FILL AND CIRCULATE (FAC) TOOL Technical Manual- Revision 2-B

FAC TOOL TECH MAN.doc Last printed 2005-09-28

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TABLE OF CONTENTS

Page I. INTRODUCTION 2

a. General Description 3 b. Features and Benefits 3 c. Technical Data 4

II. TOP DRIVE 5

a. Part Descriptions 6 b. Space Out 10 c. Rig Up 11 d. Filling 11 e. Circulating 12 f. Rig Down 13

III. NON-TOP DRIVE 14

a. Part Descriptions 15 b. Space Out 18 c. Rig Up 19 d. Filling 19 e. Circulation 20 f. Rig Down 21

IV. MAINTENANCE AND SAFETY 22

a. Maintenance of the FAC Tool 23 b. Safety Using the FAC Tool 25

V. MUD SAVER VALVE 26

a. Parts and Descriptions 27 b. Main Assembly 31 c. Assembly/Disassembly- Tungsten Carbide Bob 35 d. Assembly/Disassembly- Rubber Nose Bob 37

VI. SPECIAL APPLICATIONS 39

a. Push Plate 40 b. Reverse Flow 41 c. Duel Sealing Element 41 d. Side Door Elevators 42

VII. DETAILS AND BILL OF MATERIALS 43

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INTRODUCTION

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GENERAL DESCRIPTION The Davis-Lynch Fill And Circulate Tool (FAC Tool) is a surface tool used during the Casing Running Operation. The FAC Tool is designed to both fill the casing with drilling fluid while running it in the hole and to enable quick circulation of the casing string at any time without installation of a casing swage.

The Davis-Lynch FAC Tool is available for both rig types; top drive rigs and non-top drive (conventional rotary table) rigs. It comes in three tool sizes, Large (FACL), Medium (FACM) and Small (FACS), for running casing sizes from 4 1/2" to 20”.

The Tool also has other unique applications for both rig types. A special setup is available when running auto-fill float equipment that prevents drilling fluid spill over by sealing off the casing joint while lowering the string into the hole and channels the flow back to the mud tank. Another application available for both rig type allows the casing crew to “push” the casing down hole with the weight of the top drive or hook in high drag situations. Yet another variation of the Davis Lynch FAC Tool is available when running casing of two different sizes, two different weights or any time the inside diameters of the pipe are different. This technical manual is divided into sections to clearly explain and teach proper usage of the Davis FAC Tool. Please read and follow the directions given.

FEATURES AND BENEFITS • Fast filling or circulation of the casing string. • Fluid Pressurized Sealing Element is easy to insert into casing and seals

more firmly as circulation pressure increases. • Tapered Aluminum Gauge Ring below Sealing Element protects casing

threads against damage and acts to centralize FAC Tool in casing. • Mud Saver Valve prevents mud from dripping on the rig floor by retaining the

static head of mud in rig Kelly hose (top drive rigs) as tool is moved upward in derrick for insertion into next joint of casing.

• Flexible Steel Reinforced Rubber Hose with Bronze Guide Cone gives added flexibility for inserting FAC Tool in casing. Rubber coating on Guide Cone absorbs impact blows to casing during stabbing, filling and circulating.

• Reverse Flow through the Mud Saver Valve allows any pressure trapped below FAC Tool to be released prior to removal from casing.

• Mud Saver Valve can be checked or changed by one simple break in FAC Tool.

• No “Hands On” manipulation of FAC Tool is required to go from the Fill operation to the Circulate operation.

• Sealing Element or Sealing Assembly (Seal Retainer, Sealing Element and Gauge Ring) can be easily replaced by a single break at Retainer Sub.

• Same basic tool body can be adapted for use with several size casing strings by changing the Seal Assembly.

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TECHNICAL DATA • The Large FAC Tool (FACL) for both top drive and non-top drive rigs can

handle casing sizes from 7” through 20”. • The Medium FAC Tool (FACM) for both rig types can handle casing sizes

from 6" through 7 5/8”. • The Small FAC Tool (FACS) for both rig types can handle tubing sizes of

4 1/2" through 5 1/2”. • Each casing size requires a different size Seal Assembly. One Seal

Assembly size will handle the most popular weights for most casing sizes. Some casing sizes require more than one Seal Assembly size depending on the weight range.

• The Sealing Element has been tested up to 5000 psi for smaller casing sizes and 2500 psi for larger casing sizes.

• The Mud Saver Valve opens between 300 to 400 psi and closes between 100 and 200 psi.

• The High Pressure Flexible Hose has a working pressure of 2000 psi and a burst pressure of 5500 psi. During the circulation operation, the pressure differential outside to inside the hose is close to zero.

• The High Pressure Derrick Hoses (Non-Top Drive Tool) have a working pressure of 5000 psi and a burst of 17500 psi.

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TOP DRIVE

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PART DESCRIPTIONS • Drill Pipe Connector: The FAC Tool built for top drive rigs connects to the

drill pipe threads of the rig’s top drive unit via the Drill Pipe Connector. The threads of the Drill Pipe Connector are standard 4 1/2 IF, but crossovers are available for other drill pipe threads.

• Extension: For applications where long elevator links are used, Extensions are placed between the Drill Pipe Connector and the Mandrel. On the Extension are two Pad Eyes that make it easy to manipulate the Tool around the Rig during rig up or rig down. Also, while the Tool is in use, a Safety Cable attaches to one of the Pad Eyes in the event the Tool should accidentally come loose from the top drive. In place of the Extensions, a Drill Pipe Pup can be used between the top drive connection and the Drill Pipe Connector.

• Mandrel: The Mandrel houses the specially designed Seal Assembly that is used to seal off the casing string. The Seal Assembly has three parts: the Seal Retainer, the Sealing Element, and the Gauge Ring.

• Seal Retainer: Aluminum part that keeps (retains) the Sealing Element from being extruded upward while circulating.

• Sealing Element: Elastomeric Seal that seals off the casing for circulation. It is hollow so circulation pressure can energize the seal it creates against the casing bore.

• Gauge Ring: Tapered Aluminum piece that guides the Seal Assembly into the pipe and has holes to allow energizing pressure into the Sealing Element.

• Retainer Sub: The Seal Assembly is held in place with the Retainer Sub. • Flexible Hose: The Retainer Sub is also used to connect a high pressure

Flexible Hose. This Hose prevents any hard “stack out” between the FAC Tool and the casing and compensates for misalignment and casing movement during make up.

• Mud Saver Valve: Below the Flexible Hose is the heart of the FAC Tool, the Mud Saver Valve. It is essentially a two-way check valve. This Valve opens with pressure when the mud pump is turned on and closes when the mud pump is turned off. It also permits flow in the upward direction for releasing pressure.

• Nose Guide Cone: At the very bottom of the FAC Tool, connected to the bottom of the Mud Saver Valve, is the Nose Guide Cone. The Nose Guide Cone is tapered to easily guide the Tool inside the casing joint. It is made of soft bronze to protect against damage to the casing threads and is overlaid with rubber for further protection.

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FACL- Descriptions, Lengths and Dimensions

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FACM- Descriptions, Lengths and Dimensions

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FACS- Descriptions, Lengths and Dimensions

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SPACE OUT The first procedure to do before the FAC Tool is rigged up is to make sure the tool is properly dressed (configured) for the particular rig and casing it is to be run on. The rig type (top drive or non-top drive); the bail length; casing size and weight; and float equipment type (manual fill or autofill) must all be checked against the FAC Tool that is on location. The earlier the problem is detected, the more time is given to correct a problem if needed. The calculations for properly dressing the FAC Tool and the procedures for rigging up of the FAC Tool are different for Top Drive and Non-Top Drive rigs. The following formula is used to calculate the proper space out of the Sealing Element above the casing joint according to the Figure below. This is for the Top Drive Rig.

Bail Length – Hang Point to Drill Pipe Connection Length – Seal Center to Coupling Distance (2 ft) - Coupling to Elevator Top Distance – Elevator Top to Hang Point Length =

Tool Length from Drill Pipe Connection to Seal Center

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RIG UP Before the tool is rigged up, final assembly of the FAC Tool is done on the catwalk. Connect the assembled top part (Drill Pipe Connector to the Retainer Sub) to the bottom part (top of Valve Hose to the Nose Guide Cone) by placing the two included rollers under the Valve. Once complete, make sure all connections on the FAC Tool are tight.

The FAC Tool should be rigged up before the casing crew rigs up their bails and elevator. However, if a float collar or stage collar is already made up to a casing joint before hand, and the equipment is made up to the box joint of the casing, the FAC Tool can not be rigged up first. You have to wait until the casing crew has run at least one joint above the collars to rig up the FAC Tool.

WARNING! Inserting the FAC Tool into a float collar or stage collar without a joint on top will damage the internals of the collars.

Close the blind rams to protect against accidental dropping of any equipment

down hole. The fully assembled FAC Tool can then be dragged up the V-Door with the air hoist and lowered into the hole on the rig floor so that the Drill Pipe Connector is head height above the floor. The slips used for drill pipe work well to support the tool so that the air hoist can be disconnected and the Top Drive unit lowered into position. Use backup tongs to keep the FAC Tool from rotating while the driller makes up the Drill Pipe Connection and then torque tight to drill pipe specifications. The casing crew can now rig up their bails, elevator and spider. Once the bails are hung on the top drive, secure the loose end of the Safety Cable by wrapping through either bail eye and connecting with the bow shackle. To keep the shackle pin from accidentally rotating out, bailing wire should be used as anti rotation on this pin. Before casing is run, grease the Sealing Element so it will slide in the casing easily. Draw a chalk line between the connections of all the parts in the event a connection should back off. All connections, except for the top drive drill pip connection are left hand and tend to tighten during use of the FAC Tool.

FILLING

Once the FAC Tool is rigged up and the casing crew is ready to run casing, operating the tool is essentially done by turning the rig’s mud pump on and off. The proper amount of drilling fluid needed to fill the pipe must be calculated, and depends on the average joint length and average joint capacity.

Average Joint Length (ft) = Total Length of Casing String (ft) / Total # Joints

Average Joint Capacity (BBL) = Capacity (BBL) per foot X Average Joint Length

The capacity per foot can be found in casing tables. Once the amount of fluid

is obtained, the output of the rig’s mud pump must be calculated. Find out the barrels per stroke and pump efficiency.

Strokes per Joint = Average Joint Capacity / (Barrels per stroke × Efficiency)

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This is the amount of strokes to pump to properly fill in each joint. The pump rate at which this amount is filled depends on the casing size and how fast the casing crew runs the pipe. Larger casing sizes have more capacity so the rate has to be faster in order to have the pipe filed before the elevator is raised to lift the next joint. Also, if the casing crew runs the casing fast, the pump rate has to be greater. It is recommended to keep the mud level at least two joints down so wait until two joints have been run before the filling is started.

Once the joint is filled, turn off the mud pump and watch the pressure gage. The pressure should drop to between 120 and 200 psi and not drop off any more. If the pressure continues to drop, the Valve has not properly closed and will leak mud if taken out of the pipe. Occasionally, lost circulation material or sticky mud will temporarily clog the Valve. Have the driller keep the Tool inside the pipe and turn on the mud pump briefly to flush out the Valve and then turn the pump off again. Watch the pressure gage to see that the pressure does not continue to bleed off. Subtract the strokes pumped to clear the Valve from the amount pumped to fill the next joint to keep the mud level the same.

CIRCULATING

To circulate the casing, have the pipe set in the floor spider and have the elevators unlatched. Slowly lower the elevators until the Sealing Element is inside the pipe one to two feet below the top of the coupling. A locater mark can be made above the Sealing Element for ease of determining depth. Once again latch the elevators. Turn on the mud pump and circulate the number of strokes required by the company man. If desired, the casing can be circulated while being lowered into the hole.

WARNING! The pressure should be monitored at all times. If there is an unexpected problem such as a completely bridged-off annulus, or if something completely plugs up the FAC Tool Valve, there will be a sudden pressure spike. If this happens, the maximum pressure rating on the FAC Tool could be surpassed and endanger personnel.

The circulation rate through the FAC Tool depends on the well conditions and the type of FAC Tool. Find out from the company man the maximum rate for the well condition. The large FAC Tool (FACL) can sustain a higher pump rate than the FACM or FACS Tools. The smallest flow area through the FACL is 3.0 sq. in. The smallest flow area through the FACM is 1.7 sq. in and 1.2 sq. in. for the FACS. In most cases the FACL Tool can handle pump rates as high as 25 BPM, while the FACM and FACS can handle rates up to 15 BPM. One circulation is complete, turn off the mud pump. Sometimes the drilling fluid will cake the inside the Valve after long circulation periods. If the pressure steadily drops there is no a seal, clear the Valve of caked drilling fluid by cycling the Valve open and closed several times while the Valve is still in the casing. Open the standpipe valve to bleed off in the Mud Saver Valve to zero. Unlatch the elevator and have the driller slowly pull the Sealing Element out of the pipe. There is still a little pressure below the Seal, equal to the static head pressure in the Kelly hose.

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RIG DOWN Make sure all the pressure above the Valve has been bleed off. The tool should be removed from the last joint so that just the Valve and Valve Hose is just inside the pipe. Install the Breakout Plate between the Valve Hose and the Retainer Sub and be sure the quick release pin on the Breakout Plate is latched. Connect the air hoist line to one of the Pad Eyes on the FAC Tool and unlatch Safety Cable from the bail eye. There will be drilling fluid still in the tool from the Valve up to the top of the Drill Pipe Connector so be sure to notify and clear personnel on the floor. Next, have the driller break the connection between the Drill Pipe Connector and the top drive, and slowly back off the drill pipe threads and lower the FAC Tool on to the rig floor and then down the V-door. While on the catwalk, break the connection between the Retainer Sub and the top of the Valve Hose, and place all parts and accessories in the basket.

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NON-TOP DRIVE

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PART DESCRIPTIONS • U-Bolt: The U-Bolt hangs in the hook of the rig and suspends the FAC Tool.

It is adjustable to fit hook weight sizes from 150 Tons to 750 Tons. • Cross Member: The Cross Member straddles the elevator bails to prevent

twisting of the tool and provides a means of quick disconnect of the Tool. • Top Sub: The Top Sub fastens to the Cross Member with a single Pin that

permits quick rig down of the FAC Tool. • Mandrel: The Mandrel is threaded into the Top Sub. The Mandrel houses

the Seal Assembly used for sealing the casing string. For jobs when long elevator bails are used, Extensions are placed between the Top Sub and the Mandrel.

• Retainer Sub: The Retainer Sub retains the Seal Assembly. • Flexible Hose: This high pressure Flexible Hose allows easy stabbing of the

Tool and prevents hard “stack out” while lowing the hook. It is attached to the Retainer Sub.

• Mud Saver Valve: This is the heart of the Tool. Activated by only pressure, it saves the drilling fluid above the Valve and permits bleed off of pressure below the Valve.

• Nose Guide Cone: Located at the bottom of the Tool, it is “guides” the Tool into the casing. It is made out of bronze and coated with rubber to prevent marring of the casing threads.

• Turn Buckle Assembly: It connects to the Cross Member with single Pin and is part of the non-top drive hold down apparatus for the circulation process. Consisting of the Turn Buckle Rod, the left hand threaded Turn Buckle End at the top and the right hand threaded Turn Buckle End at the bottom, tension is adjusted by rotating the Rod.

• Ropes: The Hold Down Ropes are made out of high strength Spectra® and connect the Turn Buckle Assembly to the bail eyes. They are used as a means of tying down the Tool during circulation.

• Plug Valve: A high pressure Plug Valve is connected to the Top Sub by a 1502 Hammer Union. Closing this Valve can be closed to shut off casing pressure.

• 50 Foot Hose/70 Foot Hose Assembly: Two 2” ID High Pressure (5000 psi WP) Hoses, joined by a Chiksan Swivel, provide the connection between the rig’s mud pump and the FAC Tool. Both ends of the Hose Assembly have 1502 Hammer Unions.

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Descriptions, Lengths and Dimensions

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Valve and Seal Assembly/ Turnbuckle Assembly

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SPACE OUT For Non Top-Drive Rigs use the following formula according to the Figure

below. In addition, the Turnbuckles need to be checked so that the lengths are not too long and don’t interfere with the elevator. They should be about 1 foot above the elevator top. They have a one-foot adjustment in order to shorten or lengthen as necessary by rotating the rods Bail Length – Hang Point to Hook Bottom Length – Seal Center to Coupling Distance (2 ft) -

Coupling to Elevator Top Distance – Elevator Top to Hang Point Length = Tool Length from Hook Bottom to Seal Center

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RIG UP Before the tool is rigged up, final assembly of the FAC Tool is done on the catwalk. Connect the assembled top part (Drill Pipe Connector to the Retainer Sub) to the bottom part (top of Valve Hose to the Nose Guide Cone) by placing the two included rollers under the Valve. Once complete, make sure all connection on the FAC Tool are tight. Like the top drive FAC Tool, the Non-Top Drive FAC Tool is rigged up easiest before the casing crew’s equipment is installed. Be sure the blind rams are closed and drag the FAC Tool, without the 50/70 Foot Hose Assembly, up the V-Door using the air hoist. Have the driller slowly lower the hook until the U-Bolt can be lowered over the hook. Raise the hook until the FAC Tool is vertical. Tighten the upper Hammer Nuts under the U-Bolt until there is a slight amount of slack under the hook, and then jam the lower Hammer Nuts up against the upper nuts so they will not loosen during use of the FAC Tool. Connect the loosed end of the 50 Foot Hose to the Plug Valve and attach the Hose Hobble for safety. Next, raise 50/70 Hose Assembly into the derrick at the middle Style 30 Swivel assembly, and secure to the rig framing by the chain. The Hose Assembly should be secured at a height so that when the hook is at its lowest position during case running, the 50 Foot Hose will have a slight loop in the bottom and be above everyone’s head. Secure the Safety Cable to the derrick framework, also. Connect the loose end of the 70 Foot Hose to the rig’s standpipe and secure the Hose Hobble. The last procedure for rig up is left until the casing crew has rigged up their equipment. Once this is complete, loop the Ropes around the bottom bail eye, and over the lower Turn Buckle Rod ends. Rotate the Turn Buckle Rods until the Ropes are taught and jam the square Jam Nuts against the lower Turn Buckle Rod ends. Be sure to grease the Sealing Element for the circulating operation. Draw a chalk line between the connections of all the parts in the event a connection should back off. All connections, except for the top drive drill pip connection are left hand and tend to tighten during use of the FAC Tool.

FILLING If the non-top drive FAC Tool is properly rigged up and the casing crew is ready to run casing, filling is done by turning the mud pump on and off. First make sure the Plug Valve is open prior to pumping through the tool. Use the following formula to calculate the proper amount of drilling fluid required to fill the pipe.

Average Joint Length (ft) = Total Length of Casing String (ft) / Total # Joints

Average Joint Capacity (BBL) = Capacity (BBL) per foot X Average Joint Length The capacity per foot can be found in casing tables. Once the amount of fluid is obtained, the output of the rig’s mud pump must be calculated. Find out the barrels per stroke and pump efficiency.

Strokes per Joint = Average Joint Capacity / (Barrels per stroke × Efficiency)

The pump rate at which this amount is filled depends on the casing size and how

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fast the casing crew runs the pipe. Larger casing sizes have to be filled at a higher pump rate than smaller casing sizes because they have a greater volume, but generally are not run as fast. The pipe should be completely filled by the time the joint being run is latched by the spider and the elevator is unlatched.

Once the joint is filled, turn off the mud pump and watch the pressure gage. The pressure should drop to between 120 and 200 psi and not drop off any more. If the pressure continues to drop, the Valve has not properly closed and will leak mud if taken out of the pipe. Occasionally, lost circulation material or sticky mud will temporarily clog the Valve. Have the driller keep the Tool inside the pipe and turn on the mud pump briefly to flush out the Valve and then turn the pump off again. Watch the pressure gage to see that the pressure does not continue to bleed off. Subtract the strokes pumped to clear the Valve from the amount pumped to fill the next joint to keep the mud level the same.

CIRCULATING

To circulate the casing, have the pipe set in the floor spider and have the elevators unlatched. Slowly lower the elevators until the Sealing Element is inside the pipe one to two feet below the top of the coupling. A locater mark can be made above the Sealing Element for ease of determining depth. Once again latch the elevators. Turn on the mud pump and circulate the number of strokes required by the company man. If desired, the casing can be circulated while being lowered into the hole.

WARNING! The pressure should be monitored at all times. If there is an unexpected problem such as a completely bridged-off annulus, or if something completely plugs up the FAC Tool Valve, there will be a sudden pressure spike. If this happens, the maximum pressure rating on the FAC Tool could be surpassed and endanger personnel.

The circulation rates for the non-top drive FAC Tool and the top drive FAC tool are different in one respect. The non-top drive tool is limited by the 50/70 Foot Mud Hoses, even though they have a high pressure rating. Highly viscous drilli ng fluid pumped at too high a rate will cause too much friction on the hose interior. Use the following chart based on mud weight to determine a safe circulation rate.

RECOMENDED PUMP RATES FOR 2" HOSE

7

8

9

10

11

12

13

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6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11PUMP RATE (BBL/MIN)

MU

D W

EIG

HT

(LB

S/G

AL

WATER

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RIG DOWN Bleed off all pressure in the FAC Tool. To drain most of the drilling fluid out of the Hose Assembly have the driller raise the hook as high as possible in the derrick. Next, there are several ways to rig down after the hoses have been drained.

One way is to wrap one of the air hoists closest to the v-door around the back of the hook and tie it off on the opposite side of the v-door from the hoist. The FAC Tool should be raised high enough above the pipe so as to clear it. Slowly apply tension to this hoist line while the driller lowers the FAC Tool. This will bring the hook closer to the v-door so as to stab it in the “mouse hole” until the elevator is resting on the rig floor. Disconnect the bottom of the links (bails) from the elevators. Have the driller raise the hook high enough to pull the FAC Tool out of the elevator and disconnect the hose from the tool. Tie a line around the FAC Tool and remove it from the hook and lower down the v-door. Disconnect the 50/70 Foot Hose Assembly from the rig.

Another method is to drain the Hose Assembly as specified above. Disconnect the hose from the FAC Tool. Next, tie one of the hoist lines to the nipple coming out of the Top Sub. Remove the safety wire from the bent pin and remove the 2” Pin from the Top Sub. Raise this part out of the elevator and down the v-door. This method is used mostly when the elevator can not be removed from the pipe. The remaining FAC Tool can them be removed from the hook.

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MAINTENANCE AND SAFETY

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MAINTENANCE OF THE FAC TOOL CLEANING After use, the FAC Tool should be cleaned of mud and oil in order to maintain a good appearance to customers. This also allows the tool to be inspected properly. The Davis Lynch FAC Tool is rugged enough to withstand normal service if used properly and is not abused. After cleaning, the following items should be checked for the both the Top Drive and Non-Top Drive tools. TOP DRIVE and NON-TOP DRIVE FAC TOOL Visual Damage: Always visually inspect the tool after use for obvious damage, bent or broken parts. Damage will not occur unless the FAC Tool is misused or mishandled. Threads: All Stub Acme threads should be cleaned and visually inspected after use but do not need magnetic particle inspections. Galling may occur if the treads are assembled dry, therefore, pipe dope or grease should always be used on the threads. Valve Hose: Visually inspect the Valve Hose for cuts and tares. This hose is double reinforced and the rubber exterior does not hold the pressure, but occasionally the reinforcing underneath can be damaged if the hose is folded or accidentally smashed during use. If there is any question, pressure-check the hose to at least 1000 psi. Also, check the crimped ends of the hose for damage. Mud Saver Valve: The Valve should be disassembled so that the Bob Assembly, Main Spring, Main Sleeve and seals can be serviced. Drilling fluid is designed to “cake” and will dry inside the Valve making it inoperable. The Bob and Main Sleeve are coated with a Tungsten overlay and needs to be checked for cracking and cutting. The Main Spring should be checked to see it has not shortened due to use. If it is shorter than 13” replace the Spring. Replace all O-Rings after every job, but the Polyseals may be used again for several jobs and replaced only if worn. Also, inspect the Nose Guide Cone for fluid wear. In time the discharge holes can become washed out and may lead to the tip breaking off. TOP DRIVE FAC TOOL Drill Pipe Connector: The Drill Pipe Connector is the only part of the FAC Tool that requires a magnetic particle inspection test on the Drill Pipe Box thread after use. Rigs usually torque this thread to about 15,000 ft-lbs (or more) with the Top Drive unit. This torque can deform and damage the drill pipe box thread. Therefore, this thread must be inspected after every use for cracks and elongation as if it were a drill pipe. The thread should meet and pass API specifications.

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NON-TOP DRIVE FAC TOOL 50-70 Ft Hoses: Visual inspection of the hoses is required after every use. Visually look for crimps, bubbles in exterior rubber coating, and cuts. The hoses should be flushed out with fresh water to prevent dried mud buildup. Examine the two elbow swivels that connect the two hose for problems. Pressure check the hoses to 2600psi for five minutes if there is any question of safety. The swivels should not be loose at the swivel area but still be able to rotate freely. Plug Valve and Chiksan: The smooth radius Chiksan coming out of the Top Sub should be checked for mobility and greased at the grease nipple. The Plug Valve should also be checked for operability and greased. Hold Down Ropes: The hold down ropes should be inspected for damage and cutting. Hammer Unions: The Seal in the female half of the 1502 Hammer Unions should be checked and replaced if cut or damaged. Cross Head Assembly: The Cross Head Assembly including welds, the U-Bolt, Hammer Nuts, Pins, and Turn Buckle Rods do not need inspection other than visibly examination for bent or abused parts.

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SAFETY USING THE FAC TOOL Extreme caution is always important to any tool hanging above the rig floor. The Davis Lynch FAC Tool is no exception. Standard rig safety procedures should be followed while running the Tool. Use the following check list of safety features and procedures when using the FAC Tool.

• Make sure all connections are torqued with at least a 48” chain wrench. • Draw a line at all connections to monitor accidental back out. • Torque Drill Pipe Connector (Top Drive only) to drill pipe specifications. • Secure Safety Cable from Pad Eye to Top Drive and use bailing wire on

shackle screw (Top Drive only). • Check all Hammer Union connections. • Secure all Hose Hobbles and Hose Safety Cables.

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MUD SAVER VALVE

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PARTS AND DESCRIPTIONS The Mud Saver Valve is a bi-directional check valve that is actuated by

pressure. To open the Valve, the rig’s mud pump is turned on to build pressure above the seal created by the Bob and Main Sleeve. There are two kinds of Valves made that use different seals methods. The first kind employs a metal-to-metal seal between the Bob and Sleeve using a precision ground Tungsten coating. The second kind of seal uses a Rubber coated Bob sealed against a Tungsten coated Sleeve. When enough pressure is generated to push the spring-loaded sleeve downward, usually between 300 to 400 psi, the pressure acting on the differential top and bottom areas of the Sleeve fully opens the Valve to either fill or circulate the casing. When the mud pump is turned off, pressure drops and permits the Main Spring to push the Sleeve upwards until it contacts the Bob again creating a seal. The Valve closes between 150 and 200 psi. The Bob is “floating”, which means it allows backward flow up through the FAC Tool back to the mud tanks. The reverse flow pressure lifts the Bob with as little as 10 psi in order to bleed off the circulating pressure or permit reverse flow in autofill applications.

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Tungsten Coated Bob Valve

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Rubber Coated Bob Valve

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Mud Saver Valve Operation Configurations

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MAIN ASSEMBLY

WARNING! The Mud Saver Valve contains a preloaded spring that requires a press for assembly and disassembly. Servicing the Valve in the field is not recommended and could result in injury if the Valve were taken apart.

STEP 1- Place the Valve Housing on the floor so that the large OD chamfer is facing down. STEP 2- Apply grease to the inside of the Valve Housing. Install a 2-243 O-Ring (FACL) or a 2-230 O-Ring (FACM, FACS) on the outside seal groove. Install a 2500-3000 Poly Seal (FACL) or a 2500-1875 Poly Seal (FACM, FACS) to the inside seal groove of the Stop Ring. With the lip of the Poly Seal facing down, gently tap the Stop Ring down the bore of the Valve Housing until it shoulders. STEP 3- Insert the Main Spring on top of the Stop Ring. The spring will extend into the upper box threads. Both ends of the Main Spring are the same. STEP 4- Install two 2500-4000 Poly Seals (FACL) or two 1875-2375 Poly Seals (FACM, FACS) in the outside seal grooves of the Main Sleeve with the lip of the Poly Seal facing the large end of the Main Sleeve. Insert the Main Sleeve so it rests on the Main Spring. Insert the Spacer on top of the Main Sleeve, making sure it is relatively concentric with the Main Sleeve. Both ends of the Spacer are the same. Insert the Bob Assembly on top of the Spacer with the Bob facing down and the Nose Piece Facing up. Make sure it is relatively concentric with the Spacer. STEP 5- Place above parts in a press. Install a 2-247 O-Ring (FACL) or a 2-232 O-Ring (FACM, FACS) in the thread relief of the Hose Adapter. Place on top of the Baffle of the Bob Assembly and center as close as possible. Press down on the Nose Piece of the Bob Assembly and compress the Main Spring. The Main Spring needs to be compressed enough so that the Hose Adapter can be screwed in (LEFT HAND THREADS) almost all the way by hand and the O-Ring starts to enter the Valve Housing. STEP 6- Remove the Valve from the press and place in a vise. Complete the make up of the Hose Adapter into the Valve Housing and torque to about 500 ft-lbs. (One man on a 3 ft wrench). While in the vise, install the Nose Guide Cone (LEFT HAND THREADS) to about 500 ft-lbs. No O-Ring is required for the Nose Guide Cone. Finally, install a brass 5/16-18 NC x 3/8” long set screw in the Valve Housing to prevent accidental back out of the Nose Guide Cone.

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Use the following illustrations as a pictorial guide.

STEP 1

STEP 2

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STEP 3

STEP 4

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STEP 5

STEP 6

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ASSEMBLY/DISASSEMBLY- TUNGSTEN CARBIDE BOB Use the following illustrations for the assembly or disassembly.

STEP 1

STEP 2

STEP 3

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STEP 4

STEP 5

STEP 6

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ASSEMBLY/DISASSEMBLY: RUBBER NOSE BOB

Use the following illustrations for assembly and disassembly.

STEP 1

STEP 2

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STEP 3

STEP 4

STEP 5

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SPECIAL APPLICATIONS

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PUSH PLATE The Davis Lynch FAC Tool can be used to push casing when the casing weight alone is not enough to lower the pipe in the hole. On all tool types and sizes the Push Plate operates the same. It is a threaded disk that rotates up and down on a section of the tool. Initially, the disk should be midway to close to the bottom of the threaded length. The elevators should be unlatched so the Sealing Element can be lowered into the casing bore until the plate contacts the face of the coupling. Latch the elevator slips and push the casing down hole as required. The maximum load that be applied to the Push Plate is far greater than the weight of the top drive or hook so there is no problem in overloading the Push Plate. Once the casing joint is run, have the driller pick up on the hook to take the load off the Plate. Rotate the Push Plate upwards so there is enough clearance to unlatch the elevator slips. Raise the FAC Tool Sealing Element out of the casing joint and rotate the Push Plate back down for the next joint. Study the following figure for an illustrated sequence of this procedure.

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REVERSE FLOW When running autofill float equipment, the filling operation of the FAC Tool does not apply. As casing is run in the hole, mud in the hole is displaced up through the casing bore and will spill over on to the rig floor. The Mud Saver Valve on the Davis FAC Tool is a two-way valve. The cracking pressure of the Valve in the reverse direction (UP) is approximately 10 psi. This allows fluid flow up through the Valve back to the mud tank. Sealing Element is engaged inside the casing bore before the joint is lowered as if to circulate. An extra seven feet of extension is usually added above the Mandrel so that the Sealing Element is around five feet down in the joint being lowered. The displaced drilling fluid flows up through the Mud Saver Valve and back to the mud tank. If circulation is required, follow the guidelines the circulation section.

DUEL SEALING ELEMENT A simple adaptation of the Davis FAC Tool is used for running casing strings of two different sizes or if the weights of a casing size are vastly different to prohibit using the same Sealing Element. A special Connector Sub connects two Mandrels. The lower Mandrel contains the smaller of the two Seal Assemblies and the upper Mandrel contains the larger. Filling is done as normal. When the smaller casing has to be circulated, the FAC Tool is lowered so that the lower Seal Assembly is inside casing. When the larger casing size is circulated, the upper Seal Assembly is lowered into the pipe, but since the lower Seal Assembly is smaller, it does not contact the inside the pipe so the upper Sealing Element can still be energized.

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SIDE DOOR (CENTER LATCH) ELEVATORS

Although it is possible, it is not recommended to use the Davis Lynch FAC Tool when using side door or center latch elevators. It is not recommended, because of lost efficiency due to the extra time in running the casing. The lost time has to be compared to the cost of providing slip type elevators. Also, special considerations are needed when dressing the FAC Tool and when filling or circulating.

On side door elevators the top shoulder of the elevator is always located under the bottom shoulder of the coupling when the casing is lowered into the hole. Because there are no slips it can not be latched anywhere along the pipe. The elevator has to be latched both in slip type and in side door type when circulating. Therefore, the Sealing Element has to be spaced out so that it will be down inside the casing at least one foot when the elevator is shouldered on the pipe for circulation purposes. If the casing is to be filled, either of two methods is to be used. One is to space out the Sealing Element as mentioned above, but before the elevator is lowered and while the Sealing Element is not inside the pipe do all the filling of that joint. This will cause a pause in running the pipe until the pipe is properly filled. This adds time to the case running operation. The second method is to space out the Sealing Element as above, but fill the casing as if you were circulating. This method takes even longer than method one, because the pressure would then have to be bleed off on every joint.

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DETAILS AND BILL OF MATERIALS

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FACL Top Drive - Top Half Detail

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FACL Top Drive and Non-Top Drive- Bottom Half Detail

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FACM Top Drive- Top Half Detail

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FACM Top Drive and Non-Top Drive- Bottom Half Detail

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FACS Top Drive- Top Half Detail

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FACS Top Drive and Non-Top Drive- Bottom Half Detail

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FACL Non-Top Drive- Top Half Detail

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FACM Non-Top Drive- Top Half Detail

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FACS Non-Top Drive- Top Half Detail