely
released, a box connection is left on the well. Then at a later date, the well can be
tied back using the DMR-T pin to re-establish the connection. The connector can be
driven, jetted, or run into a pre-drilled hole.
The connector is run box up pin down. The pin engages the box using four
rectangular lugs on the outside diameter of the pin which drop into a double step
L-slot in the box. Rotation to the left engages the connection which is then pinned in
position by a single shear pin.

April 2003 17-3

The connector is released by pulling slight tension, and rotating to the left applying
about 25,000 ft-lbs of torque to shear the brass pin and then following the double
step profile until the connector releases.
Tieback is effected using the DMR-T pin connector which stabs and locks to the
DMR box without rotation or alignment requirements. An expanding lock ring on the
pin snaps into a mating recess in the box to lock the connection. An o-ring on the pin
serves as the pressure seal between the mating components.

ALT-2 Squnch Joint Connector

The ALT-2 Squnch Joint Connector is a
threadless automatic-lock/mechanical-release
connector that requires no rotation for make-up.
It is designed to save expensive rig time with its
extremely fast make-up characteristics. An
expanding lock ring on the pin connector
engages a mating recess in the box connector to
lock the components together. An o-ring on the
pin provides the primary pressure seal. The pin
connector has an anti-rotation lug below the seal
profile which is engaged by a key slot on the box
connector so to prevent rotation the connectors
in relation to one another. A series of tapped
holes around the circumference of the box
penetrating the recess for the lock ring. To
release the connector hex socket screws are
made up into the tapped holes and depress the
lock ring out of the mating profile in the box
permitting connection release. 30” ALT-2 Squnch Joint Connector
Because it is necessary to be hands on with this
connector to release it, it requires a diver to release the connection subsea.

RL-4 Connector
A left hand threaded RL-4 Connector is
sometimes used for remote release of the
conductor string above the mudline. This
preloaded driveable connector has four
interwoven threads which engage
simultaneously and make up fully in 1/4 to 1/2
turns. The thread form is self locking and utilizes
an o-ring seal as the primary pressure seal. By
using the left hand thread the connector can be
released for abandonment by right hand rotation
eliminating the likelihood of inadvertently
backing the conductor off at the wrong
connection.
30” RL-4 Conductor Connector

17-4
ML Mudline Suspension Systems
Casing Hangers
Mudline hangers are designed to
nest one inside the other. Each
hanger except the last includes the
profile to suspend the casing hanger
for the next casing string. The tops of
each hanger is below the top of the
preceding hanger so that the
running/tieback interface
connections are below one another
facilitating washout of cement around
the running tieback thread, and
affording space to install corrosion
caps upon abandonment.
ABB Vetco Gray’s new mudline
suspension systems use two types of
mudline hangers.
20” MLC Casing Hanger
Fluted no-go landing rings are
incorporated on mudline hangers
wherever annular space permits a shoulder in the preceding hanger, and a full size
drill bit can be passed.
Expanding mudline hangers are used where
landing seat in a previous hanger would not permit
passing a full size drill bit.

External Fluted Landing Shoulder Mudline

Hangers
Most fluted landing shoulder mudline hangers
include a removable landing ring so that one
hanger body can accommodate a number of
casing programs. For instance, a single 20"
hanger body can be used inside a 48", 36" or 30"
conductor by installing a 48", 36" or 30" fluted
landing ring on the 20" hanger body. Four flow-by
slots in the removable landing ring permit mud and
cement to pass by the mudline hanger when it is
run and landed on the preceding hanger seat.
Some casing programs, particularly those with
intermediate casing strings, require mudline
hangers with integral landing shoulders on the
hanger bodies. Flow-by slots are included in the
hanger body for adequate flow-by in the running
and landed positions. 13-3/8” MLC Casing Hanger

Fluted landing rings or integral no-go shoulder

style mudline hangers are typically used in 24", 20", 18 5/8" and 16" casing strings.

April 2003 17-5

Expanding Collet Landing Ring Mudline Hangers
Smaller mudline hangers use a patented expanding
serpentine collet landing ring to suspend casing string
weight.
The expanding collet ring is included on the outside
diameter of the mudline hanger assembly and is free to
collapse and expand, when lowered through a casing
string with an inside diameter very nearly the same as the
hanger body itself.
Once collapsed inside the preceding hanger, the collet ring
expands only when a unique recessed profile in the
previously installed hanger is reached. The recessed
profile does not resemble BOP, annular or pipe ram bores, 9-5/8” MLC Casing
or any casing coupling internal profiles, and cannot set Hanger
prematurely in the wrong position.
The expanding collet landing ring is machined from a one
piece forging and slotted on both ends for radial spring action to
assure positive setting. Sixteen flow-by slots, approximately 7/8"
wide, extend three-quarters of the length of the collet. Eight slots
extend from the bottom up and eight slots (offset 15o from the first
eight slots) extend from the top down. The slots provide the
flow-by path and allow the serpentine-shaped, continuous piece
collet ring to radially collapse and expand during running and
landing.

MLC Collet Landing Ring

Each expanding collet ring has a single external load bearing
shoulder distributing the hanging load into the previously
installed hanger body.
A retention lip on the hanger body is engaged by a mating lip at
the bottom of the serpentine collet which retains the collet in the
running position. Once the collet engages its mating profile in the
previous hanger, the casing weight causes the lip on the collet to
slip off the retention lip and as the casing is further slacked off the
hanger body travels down through the serpentine collet stopping
as the load shoulder on the hanger lands on top of the collet. A 7” MLC Casing
step on the hanger body behind the serpentine collet forces the Hanger
collet out into its mating profile and locks it in the set position.
The mudline hanger can be easily retrieved or reciprocated by
lifting straight up, pulling the hanger radial backup surface from behind the collet
landing ring, which collapses inward to the as-run position. Even in lightweight
(thinnest wall) casing running strings, the collet landing ring will remain collapsed
and retained in its lowermost as-run position, as long as the casing hanger is not
pulled out of the casing string.

17-6
MLL and MLS Collet Ring
Each expanding collet ring has two external shoulders (MLL and MLS) distributing
the hanging load into the previously installed hanger body. Because of this dual
shoulder load sharing, engagement depth is less and the outer mudline hanger can
have a thicker wall.
The inner casing wall thickness is also increased because the expanding collet ring
does not have to retract as far as it would using only one external shoulder.
The collet landing ring is retained in the running position by two tensile coupons.
When the collet-style landing ring latches into its profile in the previously installed
hanger body, the weight of the casing hanger string parts the two tensile coupons,
allowing the hanger body to continue traveling downward to land out on its mating
bearing surface on the collet landing ring. This continued downward movement
positions a radial backup surface behind the collet landing ring, holding it securely
in the expanded position.
A tensile coupon is a long steel strap, factory installed on the hanger assembly by
two button head screws. The upper end of the tensile coupon is inserted in a recess
on the landing ring. The lower end of the coupon is inserted into a recess in a
retainer ring on the hanger body, after the collet landing ring has been slipped onto
the hanger body. The external radial shoulder at the lowermost portion of the collet
landing ring is overlapped and radially trapped by a mating radial shoulder in the
retainer ring.
When the collet landing ring and mudline hanger are assembled, the two tensile
coupons align the lower flow-by slots in the expanding collet ring with the slots in the
retainer ring and retain the collet landing ring in the running position for installation.
This orientation also aligns the collet ring upper flow-by slots with the hanger body
flow-by slots and maximizes contact surfaces between the top of the collet landing
ring and the hanger body shoulder.
The tensile coupons separate at the notched section in the upper end of the
coupon. By parting at the notch, the longer, lower piece of the coupon attached to
the retainer ring maintains the expanding collet ring in its oriented position, so that
its flow-by slots are aligned with the hanger body flow-by slots. Flow-by enters
through the lower collet ring slots and passes through a recessed section under the
ring to the upper collet landing ring flow-by slots. This recessed section provides
adequate flow-by, even when the expanding collet landing ring is collapsed during
installation. Tensile coupons rupture at approximately 15,000 lbs. For a mudline
hanger with two coupons, it takes 30,000 lbs of weight to set the hanger. After
landing out, the mudline hanger is ready for cementing.
The mudline hanger can be easily retrieved or reciprocated by lifting straight up,
pulling the hanger radial backup surface from behind the collet landing ring, which
collapses inward to the as-run position. Even in lightweight (thinnest wall) casing
running strings, the collet landing ring will remain collapsed and retained in its
lowermost as-run position, as long as the casing hanger is not pulled out of the
casing string.
The ABB Vetco Gray ML mudline hangers are machined from single body, or
one-piece, forgings and can be supplied for most casing programs to exceed the
tensile and pressure ratings of the casing strings they are suspending. The only
casing connection is in the bottom of the mudline hanger. Some systems available

April 2003 17-7

on the market today include a casing pup joint between a lower hanger housing and
an upper running and tieback collar. The casing pup joint, which is a part of the
mudline hanger assembly, limits the mudline hanger pressure and running strength
ratings to the capacity of the casing joint between the two mudline hanger parts.
Two potential leak paths are created by the casing pup joint connecting two portions
of a mudline hanger assembly.
Running tools used in the ML systems include the threads and seals required to
install the casing strings and maintain the pressure integrity of the running
tool-to-mudline hanger connection. Strength is provided by a one thread-per-inch
loose left hand thread form, typically on 24", 20", 18-5/8" and 16" running tools. A
large pitch loose thread form improves tieback operations with large diameter pipe.
Loose threads still provide the necessary strength needed for installing long casing
strings but provide flexibility when removing the running tool and installing the
tieback tool. Perfect vertical alignment is not necessary when loose threads are
used in large diameter mudline hangers.
Separate running and tieback threads are included in the 13-3/8" and smaller
hangers (except on 7" ML-C hangers). During drilling, the mudline hanger running
tool is threaded into the lower left-hand thread in the hanger body, while still on the
jackup rig drill floor. The running tool and mudline hanger assembly are then made
up to the last joint of the casing string and run on a casing running string. Casing
joints extend the running tool and mudline hanger to the jackup rig. Buttress or
premium casing couplings used to connect the joints of casing are conventionally
right-hand make-up.
When a well is abandoned, all running tools must be disconnected from the mudline
hangers at the mudline. Since a greater amount of torque can be transmitted in the
right-hand direction (same direction as casing string coupling makeup), it is an
important feature that ABB Vetco Gray running tools release from the mudline
hangers using right-hand rotation. This eliminates strap welding, tack welding pins
to boxes, or Bakerloking couplings together to produce greater torque
transmission. When the ML system is completed using tieback equipment, casing
strings connecting the tieback tools to the surface also create high-strength,
pressure-tight tieback connections because righthand rotation is used to make up
tieback threads in the ABB Vetco Gray ML mudline hangers.
Washout ports for the ABB Vetco Gray high pressure mudline suspension systems
are located in the mudline hangers (ML-C hangers have washout ports in the
running tool), whether fluted landing ring or expanding collet landing ring type. The
washout ports are positioned radially through the hanger body to direct a generous
volume of fluid up the outside diameter of the mudline hanger. The large volume of
pressurized fluid pumped down through the mudline hanger ID and discharged
through the small washout ports creates a high velocity jetting effect to break up
cement deposits and debris accumulated in the annular area above the washout
ports.
When the washout ports are closed, the pressure inside the hanger is sealed off by
a primary seal (metal-to-metal for the tieback tool, resilient for the running tool). The
wall thickness of the running tool, in addition to that of the hanger, is used to contain
pressure. O-rings above and below the washout ports provide additional sealing.
The requirements for high pressure and reasonable flow-by are all met.

17-8
April 2003 17-9
Annulus washout is further enhanced by the stacked down arrangement of ML
mudline hangers which places the washout ports in each hanger body below the
mudline hanger/running tool connection of the preceding mudline hanger. When
washout fluid is introduced through the washout ports, the entire 13-3/8" x 9- 5/8"
annulus above the 9-5/8" mudline hanger washout ports is washed free of cement
and drilling mud.
In the deep stacked down arrangement of the ML-L system, the expanding collet
landing ring of the 9-5/8" mudline hanger lands roughly two feet below where the
13-3/8" fluted landing ring sits in the 20" mudline hanger. This positions the washout
ports of the 9-5/8" hanger well below the top of the 9-5/8" hanger body and below
the connection between the 13-3/8" mudline hanger and running tool.
The deep stacked down arrangement of the ML-L system promotes a debris-free
system. Extra clearance between each mudline hanger, below the washout ports,
accumulates residual debris out of the way of running tool reconnection,
abandonment or tieback operations.
One-way polypak seals on the running tool isolate running and tieback threads
during drilling so that no pressure can build up between the hanger and the running
tool during makeup. Tieback tool seals also isolate both thread forms when
installed in the mudline hanger, preventing corrosion and marine growth from
interfering with threaded connections.
In the deep stacked down ML-L system, the one-way polypak seals on the running
tool isolate running and tieback threads during drilling and annulus cleanout. In the
washout mode shown in the upper half section of, the running tool has been rotated
to expose the washout ports in the hanger body. The polypak seal above the
running tool/tieback threads and the resilient seal below the threads (the upper
washout port isolation seal) remain sealed.
On 13-3/8" and smaller running tools, the metal-to-metal seal surface of the
mudline hanger is protected during drilling by a resilient seal on the running tool
nose. Each running tool seals above and below a 10o tapered surface in the
mudline hanger bore that forms a metal-to-metal seal with the tieback tool nose.
The 8 o tapered nose of the tieback tool rotates and wedges against the 10 o tapered
hanger surface, creating a metal-to-metal seal.
The metal-to-metal seal between the tieback tool and mudline hanger features a
controlled amount of surface bearing load. A shoulder is provided on the tieback
tool which controls the loads across the metal-to-metal sealing surfaces within the
elastic limits of the material. This ensures a metal-to- metal seal which is pressure
energized and unaffected by temperature cycles. The metal seal nose on the
tieback tool is also reusable because no plastic or permanent deformation of the
seal profile takes place.
Mudline suspension equipment is used many times on deviated wells. The upper
shoulder on the mudline hanger body acts as a centralizer above the collet ring and
the retainer ring provides centralization below. The collet rings are centralized so
that, once the tensile coupons are parted, the hanger body lowers behind the collet
ring, locking the mudline hanger in place and distributing casing load equally
around the circumference of the expanding collet landing ring.

17-10
Running Tools
In the mudline suspension assembly each hanger is run using a Running Tool to
attach the casing running string to the casing downhole. For 20” casing hangers the
running thread is a one pitch left hand square thread box. The 20” running tool has a
matching thread on its pin and a thread box matching the casing at the top. A series
of o-rings on the pin maintain pressure integrity throughout the running and
cementing of the casing.
The 13-3/8” and smaller hangers have a two pitch modified left hand square thread.

13-3/8” MLC Running Tool

20” MLC Running Tool

9-5/8” MLC Running Tool

7” MLC Running Tool

April 2003 17-11

Corrosion Caps
Once the running string is backed of during the
abandonment procedure an corrosion cap may be run on
drill pipe to protect the top of the hanger from debris and
marine life until the well is tied back to a platform.
The corrosion caps make up to the running threads of the
mudline hanger. A series of o-rings on the outside diameter
seal between the corrosion cap and the hanger. The top of
the corrosion cap has a fishing neck with four lugs on the
outside diameter. The corrosion cap running tool has
J-slots in the lower bore which engage the fishing neck
lugs to carry the corrosion cap into position for make up.
Corrosion caps are available with an open port at the top
so they will not retain pressure which may migrate up the
hold during the abandonment period. Corrosion caps are
also available with a check valve in the top port so MLC Corrosion Cap
pressure will be retained when the Corrosion cap Running and Retrieving
running/retrieving tool engages the corrosion cap. Tool

MLC Corrosion Cap Running And Retrieving Tool

The Corrosion Cap Running And Retrieving Tool has the J-slots in the lower bore to
engage the fishing neck of the corrosion cap. A series of o-rings permit the tool to
seal to the corrosion cap fishing neck. If the corrosion cap has a check valve, a
stinger is run in the Corrosion Cap Running And Retrieving Tool to unseat the check
valve and release any pressure below the cap before the cap is backed off. The top
of the Corrosion Cap Running And Retrieving Tool has a drill pipe tool joint thread
so that the corrosion caps can be run on drill pipe.

20” MLC 13-3/8” MLC 9-5/8” MLC 7” MLC

Corrosion Cap Corrosion Cap Corrosion Cap Corrosion Cap

17-12
Tieback Tools
Tieback tools permit casing risers run from a platform or jacket set over the well to
re-establish connections to each casing string in the well. Tieback tools for the 20”
casing are the same as the running tools in most systems although a separate
tieback thread is available if desired.

20” Latch And Lock Tool

A 20” Latch And Lock Tieback Tool is offered
which permits tieback to the 20” casing
without rotation of the casing. The tool has
an expanding lock ring with the mating profile
for the 20” running threads in the casing
hanger. This ring ratchets into the casing
hanger running thread and locks with about
1/8 of a turn right hand.
It should be noted that the 20” Latch And
Lock Tieback Tool has a restricted bore 20” Latch and Lock
relative to the 20” Running Tool.
O-ring seals are provided on the 20” Latch And Lock Tieback Tool.
13-3/8” and smaller Tieback Tools have a three pitch right hand modified square
thread on the pin to mate with the tieback thread on the mudline casing hangers
using right hand rotation. The nose of these tieback tools seals metal to metal on a
taper in the thread box of the mudline hanger. A back up o-ring seal is provided as
well.
Optional 13-3/8" and 9-5/8" Latch and Lock Tieback tools are available.

13-3/8” MLC Tieback Tool 9-5/8” MLC Tieback Tool

April 2003 17-13

Additional Service Tools
Additional service tools include clean and flush tools for each size hanger so that
gumbo or cement tailings can be cleaned from the mudline hanger bores if there is
a problem setting the mudline hangers.
Dummy hangers which are run on drill pipe permit confirmation of the viability of the
hanger landing profile before the casing is run.
Impression blocks allow location and space out of corrosion cap tops if they are not
concentric to the casing bore of the previous string.

17-14
Typical Operating Sequence For Drilling Well From Jackup using the MLC
Mudline System and the CWCT-NT2 Surface Wellhead System
1. Drill the 36" hole, or rig up a hammer to drive the 30” conductor.
2. Run 30" conductor. The 30" landing ring must be positioned properly. The
releasable (diver or diverless) connection on the 30" should be located
close to, but above the mudline (about 5 feet). Cement to the mudline if the
conductor is run into a drilled hole.

April 2003 17-15

 3. Nipple up the 29-1/2" diverter system using 30” VG-loc adapter (no welding
required).

17-16
 4. Drill the 26" hole.
5. Run the 20" surface pipe.
6. Land the 20" fluted hanger on the 30" landing ring. Cement to the surface.
Open the 20" washports by rotating the string 1-1/2 turns to the right. Flush
annulus, and spot retarder. Close the washports. Then test the 20" casing.

April 2003 17-17

 7. Nipple down 29-1/2" diverter system and install 20” CWCT starting head
using the VG-loc connection (no flange to be cut on the conductor, or
welding required on the casing head).

17-18
 8. Nipple up the 20” BOP or the 29-1/2” diverter (NT-2 connector saves nipple
up time).

April 2003 17-19

 9. Drill the 17-1/2" hole.
10. Run the 13-3/8" casing. Land the 13-3/8" fluted hanger in the 20" casing
hanger. Cement the casing. Open the 13-3/8" hanger washports with 4
turns right-hand rotation. Flush the 20" x 13-3/8" annulus. Spot cement
retarder. Close the ports. Test the 13 3/8" string.

17-20
 11. Nipple down the BOPand raise it for surface hanger installation. (NT-2
connector saves nipple down time).

April 2003 17-21

 12. Install the 20” X 13-3/8” slip type casing hanger.
13. Cut the 13-3/8" casing.

17-22
 14. Install 9-5/8" casing spool and test. (NT-2 connector saves nipple up time).

April 2003 17-23

 15. Nipple up 13-5/8" BOP and test. (NT-2 connector saves nipple up time).
16. Drill 12-1/4" hole.

17-24
 17. Run the 9-5/8" casing. Land the 9-5/8" collet ring in the 13-3/8" hanger.
Observe or feel pipe for signs of collet engagement. Cement the casing.
Open the 9-5/8" washports with four turns right-hand rotation. Flush the
13-3/8" x 9-5/8" annulus. Spot cement retarder. Close the ports. Test the
9-5/8" casing.

April 2003 17-25

 18. Nipple down the BOP and raise it for the surface casing hanger installation
(NT-2 connector saves nipple down time).
19. Install the 13-3/8” X 9-5/8” slip type casing hanger.

17-26
 20. Cut the 9-5/8"casing

April 2003 17-27

 21. Nipple up the 9-5/8” casing spool and test (NT-2 connector saves nipple up
time).

17-28
 22. Nipple up BOP and test (NT-2 connector saves nipple up time).

April 2003 17-29

 23. Drill the 8-1/2" hole to pay zone.
24. Run and set the production packer.
25. Run test the tubing string and SCSSV.
26. Production test well.
27. Kill the well.
28. Pull test string and suspend well with cement plugs.
29. Nipple down the BOP (NT-2 connector saves nipple down time).
30. Nipple down the 9-5/8” casing spool and remove it (NT-2 connector saves
nipple down time).
31. Spear casing and remove the casing hanger.
32. Rotate to right to release and pull the 9-5/8" riser.
33. Run in and set corrosion the cap.
34. Repeat Step 17 for 13-3/8" and 20".(NT-2 connector saves nipple down
time for each casing spool. The casing head is easily released without
cutting the pipe using the VG-loc release mechanism).
35. Release the conductor and pull the 30" riser.
36. Install a mud can over capped well and fill with corrosion inhibitor.

NOTE: The well can now be completed as a tieback or with a subsea tree. If the well
is a duster or strictly exploratory and not to be produced, after Step 18 the pipe can
be cut below the mudline. All components are then removed from the sea floor by
pulling the 30" riser.

17-30
 SURFACE WELLHEADS AND COMPLETIONS
TRAINING MANUAL

Section 18

Overview To API Specification 6A

Specification For Wellhead and Christmas Tree Equipment
17th Edition
This page left blank
API Specification 6A is a specification for wellhead and christmas tree equipment,
formulated by the API Production Department Committee on Standardization of
Valves and Wellhead Equipment. It is published as an aid to the procurement of
wellheads and valves, as well as a guide to the manufacturers.
The Seventeenth Edition of API Specification 6A, is the current internationally
accepted reference for the manufacture and use of equipment used to control
pressure and flow at the surface location of oil and gas wells.
API Specification 6A first appeared in 1961, when the existing flanged end
specifications were consolidated into one specification for flanged end wellheads
and loose flanges. Over the thirty-five years from 1961 to April 1996 the
specification went through various changes, as evidenced by the sixteen prior
editions. These changes reflect the innovation and advances of the petroleum
industry over that period and the adjustments by the API Specification 6A
committee to stay current with international industry practices as they became
widely accepted. The Seventeenth Edition of Spec 6A is the latest major update
and/or technical correction as called for by the API charter.
During the development of the previous editions, standards and technical
requirements incorporated recommendations for the mechanical properties of
pressure-containing parts, guidelines for hydrostatic testing, dimensional
standards, marking requirements, temperature limitations, and bolting material. In
the recent editions specific criteria were established for the design of 20,000 psi
flanges, welding and welder qualifications, material requirements for corrosive
service, cold weather service, and other categories.
API Specification 6A, Seventeenth Edition, reflects changes in the oil and gas
industry. As the search for oil and gas reached new horizons in the 1970’s, so did
the challenges facing operators and manufacturers. As deeper targets were
approached in drilling, well pressures surged past 20,000 psi and flowing conditions
became hotter and more corrosive. The industry developed new technologies to
safely control these challenging well conditions. Among the new technologies was
a special emphasis on the product engineering and quality assurance capabilities
of the manufacturers. Until the publication of the Fifteenth Edition of Specification
6A there was a proliferation of product specifications and quality programs, but little
area of agreement which might promote functional interchangeability from a quality
standpoint. Many operators, nations, and various government agencies developed
their own unique requirements to address these new problems. As the petroleum
industry expanded in the Seventies and then contracted in the Eighties, the
problems of short supply and excess inventory of wellhead equipment and valves
found a common denominator; Company A’s specifications did not match Company
B’s specifications, and rarely would they function as acceptable substitutes for each
other.
This overview has been developed since it is recognized that the API document is
written by and for experts in the design and manufacture of the covered equipment.
It can be tedious to sift through and assess by other interested parties. By
highlighting the key elements of the document which permit the best use of the
specification, we hope to make the document more “user friendly”.

January 2002 18-1

Scope of API Specification 6A
Section 1 of Specification 6A addresses the scope of coverage of the document.
The intent of API Specification 6A is to provide for the availability of safe,
dimensionally and functionally interchangeable wellhead and christmas tree
equipment. The responsibility for design, material selection, and compliance rests
with the manufacturers. The document does not apply to field use or field testing of
the wellhead and christmas tree equipment.
Included in the new edition of API Specification 6A are criteria for performance,
design, materials, testing, inspection, welding, marking, handling, storing, shipping,
and documentation of the covered equipment. Specific equipment covered by this
document includes:

Wellhead Equipment
• Casing Head Housings
• Casing Head Spools
• Tubing Head Spools
• Crossover Spools
• Multistage Head Housings & Spools
Connectors and Fittings
• Crossover Connectors
• Tubing Head Adapters
• Top Connectors
• Tees and Crosses
• Fluid Sampling Devices
• Adapter and Spacer Spools
Casing and Tubing Hangers
• Mandrel Hangers
• Slip Hangers
Valves and Chokes
• Single Completion Valves
• Multiple Completion Valves
• Actuated Valves
• Valves Prepared for Actuators
• Check Valves
• Chokes

18-2
 • Surface and Underwater Safety Valves and Actuators for Offshore Service
Loose Connectors [Flanged, Threaded, Other End Connectors (O.E.C.) and
Welded]
• Weld Neck Connectors
• Blind Connectors
• Threaded Connectors
Adapter and Spacer Connectors
• Other Equipment
• Actuators
• Ring Gaskets
Product Specification Levels
Recognizing that operating conditions, and environmental and safety regulations,
vary widely from one wellsite to another Product Specification Levels were
established which define the manufacturing and quality control process with
incremental degrees of technical stringency to permit users of the products to easily
order and inventory equipment which is cost effective and appropriate for the
conditions in which the products will operate.
Product Specification Level 1 through 4 represent an increasingly higher level of
technical requirements invested in the end product. Manufacturing requirements
such as recording and documentation of processes, chemical and mechanical
testing of raw materials, traceablity of materials, surface and non-destructive
examination, welding, and pressure testing are increasingly stringent with higher
PSL. The more severe the service conditions, the more environmentally sensitive
the location of the wellsite, prudent operators specify PSL accordingly at higher
levels.
Product Specification Levels establish the technical requirements for each of four
different levels: PSL 1, PSL 2, PSL 3, PSL 4.
PSL 1
PSL 1 includes practices currently being implemented by a broad spectrum of
industry for the service conditions recommended in Appendix A of API Specification
6A.
PSL 2
PSL 2 includes all the requirements of PSL 1 plus additional practices currently
being implemented by a broad spectrum of industry for the service conditions
recommended in Appendix A of this specification.
PSL 3
PSL 3 includes all the requirements of PSL 2 plus additional practices currently
being implemented by a broad spectrum of users for the service conditions
recommended in Appendix A of this specification.

January 2002 18-3

PSL 4
PSL 4 includes all the requirements of PSL 3 plus additional practices currently
being implemented by a broad spectrum of users for the service conditions
recommended in Appendix A of this specification.
The implementation of Product Specification Levels is the responsibility of the
manufacturers. In the past, verification of particular technical or quality
requirements were performed by representatives of the operator, third party
inspectors, or independent agencies such as Det Norske Veritas (DNV) or the
American Society of Mechanical Engineers (ASME). In conjunction with the
technical revisions of API Specification 6A, API also formed a Quality Program
Standardization Committee and published API Specification Q1, an API
Specification for Quality Programs.

Determination Of The Appropriate Product Specification Level

For A Particular Well Or Project
Although it is clear that Specification 6A does not intend to regulate the decisions of
manufacturers and end users when determining specific quality control
requirements, some guidelines for assessing these requirements based on
widespread industry practice have been provided. In Appendix A, guidelines for
purchase have been included to address these requirements and to assist in the
proper specification of applicable equipment when placing orders with
manufacturers. These guidelines include a defined decision path based on service
conditions leading to selection of an appropriate PSL.
The generally accepted criteria for determining a PSL is shown here.
PSL 1 - Non NACE, Low Pressure
PSL 2 - Non NACE, Medium Pressure
NACE, Low H2S, Low Pressure, Close Proximity
NACE, High H2S, Low Pressure
PSL 3 - Non NACE Medium Pressure, Close Proximity
NACE, Low H2S, Medium Pressure, Close Proximity
NACE, High H2S, Low Pressure, Close Proximity
NACE, High H2S, Low Pressure, Close Proximity
NACE, High H2S, Medium Pressure
Low H2S. High Pressure
PSL 4 - NACE, High H2S, Medium Pressure, Close Proximity
Low H2S, High Pressure, Close Proximity
High H2S, High Pressure
The Recommended Minimum PSL for Primary Parts of Wellhead and Christmas
Tree Equipment chart which is reproduced here from Appendix A includes several

18-4
terms used which require clarification. These terms include: Primary Parts, NACE,
High H 2S concentration, and Close Proximity. These terms will be addressed on the
following pages. An explanation of these terms is also included on pages A1-A2 in
Appendix A of API Specification 6A Seventeenth Edition.

Primary Parts
The Seventeenth edition states on page A1 that primary parts of a wellhead
assembly include as a minimum the tubing head, tubing hanger, tubing head
adapter, and lower master valve. All other components are considered secondary.
The concept of primary and secondary parts or components has been used for
many years in the description of parts for use on critical service wells. Primary
components are generally defined as those parts or assemblies which directly
control the wellbore fluids. Failure of primary component pressure containment
could lead directly to the leakage of well fluids to the environment. The final
determination of which components or parts will be regarded as primary is the
responsibility of the operator or end user and may vary from well to well at his
choosing for each different set of service conditions. One additional point of interest
for adopting the primary/secondary approach to wellhead and christmas tree
components is the possibility of reduced costs by carefully selecting the PSL to
match not only the expected severity of the wellbore conditions as drilling
progresses, but the relative position of the parts in the overall assembly.

Low, Medium, and High Pressure

Pressure ratings below 5,000 psi are considered low pressure, pressure ratings of
5,000 and 10,000 psi are considered medium pressure, and pressure ratings of
15,000 psi and above are considered high pressure.

NACE
The National Association of Corrosion Engineers publishes a specification
MR-01-75 which defines conditions which may lead to Stress Corrosion Cracking of
metal components under stress. This corrosion may lead to catastrophic failure of
the component. The specification sets the level of hydrogen sulfide concentration at
which stress corrosion cracking may occur, and specifies physical and mechanical
properties of commonly used alloys which resist stress corrosion cracking.
Materials which meet MR-01-75 requirements have been referred to as NACE
materials. Any system which has a Partial Pressure of Hydrogen Sulfide equal to or
greater than 0.05 psia. requires material selected from those approved by NACE.

High H2s Concentration?

The detrimental effects of hydrogen sulfide, (a deadly gas) which may escape from
a well in the event of a well control failure is a function of the level of H2S
concentration in the produced fluid, the pressure, and rate of flow from the well.
Establishing a “Radius of Exposure” is an attempt to quantify the likely
contamination of the environment from a given well if a breach of well control were
to develop. The following is taken from the recommendations of the Texas Railroad
Commission, however other authorities may utilize a different formula.

January 2002 18-5

Use “Yes” if the 100 PPM radius of exposure (ROE) of H2S is greater than 50 feet
from the wellhead. The 100 PPM ROE is:
X= [(1.589)(mole fraction H2S)(Q)]0.6258
Where: X= radius of exposure in feet
Q= Maximum volume determined to be available for escape in cubic feet per day
H2S= Mole fraction of hydrogen sulfide in the gaseous mixture available for escape

Close Proximity?
API 6A recommends that the Close Proximity assessment should consider the
potential impact of an uncontrolled condition on life and environment near the
wellhead.
Use “Yes” if the well meets any of the following conditions:
1. 100 PPM radius of exposure (ROE) of H 2S is greater than 50 feet from the
wellhead and includes any part of a public area except a public road.
2. 100 PPM ROE of H 2S is greater than 50 feet from the wellhead and includes
any part of a public area including a public road.
3. Well is located in any environmentally sensitive area such as parks, wildlife
preserves, city limits, etc.
4. Well is located within 150 feet of an open flame or fired equipment.
5. Well is located within 50 feet of a public road (lease road excluded).
6. Well is located in state or federal waters.
7. Well is located in or near inland navigable waters.
8. Well is located in or near surface domestic water supplies.
9. Well is located within 350 feet of any dwelling.

These conditions are recommended minimum considerations. It will be necessary

to meet any local regulatory requirements.

Other Referenced Standards and Specifications

Section 2 of Specification 6A lists referenced standards and specifications from
other publications. Industry organizations such as ASME, ANSI, NACE, SPPE, and
API all have published standards and specifications which in some cases may
apply to the scope of equipment covered under API Specification 6A and where
applicable these standards are referenced.

Abbreviations and Definitions

Section 3 of Specification 6A describes the abbreviations used in the specification
and contains a glossary of terms used.

18-6
Design and Performance General Requirements
Section 4 of Specification 6A defines general requirements for design and
performance of the equipment covered. Methodology for specifying design and
performance capabilities are described.

Design Requirements
Products shall withstand rated working pressures without deformation which
reduces overall performance.
Products shall be capable of functioning throughout the rated temperature range.
Products shall be capable of functioning consistent with the materials class
selected.
No observable leakage is allowed.
Products shall be capable of sustaining rated loads without deformation which
reduces overall performance.
Products shall be capable of performing and operating as intended for the number
of cycles specified.
The force or torque required for operation shall be within that described in the
manufacturer’s specification, as applicable.

Performance Requirements
All products shall be designed to perform to the requirements of either PR 1 or PR 2
(Performance Requirement 1 or 2). The latter represents more rigorous
performance requirements.

Service Conditions
Service conditions refer to classification for pressure, temperature, various
well-bore constituents, and operating conditions.
Pressure Ratings indicate rated working pressures expressed as gage pressure.
Temperature ratings indicate temperature ranges, from minimum ambient to
maximum flowing fluid temperatures, expressed in degrees Fahrenheit (oF) or
degrees Celsius (oC).
Materials Classes indicate the type of material appropriate for components used
based on the well service conditions.

January 2002 18-7

Pressure Ratings
Equipment shall be designed to operate in only the following maximum rated
working pressures:
PSI MPa
2000 13.8
3000 20.7
5000 34.5
10000 69.0
15000 103.4
20000 138.

18-8
Temperature Ratings
The temperature ratings for equipment built in accordance with the Seventeenth
edition are shown in the following table. For equipment built to PSL 1-4, the
components must be designed to operate in one or more temperature
classifications as illustrated. The minimum temperature is the lowest temperature
to which the components may be subjected, and the maximum is the highest
temperature to which the equipment may be subjected. As a general rule of thumb,
the minimum temperature is usually the lowest ambient temperature in the
geographical area, and the maximum temperature is the highest temperature to
which the equipment would be exposed during drilling or production.
In addition to the standard (or monogramable) classifications shown here, two
additional classifications have been established for elevated temperature service.
Temperature classification X is for service from 0°F to 350°F and temperature
classification Y is for service from 0°F to 650°F. Derated working pressures for
some equipment is shown in Appendix G. However, because of other special
requirements at elevated temperatures, materials engineering experts should be
consulted for the correct information whenever these conditions are encountered.
The “room temperature” classification, defined as any temperature between 40o
and 120o Fahrenheit, is primarily intended to address the thermal conditions
prevailing during certain performance verification procedures.
Temperature Class V has been added for the 17th Edition to bring it in line with
impact requirements in API 17D the Specification for Subsea Wellhead and
Christmas Tree Equipment.

Temperature Operating Range Minimum to Maximum

Classification o
F o
C
K -75 to 180 -60 to 82
L -50 to 180 -46 to 82
P -20 to 80 -29 to 82
R Room Temperature Room Temperature
S 0 to 150 -18 to 66
T 0 to 180 -18 to 82
U 0 to 250 -18 to 121
V 35 to 250 2 to 121

January 2002 18-9

Relative Corrosivity of Retained Fluid
To aid in material selection a purchaser may determine the relative corrosivity of the
retained fluid by considering environmental factors, and production variables. The
following table is provided in Appendix A purchasing guidelines to provide an
indicator for selection of a Material Class. That is the Relative Corrosivity of
Retained Fluid Classification A would require Materials Class AA Components.
No single retained fluid may be able to predict the field performance of any single
type of metallic or nonmetallic material. The interaction between environmental
factors and production variables affect the performance of materials. Additional
factors which should be considered include the effects of fluids introduced to the
wellbore through drilling and workover operations as well as the produced fluids.

Constituents
Classification*** Characteristics
CO 2* H2S**
A- General Service non-corrosive <7 <.05
B- General Service Low Slightly corrosive 7 to 30 <.05
Co2
C- General Sevice High Moderate to highly corrosive >30 >0.05
CO2
Sour Service Sulfide stress cracking <7 >0.05
E- Sour Service Low Sulfide stress cracking 7 to 30 >0.05
CO2 & slightly corrosive
H- Sour Service Sulfide stress cracking >30 >0.05
High CO2 & highly corrosive

* Partial Pressure of Carbon Dioxide (in psia)

** Hydrogen Sulfide Partial Pressure (in psia) as defined by NACE MR-01-75.
*** All Retained Fluid Classifications include oil, water, and hydrocarbon gasses.

18-10
Materials Classes
The question of materials selection for API Specification 6A equipment is
addressed in the Seventeenth Edition by component class and by well service
condition. Components are divided into categories such as Mandrel Casing and
Tubing Hangers, Bodies, Bonnets, End and Outlet Connections, and Ring Gaskets.
Physical and Mechanical properties for the different equipment classes are defined.
The question of material selection as it relates to well service conditions is
addressed by the establishment of Materials Classes for varying levels of relative
corrosivity in the well fluids. The Materials Classes, as shown in the table below, are
used to indicate metal alloys appropriate for use in the manufacture of either
pressure containing components or pressure controlling components.

Pressure Containing Parts Pressure Controlling Parts

Materials Class (bodies, bonnets & (stems, gates, seats and
connections) mandrel hangers)
AA - General Service Carbon, Low Alloy Steel Carbon, Low Alloy Stee
BB - General Service Carbon, Low Alloy Steel Stainless Steel
CC - General Service Stainless Steel Stainless Steel
DD - Sour Service* Carbon, Low Alloy Steel** Carbon, Low Alloy Steel**
EE - Sour Service* Carbon, Low Alloy Steel** Stainless Steel**
FF - Sour Service* Stainless Steel** Stainless Steel**
GG - Sour Service* CRAs** CRAs

*As defined by NACE Standard MR-01-75

**In compliance with NACE Standard MR-01-75
The constituent ranges of CO2 and H 2S shown for the API ratings are expressed in
terms of psia. or pounds per square inch absolute. The quantity of each constituent
is the Partial Pressure of that constituent. Partial Pressure is the relative pressure
of each constituent in a multi-phase system as a part or proportion of the entire
system.
Partial Pressure = Mol% x Shut-in pressure/100
If CO2, is 4% of the retained fluid and the shut-in pressure is 5000 psia. the Partial
Pressure would be:
P.P. = (4%) x (5000 psia.)/100
and the constituent Partial Pressure for the CO2 would be 200 psia.
It should be noted that the levels of corrosivity indicated in the Retained Fluid Table
are not meant to form the basis for decisions on material selection. The synergistic
effects of combinations of various wellbore constituents must be taken into
consideration when considering material selection for a given well. Each well
environment should be individually evaluated based on the anticipated exposure of
the equipment during the producing life of the well.

January 2002 18-11

The charts illustrated on the following pages are graphic illustrations of the
guidelines established by the National Association of Corrosion Engineers for
determining the region of Sulfide Stress Cracking from H2S in both Sour Gas
systems and Sour Multiphase systems. These charts are helpful in determining
whether a given set of production fluid constituents will cause Sulfide Stress
Cracking. They are also useful in determining the Mol% when PPM (parts per
million) are given or vice versa. Mol% in the oil and gas industry is usually given or
expressed as just “per cent” rather than “Mol per cent.

Charts did not come through

18-12
Materials - General Requirements
Section 5 of Specification 6A describes general requirements for materials of
manufacture for the components covered.
Requirements for written material specifications covering both metallic and
nonmetallic components are defined.
Requirements related to processing materials such as casting practices, hot
working practices, melting practices, heat treating, and quenching practices are
established for the various Product Specification Levels.
Requirements for qualifying materials such as verifying chemical composition, and
mechanical testing for the different Product Specification Levels are covered.

Welding
Section 6 of Specification 6A establishes general requirements for welding on the
equipment covered and for the different Product Specification Levels.
Welding may be used for fabrication, corrosion resistance, enhanced reliability, or
repair.
Requirements for welding and quality assurance of welded components become
more stringent with higher Product Specification Levels. For example no repair
welding is permitted for PSL 4 equipment.

Quality Control
Section 7 of Specification 6A covers quality control requirements for the equipment
covered and at the different Product Specification Levels.

API Specification Q1
API Specification Q1 for Quality Programs was published to outline the
requirements which manufacturers must meet to qualify for approved use of the
API monogram. In the past, manufacturers could apply to API for a license to
monogram oilfield equipment and become an authorized manufacturer via this
application process. With the advent of the Q1 program, manufacturers will not be
licensed to apply the API monogram to their equipment unless they have
successfully passed an audit of their facilities by the API Q1 Audit Committee. Any
manufacturer may voluntarily comply with the requirements of the specification, but
only those who pass the audit will be licensed to apply the monogram. The intent of
API Specification Q1 is to apply widely accepted industry practices to a quality
program standard which can be used throughout the oil and gas industry. In
addition, the Specification Q1 audit program will independently verify the technical
capabilities of manufacturers and their compliance to new requirements such as
Design Verification, Product Specification Levels, and Performance Verification
mandated by API Specification 6A.

January 2002 18-13

API Specification Q1 outlines and defines quality program requirements for the
following categories:
Organization Inspection and Testing
Materials Traceability Quality Manuals
Personnel Qualification Measuring and Testing Equipment
Special Processes Design Control
Quality Program Plan Handling, Storing and Shipping
Instructions and Procedures Acceptance Status
Specifications and Drawings Non Conformance
Process Control Corrective Action
Procurement Control of Critical
Components Audits
Material/Product Identification Control Quality Records

Equipment Marking
Section 8 of Specification 6A defines the marking requirements for the equipment
covered. Marking requirements include what must be marked on the component,
and the location of the marking. Information which must be marked on a component
include:
Manufacturer’s name or mark API Specification 6a 17th Edition
Temperature Class Material Class
Product Specification Level Performance Requirement Level
Nominal Size (bore when required) Thread Size (threaded products only)
End and Outlet Connector Size Rated Working Pressure
Ring Gasket Type and Number Date of Manufacture
Serial Number (when applicable) Hardness Test Values (when applicable)

Storing and Shipping

Section 9 of API Specification 6A describes the requirements for storing and
shipping of the equipment covered.

Equipment - Specific Requirements

Section 10 of Specification 6A addresses specific design, manufacturing, and
performance requirements for the equipment covered.
Also included are specific dimensional requirements for the equipment covered.

18-14
Equipment Classes Covered
• API Flanged End and Outlet Connections
• API Threaded End and Outlet Connections
• Studs and Nuts
• Ring Gaskets
• Valves
• Casing and Tubing Heads
• Casing and Tubing Hangers
• Tubing Head Adapters
• Chokes
• Tees and Crosses
• Test & Gauge Connections for 15M/20M Equipment
• Fluid Sampling Devices
• Christmas Trees
• Crossover Connectors
• Adapter and Spacer Spools
• Actuators
• Lock Screws, Alignment Pins, and Retainer Screw Packing Mechanisms
• Other End Connectors
• Top Connectors
• Surface and Underwater Safety Valves and Actuators for Offshore

January 2002 18-15

Performance Requirements
Performance Requirements PR1 and PR2 are assigned to all API Specification 6A
equipment. These performance requirements must be verified by a testing
procedure performed on a prototype of a specific design, or by a means which
verifies the specified performance that meets or exceeds the test requirement.
Specific performance requirements for API Specification 6A equipment are defined
in Section 10 of the Specification. Procedures for testing designs to verify
performance are defined in Appendix F of the specification.

Casing and Tubing Hanger Groups

It is noteworthy that among the equipment specific requirements in Section 10, that
casing and tubing hanger Groups 1-5 are established which define the design
capabilities of the hanger.

Group 1
Hangs Pipe
No annular seal

Group 2
Hangs Pipe
Seals pressure from one direction

Group 3 Same as Group 2 and:

Seals Pressure from top and bottom with or without ring joint isolation seal
and down hole lines

Group 4 Same as Group 3 and:

Hanger held in place by mechanical means applied to a retention feature.
Retention of the hanger is independent of any subsequent member
wellhead component.

Group 5 Same as Group 4 and:

Hanger will receive back pressure valve.

Casing/Tubing Hanger Performance Requirements

Casing and Tubing Hanger performance requirements vary based on the
design requirements of each group.

Group 1
Must be able to suspend manufacturer’s rated load without collapsing the
tubulars or hangers below drift diameter.
Threaded connections shall meet pressure retaining requirements.

18-16
Group 2 Same as Group 1 Additionally
Pressure load must be considered with the hanging load.

Group 3 Same as Group 2 Additionally

All seals must retain working pressure from either direction.
If a crossover seal means is included on the hanger, then it must hold the
higher rated working pressure from above. If down hole lines are included
they must hold the rated working pressure of the hanger and any effects of
the pressure load must be included in the load rating.

Group 4 Same as Group 3 Additionally

Minimum retention load capacity of the hanger’s retention feature shall be
equal to the force generated by the working pressure on the annular area.

Group 5 same as GROUP 4 Additionally

Minimum retention load capacity of the hanger’s retention feature shall be
equal to the force generated by the working pressure acting on the full area
of the largest hanger seal.
Back pressure valve (BPV) preparation shall be capable of holding rated
working pressure from below.
BPV preparation must meet the requirements of Section X G2d.
Note 1. The load and pressure ratings for casing and tubing hangers may be a
function of the tubular grade of material and wall section as well as the
wellhead equipment in which it is installed. Manufacturers shall be
responsible for supplying information about the load/pressure ratings
of such hangers.
Note 2. Field test pressures may be different than the rated working pressures
of a hanger due to casing collapse restrictions or load shoulder limits.
Note 3. Nothing in this section shall be interpreted to be a requirement of a
wrap-around seal type tubing hanger.
Tubing Head Adapter Groups
Similar to Casing and Tubing Hanger Groups, Tubing Head Adapter Groups are
established based on the design capabilities of the component.

Group 1 Tubing Head Adapters

Seal the tubing bore from the tubing annulus.

Group 2 Tubing Head Adapters

Seal the tubing bore from the tubing annulus, and suspend the tubing.

January 2002 18-17

Repair and Remanufacture Requirements
Section 11 of Specification 6A describes requirements for repair and remanufacture
of the equipment covered.
Repair and remanufacturing levels 1 - 4 (RL 1-4) are established as a means of
maintaining the same level of technical specification on repaired equipment as was
provided by the Product Specification Level when the equipment was originally
manufactured.
Procedures for identification, disassembly, evaluation, repair, and reassembly and
testing, are established.
Remanufacturing procedures are defined as well.

Appendices to API Specification 6A

Appendix A
Appendix A of Specification 6A provides purchasing guidelines. Standard wellhead
configuration diagrams are provided. The decision path for determination of
appropriate PSL is covered in detail.

API Data Sheets

Appendix A provides a series of data sheets which are handy forms to be filled out
by an operator to define the specific needs for a particular well or project. Forms for
general well conditions, and each of the major wellhead and tree component
assemblies are provided as an aid to clearly defining the requirements of a well or
project.

Appendix B
Appendix B provides the metric equivalent tables of each of the tables contained in
the body of the specification.

Appendix C
Appendix C provides the method of calculating stud bolt lengths for Type 6B and
6BX flanges. It is noteworthy that the required length of a stud bolt varies according
to several variables including the type of ring gasket used, the flange thickness
tolerances and the type of stud.

Appendix D
Appendix D provides a formula for calculating the required flange bolt torque for API
flanges, and a table which gives values based on the formula for standard API stud
bolt sizes and material strengths.

Appendix E
Appendix E provides cross-sectional drawings of recommended weld groove
designs for various applications for the equipment covered.

18-18
Appendix F
Section 10 of Specification 6A establishes the required performance capabilities for
the equipment covered but does not provide a testing procedure to verify the
required performance capability. Appendix F establishes Performance Verification
Test Procedures to qualify product designs to PR1 or PR2. Although these
procedures are not required to qualify a component under API 6A many operators
require this testing to verify performance for a particular design. It should be noted
that this testing is to be performed on a design prototype or production model. Once
the performance verification test is complete, the appropriate PR rating applies to
all components manufactured within the same product family, within the scaling
requirements established.

Product Families
A Product Family is established when the members of the product family meet the
following design requirements:
• The design principles of physical configuration and functional operation are
the same.
• The design stress levels in relation to material mechanical properties are
based on the same criteria.
Scaling
Appendix F tests may apply to all components manufactured within a Product
Family.

Limitations of Scaling
The test product may be used to qualify products of the same family having equal or
lower pressure ratings.
Testing of one size of a product family shall verify products of one nominal size
larger and one nominal size smaller than the tested size. Testing of two sizes
verifies all nominal sizes between the two sizes tested.

Performance Verification Testing

The following tables summarize the performance verification tests described in
Appendix F of API Specification 6A.

January 2002 18-19

Performance Verification Tests For Valves
Performance Requirement Level PR1 PR2
Open/Close Cycling Dynamic Pressure Test at Room 3 cycles 160 cycles
Temperature
One hour hold period
Low Pressure Seat Test at Room Temperature Objective Evidence at 5 to 10% of rated
working Pressure
Open/Close Cycling Dynamic Pressure Gas Test at Objective Evidence 20 cycles at each
Maximum and Minimum Temperature extreme
Low Pressure Seat Test at Maximum and Minimum One hour hold period
Objective Evidence at 5 to 10% of rated
Temperature working Pressure
Retained Fluid Compatibility Objective Evidence Immersion Test
Measure the breakaway and Measure the
Operating Force or Torque running torque breakaway and
running torque
Maximum pressure at
Pressure/Temperature Cycling Objective Evidence minimum to
maximum
temperature

Performance Verification Tests For Valve Actuators

Performance Requirement Level PR1 PR2
Open/Close Cycling Dynamic Pressure Test at Room 3 cycles 160 cycles
Temperature
Open/Close Cycling Dynamic Pressure Test at Objective Evidence 20 cycles at each extreme
Maximum and Minimum Temperature
Actuator Fluid Compatibility Objective Evidence Immersion Test
(Retained Fluid Actuators Only)
Measure the Measure the breakaway and
Operating Force or Torque breakaway and running torque
running torque
Maximum pressure at
Pressure/Temperature Cycling Objective Evidence minimum to maximum
temperature

Performance Verification Tests For Chokes

Performance Requirement Level PR1 PR2
Open/Close Cycling Dynamic Pressure Test at Room Objective Evidence 160 cycles
Temperature a
Seat to Body Seal Test at Room Temperature Objective Evidence 3 cycles
Open/Close Cycling Dynamic Pressure Test at Objective Evidence 20 cycles at each extreme
Maximum and Minimum Temperaturea
Retained Fluid Compatibility Objective Evidence Immersion Test
Objective Evidence Measure the breakaway and
Operating Force or Torque running torque
Maximum pressure at
Pressure/Temperature Cycling Objective Evidence minimum to maximum
temperature

a
Does not apply to positive chokes.

18-20
Performance Verification Tests For Casing Head Housings, Casing Head
Spools, Tubing Head Spools, Crossover Connectors, and Adapter and
Spacing Spools
Performance Requirement Level PR1 PR2
Load Cycling Objective Evidence Objective Evidence
Must meet Performance
Penetrations for Lock Down Screws, Alignment Pins, Requirement for Lock Down
Objective Evidence Screws, Alignment Pins, and
and Retainer Screw Packing Mechanisms Retainer Screw Packing
Mechanisms
Pressure Objective Evidence Objective Evidence
Thermal Cycles Objective Evidence Objective Evidence
Fluid Compatibility Objective Evidence Objective Evidence

Performance Verification Tests For Group 1 Slip Hangers

Performance Requirement Level PR1 PR2
3 cycles from maximum
Load Cycling Objective rated load to minimum rated
Evidence load with 5 minute hold
periods at each load cycle

Performance Verification Tests For Group 2 Slip Hangers

Performance Requirement Level PR1 PR2
3 cycles from maximum
Load Cycling Objective Evidence rated load to minimum rated
load with 5 minute hold
periods at each load cycle
1 cycle at room 1 cycle at maximum rated
Pressure Seals temperature from pressure from minimum
one direction rated temperature to
maximum rated temperature
Fluid Compatibility Objective Evidence Immersion Test

January 2002 18-21

Performance Verification Tests For Group 3 Slip Hangers
Performance Requirement
Level PR1 PR2
3 cycles from maximum rated load to
Load Cycling Objective Evidence minimum rated load with 5 minute hold
periods at each load cycle
Pressure test at maximum rated pressure
1 cycle at room temperature from minimum rated temperature to
Pressure from Above Seals and rated pressure maximum rated temperature and 1 cycle of
ring joint isolation seal at rated working
pressure at room temperature
Pressure test at maximum rated pressure
from minimum rated temperature to
Thermal Cycle Objective Evidence maximum rated temperature and 1 cycle of
ring joint isolation seal at rated working
pressure at room temperature
Fluid Compatibility Objective Evidence Immersion Test
1 cycle at room temperature Pressure test at maximum rated pressure
Pressure from below seal and rated pressure from minimum rated temperature to
maximum rated temperature

Performance Verification Tests For Group 4 Slip Hangers

Performance Requirement
Level PR1 PR2
3 cycles from maximum rated load to
Load Cycling Objective Evidence minimum rated load with 5 minute hold
periods at each load cycle
Pressure test at maximum rated pressure
1 cycle at room temperature from minimum rated temperature to
Pressure from Above Seals and rated pressure maximum rated temperature and 1 cycle of
ring joint isolation seal at rated working
pressure at room temperature
Pressure test at maximum rated pressure
from minimum rated temperature to
Thermal Cycle Objective Evidence maximum rated temperature and 1 cycle of
ring joint isolation seal at rated working
pressure at room temperature
Fluid Compatibility Objective Evidence Immersion Test
1 cycle at room temperature Pressure test at maximum rated pressure
Pressure from below seal and rated pressure from minimum rated temperature to
maximum rated temperature
Same as above with retention feature
Retention Feature Test by Objective Evidence retaining hanger with annular pressure from
Annular Pressure below

Performance Verification Tests For Group 1 Mandrel Hangers

Performance Requirement
Level PR1 PR2
3 cycles from maximum rated load to
Load Cycling Objective Evidence minimum rated load with 5 minute hold
periods at each load cycle
Internal Pressure Test Objective Evidence One cycle at room temperature

18-22
Performance Verification Tests For Group 2 Mandrel Hangers
Performance Requirement
Level PR1 PR2
3 cycles from maximum rated load to minimum
Load Cycling Objective Evidence rated load with 5 minute hold periods at each load
cycle
1 cycle at room Pressure test at maximum rated pressure from
Pressure Seals temperature and rated minimum rated temperature to maximum rated
pressure temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Pressure test at maximum rated pressure from
Thermal Cycle Objective Evidence minimum rated temperature to maximum rated
temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Fluid Compatibility Objective Evidence Immersion Test
Internal Pressure Test Same as Group 1 Same as Group 1

Performance Verification Tests For Group 3 Mandrel Hangers

Performance Requirement
Level PR1 PR2
3 cycles from maximum rated load to minimum
Load Cycling Objective Evidence rated load with 5 minute hold periods at each load
cycle
1 cycle at room Pressure test at maximum rated pressure from
Internal Pressure Test temperature and rated minimum rated temperature to maximum rated
pressure temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Pressure test at maximum rated pressure from
Thermal Cycle Objective Evidence minimum rated temperature to maximum rated
temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Fluid Compatibility Objective Evidence Immersion Test
1 cycle at room Pressure test at maximum rated pressure from
Pressure from below seal temperature and rated minimum rated temperature to maximum rated
pressure temperature
1 cycle at room Pressure test at maximum rated pressure from
Pressure from above seal temperature and rated minimum rated temperature to maximum rated
pressure temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature

Performance Verification Tests For Group 4 Mandrel Hangers

Performance Requirement PR1 PR2
Level
3 cycles from maximum rated load to minimum
Load Cycling Objective Evidence rated load with 5 minute hold periods at each load
cycle
1 cycle at room Pressure test at maximum rated pressure from
temperature and rated minimum rated temperature to maximum rated
Internal Pressure Test temperature and 1 cycle of ring joint isolation seal
pressure at rated working pressure at room temperature
Pressure test at maximum rated pressure from
Objective Evidence minimum rated temperature to maximum rated
Thermal Cycle temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Fluid Compatibility Objective Evidence Immersion Test
1 cycle at room Pressure test at maximum rated pressure from
Pressure from below seal temperature and rated minimum rated temperature to maximum rated
pressure temperature
1 cycle at room Pressure test at maximum rated pressure from
Pressure from above seal temperature and rated minimum rated temperature to maximum rated
pressure temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Retention Feature Test by Objective Evidence Same as above with retention feature retaining
Annular Pressure hanger with annular pressure from below

January 2002 18-23

Performance Verification Tests For Group 5 Mandrel Hangers
Performance Requirement
Level PR1 PR2
3 cycles from maximum rated load to minimum
Load Cycling Objective Evidence rated load with 5 minute hold periods at each load
cycle
1 cycle at room Pressure test at maximum rated pressure from
Internal Pressure Test temperature and rated minimum rated temperature to maximum rated
pressure temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Pressure test at maximum rated pressure from
Thermal Cycle Objective Evidence minimum rated temperature to maximum rated
temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Fluid Compatibility Objective Evidence Immersion Test
1 cycle at room Pressure test at maximum rated pressure from
Pressure from below seal temperature and rated minimum rated temperature to maximum rated
pressure temperature
1 cycle at room Pressure test at maximum rated pressure from
temperature and rated minimum rated temperature to maximum rated
Pressure from above seal temperature and 1 cycle of ring joint isolation seal
pressure
at rated working pressure at room temperature
Retention Feature Test by Full Same as above with retention feature retaining
Blind Pressure Objective Evidence hanger with annular pressure from below
Back Pressure Valve Objective Evidence 3 cycles from atmosphere to maximum rated
Preparation Test pressure from below

Performance Verification Tests For Group 1 Tubing Head Adapter

Performance Requirement PR1 PR2
Level
Internal Pressure Test Production hydrostatic Production hydrostatic test
test

Performance Verification Tests For Group 2 Tubing Head Adapters

Performance Requirement Level PR1 PR2
3 cycles from maximum rated load to minimum
Load Cycling Objective Evidence rated load with 5 minute hold periods at each load
cycle
Internal Pressure Test Production hydrostatic Production hydrostatic test
test
Thermal Cycle Objective Evidence Objective Evidence
Fluid Compatibility Objective Evidence Objective Evidence

Performance Verification Tests For Lockdown Screws, Alignment Pins, and

Retainer Screw Packing Mechanisms
Performance Requirement
Level PR1 PR2
Pressure test at maximum rated pressure from
Pressure and Thermal Objective Evidence minimum rated temperature to maximum rated
Cycling temperature and 1 cycle of ring joint isolation seal
at rated working pressure at room temperature
Operating Force or Torque Objective Evidence Apply maximum load at rated torque and perform
pressure test as above.

18-24
Performance Verification Tests For Other End Connectors
Performance Requirement
Level PR1 PR2

Pressure and Thermal Cycles Objective Evidence Pressure test at maximum rated pressure from minimum
rated temperature to maximum rated temperature
Bending Moments Objective Evidence One cycle at maximum rated load
Make and Break Objective Evidence Subject to manufacturers make and break cycles
Fluid Compatibility Objective Evidence Immersion Test

Performance Verification Tests For Fluid Sampling Devices

Performance Requirement Level PR1 PR2
Pressure and Temperature Objective Pressure test at maximum rated pressure from
Evidence minimum rated temperature to maximum rated
Cycles temperature
Fluid Compatibility Objective Immersion Test
Evidence

Appendix G
Appendix G establishes criteria for design and rating of equipment for elevated
temperatures.

Appendix H
Appendix H defines the recommended practice for heat treating equipment
qualification.

Appendix I
Appendix I provides a caution for operators noting that the tolerances for the
outside diameters of API casing and tubing 4-1/2” and larger has increased
effective March 1987. The tolerance formerly was from -0.75% to +0.75% of the
nominal outside diameter. The new tolerance is from -.0.5% to +1% of the nominal
outside diameter.
It should be noted that slip type casing and tubing hangers and seal systems
manufactured before March 1987 may not be designed to suspend casing or tubing
near the maximum or minimum tolerance now in effect.

Appendix J
Appendix J defines the different purpose, scope and ;use of API Specification 6A
and API Recommended Practice 6AR as they apply to repair and remanufacture of
wellhead and christmas tree equipment.
The principle difference is that if the repair and remanufacture of equipment is
performed by an API licensed facility and the equipment was originally
monogrammed under Specification 6A 15th Edition or later, the components
repaired or remanufactured can retain the API monogram and the equivalent
PSL/RL. In this case the repair and remanufacture facility must meet the
requirements of API Specification 6A 17th Edition Section 11.

January 2002 18-25

API Recommended Practice 6AR is designed to establish practices for repair and
remanufacture of equipment which was not originally monogrammed, or which has
lost its traceability or no longer evidenced an API monogram and PSL stamping.

Appendix K
Appendix K defines the circumstances which permit the marking of equipment
under the specification with the API monogram.

18-26
 1
API 6A 17th Edition Significant Changes From Prior Editions
The changes in the seventeenth edition of the specification represent a continued
trend toward international standardization of wellhead and Christmas tree
specifications. It includes an expanded listing of components covered in the scope
of the document, and includes three new appendices. The new addition contains
changes that have been balloted and approved by API Committee 1,
Subcommittee 6 (C1 SC6) since Supplement 2 to API 6A 16th Edition was released
in 1992.
These changes can be subdivided into the following broad categories based on the
reasons for which they were developed:
• Elimination of conflicting requirements between 6A and other API Standards.
• Expanded coverage to promote increased safety, standardization and/or
quality control.
• Facilitation of international or global usage.
• Facilitation of new, improved or more cost effective manufacturing
processes.
• Elimination of conflicting requirements between 6A and other API Standards.
1
Excerpt from paper published for ASME/API Energy Week Conference, January
29-February 2, 1996. By Anton Dach and Timothy Haeberle, ABB Vetco Gray
Engineering.
Many API specifications are now interrelated due to references back and forth to
specific sections in the various documents. Although this interrelation helps to
promote standardization, there are some negative effects in some instances,
problems can be caused when several standards start off with identical
requirements, but then fail to stay in synchronization due to different revision
schedules. Correcting problems such as these was part of the focus of the 17th
Edition as shown below.

API 14D To Be Replaced By API 6A And API 6AV1

One of the most significant changes related to the 17th Edition of API 6A is the
addition of design, materials, welding, and quality control requirements for surface
safety valves (SSV’s) and underwater safety valves (USV’s). These requirements
had been previously covered in API 14D but conflicts between supposedly similar
requirements in 6A and 14D have been a confusing and costly problem in the
manufacture of equipment for a number of years. Although the two documents had
attempted to duplicate the aforementioned requirements, the different revision
schedules for the documents had resulted in a synchronization problem with API
14D lagging behind.
With the release of API 6A 17th Edition the basic SSV and USV design and
manufacturing requirements have been unified in the 6A document with PSL 2 as a
minimum. The verification testing requirements that were covered in Section 900 of
API 14D 9th Edition are now covered in the new API 6AV1 1st Edition,
“Specification for Verification Test of Wellhead Surface Safety Valves and
Underwater Safety Valves for Offshore Service”. Thus, the new API 6A and 6AV1
requirements maintain the basic design, material, quality, and testing levels

January 2002 18-27

required in the 9th Edition of API 14D, so the standards have not been weakened. It
should be noted that existing SSV and USV design verification testing completed
under API 14D will satisfy the requirements of the new API 6AV1. Therefore,
existing designs will not have to be requalified by the manufacturers in order to
switch from API 14D. As part of this move from API 14D to API 6A and API 6AV1,
the recommended practice for failure reporting that was covered in Appendix C of
API 14D is now covered by Appendix L of API 6A. In summary, while two
documents must still be referenced to cover SSV and USV equipment, the costly
problem of conflicting design, materials, welding, and quality control requirements
has a solution. The only downside is the problems that arise during the transition
period that will exist until API 14D can be withdrawn. A discussion of this issue is
included in the section of this paper titled “Regulatory Standardization and
Customer Acceptance Issues.

API 17D Temperature Classes Are Now Addressed By API 6A

When API 17D 1st Edition was released in 1992, it referenced back to API 6A for
most of the materials, welding, and quality control requirements. However, API 17D
introduced a new “Operating Temperature Rating” that was not covered in API 6A.
To correct this situation, the new edition of 6A adds an Operating Temperature
Class Rating “V” that covers from 35 to 250 F. (2 to 121 C.). To meet the API 17D
impact testing requirements, API 6A also includes a new requirement that
equipment for Operating Temperature Class V shall be impact tested at 0 F. (-18
C.).

Independent Screwed Wellhead Transferred to API C1 SC11

Independent screwed wellhead equipment has been manufactured for years to
requirements much different than those specified for API 6A equipment. In spite of
the fact that API 6A contained requirements for independent screwed wellhead
equipment, These, components were typically manufactured to requirements very
similar to API Spec 11 equipment. Thus all requirements for independent screwed
wellhead equipment have been removed from the 17th Edition of API 6A and plans
call for these requirements to be issued as a stand alone API Spec 11 IW.

Expanded Coverage To Promote Increased Safety, Standardization, and/or

Improved Quality Control
The primary interests of customers purchasing API 6A equipment are related to
product safety, standardization (or interchangeability) and a high level of quality
control. In these areas, the 17th Edition of API 6A provides a number of
improvements as detailed below.

Design And Equipment Rating Options For Elevated Temperature Service

Another significant change included in the 17th Edition of API 6A is the addition to
Appendix G of new design and equipment rating options for elevated temperature
service. These new options are the result of a long term, in depth collaboration
between the C1 SC6 Materials Task Group and the C1 SC6 Design Task Group.
The 6th Edition of API 6A was limited in that it only provided a standardized means
of rating 6B flanges at 2000, 3000 and 5000 psi for service above 250 F (121 C).
The new provisions in Appendix G provide the manufacturer with a number of
options for rating all API 6A equipment. Furthermore, the manufacturer can select
from the various options to provide the customer equipment with the best possible

18-28
derated working pressure, or in many cases, equipment with a full rated working
pressure. The new options include design using derating factors published in the
specification, design using elevated temperature tensile test data on a QTC
representing the actual component or design based on elevated temperature
tensile test data on the material grade being used.

Quality Control Requirements for Choke Trim

With the release of the 17th Edition, API 6A now contains quality control
requirements for choke trim, with choke trim being defined as “pressure controlling
choke components, including choke beans”. Choke trim was not addressed in the
prior editions of API 6A. The new requirements stipulate that choke trim must be
subjected to the same surface, NDE and serialization requirements as valve bore
sealing mechanisms, with an exemption for brazed, press-fit and shrink-fit joints
from the surface NDE requirements.

Specification Requirements For Valves Adapted For Actuators

In many cases, valves and the actuators used to operate them are manufactured by
different companies. Unfortunately, the requirements in prior editions of API 6A
made it difficult to monogram these components independently. The 17th Edition
now includes specific requirements for valves adapted for actuators, allowing them
to be monogrammed after testing with a “simulated” bonnet instead of with an
actuator. The valve adapted for an actuator must successfully complete all tests
except for the backseat test. If the bonnet and actuator are furnished as a unit for
PSL 4, then a gas back seat test shall be conducted. In addition to these new
requirements, a number of revisions were made to clarify the intent of the
requirements for valves adapted for actuators.

Crossover Connection Requirements

Restricted area packoffs are a proprietary part of manufacturer’s designs and the
requirements specified in the 16th Edition of API 6A failed to provide adequate
flexibility for coverage of the various designs. The maximum seal area
requirements shown in the 16th and earlier editions of API 6A were an attempt to
show “How To” in the strength of design. In some cases the dimensions shown did
not correlate with calculations. These dimensions were undocumented and
appeared to be incorrect. The maximum seal diameter of the crossover connection
is dependent on the restricted area packoff design. The manufacturer must take
into account all of the loading on each component of the lower connector. Section
300 of the 17th Edition covers these requirements and no specific dimensions need
to be provided. The requirements in the 17th Edition properly identify what must be
taken into account, but leaves the “How To” up to each manufacturer, based on his
particular design or designs.

Deletion of Triple and Quadruple Segmented Flanges

New analysis of old designs can sometimes render them obsolete, and this is what
has happened in the case of segmented flanges. Triple and quadruple segmented
flanges have been deleted from the 17th Edition of API 6A after a detailed study.
The high strength bolting required for triple and quadruple flanges simply does not
meet the requirements for H2S service. Present surveys indicate usage of triple
and quadruple segmented flanges to be less than 10% of the total segmented
flanges being manufactured, so only a small portion of the market will be affected.
This change does not affect dual segmented flanges.

January 2002 18-29

Usage of Other End Connectors (OEC’s) On Mandrel Hangers
The original intent for the 16th Edition was to allow OEC’s to be used on mandrel
hangers when they met the specified requirements. Unfortunately, the wording did
not reflect this intent. This has been corrected in the 17th Edition to clearly show
that mandrel casing hangers and mandrel tubing hangers can now be
monogrammed with any type of threaded connections, provided that they meet the
specified design requirements.

Adapter and Spacer Spool Coverage Added

Adapter spools had been listed as an API 6A product in prior editions, but were not
covered by detailed requirements. A new section has been added to the 17th
Edition to permit manufacturing of this important class of equipment under API
rules. Previous requirements did not permit a change of pressure ratings in a
wellhead component without a restricted area sealing means. In addition, a simple
spacer spool was not covered by the previous requirements since heads and
housings were required to have a means for suspending casing or tubing within
them. It had been the practice to make this type of equipment under API rules prior
to the 15th Edition of 6A. The key provision of the new requirements is to limit the
working pressure rating of the body to the lowest rating of the end and outlet
connectors rather than the highest as is permitted in a crossover spool.

Hardness Testing for Compliance With NACE MR0175

In order to insure that components destined for sour service meet the required
maximum hardness values, wording has been added to a number of sections to
clarify that hardness testing of individual components is required. While NACE
MR0175 has been interpreted to allow hardness sampling, it is quite clear now in
particular sections of API 6A that each part must be individually tested.

Enhanced Elastomer Storage and Age Control

A small yet significant addition has been made to the requirements for storage and
age control or elastomeric materials. While the requirements for storage and age
control were left up to the manufacturer in prior revisions of API 6A, the 17th Edition
now includes detailed requirements as to how elastomers should be stored to
prevent rapid deterioration.

Equipment Marking
The equipment marking requirements have been revised in the 17th Edition to
clarify exactly what is necessary for each piece of equipment. Also, the 17th Edition
contains new requirements for several items for which no marking was identified in
the prior revisions.

Guidelines For Repair And Remanufacturer Of API 6A Equipment Made

Prior To The 15th Edition of 6A
A new Appendix J has been added to clarify applicability of requirements in API 6A
versus guideline sin API RP 6AR for repair and remanufacture of wellhead and
christmas tree equipment. Equipment made prior to the 15th Edition of 6A can be
repaired or remanufactured under the guidelines established in API RP 6AR.
Equipment made to the 15th and later Editions of 6A can be repaired or

18-30
remanufactured to the requirements of API Spec 6A Section 11. This new appendix
provides a clear explanation of the options related to repair and remanufacturer,
and provides answers to the most commonly asked questions related to this issue.

Facilitation Of International Usage

For a number of years, a key objective of the API staff and API committee members
has been to make API 6A and other API specifications international in scope, with
acceptance and usage throughout the world. Much progress has been made with
respect to this objective, but the 16th Edition of API 6A still contained several
requirements that reflected its prior US focus. The following changes were made to
facilitate international acceptance by both the manufacturers and the users of API
6A equipment.

Section, Table and Figure Re-numbering

In an attempt to facilitate the acceptance of API 6A 17th Edition as the replacement
for the current ISO 10423, this new edition has been totally re-numbered and
formatted using the ISO guidelines. While this step was necessary to fulfill the ISO
related objectives, it should be noted that the re-numbering has placed 6A out of
synchronization with PI 17D 1st Edition since it relies heavy on reference to specific
parts of API 6A.

Determination of Equivalent Standards

Prior to the 17th Edition, any manufacturer wishing to utilize an equivalent to one of
the US based reference standards listed in 6A had to submit the proposed
equivalent to API or review. The new policy transfers the responsibility for
evaluating and justifying the equivalency of alternate national or international
standards from API to the individual manufacturers.

International Standards
Throughout the entire API 6A 17th Edition, any prior reference to an “industry
recognized standard” has been changed to read “nationally or internally recognized
standard”.

Optional PSL 3 Gas Test Added

An optional gas test has been added to PSL 3 in the 17th Edition of API 6A. This
optional test was included to satisfy a broad base of API 6A user and manufacturer
requirements in the North Sea area. It allows for the following:
A high and low pressure (300 psi) gas seat test in addition to or in place of the
extended hydrostatic seat test.
• A gas body test in addition to the hydrostatic body test.
• A gas backseat test in conjunction with the gas body test.
• H2S Radius Of Exposure Redefined
One of the factors used in determining the appropriate PSL for equipment is “close
proximity” and one of the factors used in determining “close proximity” is the “radius
of exposure” (ROE). In Appendix A of the 16th Edition, the only option allowed for
determining the ROE was based on the procedure published by the Texas Railroad

January 2002 18-31

Commission. In the 17th Edition, Appendix A has been revised to identify that other
methods of calculating the ROE may apply, depending on local regulations.

Facilitation Of New, Improved Or More Cost Effective

Manufacturing Processes
The 15th Edition of API 6A issued in 1986 contained a major expansion into the
area of manufacturing process control. Many of the process control requirements
impose by that edition were totally new and had not been fully proven. Once in
effect, it became quite clear that there were problems. Therefore, since 1986, a
significant amount of committee time has been dedicated to revising those process
controls into technically and commercially viable requirements. Like the 16th
Edition, the 17th Edition also contains a number of changes aimed at correcting
those 15th Edition process control requirements. It should also be noted that since
detailed process controls are now art of API 6A, there will be an ongoing need for
revisions as new or improved manufacturing processes that are quite acceptable
from the technical standpoint fall outside of the API requirements. Listed below are
several examples of the changes that have been made in the 17th Edition for the
reasons discussed above

Qualification Test Coupon (QTC) And Mechanical Property Testing

Requirements
The 17th Edition contains several changes to these requirements that will promote
more cost effect manufacturing without any degradation of quality. First, the
requirements for the location of mechanical test specimens have been revised to
facilitate more cost effective usage of rolled bar. Prior requirements favored forged
bars that are made with separate, but smaller QTC’s. Additionally, the
requirements for trepanned cores, prolongation’s and sacrificial production parts
have been revised to allow broader application of these types of QTC’s.
Furthermore, the requirement for hardness testing on each QTC has been reduced
from two hardness measurements to one. (It did not make sense that the test bar
had to have more hardness measurements than the actual components.) Another
key change to the 17th Edition is a new provision that allows testing of tensile and
impact specimens from multiple QTC’s This will allow manufacturers to upgrade
material that may have not been previously impact tested without having to repeat
the tensile test. In regards to heat sinks, requirements were also added to cover the
production parts they represent when age hardening treatments are performed.
Previously, age hardening cycles such as those used on nickel base alloys were not
addressed by API 6A.

Heat Sink Requirements

Prior to the 17th Edition heat sinks fro PSL 4 equipment had to be made of the exact
same alloy. This proved to be quite costly for raw material suppliers since heat
sinks are almost entirely used only for the oil and gas industry’s PSL 4 requirements
and many times have to be made for a particular order of metal. thus, the revisions
to the heat sink requirements include the creation of six new alloy classes that can
be used to make heat sinks. Any material that falls into one of these alloy classes
can be used as a heat sink for any other material in that alloy class. This will reduce
the number of heat sinks that raw material suppliers must invest in without affecting
the quality of the heat treatment process as demonstrated by a detailed review of

18-32
the coefficients of thermal conductivity of numerous materials by the C1 SC6
Materials Task Group.

Regulatory, Standardization And Customer Acceptance Issues

As noted in the introduction, there were some regulatory issues and customer
acceptance issues that clouded the future of the new API 6A 17th Edition at the time
of its release.
The main regulatory issue left unresolved was the acceptance of the combined
requirements of API 6A 17th Edition and API 6AV1 1st Edition as a replacement for
API 14D by ASME SPPE-1 and the United States Minerals Management Service
(MMS). It is the US MMS that has jurisdiction over the production of oil and gas in
US offshore waters, and it is the US MMS that will make a ruling on whether or not
the combined requirements of API 6A 17th Edition and API 6AV1 1st Edition provide
the necessary requirements for the standardization of wellhead surface safety
valves and underwater safety valves. However, the issue is more that whether or
not API 14D can be superseded by API 6A and API 6AV1. The issue also involves
whether SSV’s and USV’s need to be covered by a separate quality assurance
audit. Currently, valve manufacturers must undergo both an ASME SPPE-1 audit
and an API Q1 audit. Is the cost of the ASME audit justified?
The main standardization issue left unresolved was the status of the new API 6A
and the old API 14D as ISO documents. Currently, API 6A 16th Edition with only
Supplement 1 is accepted as ISO 10423, while API 14D 8th Edition is accepted as
ISO 10433. Thus, even before the new API documents were released, the API and
ISO documents were already one revision out of synchronization. The fact that the
API and ISO documents are now further out of synchronization and contain
different requirements presents a major problem for equipment manufacturers and
end users. Attempting to maintain dual inventories and dual manufacturing
specification systems creates a financial burden that is out of place in an industry
seeking to drastically reduce equipment costs. Furthermore it is yet to be seen if
the ISO process and the slow cycle time on revision and release of ISO documents
will be acceptable to the oil and gas industry in an age of rapidly changing
technology.
This is not an issue that can be resolved by the API staff or the API committee
members alone. API SC6 and its parent committee, C1, are implementing plans to
improve communication and coordination with the relevant subgroups of ISO TC
67. This synchronization problem must now be addressed by the ISO TC 67 and/or
the companies tat purchase wellhead and christmas tree equipment. Like the
situation with ASME as described above, the API/ISO situation also adds to the
audit costs of manufacturers. Just as the need for both an ASME SPPE-1 and an
API Q1 audit can be questioned, the need for a third audit by ISO is an additional
burden. Does the industry need the expense of three separate audit programs to
cover the same basic equipment? Can the industry afford to provide the
“volunteers” to staff the various API, ISO and ASME committees overseeing these
similar specifications and audit programs?
In regard to customer acceptance issues, it is worth noting that at the same time
API C1 SC 6 has been working to make API 6A an internationally acceptable
specification, other documents with differing or conflicting requirements are being
released elsewhere in the world to cover the manufacture of wellhead and
christmas tree equipment. The recently released NORSOK standards provide a
new nationally focused set of requirements for Norway and were developed to

January 2002 18-33

standardize equipment requirements and reduce costs for Norwegian oil and gas
companies. Could the needs of the Norwegian oil and gas companies be
addressed in the API specification? Will there be other individual countries or
countries bound geographically that elect to generate their own specifications? In
an industry seeking to reduce equipment costs through international
standardization, these are important questions.

Conclusions
API 6A 17th Edition represents the state-of-the-art in international standardization
of requirements for wellhead and christmas tree equipment.. The revisions made to
create the 17th Edition have resolved a number of long term problems and
expanded the scope and coverage of API 6A. The design, materials, and quality
control aspects of API 6A have all been improved with an emphasis on making the
document more acceptable for usage around the world.

18-34