bcco-1

GAS LIFT

Baker Oil Tools

This document is and contains unpublished, copyrighted and confidential information of Baker Hughes, and is revealed for limited purposes only. This documentis the property of Baker Hughes and is to be returned to Baker Hughes on request and may not be reproduced, used or disclosed to persons not having a need toknow consistent with the purpose of the document, without the written consent of Baker Hughes. This document is not rented, loaned or sold, either alone or inconjunction with equipment or product. 2/11/05 Baker Hughes Incorporated.

TECHNICAL UNITTubing Retrievable Equipment

Unit No. 10401Rev. New

BCCO-1 Tubing Retrievable Injection Pressure Operated Valve

Product Family No. H86101

DescriptionThe BCCO-1 Tubing Retrievable Injection

Pressure Operated Gas Lift Valve is a 1 inch ODvalve primarily controlled by injection gas pres-sure. The valve is used to control gas pressure andits flow from the casing annulus into the tubing dur-ing gas lift operations. The valve is installed on out-side mount tubing retrievable mandrels.

The valve is designed with a sealed chamber,including a bellows assembly, that contains a nitro-gen charge over a dampening fluid which providesthe closing force of the valve. When injection gaspressure exceeds the closing force, the bellowscompresses, thus lifting a valve stem off of a seat,allowing gas to be injected through the valve andinto the tubing.

The BCCO-1 Injection Pressure Operatedvalve consists of a tail plug, bellows assembly, bel-lows housing, stem with tungsten carbide ball andseat housing with floating seat. The valve is avail-able in either stainless steel or nickel alloys for cor-rosion resistance in wells with high concentrationsof H2S or CO2. Elastomeric materials for the valveare available for standard service or special ser-vice to suit individual well conditions.

Drawing No. 399-917

Date: February 11, 2005Page: 1 of 8

Unit No. 10401Rev. New Page 2 of 8

WARNINGUse of Baker equipment contrary to

manufacturers specification may result in property damage, serious injury or fatality.

2-11-05

Features/Benefits Stainless steel or premium materials Three-ply Nickel-Copper Alloy 400 bellows Mechanical stop prevents bellows overstroke Viscous fluid shear dampening prevents

bellows fatigue and stem-seat pounding

Tungsten Carbide ball Replaceable floating Nickel-Copper Alloy 400

seat (Tungsten Carbide insert available) Silver brazed bellows connections Optional reverse flow check valve Pressure rating up to 1,800 psi test rack open

maximum Temperature rating to 250F (standard service) Compatible with other manufacturers' industry

standard outside mount tubing retrievablemandrels

BCCO-1 Tubing Retrievable InjectionPressure Operated Valve

Specification Guide

Type NominalOD (in.)

Overall Length (in.) Connecting Thread

Reverse Flow Check Valve

Required

BCCO-1 1.000 13.680 1/2"-14 NPT BCCK-1 (H86122)

Available Ports And Specification TableAb Effective

Bellows Area (in.2)Port

Size (in.)Ap Area

of Port (in.2) Ap/Ab 1-(Ap/Ab) PPEF

0.31

1/8 0.013 0.042 0.958 0.0443/16 0.029 0.094 0.906 0.1041/4 0.051 0.165 0.835 0.1985/16 0.079 0.255 0.745 0.3423/8 0.113 0.365 0.635 0.575

PPEF = Production Pressure Effect Factor.

OperationThe dome of the valve is charged with nitrogen

to a predetermined test rack opening pressure. Be-fore setting the test rack opening pressure, thevalve temperature or dome charge should be sta-bilized in a temperature controlled water bath (in-dustry standard is 60F). A reverse flow checkvalve assembly is installed on the valve and bothare then screwed into the lug of an outside mounttubing retrievable mandrel.

In operation, high pressure gas that is injectedinto the casing annulus enters through the ports inthe valves seat housing. When the gas pressureovercomes the Nitrogen charge contained by thebellows assembly, the bellows is compressed andthe valve stem ball is lifted off the valve seat there-by opening the valve. The high pressure gas thenflows through the seat, through the reverse flow

check assembly, through the lug of the outsidemount tubing retrievable mandrel and into the tub-ing. When the gas pressure in the casing annulusdrops below the nitrogen charge pressure con-tained in the bellows assembly, the bellows ex-tends, causing the valve stem ball to engage theseat and close the valve.

Reverse flow through the valve is prevented bythe auxiliary reverse flow check assembly. Thecheck dart in the reverse flow check assemblyseats against a fixed elastomeric primary seal witha metal to metal secondary seal. The lower con-nection of the valve that makes up into the auxiliaryreverse flow check or conventional mandrel is a1/2" NPT pin.

The stem ball, seat and bellows assembly ofthe valve are protected from damage during valveoperation by the dampening effect of silicon fluid



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contained in the bellows. When the bellows com-presses or extends, the silicon fluid has to fluidshear past a rod installed in the bellows assembly.

The valve is available with stem and seat sizesof 1/8 through 3/8 inch and is utilized both for con-tinuous flow and intermittent gas lift.

Tubing Flow Application Drawing No. 399-918


Unit No. 10401 Rev. New Page 4 of 8

2-11-05

Recommended Tools And Supplies For Assembly, Setting, And Disassembly1. Hydraulic Sealant (Loctite #569) 2. Thread Lubricant (Anti-galling compound such

as API modified thread compound) 3. Seal Lubricant (Silicon O-ring lubricant) 4. #6 Mirror Image - Diamond Lapping Compound 5. G.E. Silicon Oil SF96-5006. Hypodermic Syringe in Cubic Centimeters7. #1 Parmalee Pipe Wrench (friction), 2 required 8. Small Bench Vise9. High Pressure Nitrogen System (2,000 psi)10.Hydro Test Tank11.Hydro Test System (Pump - 6,000 psi)12.Test Rack with High Pressure Air Source13.Cooling Tank (60F)14.Lapping Lathe15.Valve Core Tapper 16.Valve Core Wrench17.Charging Fixture18.Buffing Wheel or Cloth19.File (Bastard Mill)20.Ice Pick21.3/8" x 6" Wood Dowel22.Internal Snap Ring Pliers23.Adjustable Wrench 6"24.7/8" Open End Wrench25.1/2" Box End Wrench26.7/16" Box End Wrench27.8" Pipe Wrench28.Small adjustable crescent wrench or (9 mm)

open end wrench29.Wooden Mallet30.Gas Flow Measurement Device (up to 35 Stan-

dard cu ft per Day Scale)

Disassembly ProcedureRefer to Drawing No. 399-917.1. Insure valves are uniform and straight (not

bent).2. Check valve in test rack to determine as re-

ceived condition. Compare the test rack open

to the opening pressure (Pvo) stamped onvalve. If depressured/abnormally pressured,valve may have bad bellows or leaking tail pluggasket/seal. Separate these valves for specialhandling so rebuild technician will carefullycheck for bellows leakage during hydrostaticaging. At this point a preliminary check is madeon the stem and seat leakage by checking thevalve in the test rack before disassembly. Notecondition.

3. Place the valve into a mounted friction wrenchgripping onto the Dome (4) with the Tail Plug (1)protruding to the right.

4. Remove the Tail Plug (1) from the Dome (4).Look for looseness or damage to Tail Plug ifvalve Pvo was abnormal.

CautionIf the Tail Plug (1) resists removal, there mayexist high pressure behind the Tail Plug andcaution must be exercised when removing.

5. Using the valve core tapper, depress the ValveCore (5) In the Dome (4) and depressure bel-lows so that the nitrogen charge is vented to at-mosphere. Leave Valve Core installed toprevent loss of dampening fluid and/or entry ofcleaning solvent.

Danger!If this step is not accomplished, there is apossibility of injury to people in the workarea when the Dome (4) and Bellowsassembly is removed from the BellowsHousing (10).

6. Place the valve into the mounted frictionwrench in such a way that the Bellows Housing(10) is protruding to the right. Lock the secondfriction wrench onto the Bellows Housing, loos-en and remove.

Danger!If the dome and bellows assembly resistsmovement at this time, it is because step 5has not been accomplished.

CautionThe Bellows (7) can be easily damagedduring this operation so special care mustbe taken at this time to avoid any damage.a. Discard Bellows (7) that are deformed,

smashed, snaked or otherwise damaged andchanged from their original permanent set.



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7. Place the Bellows Housing (10) into the mount-ed friction wrench so that only the Seat Housing(16) is protruding to the right. Loosen and re-move the Seat Housing with the 7/8" open endwrench.

8. Remove the Retainer Ring (13) from the SeatHousing (16) using the internal snap ring pliers.

9. Using the 3/8" diameter wooden dowel, removethe Seat (15) from the Seat Housing (16). Insertthe dowel through the lower end of the SeatHousing until it lands on the seat. Tap the Seatout.

10.Place the Dome (4) in the mounted frictionwrench so that the Bellows (7) and BellowsAdapter (9) protrude to the right. Using thesmall adjustable crescent wrench or (9 mm)open end wrench on the wrench flats of the Bel-lows Adapter as a backup, loosen and removethe Ball Stem (11) with the 7/16" wrench. Donot squeeze, twist or damage the Bellows inany manner during the disassembly or assem-bly procedures. The application of a moderateamount of heat (not to exceed 300F) may benecessary to release the Ball Stem from theLoctite which was applied during assembly.NOTE: The Seat and the Ball Stem have beenlapped as a matched set. It is therefore essential tokeep the lapped pair separate from similar parts ofother valves which may have been dissembled atthe same time. If either the Ball Stem or the Seat isdamaged, both parts must be replaced with a newmatched pair.

11.Using an ice pick, remove all O-rings.12.Wash all parts in solvent or other cleaning

agent and blow them dry with air. Visually in-spect all parts for fluid cutting, thread damage,cracks or abrasion. Reject any damaged parts.

13.Buff the Bellows (7) and Bellows assemblyclean.

Warning!Use extreme care cleaning the bellows. Thebellows material is very thin and even asmall nick or dent from the file can renderthe Bellows defective.

14.If the valve has been in service, discard seatRetainer Ring (13), Tail Plug Gasket (3) and allO-rings.

Assembly ProceduresRefer to Drawing No. 399-917.1. Using lapping compound and lathe, lap the

Seat (15) and Ball Stem (11) as a matched set.Lap them so that there is a completely matedsurface between the Seat and Stem Ball.

2. Insert the O-ring (14) into the Seats O-ringgroove (15). Be sure not to mix the matchedSeats and Ball Stems (11). Lubricate the O-ring.

3. With the lapped surface of the Seat (15) facingout of the Seat Housing (16), insert the Seat.Use the 1/8" wooded dowel to push the Seatinto the Seat Housing so as not to scar thelapped surface of the Seat. The Seat must beseated at the flat bottom of the Seat Housing.

4. Using the internal snap ring pliers, insert theRetainer Ring (13) into the Retainer Ringgroove just above the Seat (15) in the SeatHousing (16). Be sure it is completely seated inthe groove.

5. Apply hydraulic sealant (Loctite #569) to theBall Stem (11) and thread it into the Dome (4)and Bellows Adapter (9). Place the Dome in themounted friction wrench so that the Bellows (7)and Bellows Adapter protrude to the left. Usingthe small adjustable crescent wrench or (9 mm)open end wrench on the wrench flats of the Bel-lows Adapter as a backup, tighten the BallStem with the 7/16" wrench. Do not squeeze,twist or damage the Bellows in any manner dur-ing the assembly procedures. NOTE: It is important that the assemblies containingthe matched Seat and Ball Stems remain matched.

6. Lubricate and install the O-ring (6) into thegroove on the Dome (4).

7. Lubricate the threads and place the Dome (4)and bellows assembly into a mounted frictionwrench with the Bellows (7) convolutions pro-truding to the left of the wrench. Install the Bel-lows Housing (10) onto the bellows assembly.Lock the second friction wrench over the Bel-lows Housing and tighten the threads. NOTE: Care must be taken not to dent or inflict anydamage to the Bellows (7) surface during thisapplication.


Unit No. 10401 Rev. New Page 6 of 8

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8. Lubricate threads and install Seat Housing (16)with matching Seat (15) onto Bellows Housing(10), tightening the threads with the 7/8" openend wrench.

9. Remove the old Valve Core (5) using the ValveCore wrench. If silicon fluid has leaked from thevalve or has been removed, the fluid must bereplaced. Drain off any remaining fluid from thedome and bellows assembly. Hold the valvevertically and inject 4 cubic centimeters of theG.E. silicon oil (SF96-500) into the bore at theupper end of the dome and Bellows assemblyusing a large hypodermic syringe.

10.Lubricate and install the new Valve Core (5) inthe opening at the top of the Dome (4) and bel-lows assembly using the Valve Core wrench.Screw the core in firmly, but do not over-tighten.NOTE: New bellows assemblies already have theG.E. silicon oil in them and more fluid should not beadded.

11.Screw the charging fixture completely into thetop of the Dome (4) and attach it securely to thenitrogen high pressure system. Pressure upBellows (7) to 800 psig with nitrogen charge.Apply charge slowly with valve in vertical posi-tion.

12.Check Ball Stem (11) and Seat (15) for leakagein test rack by the following procedure: BallStem and Seat leakage test can be done at am-bient temperature.a. Calculate valve closing pressure (Pvct)

where:

Pvc = Pvo x (1-Ap/Ab)

where:

Pvc = Closing pressure of the valve at avalve temperature of 60F whenthe injection gas pressure and productionpressure are equal at the instant the valvecloses.

Pvo = Valve opening pressure in the testrack at valve temperature of 60F.

Ap = Effective pressure area of the valvestem and seat contact, square inches.

Ab = Effective are of the bellows, squareinches.

b. Ball Stem (11) and Seat (15) shall be dry dur-ing this test. No oil, grease or similar materialshall be allowed on the Ball (12) and Seat.

c. Install the valve in the tester, open the valvewith gas pressure and reduce the pressure toPvct.

d. Direct the downstream side of the valve tothe flow measurement device. If the flow rateis greater the 35 standard cubic feet per day,the Ball Stem (11) and seat shall be rejected.(If a flow measurement device is not avail-able, immerse the bottom of the valve in acup of water. A leakage rate of no more thanone bubble per second is acceptable.)

e. To correct a badly leaking valve seat, per-form the following steps until the valves seatdoes not leak in the test rack.

(1). Bleed the pressure from the test rack andremove the valve. Tap lightly a few timeson the top of the valve with a woodenmallet to settle the stem ball into the Seat(15).

(2).Check valve in test rack. If valve contin-ues to leak, disassemble valve and re-place O-ring on Seat (15).

(3).Check valve in test rack. If valve contin-ues to leak, disassemble valve and relapSeat (15) and Ball Stem (11).

(4).Check valve in test rack. If valve contin-ues to leak, disassemble valve and re-place Seat (15) and Ball Stem (11) with anew matched set.

13.Install the O-ring (2) and Tail Plug Gasket (3) onthe Tail Plug (1). Lubricate threads and installtail Plug With properly stamped stem and seatsize. Tighten Tail Plug.

14.Place valve in pressure chamber or ager in avertical position. Fill chamber with water andpressure up on the chamber to 5,000 psig andhold for a minimum of 1 hour. Remove valve.

15.Check valve in test rack. If pressure haschanged significantly from original set pres-sure, record pressure and place in pressurechamber for a minimum of 15 minutes and re-peat process until valve stabilizes.



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Caution! An opening pressure much lower than thePvo (50 psig) is an indication that theBellows (7) failed during the hydrostaticpressure process. If the Bellows failed,release the remaining Dome (4) chargepressure completely. Remove and discardthe Dome and bellows assembly. Install anew Dome and Bellows assembly and beginthe charging and setting procedure.

CautionAn opening pressure much higher than thePvo (50 psig) is an indication that the tailplug leaked during the hydrostatic pressureprocess allowing water to enter the Bellows(7) and increase the Dome (4) pressure. Ifthe tail plug leaked, release the remainingNitrogen charge pressure completely.Remove and discard the Dome and Bellowsassembly. Install a new Dome and Bellowsassembly and begin the charging andsetting procedure.

Valve Setting ProcedureRefer to Drawing No. 399-917.

Valves should be stored on the shelf for a min-imum of 5 days. The original set pressure of eachvalve shall be checked before being set up per gaslift design. If the original pressure the valve was setat has changed more than 10 psig, that valve shallbe rejected.1. Obtain the calculated test rack opening (Pvo)

pressure for the valves to be set.2. Remove the Tail Plug (1).

Caution!If the Tail Plug (1) resists removal, there mayexist high pressure behind the Tail Plug andcaution must be exercised when removingthe Tail Plug.

3. Screw the charging fixture completely into theDome (4) and attach it securely to the Nitrogen

high pressure system. Charge the Bellows (7)to a pressure 50 psig greater than the designsetting pressure required (Pvo).

4. Place valve in water bath set at 60F for 15 min-utes.

5. Remove the valve from the water bath and in-sert in tester.

CautionDo not hold the valve by the Dome (4) as thatwill heat the dome and cause incorrect setpressures.

Apply pressure in the tester to open the valve:Using the valve core tapper, adjust the domepressure by tapping the Valve Core (5) releas-ing nitrogen pressure from the Bellows (7) untilthe proper opening pressure (Pvo) is achieved.If it takes longer than 30 seconds to obtain thedesired opening pressure, remove the valvefrom the tester and return it to the water bath.

6. Lubricate thread and install Tail Plug (1) intoDome (4) and tighten. Place valve in pressurechamber or ager in a vertical position. Fillchamber with water and pressure up on thechamber to 5,000 psig and hold for a minimumof 15 minutes. Release the pressure and cyclethe pressure at 5,000 psig a minimum of threetimes without pausing between cycles.

7. Remove valve from chamber and place in wa-ter bath for a minimum of 15 minutes.

8. Remove a valve from the water bath and installit in a tester and check the opening pressure. Ifthe opening pressure has changed 5 psig ormore, repeat steps 4 through 7 until the pres-sure does not change more than 5 psig.

9. The Pvo should be stenciled on side of TailPlug (1) to prevent mixing up of the valves atthe well installation.

BC

CO

-1 Tubing Retrievable Injection

Pressure Operated Valve

Unit N

o. 10401R

ev. New

Page 8 of 82-11-05

BCCO-1 Tubing Retrievable Injection Pressure Operated ValveAssembly Drawing No. 399-917

Parts ListRefer to Drawing No. 399-917.

Item No. Description

No. Reqd.

Stainless Steel Service Nickel Alloy Corrosive ServicePart No. Material Part No. Material

1 Tail Plug 1 104002 17-4 PH 104002 17-4 PH2 O-ring #013 1 0-013-70V Viton 0-013-70V Viton3 Tail Plug Gasket 1 104003 BeCu 104003 BeCu4 Dome 1 104001-02 316 SS 104001-03 Nickel-Copper Alloy5 Valve Core 1 P-200-01 N/A P-200-01 N/A6 O-ring #017 1 0-017-70V Viton 0-017-70V Viton7 Bellows 1 P-201-01 Nickel-Copper Alloy P-201-01 Nickel-Copper Alloy8 Cushion Rod 1 100110-02 316 SS 100110-03 Nickel-Copper Alloy9 Bellows Adapter 1 101002-02 316 SS 101002-03 Nickel-Copper Alloy

10 Bellows Housing 1 101003-02 316 SS 101003-03 Nickel-Copper Alloy11 Ball Stem 1 104004-02 316 SS 104004-03 Nickel-Copper Alloy12 Ball 1 P-300 Tungsten Carbide P-300 Tungsten Carbide13 Retainer Ring 1 I-625 BeCu I-625 BeCu14 O-ring #111 1 0-111-70V Viton 0-117-70V Viton15 Seat 1 100105 Nickel-Copper Alloy 100105 Nickel-Copper Alloy16 Seat Housing 1 101006-02 316 SS 101006-03 Nickel-Copper Alloy

Unit No. 10401DescriptionFeatures/BenefitsSpecification GuideAvailable Ports And Specification TableOperationTubing Flow Application Drawing No. 399-918Recommended Tools And Supplies For Assembly, Setting, And DisassemblyDisassembly ProcedureAssembly ProceduresValve Setting ProcedureBCCO-1 Tubing Retrievable Injection Pressure Operated ValveAssembly Drawing No. 399-917Parts List

bcco-1

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