Upper and Lower Kelly Cock Valves for Drill String Shutoff

Description

Goldenman manufactures Upper and Lower Kelly Cock Valves for controlling drilling-fluid flow and isolating internal drill-string pressure during conventional rotary drilling operations.

The valves use a manually operated quarter-turn ball mechanism with a full-opening flow bore. An external hexagonal operating stem allows the valve to be opened or closed using a dedicated Kelly valve wrench.

Positive open and closed stops provide clear operating positions and help prevent incomplete ball alignment.

The complete product range includes:

• Upper Kelly Cock Valves
• Lower Kelly Cock Valves
• One-Piece Kelly Valves
• Two-Piece Kelly Valves
• Unidirectional Sealing Valves
• Bidirectional Sealing Valves
• Standard-Service Valves
• H₂S and Sour-Service Valves
• 5,000 psi Working-Pressure Valves
• 10,000 psi Working-Pressure Valves
• 15,000 psi Working-Pressure Valves
• Right-Hand Connection Configurations
• Left-Hand Connection Configurations
• NC, IF, FH and REG Connections
• Custom Crossover Connection Configurations
• Replacement Ball, Seat, Stem and Seal Kits

Upper and lower valves can be supplied individually or as a matched Kelly pressure-control package.

Product Short Description

Goldenman Kelly Cock Valves are full-opening manually operated ball valves installed above or below the Kelly to provide rapid drill-string shutoff at the rig floor.

The Upper Kelly Valve is normally positioned between the swivel and the Kelly. It provides a means of isolating internal flow and pressure at the upper end of the Kelly assembly.

The Lower Kelly Valve is installed between the Kelly and the drill string. It can be closed before disconnecting the Kelly from the drill pipe, helping retain drilling fluid in the Kelly and providing an internal pressure-control barrier.

Standard working-pressure options are:

• 5,000 psi / 34.5 MPa
• 10,000 psi / 69.0 MPa
• 15,000 psi / 103.5 MPa

Each valve is manufactured according to the ordered pressure rating, sealing direction, service class, connection configuration, temperature range and drilling-fluid environment.

Product Highlights

• Upper and Lower Kelly Valve configurations
• Full-opening ball-valve design
• Manual quarter-turn operation
• External hexagonal operating stem
• Positive open and closed stops
• Clear operating-direction marking
• 5,000 psi working-pressure option
• 10,000 psi working-pressure option
• 15,000 psi working-pressure option
• One-piece and two-piece body designs
• Unidirectional and bidirectional sealing options
• Standard and sour-service configurations
• Full-bore drilling-fluid passage
• Low internal flow restriction
• Compatible with drilling-fluid circulation
• Allows passage of compatible downhole tools
• High-strength alloy-steel pressure body
• Corrosion- and erosion-resistant ball components
• Replaceable seat and seal assemblies
• Replaceable operating stem
• Right-hand and left-hand connections
• NC, IF, FH and REG connection options
• API Spec 7V configurations available
• API Spec 7-2 rotary-shouldered connections
• Individual serial-number traceability
• Full-body material traceability
• UT and MPI inspection
• Shell-pressure testing
• Closure-pressure testing
• Stem-seal testing
• Opening- and closing-torque verification
• Complete redress and spare-parts kits

General Technical Specifications

Parameter	Available Configuration
Product	Upper and Lower Kelly Cock Valve
Alternative names	Kelly Valve, Kelly Safety Valve, Full-Opening Safety Valve
Valve type	Manual full-opening ball valve
Operating method	External hexagonal wrench
Operating movement	Quarter turn
Standard working pressures	5,000, 10,000 and 15,000 psi
Metric working pressures	34.5, 69.0 and 103.5 MPa
Body construction	One-piece or two-piece
Sealing direction	Unidirectional or bidirectional
Product standard	API Spec 7V where ordered
Connection standard	API Spec 7-2 for applicable rotary-shouldered connections
Connection configurations	NC, IF, FH, REG and customer-specified
Connection hand	Right-hand, left-hand or combination
Body material	High-strength heat-treated alloy steel
Ball material	Corrosion- and erosion-resistant alloy or stainless steel
Seat material	Metallic or engineered seat system
Seal materials	HNBR, FKM, PTFE, PEEK or project-specific material
Flow bore	Full opening
Drilling fluids	WBM, OBM, SBM and compatible workover fluids
Service	Standard, H₂S, CO₂ and corrosive-fluid configurations
Operation position	Surface and upper drill-string assembly
Inspection	Material, NDE, dimensional, pressure and functional testing
Supply	Complete valve, operating wrench and redress kit

Pressure-Rating Options

Working Pressure	Metric Rating	Typical Application
5,000 psi	34.5 MPa	Conventional land drilling and moderate-pressure wells
10,000 psi	69.0 MPa	High-pressure drilling and broad international rig applications
15,000 psi	103.5 MPa	High-pressure and high-risk drilling programs

The selected working pressure must be equal to or greater than the maximum anticipated internal drill-string pressure, subject to the well-control program and applicable design margin.

Working pressure should not be confused with:

• Shell test pressure
• Closure test pressure
• Burst pressure
• Maximum pump discharge pressure
• Maximum anticipated surface pressure
• Maximum allowable working pressure of another rig component

The complete pressure-control system is limited by its lowest-rated component.

What Is a Kelly Cock Valve?

A Kelly Cock Valve is a manually operated full-opening valve installed in the Kelly or upper drill-string assembly.

Its primary functions are to:

• Shut off drilling-fluid flow through the Kelly
• Isolate internal drill-string pressure
• Reduce drilling-fluid loss when breaking connections
• Support kick-control procedures
• Provide an additional internal drill-string barrier
• Allow rapid manual closure at the rig floor
• Retain drilling fluid in the rotary hose, swivel and Kelly assembly
• Support safe connection and disconnection procedures

The valve is commonly referred to as:

• Kelly Valve
• Kelly Cock
• Kelly Safety Valve
• Full-Opening Safety Valve
• Drill Stem Safety Valve

The exact product name should be distinguished from an Inside Blowout Preventer and a Stabbing Valve.

Upper Kelly Cock Valve

The Upper Kelly Cock Valve is normally installed between the rotary swivel and the upper end of the Kelly.

Its primary functions include:

• Isolating the Kelly from the swivel and rotary-hose side
• Controlling internal flow at the upper end of the Kelly assembly
• Providing an additional shutoff point in the drill-string pressure-control system
• Supporting emergency internal-pressure isolation
• Allowing pressure-control procedures when the lower valve is unavailable or inaccessible

Upper Kelly Valve connections are frequently configured to match the left-hand connection arrangement used between the swivel stem and Kelly.

The actual connection hand and orientation must be confirmed from the rig assembly drawing.

Upper Kelly Valve Configuration

A complete Upper Kelly Valve specification includes:

• Swivel-side connection
• Kelly-side connection
• Left- or right-hand thread
• Working pressure
• Service class
• Flow-bore diameter
• Maximum outside diameter
• Overall length
• Operating-stem position
• Closing direction
• Standard or sour service

The closing direction must be permanently marked adjacent to the operating stem.

Lower Kelly Cock Valve

The Lower Kelly Cock Valve is installed below the Kelly and above the drill string or Kelly Saver Sub.

Its primary functions include:

• Closing the Kelly before disconnecting it from the drill string
• Retaining drilling fluid inside the Kelly and rotary-hose system
• Reducing mud discharge onto the rig floor
• Providing internal pressure control during connection handling
• Isolating pressure coming from the drill string
• Supporting kick and well-control procedures
• Providing a full-opening flow path during normal drilling

The Lower Kelly Valve normally uses right-hand drill-string connections, but the final connection configuration must match the Kelly, Saver Sub and drill-pipe assembly.

Upper vs Lower Kelly Valve

Selection Factor	Upper Kelly Valve	Lower Kelly Valve
Normal position	Between swivel and Kelly	Below Kelly and above drill string
Main isolation point	Upper end of Kelly assembly	Lower end of Kelly assembly
Typical connection hand	Often includes left-hand connection	Commonly right-hand drill-string connection
Main operational benefit	Isolates swivel and upper Kelly flow	Retains mud and controls drill-string backflow
Accessibility	High on Kelly assembly	At lower Kelly end near rig floor
Normal drilling position	Fully open	Fully open
Emergency function	Internal shutoff barrier	Internal shutoff barrier
Required specification	Rig-specific upper connections	Kelly and drill-string connections

Both valves should be included in the rig well-control and pressure-control procedure.

Operating Principle

The valve contains a ball with a central flow passage.

Open Position

When the ball bore is aligned with the valve body bore:

• Drilling fluid passes through the valve
• Pressure loss is minimized
• Compatible wireline or downhole tools can pass through
• Normal circulation continues
• The valve remains part of the rotating drill string

Closed Position

When the ball is rotated 90 degrees:

• The solid side of the ball blocks the flow passage
• The seat system seals against the ball
• Internal fluid movement is stopped or isolated
• Pressure is retained on the qualified side or sides of the valve
• The operating stem reaches the positive closed stop

The external operating-stem indication must correspond with the actual ball position.

Full-Opening Flow Bore

A Full-Opening Kelly Valve has an internal bore designed to minimize restriction through the valve.

This supports:

• High drilling-fluid circulation rates
• Reduced pressure loss
• Efficient mud-pump operation
• Passage of selected survey tools
• Passage of compatible wireline equipment
• Core-barrel and fishing-tool access
• Reduced erosion from high local fluid velocity
• Easier internal cleaning and inspection

The minimum valve ID must be checked against every tool that is expected to pass through the Kelly assembly.

One-Piece Kelly Valve

A One-Piece Kelly Valve uses a pressure-containing body manufactured from one continuous alloy-steel component.

Advantages include:

• Reduced number of body connections
• Reduced potential external leak paths
• Compact overall length
• High structural continuity
• High tensile and torsional capacity
• Smooth outside diameter
• Reduced risk of connection loosening
• Suitable integration into the drill-string assembly

Internal valve components are installed through the designed access end or replaceable internal cartridge system.

Two-Piece Kelly Valve

A Two-Piece Kelly Valve uses a body assembled from two pressure-containing sections.

Advantages can include:

• Larger internal bore for a given outside diameter
• Easier access to internal components
• Increased material allowance for future connection recuts
• Flexible connection combinations
• Simplified shop redressing
• Increased configuration range

The body connection must be included in the pressure, tensile, torque and fatigue design.

One-Piece vs Two-Piece Design

Selection Factor	One-Piece Valve	Two-Piece Valve
Body construction	Single pressure body	Two assembled body sections
External leak paths	Reduced	Includes body joint
Overall length	Normally shorter	Can be longer
Available internal bore	Body geometry dependent	Can support a larger bore
Maintenance access	Design dependent	Usually easier
Connection recut allowance	Limited by length	Can provide greater allowance
Structural continuity	High	Joint-dependent
Main selection basis	Compact reliability	Bore size and serviceability

Manual Quarter-Turn Operation

The valve is operated by inserting a hexagonal wrench into the operating stem and rotating the stem through the specified quarter-turn movement.

The operating system includes:

• External hexagonal socket
• Operating stem
• Stem-to-ball drive
• Open stop
• Closed stop
• Position marking
• Stem seals
• Retaining components

The operating wrench should:

• Match the hexagonal socket exactly
• Provide sufficient leverage
• Remain accessible on the rig floor
• Be included in the well-control equipment inventory
• Be inspected for rounding or deformation

Improvised tools should not be used to operate the valve.

Positive Open and Closed Stops

Positive mechanical stops limit stem movement at the fully open and fully closed positions.

They help:

• Align the ball bore with the body bore
• Prevent over-rotation
• Provide repeatable operating positions
• Reduce damage to the stem and ball drive
• Improve visual position confirmation
• Reduce partial closure during circulation

The operating stem and body should be clearly marked to show:

• Open position
• Closed position
• Closing direction
• Normal flow direction where applicable

Sealing Direction

Kelly Valves can be configured for different pressure-sealing requirements.

Unidirectional Sealing

A unidirectional valve is qualified to seal pressure from the specified direction.

The normal flow and pressure direction must be marked on the valve.

Bidirectional Sealing

A bidirectional valve is designed and tested to seal pressure from either side of the closed ball.

Bidirectional sealing is selected where the valve may be exposed to pressure from:

• The bit side
• The swivel side
• Both sides during different operating stages
• Pressure trapped between barriers

The purchase order must clearly identify the required sealing direction and API Spec 7V service class.

API Spec 7V Service Selection

The purchaser should define the required API Spec 7V service class according to:

• Required pressure-sealing direction
• External stem-seal requirements
• Requirement to operate the valve under pressure
• Drill-string tensile loading
• Temperature range
• Drilling-fluid environment
• Well-control procedure

The product datasheet and pressure-test report must identify the exact service class supplied.

A generic statement such as “API Kelly Valve” is not sufficient for technical procurement.

Kelly Valve vs Inside Blowout Preventer

Kelly Cock Valve	Inside Blowout Preventer
Commonly a quarter-turn ball valve	Commonly a dart, plunger or check-type valve
Manually opened and closed	Often allows downward flow and prevents backflow
Installed near the Kelly or rig floor	Installed or stabbed into the drill string
Full-opening bore available	Internal mechanism can restrict bore
Operator selects open or closed position	Can operate automatically from pressure direction
Used as an upper or lower Kelly valve	Used as an internal well-control device

The products complement each other but are not interchangeable.

Kelly Valve vs Stabbing Valve

A Stabbing Valve is kept on the rig floor and installed into an open drill-pipe connection during a well-control event.

A Kelly Valve is already installed in the Kelly or drill-string assembly.

Kelly Valve	Stabbing Valve
Permanently assembled in Kelly string during drilling	Installed when required
Rotates with the drill string	Stabbed into an open connection
Immediately available through operating stem	Requires connection makeup
Upper and lower configurations	Normally one portable configuration
Full-opening ball design	Ball or other closure design

A complete rig well-control package normally includes both.

Kelly Valve vs Top Drive Safety Valve

Conventional Kelly Valves are used with a Kelly-and-swivel rotary drilling system.

Top Drive Safety Valves are integrated into a top-drive drilling system and normally include upper and lower valve positions designed for the specific top-drive model.

The products should have separate pages because their procurement requirements differ.

A Top Drive Safety Valve requires:

• Top-drive manufacturer
• Top-drive model
• OEM interface dimensions
• Actuation type
• Upper or lower position
• Remote-control requirements
• Saver-sub configuration

Kelly Valve vs Mud Saver Valve

A Mud Saver Valve is primarily intended to reduce drilling-fluid discharge while making and breaking drill-pipe connections.

A Kelly Cock Valve provides a manually controlled pressure barrier and can also help retain drilling fluid.

The Kelly Valve should not be replaced by a simple mud saver where a rated shutoff barrier is required.

Well-Control Function

The Kelly Valve provides an internal drill-string barrier but does not replace:

• Annular BOP
• Ram BOP
• Drill Pipe Ram
• Blind or Shear Ram
• Inside BOP
• Stabbing Valve
• Choke Manifold
• Kill Manifold
• Approved rig well-control procedures

The valve is one component within a complete pressure-control system.

Its use must follow the operator’s well-control program and rig-specific procedures.

Normal Drilling Position

During normal drilling and circulation, both Upper and Lower Kelly Valves should remain fully open.

A partially open ball can cause:

• High local fluid velocity
• Ball erosion
• Seat erosion
• Pressure loss
• Turbulence
• Operating-stem vibration
• Difficulty closing the valve
• Premature seal failure

The valve should not be used as a throttling device.

Closing the Valve

A general closure sequence includes:

1. Confirm which Kelly Valve is to be operated.
2. Identify the valve pressure condition.
3. Confirm the operating wrench fits the stem.
4. Follow the approved well-control procedure.
5. Insert the wrench fully into the stem socket.
6. Rotate in the marked closing direction.
7. Move the stem completely to the closed stop.
8. Confirm the closed-position indication.
9. Monitor pressure above and below the valve.
10. Confirm that the valve is holding as required.

Operation under differential pressure must remain within the qualification and operating limits of the supplied valve.

Opening the Valve

Opening a closed valve against high differential pressure can require excessive torque and can damage the stem, ball or seat.

A general opening procedure includes:

1. Determine pressure above and below the valve.
2. Equalize pressure where required.
3. Confirm the correct opening direction.
4. Insert the approved operating wrench.
5. Rotate smoothly to the fully open stop.
6. Confirm full-bore alignment.
7. Monitor pressure and flow.
8. Inspect for abnormal leakage or operating resistance.

The model-specific manual takes priority over general instructions.

Lower Kelly Valve During Connections

Before the Kelly is disconnected from the drill string, the Lower Kelly Valve can be closed according to the rig procedure.

This helps:

• Retain mud in the Kelly
• Reduce rig-floor spillage
• Reduce contamination of the rotary table area
• Control drill-string backflow
• Reduce personnel exposure to drilling fluid
• Improve connection efficiency

The valve must be reopened fully before circulation resumes.

Body Materials

The valve body is manufactured from high-strength heat-treated alloy steel selected for:

• Internal pressure
• Axial tension
• Torsional load
• Bending load
• Rotary fatigue
• Impact resistance
• Connection strength
• Low-temperature toughness

Available body materials can include:

• AISI 4145H Modified
• AISI 4140
• AISI 4330
• Equivalent qualified alloy steel
• Controlled-hardness sour-service alloy steel

The final material is determined by the design, pressure rating, connection size and service environment.

Ball and Seat Materials

The ball and seat system must resist:

• Drilling-fluid erosion
• Abrasive solids
• Corrosion
• High contact pressure
• Repeated opening and closing
• Differential pressure
• Temperature cycling

Available materials and treatments can include:

• Stainless steel
• Precipitation-hardened stainless steel
• Nickel-alloy components
• Tungsten-carbide-coated ball surfaces
• Hard chrome or project-specific coating
• Hardened alloy-steel seats
• PEEK or engineered polymer seat inserts
• Metal-supported elastomeric seals

The exact trim should be identified on the valve datasheet.

Stem Seal System

The operating stem penetrates the valve pressure boundary and requires a reliable seal arrangement.

The system can include:

• Primary stem seal
• Secondary stem seal
• Backup ring
• Wear ring
• Stem bearing
• Retaining system
• External environmental seal

Stem-seal materials are selected from:

• Pressure
• Temperature
• Drilling-fluid type
• H₂S and CO₂ exposure
• Aromatic content
• Oil-base mud
• Chemical-cleaning fluids
• Storage conditions

Seal Material Options

HNBR

HNBR provides:

• Good resistance to oil and drilling fluids
• High mechanical strength
• Good abrasion resistance
• Broad conventional drilling-temperature capability

FKM

FKM provides:

• Improved high-temperature resistance
• Strong hydrocarbon compatibility
• Good chemical resistance
• Suitability for selected oil-based and synthetic-based fluids

PTFE and PEEK

Engineered polymer components can provide:

• High pressure support
• Low friction
• Extrusion resistance
• Chemical resistance
• Dimensional stability

Seal selection must be based on the complete fluid composition rather than mud base alone.

Standard-Service Configuration

Standard-service valves can be configured for:

• Water-Based Mud
• Oil-Based Mud
• Synthetic-Based Mud
• Completion brine
• Conventional drilling-fluid additives
• Moderate chloride concentration

The purchaser should still identify maximum temperature, mud density, solids content and chemical exposure.

Sour-Service Configuration

Sour-service Kelly Valves can include:

• H₂S-compatible body material
• Controlled body and component hardness
• Sour-compatible trim materials
• H₂S-compatible seals
• Full heat-number traceability
• Hardness mapping
• Project-specific NDE
• Material documentation aligned with NACE MR0175/ISO 15156 requirements

Sour-service suitability must cover the complete valve assembly rather than only the internal trim.

Drilling-Fluid Erosion

High-velocity drilling fluid containing barite, sand and drilled solids can erode:

• Ball bore
• Seat edges
• Stem cavities
• Internal body transitions
• Seal-support surfaces

The full-opening bore and smooth internal profile help reduce localized erosion.

The valve should always remain fully open during circulation.

Rotary-Shouldered Connections

Available connection families include:

• NC Connections
• IF Connections
• FH Connections
• API Regular Connections
• Left-Hand Rotary Connections
• Right-Hand Rotary Connections
• Customer-Specified Connections

Common connection sizes can include:

• NC26
• NC31
• NC38
• NC40
• NC46
• NC50
• 3-1/2 IF
• 4 IF
• 4-1/2 IF
• 4 FH
• 4-1/2 FH
• 5-1/2 FH
• 6-5/8 REG

Availability depends on valve OD, bore, pressure rating, load capacity and approved drawing.

Preferred and Non-Preferred Connections

API-based valve designs can distinguish between preferred connections and customer-requested non-preferred connections.

A non-preferred or custom connection requires review of:

• Valve neck cross section
• Tensile capacity
• Torsional capacity
• Internal bore
• Pressure-test fixture
• Thread-gauge availability
• Fatigue performance
• Product marking
• Applicable standard scope

The connection designation must be included in the purchase order and valve marking.

Right-Hand and Left-Hand Threads

The thread hand must match the installed location.

Incorrect thread-hand selection can prevent assembly or allow connection loosening during drilling rotation.

The purchase order should identify:

• Top connection size
• Top connection hand
• Bottom connection size
• Bottom connection hand
• Box or pin orientation
• Makeup torque
• Rig rotation direction
• Upper or lower Kelly position

Do not assume that every Upper Kelly Valve uses the same connection combination.

Connection Inspection

API rotary-shouldered connection inspection includes:

• Thread form
• Taper
• Lead
• Pitch diameter
• Thread height
• Root and crest condition
• Gauge standoff
• Pin nose
• Box counterbore
• Shoulder flatness
• Shoulder perpendicularity
• Surface finish
• Connection concentricity

Cold working of thread roots and stress-relief features are available where required by the approved design.

Valve Outside Diameter

The valve OD should be compatible with:

• Kelly dimensions
• Rotary table opening
• Kelly bushing
• BOP bore
• Drill-floor handling equipment
• Connection-tool clearance
• Rig-floor catline and handling area

A streamlined outside profile reduces interference during drilling and handling.

Valve Inside Diameter

The valve ID is selected according to:

• Kelly bore
• Drill-string bore
• Required flow rate
• Mud-pump capacity
• Tool-passage requirements
• Core-barrel requirements
• Survey-tool requirements
• Pressure rating
• Connection size

Increasing the bore can reduce the remaining body wall thickness and connection cross-sectional area. Bore selection must therefore be supported by pressure and load calculations.

Tensile and Torsional Capacity

The valve forms part of the rotating drill stem and must transmit:

• Kelly weight
• Drill-string tension
• Rotary torque
• Bending load
• Shock load
• Vibration
• Pressure-induced axial load

The technical datasheet should identify:

• Rated tensile capacity
• Rated torsional capacity
• Connection limit
• Body limit
• Maximum recut allowance
• Applicable design assumptions

The lowest calculated capacity controls the valve rating.

Manufacturing Process

Goldenman Kelly Valve manufacturing includes:

1. Alloy-steel material verification
2. Heat-number assignment
3. Forging or bar ultrasonic inspection
4. Rough body machining
5. Quenching and tempering
6. Mechanical-property testing
7. Internal-bore machining
8. Ball-cavity machining
9. Stem-port machining
10. Top and bottom neck machining
11. Rotary-connection machining
12. Thread gauging
13. Ball manufacturing
14. Ball heat treatment and surface finishing
15. Seat manufacturing
16. Stem manufacturing
17. Seal and backup-ring preparation
18. Internal-component assembly
19. Operating-stop adjustment
20. Dimensional inspection
21. Nondestructive examination
22. Shell-pressure testing
23. Closure-pressure testing
24. Stem-seal testing
25. Opening- and closing-torque testing
26. Final function testing
27. Product marking
28. Surface protection
29. Documentation review
30. Export packaging

Heat Treatment

The body receives controlled heat treatment to establish:

• Yield strength
• Tensile strength
• Elongation
• Impact toughness
• Hardness
• Fatigue resistance
• Torsional capacity
• Pressure integrity

The heat-treatment batch is linked to the material heat number and valve serial number.

Nondestructive Examination

Available NDE includes:

• Full-body ultrasonic testing
• Magnetic-particle inspection
• Liquid-penetrant inspection for nonmagnetic components
• Surface inspection of stem and ball components
• Connection-area inspection
• Post-machining critical-area inspection

NDE acceptance follows the ordered standard, approved drawing and inspection plan.

Pressure Testing

Valve testing can include:

• Shell or body pressure test
• Closure test from the bit side
• Closure test from the swivel side
• Bidirectional closure test
• External stem-seal test
• Low-pressure seat test
• Rated-working-pressure seat test
• Pressure-hold test
• Temperature-conditioned validation test
• Gas test where specified
• Post-test dimensional and functional inspection

The exact pressure, hold time, test medium and leakage acceptance criteria follow API Spec 7V, the valve service class and the approved test procedure.

A fixed universal test multiple should not be published for every valve configuration.

Functional Testing

Functional testing verifies:

• Full opening
• Full closure
• Positive stop position
• Operating-direction marking
• Stem engagement
• Ball alignment
• Opening torque
• Closing torque
• Operation after pressure testing
• Absence of binding
• Internal-component retention

Operating-Torque Testing

Operating torque is affected by:

• Pressure differential
• Seat design
• Seal material
• Temperature
• Drilling-fluid solids
• Ball surface condition
• Stem friction
• Body deformation
• Tensile load

The purchaser should specify whether the valve must be qualified for operation under differential pressure or drill-string tension.

Quality Control and Testing

Goldenman quality control can include:

• Raw-material certificate verification
• Chemical-composition testing
• Heat-number traceability
• Heat-treatment monitoring
• Tensile testing
• Yield-strength testing
• Elongation testing
• Impact testing
• Body-hardness testing
• Component-hardness testing
• Full-body UT
• Body MPI
• Connection MPI
• Ball dimensional inspection
• Ball surface-finish inspection
• Seat dimensional inspection
• Stem dimensional inspection
• Seal-material certificate verification
• Valve OD and ID inspection
• Overall-length inspection
• Thread-gauge inspection
• Shoulder inspection
• Shell-pressure testing
• Closure-pressure testing
• Stem-seal testing
• Functional cycling
• Operating-torque verification
• Final visual inspection

Product Marking

Each valve should be permanently identified with:

• Goldenman identification
• Upper or Lower Kelly Valve
• Model or part number
• Valve service class
• Working-pressure rating
• Top connection
• Bottom connection
• Connection hand
• Valve serial number
• Heat number
• Manufacturing date
• Open and closed positions
• Closing direction
• Flow direction where applicable
• Standard-service or H₂S-service identification
• Applicable product-standard reference

Marking must remain visible after normal rig handling.

Product Documentation

Available documentation includes:

• Certificate of Conformity
• Product datasheet
• General assembly drawing
• Dimensional drawing
• Pressure-rating statement
• Service-class statement
• Material Test Certificate
• EN 10204 3.1 certificate
• Chemical-composition report
• Heat-treatment record
• Mechanical-property report
• Hardness report
• Impact-test report
• Ultrasonic-test report
• Magnetic-particle-test report
• Thread-gauge inspection report
• Dimensional inspection report
• Shell-pressure-test chart
• Closure-pressure-test chart
• Stem-seal-test report
• Functional-test report
• Operating-torque report
• Component traceability list
• Operation and maintenance manual
• Recommended spare-parts list
• Packing list
• Third-party inspection report

Spare Parts and Redress Kits

Goldenman supplies:

• Replacement Ball
• Upper and Lower Seats
• Seat Inserts
• Operating Stem
• Stem Seal
• Stem Backup Rings
• Wear Rings
• Ball Drive Components
• Retaining Rings
• Internal Cartridge Assembly
• Body Seals
• Operating Wrench
• Thread Protectors
• Standard-Service Seal Kit
• H₂S-Service Seal Kit
• High-Temperature Seal Kit
• Complete Redress Kit

Spare parts should be ordered using the valve serial number, part number, pressure rating and service class.

Inspection Before Installation

Before installing the valve:

1. Confirm Upper or Lower Kelly position.
2. Verify the working-pressure rating.
3. Verify the service class.
4. Confirm top and bottom connections.
5. Confirm right- and left-hand thread orientation.
6. Inspect pin and box threads.
7. Inspect sealing shoulders.
8. Verify the internal bore is clean.
9. Operate the valve fully open and closed.
10. Confirm positive stops.
11. Verify the position marking.
12. Inspect the operating-stem socket.
13. Confirm the correct wrench is available.
14. Review the pressure-test certificate.
15. Record the serial number in the rig equipment register.

Installation

1. Clean the valve connections.
2. Clean the mating Kelly, Swivel or Saver Sub connections.
3. Apply approved rotary-shouldered thread compound.
4. Align the connections.
5. Start makeup without cross-threading.
6. Apply the approved makeup torque.
7. Position the operating stem for rig-floor access.
8. Confirm the valve is fully open.
9. Confirm the wrench can be installed without obstruction.
10. Record the valve location and orientation.

Routine Inspection

Routine inspection should include:

• External body condition
• Corrosion
• Washout and erosion
• Operating-stem condition
• Stem-socket wear
• Open and closed markings
• Operating torque
• Internal bore condition
• Connection wear
• Shoulder damage
• Evidence of external leakage
• Pressure-test due date
• Service history
• Number of redress cycles

Inspection and maintenance intervals should follow the valve manual, rig maintenance system and operating conditions.

Maintenance and Redressing

A complete redress can include:

1. Clean and decontaminate the valve.
2. Confirm zero trapped pressure.
3. Remove internal retaining components.
4. Remove the ball and seat assembly.
5. Remove the operating stem.
6. Inspect the body cavity.
7. Inspect the internal bore.
8. Inspect the ball surface.
9. Inspect the seats.
10. Inspect the stem and stem bore.
11. Replace seals and backup rings.
12. Replace damaged metallic components.
13. Lubricate approved components.
14. Reassemble in the correct ball position.
15. Verify positive stops.
16. Complete functional testing.
17. Complete required pressure testing.
18. Issue a new service and test record.

Only trained personnel should disassemble and pressure-test the valve.

Common Failure Modes

Valve Is Difficult to Close

Possible causes include:

• High differential pressure
• Solids packed around the ball
• Seat damage
• Stem corrosion
• Stem deformation
• Incorrect wrench
• Ball erosion
• Lack of maintenance
• Partial ball misalignment

Valve Is Difficult to Open

Possible causes include:

• Trapped differential pressure
• Seat loading
• Debris around the ball
• Damaged operating stem
• Excessive seal friction
• Corrosion
• Ball or seat galling

Pressure should be equalized according to the approved procedure before applying excessive operating torque.

Valve Does Not Seal

Possible causes include:

• Seat erosion
• Ball damage
• Debris on the sealing surface
• Incorrect internal assembly
• Seal extrusion
• Stem misalignment
• Operation between open and closed stops
• Pressure applied from an unqualified direction

Stem Leakage

Possible causes include:

• Worn stem seal
• Damaged backup ring
• Stem scoring
• Excessive pressure
• Incorrect seal material
• Thermal degradation
• Chemical incompatibility
• Stem-bore damage

Excessive Internal Erosion

Possible causes include:

• Valve operated partially closed
• High fluid velocity
• Abrasive mud
• Misaligned ball bore
• Undersized internal bore
• Extended circulation with damaged seats

Connection Leakage

Possible causes include:

• Incorrect makeup torque
• Damaged shoulder
• Galling
• Thread wear
• Incorrect connection compound
• Mismatched connection type
• Connection recut beyond allowable limit

Operating-Stem Damage

Possible causes include:

• Incorrect wrench size
• Wrench not fully inserted
• Excessive torque
• Operation under excessive pressure differential
• Corrosion
• Rounded hexagonal socket
• Impact loading

Valve Body Fatigue

Possible causes include:

• Repeated high torque
• Drill-string bending
• Connection fatigue
• High vibration
• Material defect
• Unrecorded overload
• Excessive connection recutting
• Corrosion or erosion

Procurement Evaluation

A Kelly Valve should be evaluated using:

• Upper or lower installation position
• API Spec 7V service class
• Working pressure
• Sealing direction
• Full-opening bore
• Body design
• Top and bottom connection
• Connection hand
• Tensile capacity
• Torsional capacity
• Temperature rating
• Drilling-fluid compatibility
• Sour-service requirement
• Operating torque
• Pressure-test documentation
• Spare-parts availability
• Field-redress capability
• Serial-number traceability

Buying solely by pressure rating and thread size can result in an unsuitable valve.

Frequently Asked Questions

What is a Kelly Cock Valve?

It is a manually operated full-opening ball valve installed in the Kelly or upper drill-string assembly for internal pressure and drilling-fluid flow control.

What is the difference between an Upper and Lower Kelly Valve?

The Upper Kelly Valve is normally installed between the Swivel and Kelly.

The Lower Kelly Valve is installed between the Kelly and drill string or Saver Sub.

What pressure ratings are available?

Goldenman supplies:

• 5,000 psi
• 10,000 psi
• 15,000 psi

Is the valve full opening?

Yes.

The valve uses a full-bore ball design matched to the ordered valve and connection dimensions.

How is the valve operated?

A dedicated hexagonal wrench is inserted into the external operating stem and rotated through a quarter turn.

Does the valve have open and closed stops?

Yes.

Positive stops provide defined fully open and fully closed positions.

Is the valve normally open or closed?

The valve is normally fully open during drilling and circulation.

It is closed when internal drill-string isolation is required.

Can it be used to throttle drilling fluid?

No.

The Kelly Valve is an isolation valve and should not be operated as a throttling valve.

Why is the Lower Kelly Valve closed before breaking a connection?

Closing it helps retain drilling fluid in the Kelly and provides control against internal drill-string flow or pressure.

Does the Upper Kelly Valve always use left-hand threads?

Upper installations often include a left-hand connection to match the Swivel and Kelly arrangement.

The actual connection hand must be verified from the rig assembly.

What connections are available?

Available connection families include:

• NC
• IF
• FH
• REG
• Right-hand connections
• Left-hand connections
• Custom crossover combinations

What is the current API standard for Kelly Valves?

API Spec 7V is the current dedicated drill-stem-valve standard covering Kelly Valves.

Does API Spec 7-1 still apply?

Kelly Valve product requirements previously located in API Spec 7-1 have been superseded by API Spec 7V.

API Spec 7-1 can remain relevant to other rotary drill-stem elements.

What does API Spec 7-2 cover?

API Spec 7-2 covers dimensional, threading, gauging and inspection requirements for applicable rotary-shouldered connections.

Is every Goldenman Kelly Valve API Monogrammed?

API Monogram claims must match the manufacturer’s current API license and approved product scope.

A valve should not be described as API Monogrammed unless its license, model and manufacturing scope are verified.

Are bidirectional valves available?

Yes.

Bidirectional-sealing configurations are available according to the required API Spec 7V service class and pressure-test scope.

Are one-piece and two-piece bodies available?

Yes.

One-piece designs emphasize compact structural continuity, while two-piece designs can provide increased bore and maintenance access.

Are sour-service valves available?

Yes.

Sour-service configurations can include controlled-hardness materials, H₂S-compatible trim and seals, hardness documentation and project-specific NDE.

Can the valve be opened under pressure?

Operation under differential pressure depends on the valve design, service class and qualification.

Pressure should be equalized before opening unless the specific valve and operating procedure permit otherwise.

Does the Kelly Valve replace an Inside BOP?

No.

Kelly Valves and Inside BOPs perform complementary drill-string pressure-control functions.

Does it replace the rig BOP stack?

No.

It is an internal drill-string valve and does not replace annular or ram blowout preventers.

Can downhole tools pass through the valve?

Compatible tools can pass through when their maximum OD is smaller than the valve’s verified minimum ID and the valve is fully open.

What testing is available?

Available testing includes:

• Material testing
• UT
• MPI
• Thread gauging
• Shell-pressure testing
• Closure-pressure testing
• Stem-seal testing
• Functional cycling
• Operating-torque testing

Are repair kits available?

Yes.

Goldenman supplies balls, seats, stems, seals, backup rings, operating wrenches and complete redress kits.

Information Required for Quotation

Please provide:

• Upper or Lower Kelly Valve
• Required quantity
• Working pressure
• API Spec 7V service class
• Unidirectional or bidirectional sealing
• Required pressure-sealing direction
• Top connection size
• Top connection type
• Top connection hand
• Top connection box or pin
• Bottom connection size
• Bottom connection type
• Bottom connection hand
• Bottom connection box or pin
• Required valve OD
• Required minimum ID
• Required overall length
• One-piece or two-piece body
• Maximum tensile load
• Maximum operating torque
• Required connection makeup torque
• Maximum drilling-fluid pressure
• Maximum operating temperature
• Minimum operating temperature
• Drilling-fluid type
• Mud density
• Solids content
• Chloride concentration
• Oil-water ratio
• H₂S concentration
• CO₂ concentration
• Standard or sour service
• Required body material
• Required trim material
• Required seal material
• Gas-test requirement
• API Spec 7V conformity requirement
• API Monogram requirement
• Third-party inspection
• Pressure-test witnessing
• NDE requirements
• Documentation requirements
• Spare-parts package
• Redress-kit quantity
• Destination country
• Delivery schedule

Request a Technical Quotation

Goldenman supplies Upper and Lower Kelly Cock Valves for conventional rotary drilling and drill-string pressure-control applications.

The product range includes:

• Upper Kelly Valves
• Lower Kelly Valves
• One-piece and two-piece bodies
• 5,000, 10,000 and 15,000 psi working pressures
• Unidirectional and bidirectional sealing
• Right-hand and left-hand connections
• NC, IF, FH and REG configurations
• Standard and sour-service materials
• Full-opening ball-valve construction
• Operating wrenches
• Complete redress and spare-parts kits
• API Spec 7V inspection and testing configurations
• API Spec 7-2 connection inspection

Complete orders can be supplied with material traceability, mechanical-property reports, UT and MPI records, connection-gauge reports, shell and closure pressure-test charts, functional-test reports and operation manuals.

Email: info@goldenman.com