18-3/4" 15,000 psi WP TL BLOWOUT PREVENTER WITH RAM LOCKS AND SEQUENCING VALVE OPERATION AND MAINTENANCE MAINTENANCE
I. PHYSICAL DATA A. Lubricants 1. Ram lubricant, Cameron P/N 713878 or a water resistant non petroleum base grease. 2. Thread lubricant, Cameron P/N 705444 or per the latest revision of bulletin API 5A. 3. Multi-purpose lubricant or grease. 4. Multi-purpose lubricant or grease for cold weather operation. 5. Hydraulic operating system: a. Storage: Cameron P/N 718100 Preservation fluid. b. Standard operation: Use a fresh water lubricant that forms a true solution rather than an emulsion when mixed with water and/or antifreeze. 6. Seals and sealing surfaces: SAE-30 WT. Oil or equivalent. 7. Loctite 242 thread locker or equivalent. 8. Sealant thread Loctite 567 or equivalent. B. Dimensional Drawings 1. SD-010182-03-06, 18-3/4" 15,000 psi WP Double TL BOP Height: Double Studded X Flange - 83.21" (2113mm) Length: Bonnets Closed -156" (3960mm) Bonnets Open - 197.6" (5020mm) 2. SD-010182-03-07, 18-3/4"15,000 psi WP Double TL W/36" Between Cavities Height: Double Studded X Flange - 96.7" (2456mm) Length: Bonnets Closed - 156" (3960mm) Bonnets Open - 197.6" (5020mm)
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C. Drawings with Bills of Material 1. SD-010182-03-06, SD-010182-03-07,18-3/4" 15,000 psi WP Double Studded X Flange TL BOP. 2. SD-010182-03-08, 18-3/4" 15,000 psi WP TL BOP Bonnet Assembly. 3. SD-010182-03-09, Operating Piston Subassembly 4. SD-010182-03-10, Sequencing valve assembly 5. SD-010182-03-11, Shearing Blind Ram Subassemblies. 6. SD-010182-03-12, Variable Bore Ram Subassembly, 5-1/2" to 3-1/2" OD Pipe. 7. SD-010182-03-13, Pipe Ram Subassembly, 5" OD Pipe. D. Weights 1. 18-3/4" 15,000 psi WP TL double BOP, studded top X flange bottom with ram locks - 67,873 lb (29,880 kg). 2. 18-3/4" 15,000 psi WP TL double BOP, studded X flange with ram locks with 36" space between cavities - 70,767 lb (32,100 kg). 3. Bonnet assembly 18-3/4" 15,000 psi WP TL with ram locks - 5900 Ib (2676 kg). 4. Shear ram assembly weight range: 573-728 lb each (260-330 kg). 5. VBR ram assembly weight: 728 lb each (330 kg). 6. Pipe ram assembly weight: 617 lb each (280 kg). E. Lifting and Handling Bonnet subassemblies have threaded preparations to allow the installation of Note: Bonnet lifting eyes {35}. These are the lifting points from which these assemblies should be handled.(You can use the threaded holes on each side of intermediate flange with the removal tool.) 1. Lift BOP assemblies only with slings appropriately rated for the maximum weight of the BOP.
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2. Lift ram assemblies by installing a lifting eye (1-1/8"-8UN) in the threaded preparation in the ram. 3. Handle all other subassemblies using appropriately rated slings. F. External Thread Connections
Descri pti on
Size
Locati on
Open Port
1.25" SAE
BOP Body, Front
Close Port
1.25" SAE
BOP Body, Back
Unlock Port
1.25" SAE
BOP Bonnet, Side
G. Hydraulic Operating System Requirements 1. Use afresh water lubricant in the hydraulic system that forms a true solution rather than an emulsion when mixed with water and/or antifreeze. 2. Fluid Requirement: Rams (One Set) Open
Rams Close
Gallons
Litres
Gallons
Litres
22.3
84.4
25.9
98.0
Ram Lock s
Closing Ratio
Opening Ratio
7.13:1
3.10:1
Lock/Unlock Gallons
Litres
11
41.6
H. API 16A Drift Diameter API drift for 18-3/4" 15,000 psi WP is 18.720" (475 mm)
II. APPLICABLE OPERATING CHARACTERISTICS A. Subassemblies 1. Pipe Rams 5" a. Seals around 5" drill pipe or casing b. 5" Pipe Rams support 600,000 lb (272,727 kg) and seal both low or high pressure
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2. VBR (Variable Bore Ram) a. Seals around 5-1/2" to 3-1/2" drill pipe b. It is not recommended to hang off on VBRs. for 3.1/2” drill pipe c. 5.1/2" Pipe Rams support 600,000 lb (272,727 kg) and seal both low or high pressure 3. Shear Rams a. Refer to EB-702 for shear ram capabilites.
III. DISASSEMBLY PROCEDURE A. Part preparation Prior to Disassembly The work area should be clean and well lighted. B. BOP Disassembly Reference Drawings: a. BOP assemblies, P/N 2113341-03-01 and P/N 2113341-04-01 Item numbers shown in (), SD-010182-03-06 and SD-010182-03-07 b. Bonnet subassembly, P/N 2164236-03-01 and P/N 2164236-04-01 Item numbers shown in {}, SD-010182-03-08 c. Operating piston subassembly, P/N 2164235-01-01 Item numbers shown in [ ], SD-010182-03-09 1. Connect hydraulic line to the SAE flange on the bonnet assembly. 2. Apply 1500 psi (103 Bars) to this line to ensure unlock function. 3. Set this line to hydraulic block. 4. Connect the OPEN and CLOSE ports of the BOP to the hydraulic power supply 5. Apply 1500 psi (103 Bars) opening pressure to the BOP and remove the bonnet cap nuts (9). 6. Install the extension rods (P/N 2163165-01) on the two upper
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bonnet studs. 7. Apply 400 - 500 psi (27 - 34 Bars) closing pressure to the BOP to open the bonnets. 8. Install the ram trays (P/N 2113486-01) on the bonnet studs. 9. Apply 500 psi (34 Bars) opening pressure to clamp the tray between the body and bonnet and to move the rams to the open position. 10. Install a lifting eye (1-1/8"-8UN) in the side of the rams and use a pry bar in the ram tray slots to move the ram to the side of the preventer. 11. Install a lifting eye (1-1/8"-8UN) in the top of the rams and remove from the ram tray. 12. Apply 500 psi (34 Bars) closing pressure to the preventer long enough to unclamp the ram trays from their position between the body and the bonnet. 13. Remove the ram trays. 14. Remove the O-ring (21) from the seal carrier. 15. Apply 400 - 500 psi (27 - 34 Bars) opening pressure to move the bonnet assembly to the closed position. 16. Vent opening pressure and disconnect the hydraulic supply lines from the preventer and the bonnet. 17. Install lifting eyes (1-1/8"-8UN) in the bonnet and cylinder head of one bonnet assembly. 18. Use a chain sling to pick up on these two points enough to take the bonnet weight off the ram change pistons. 19. Remove the bonnet extension rods from the two upper bonnet studs. 20. Remove the ram change access caps {7} and remove the 0-rings {34} from the access caps. 21. Back out the ram change pistons {4 and 5}. It might be necessary to adjust the tension in the chain sling to achieve the proper lift to take the load off the ram change pistons and allow them to turn freely. Caution: It is highly recommended to alternate between pistons when backing out to ensure even load distribution.
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22. Remove the bonnet from the body and set it on a solid work surface. 23. Remove the ram guide pins (10). 24. Remove the ram change pistons from the bonnet. 25. Remove the wear bands {30} and polypaks {33} from the ram change pistons. 26. Remove the ram change piston seal rings {32} and bearings {50} from the bonnet. 27. Remove the bonnet seal carrier (20), bonnet seal (21), and retainer ring (22) using the seal carrier removal tool P/N 2010064-07. 28. Pick up the bonnet assembly and place it in the bonnet assembly stand or equivalent. Caution: Take care not to damage the finish on the connecting rod [13].
29. Remove the hydraulic tubing from the unlock/sequencing valve. Take care as pressure will still be contained in unlock chamber. 30. Remove sequencing valve {52}. 31. Remove the cylinder head nuts {26} from the bonnet assembly and use a sling to lift the cylinder head assembly from the bonnet. Set it on a clean surface face down. The ram change piston cylinders may come out with the cylinder head. If so, use a rubber mallet to knock the cylinders back down. 32. Install a lifting eye in the operating piston [6] and remove the operating piston assembly from the bonnet and place on its end. 33. Use two .250"-20 eye bolts to remove the operating cylinder {23} from the bonnet. 34. Remove the wear ring {29} and seal {27} from the operating piston. 35. Remove the 0-rings {28}, {8} and the back-up ring {9} from the operating cylinder. 36. Remove the ram change cylinders {6} from the bonnet. 37. Remove the 0-rings {31} from the ram change cylinders.
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38. Remove the following items from the bonnet: a. Studs {25} b. Spirolox Ring {19} c. Retainer Ring {18} d. Seal Ring {16} e. Back-Up Ring {17} 39. Remove the set screws (8 in total), the button and connecting rod. Install a lifting eye in the front plate [10] and lift it to allow access to the alignment keys that entrap the locking components. Remove all six key retaining cap screws [9], alignment keys [8] and locking components [7]. 40. Lower the assembly to the floor. Remove all sixteen cap screws [12] that hold the front plate [10] on. Remove the front plate. 41. Remove the O-Ring [11] from the front plate. 42. Pull out the stinger [18] and plug [21] and remove the polypaks [19] from each of them. 43. Remove the six cap screws [4] to separate each of the six whistle pistons [3] from the secondary piston. Remove the six O-Rings [5] from each cap screw. 44. Install an eye bolt to the secondary piston [1] and lift to remove it from the operating piston. 45. Remove the seal [2] from the OD of the secondary piston. 46. Turn cylinder head {24} on its end and remove each retainer {42}, seal {40} and Sleeve {41}. 47. Remove studs {25} from bonnet. 48. Turn the bonnet over (body side up) and remove the following items: a. Spirolox Ring {11} b. Retainer Ring {12} c. Seal Ring {14)
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d. Back-Up Ring {13} e. Spacer Ring {15} and Wear Ring {20} f. Seal Ring {16} g. Back-Up Ring {17} Note: It is not normally necessary to separate the end cap {48} from the cylinder head {24}. /t is also not necessary to remove the alignment keys on the main piston [8] and cap screws [9] that prevent the whistle piston from rotating.
IV. ASSEMBLY PROCEDURE A. Part Preparation Prior to Assembly The work area should be clean and well lighted. 1. Remove all dirt, grit, oil, and contaminants from the ram bore, ram change piston holes, bonnet stud holes, all fluid passageways in the body and bonnet. Clean detergent and fresh water should be used for cleaning. High pressure air may also be used if it is dry air. 2. Clean all internal surfaces of the bonnets using clean detergent and fresh water. Lubricate internal sealing surfaces. 3. Clean pistons and cylinders, using clean detergent and fresh water. Lubricate areas that will come in contact with other parts. 4. Sealed elastomer containers should not be opened until they are required for assembly. This is to prevent contamination and damage to the seal. 5. Thread lubricant P/N70544 or per the latest revision of bulletin API 5A. Caution: Never lay the operating piston down so that the seal surface on the con- necting rod, tail rod or OD of the piston can be damaged.
B. Bonnet Assembly Reference Drawings: a. BOP assemblies, P/N 2113341-03-01 and P/N 2113341-04-01 Item numbers shown in (), SD-010182-03-06 and SD-010182-03-07
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b. Bonnet subassemblies, P/N 2164236-03-01 & -04-01 Item numbers shown in {}, SD-010182-03-08 c. Operating piston subassembly, P/N 2164235-01-01 Item numbers shown in [ ], SD-010182-03-09 1. Place each bonnet {2} on stands or pallets with the body side up. Caution: Take care to ensure that the bonnet does not roll over.
2. Install the following parts in the connecting rod bore: a. Back-Up Ring {17} b. Seal Ring {16} c. Spacer Ring {15} d. Wear Ring {20} e. Back-Up Ring {13} f. Seal Ring {14} g. Retainer Ring {12} h. Spirolox Ring {11} 3. Install the following parts in the ram change piston bores: a. Seal Ring {32} b. Bearing {50} 4. Turn the bonnet over. Set the bonnet on a raised surface to allow the connecting rod to be installed through the bonnet past the bonnet face. Ensure that the ram change bores are to the back. Install the following items: a. Back-Up Ring {17} b. Seal Ring {16} c. Retainer Ring {18} d. Spirolox Ring {19} 5. Remove any excess lubricant to prevent it from holding debris.
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6. Coat the shorter threaded end of the studs {25} with thread lubricant. Install the coated ends in the bonnet. Apply sufficient torque until the last of the thread is flush with the surface of the bonnet. 7. Install the 0-rings {8} and back-up ring {9}, onto the operating cylinder {23}. Lubricate well with seal lubricant and install the operating cylinder on the bonnet. Apply uniform pressure to press cylinder into place. Use of the cylinder head is well advised for this purpose. Install O-ring {28} onto operating cylinder after cylinder is in place. 8. Install the 0-rings {31} on the ram change cylinders {6} and install the ram change cylinders on the bonnet. C. Operating Piston Assembly Reference Drawings: a. BOP assemblies, P/N 2113341-03-01 and P/N 2113341-04-01 Item numbers shown in (), SD-010182-03-06 and SD-010182-03-07 b. Bonnet sub-assembly, P/N 2164236-03-01 & -04-01 Item numbers shown in {}, SD-010182-03-08 c. Operating piston subassembly, P/N 2164235-01 Item numbers shown in [ ], SD-010182-03-09 The operating piston assembly is defined as all of the components that go into the main piston. In other words, it is the secondary piston and all the locking components. All seals and wear rings should be coated with lubricant to aid in the assembly and insure proper sealing. All threads must be cleaned with solvent and the female thread treated with an anaerobic sealant (Loctite). 1. Prepare stinger [18] and plug [21] by installing two polypak seals [19] on each one. Seals should have O-ring facing each other (Use P/N 2164228-01 & -02 to ease installation.). 2. Install the polypak [2] on the secondary piston [1]. Seal should face in the direction of front plate. 3. Install O-Rings [5] on the whistle piston cap screws [4]. 4. Turn the main piston [6] on its front face and install the alignment keys [8] by applying Loctite to, and fastening each cap screw [9] (see torque table). N.B. Only if they have been removed or assembly is from new. 5. Turn the main piston [6] on its back face.
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6. Slide whistle pistons [3] into the main piston and apply Loctite to threads. Take care to align key to slot in whistle piston. 7. Install the secondary piston [1] by tapping it into the main piston [6], being careful to align the cap screw holes with the threaded holes of each whistle piston. Tighten each of the six cap screws [4] (see torque table). 8. Install stinger [18] and plug [21] into the main piston. Be carefull to ensure that the stinger is in the correct position relative to the short slot on the piston and opposite the sequencing valve prep on the cylinder head {24}. When the operating piston subassembly is lowered into the operating cylinder the short slot should be closest to the ram change pistons. 9. Install O-ring [11] and 1 /4" NPT plugs [17] in the front plate (see torque table). 10. Lower the front plate [10] onto the main piston, being careful to align it to accept stinger [18] and plug [21]. 11. Hand tighten all sixteen cap screws [12] to bring the plate [10] and main piston [6] together evenly. Then tighten them as listed (see torque table). 12. Apply Loctite and install the connecting rod [13] to the front plate. 13. Install and tighten the set screws [15] into the connecting rod. 14. Apply Loctite and install the button [16]. 15. Install and tighten the set screws [15] into connecting rod. 16. Install each of six locking components [7] into the side of the main piston and install the alignment keys as described above in step 4. Operating piston subassembly is now complete. 17. Set the cylinder head {24} on its back face. 18. Install seal sleeve {41} and polypak {40} in stinger port. 19. Install the seal retainer {42} into stinger port (see torque table). Important: It is imperative to treat the threads of the retainer with a thread locking sealant.
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D. Final Bonnet Assembly Reference Drawings: Sequence Valve, P/N 2164206-02 Item numbers shown in < >, SD-010182-03-10
1. While holding the liner in position, install the anti-rotation plate <18> with the bolts <19>, using a small amount of thread adhesive <25>. 2. Install the 0-rings <13 and 24> and reassemble the Sequencing Valve as follows: a. Install the O-ring <5> on the OD of the valve seat <3> and mount the larger end between brass shims in a vise. Do not over-tighten the vise. b. Drop the poppet valve <1> into the seat, followed by the spring <2>. c. Treat the threads of the actuator with thread adhesive <25> and install the actuator <4> to the valve seat. Note: Use the proper amount of thread adhesive. Only a small amount is needed to make up the threads.
d. Install the O-ring <6> over the OD of the actuator <4> e. Install the O-ring <8> on the OD of the body <12>. f. Turn the assembly over, mount it in the vise and install the body <12> over the end of the seat. g. Install the O-rings <16 and 17> on the balance piston <14>. h. Apply thread adhesive to the threads of the balance piston and install it into the seat. i. Apply thread adhesive to the threads of the popet stop and install it on the cap. j. Install the O-ring <8> onto the cap <10>. k. Set the spring <9> on the balance piston and mount the cap onto the body. l. Mate the flanges of the body and liner together so that the ports are properly oriented for plumbing convenience.
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m. Rotate the actuator until the bottom side is parallel to the anti-rotation plate <18> as shown in the illustration. n. Install each of four bolts <11> into their holes. The sequence valve is now ready for mounting to the cylinder head. Note: Refer to step 16 for proper mounting of the sequence valve to the bonnet. The final assembly consists of lowering the operating piston assembly into the op- erating cylinder, followed by installation of the cylinder head.
3. Lubricate the ram change piston bores, connecting rod piston bore, ram change cylinder, and operating piston cylinder preparations. Caution: Take care to protect the connecting rod of the operating piston during as- sembly. This surface is coated with an abrasion resistant coating that is brittle.
4. Prepare the ram change pistons {4 and 5} for installation by installing the seal and bearing {33 and 30}. Pay attention to the proper orientation of the polypak {33}. It is different for 'OPEN' and 'CLOSE' sides. 5. Review the appropriate documentation to determine if a left or right hand bonnet is required and refer to the assembly drawing for the proper location of the 'OPEN' and 'CLOSE' ram change pistons. Caution: Take care to ensure that the ends of the ram change pistons are not damaged during this operation. 6. Lower the ram change pistons {4 and 5} into the appropriate preparations on the bonnet. Note: The 'OPEN' piston has thread size 3-1/8" while the 'CLOSE' piston has thread size 3".
7. Install the wear band {29} and seal {27} on the operating piston subassembly {3}. 8. Lower this operating piston subassembly {3} into the operating cylinder {23}. Be carefull to orient stinger for appropriate left or right hand bonnet. 9. Bring secondary piston to the fully unlocked position by blowing air through stinger. Lower the cylinder head onto the operating cylinder being careful to align the stinger port with the stinger during lowering. 10. Coat the threads and flanks of the nuts {26} and install them (see torque table).
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Caution: Take care to ensure that there are not any alignment problems between these items preventing proper assembly. Note: This is the 'unlock position'- proper assembly demands the secondary piston be in the unlocked position.
11. Install seals {34} in the groove on the ram change access caps {7}. 12. Lubricate the ram change access cap threads with thread lubricant and the ram change access cap seal bore with lubricant and install the ram change access caps. Note: There is no torque requirement for the ram access port, it makes up solid against the ram change cylinder.
13. Install the O-ring {28} on the cylinder head {24}. 14. Install the end cap {48} on the cylinder he ad by tightening each of the thirty two allen head cap screws {47} into the cylinder head (see torque table). 15. Install a 1/2" NPT pipe plug {39} into the end cap (see torque table). 16. Install the Sequence Valve {52} on the Cylinder Head, being careful to align item <18> in the direction of "VBR" or other if necessary. If Bonnet is for use on "VBR", then the "VBR" stamp should match up to "VBR" stamp on Cylinder Head. 17. Install all hydraulic tubing to the Sequence Valve and 'UNLOCK' chamber.
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Torque Table Thread Treatment Used Moly #503
API 5A
Item #
Name
[9]
Alignment Key Cap Scew
#10-24 UN
[4]
Cap Screw Whistle Piston
1.1/8"-8UN
[17]
NPT
1/4"
[12]
Front Plate Screws
1"-8UN
{42}
Seal Retainers
1"-8UN Bronze
{26}
Cylinder Head Nuts
2-3/4" -8UN
4071
5520
7588
10288
5/8”-11 UN
79
107
133
180
325
441
474
643
Size
ft-lb
Seq.Valve <11> Cap Screws {47}
End Cap Screws
1"-8UN
{39}
NPT Plug
1/2" Stainless
(9)
Bonnet Cap Nuts
5”-4 STUB ACME
N.m
ft-lb
N.m
Use Thread Sealant
Use Thread Sealant
Sealant ft-lb
N.m
4
5
723
980
USE THREAD SEALANT FINGER TIGHT AND THEN 2-3 TURNS WITH A WRENCH Use Thread Sealant Use Thread Sealant
500
678
90
122
USE THREAD SEALANT FINGER TIGHT AND THEN 2-3 TURNS WITH A WRENCH 5000* 2000°
6779* 2711°
7250* 2900°
9830* 3900°
* Minimum torque at BOP hydrostatic body shell test ° Minimum torque at BOP working pressure
E. BOP ASSEMBLY Reference P/N 2113341-04-01 and P/N 2113341-03-01, SD-010182-03-06 and SD-010182-03-07 1. Install the extension rods (P/N 2163165-01) on each of the two top bonnet studs on each side of the BOP. 2. Install lifting eyes in the bonnet and cylinder head of one bonnet assembly. Use these lifting points to bring the bonnet to the BOP straight and level and guide it over the extension rods. (You can use the bonnet removal tool)
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3. Align the ram change pistons (4 and 5) to their respective pre parations and thread them in the body. Note: The ram change pistons have different thread sizes. The 'OPEN' piston has a thread size of 3-1/8". The 'CLOSE' piston has a thread size of 3". They should make up and tighten freely, without difficulty. Make sure the proper piston is installed to line up with the proper preparation on the body. The bonnet level may have to be adjusted to allow easy tightening of these pis- tons.
4. Rest the bonnet on the extensions and remove the lifting slings. 5. Repeat steps 1 through 4 for the bonnet on the other side of the BOP 6. Connect the 'OPEN' and 'CLOSE' ports and the 'UNLOCK' chamber of the BOP to the hydraulic power supply. Note: The operation of Cameron ram type BOPS is as follows: When pressure is applied to the 'OPEN' port, the rams will open or retract within the bonnet and the bonnets will close if they are in the open position. Conversely, when pressure is applied to the 'CLOSE' port, the rams will close in on the well-bore and the bonnets will open if the cap nuts are not installed. Caution: All personnel should be clear of the bonnets when operational pressure is applied during the following steps.
7. Apply 1500 psi (103 Bars) to the unlock port and block in. 8. Apply 500 psi (34 Bars) closing pressure to the BOP (which opens the bonnets completely) and install the ram trays. 9. Apply 500 psi (34 Bars) opening pressure to the BOP to clamp the trays between the body and bonnet. This application will also retract the connecting rods into the bonnets. 10. Install the rams by sliding them on to the buttons. 11. Apply 500 psi (34 Bars) closing pressure to the unclamp the trays. This application will also close the rams. Remove the ram trays. 12. Apply 500 psi (34 Bars) opening pressure to the BOP (which closes the bonnets). The pressure may have to be increased to overcome the ram rubber. When fully closed raise pressure to 1500 psi (103 Bars) and hold. 13. Remove the extension rods.
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14. Install bonnet cap nuts (9) and tighten them (see torque table). 15. Bleed off all pressure to the BOP.
V. OPERATION AND INSTALLATION A. Preparation Prior to the installation of the preventer, ensure that the following requirements are met: 1. The capacity and the pressure rating of the accumulators and the pressure pumps must comply with the API RP 53 recommendations or appropriate regulatory agency requirements. 2. Ensure that the ring gaskets are correct for the preventer flange, the hub size, and the pressure rating. B. Installation 1. Install the preventer, ensuring that the preventer is right-side-up (outlets are below the center of the preventer). 2. Inspect the preventer, the ram subassemblies, and all rubber parts during installation. 3. Remove the external mechanical protectors. 4. Lift the BOP with the suitable lifting tool. 5. Install the BOP on a test stump/fixture. 6. Drain the fluid from the operating system. 7. Remove the 1" ball valves or pipe plugs from the inlet and outlet connections. 8. Connect the hydraulic control lines, and flush the operating system with clean fluid. 9. Test for leaks in the operating system (refer to Part VII-1.c). 10. Install rams in accordance with assembly procedure described in Part IV.
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11. While installing the rams, inspect the ram bore and bonnet. a. Inspect the vertical bore for key seating. b. Inspect the intersection between the vertical bore and the ram bore. Grind out any raised metal surfaces. Do not remove any metal below the original surface.
VI. MAINTENANCE A. Routine Maintenance 1. If more than 500 psi (35 Bars) hydraulic pressure is required to operate the ram subassemblies when there is no pressure in the well bore, determine the cause and correct any irregularities. Caution: To avoid damage to the packers, close pipe and flexpacker rams only when pipe is in the preventer.
2. Pressure test and operate the preventer once a week per API RP 53 "Periodic Field Testing" or appropriate regulatory agency requirement. B. Periodic Maintenance 1. Once a year, or every six months in cold weather conditions, completely disassemble the preventer. Note: For a detailed description of disassembly, see Part lll, DISASSEMBLY PROCEDURE.
a. Clean all parts. Do not use a wire brush on sealing areas. b. Replace all rubber seals, gaskets, and O-rings. c. Replace ram packing according to condition. d. Repair or replace damaged metal parts. 2. Reassemble the preventer. Note: For a detailed description of assembly, see Part IV, ASSEMBLY PROCEDURE.
a. After reassembling the preventer, test the rams and operating system. Refer to Part VII, TESTING for the correct procedure.
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VII. TESTING A. Hydraulic Operating System 1. Test the hydraulic operating system after installation. a. Flush the hydraulic operating system with clean operating fluid. b. Test the hydraulic system after re-assembly and installation. A purging procedure is outlined and recommended. This procedure is to be conducted at 400 psi (28 Bars), 800 psi (55 Bars), 1200 psi (83 Bars) and 1500 psi (103 Bars). 1) Apply 1500 psi (103 Bars) pressure to the UNLOCK port. 2) Apply purge pressure to the OPEN port. Verify for proper stroking of the rams. 3) Block the UNLOCK port so it does not vent. 4) Apply purge pressure to the CLOSE port. Verify for proper stroking of the rams. 5) Vent or bleed the UNLOCK port to allow closing pressure to achieve the lock. (with sequencing valve this step is automatically done) 6) Increase the pressure to the next increment and repeat steps 1) through 5) above. c. Test for leaks in the operating system. 1) Remove the hydraulic line from the OPEN port. Note: !f testing pipe, casing, or flexpacker rams, be sure that an appropriate size test mandrel is installed into the preventer. DO NOT close the rams on an open hole unless closing pressure is less that 300 psi. Flexpackers should be tested with the largest pipe size for that packer. Note: For this test ensure the secondary piston is in the 'UNLOCKED' position by applying 3000 psi (200 Bars) to the 'UNLOCK' port on the bonnet then blocking it off during the entire test.
2) Apply 300 psi (20 Bars) hydraulic pressure to the CLOSE port, and observe the OPEN port for leaks. 3) Increase the pressure to 3000 psi (200 Bars), and observe the OPEN port for leaks.
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4) Inspect for leaks between the bonnet and the BOP body. Bleed all pressure from the BOP closing line. 5) Replace the hydraulic line to the OPEN port. 6) Remove the hydraulic line from the CLOSE port. 7) Apply 300 psi (20 Bars) hydraulic pressure to the OPEN port, and observe the CLOSE port for leaks. 8) Increase the pressure to 3000 psi (200 Bars), and observe the CLOSE port for leaks. 9) Inspect for leaks between the body and the bonnet. Bleed all pressure from the BOP opening line. 10) Place the hydraulic line to the UNLOCK port. 11) Apply 300 psi (20 Bars) hydraulic pressure to the UNLOCK port. 12) Apply 3000 psi (200 Bars) hydraulic pressure to the UNLOCK port. 13) Replace the seals if leaks were new seals. 14) Repeat the procedure for each preventer. VIII. LONG TERM STORAGE A. Preventer 1. Open the bonnets and remove the ram subassemblies. 2. Remove the top seals and packers, then wash the ram subassemblies. 3. Lubricate the ram bodies, covering them with a heavy grease. Caution: DO NOT lubricate the top seals or packers. 4. Do not store the ram subassemblies inside the preventer. 5. Clean the inside and outside machined surfaces of the preventer. 6. Dry with an air blaster until no moisture is left inside or outside the preventer. 7. Inspect the ram bores and the vertical bores for burrs.
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8. Remove burrs by touching the surface lightly with a grinder using 36 to 60 grit paper. 9. Lubricate the ram bore with a heavy grease. 10. Lubricate the end and outlet connection faces with a heavy grease, and cover them with flange protectors. 11. Flush the operating system using clean operating fluid. B. Ram Locks. 1. Apply 1500 psi (103 Bars) pressure to the UNLOCK port. (This unlocks the BOP.) 2. The pressure is maintained to the UNLOCK chamber by sequencing valve. Apply 300 psi (20 Bar) pressure to the CLOSE port. (This prevents the lock from locking while closing the rams.) 3. Maintain pressure to the CLOSE port and the sequencing valve vent pressure to the UNLOCK port. (This locks the BOP.) 4. Vent pressure to the CLOSE port. Apply 1500 psi (103 Bar) pressure to the UNLOCK port until fully unlocked. (This unlocks the BOP.) 5. Maintain pressure at the UNLOCK port and apply 300 psi (20 Bar) pressure to the OPEN port. (This opens the rams.) 6. it might be necessary to repeat step (1) through (5) several times to displace the original operating fluid. 7. Vent all pressure, remove lines, and plug all. ports. 8. Install the 1" NPT pipe plugs into the OPEN and CLOSE connections. Caution: DO NOT use the bonnet lifting eyes to lift the preventer.
9. To lift the preventer, use ropes or slings around the ends of the body. C. Elastomers 1. Store rubber products inside a cool dark, dry storage area. a. The preferred storage temperature range for rubber goods is from 40°F (5°C) to 80°F (25°C).
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b. Rubber goods should be wrapped or otherwise protected from direct exposure to sunlight or artificial light with a high ultraviolet content (such as fluorescent lighting). Do not store in direct sunlight even if wrapped, as overheating will result. c. Store rubber parts in a relaxed position. Do not stretch or hang 0rings and seals. Labels should not be attached to seals with string, wire, or tape, as these items may deform the sealing surface. 2. Use airtight containers when possible to protect against circulating air. 3. Ozone is extremely harmful to rubber. Ensure that there is no equipment in the storage area which may generate ozone, such as mercury vapor lamps, high-voltage electrical equipment, electric motors, or any electric apparatus which produces arcing. 4. Keep the rubber products clean and free of solvents, oil, greases, or any other semi-solid or liquid materials during storage. Rubber goods should specifically be protected against direct contact with: manga nese, copper, copper alloys (including brass), polyvinyl chloride (PVC), creosoteimpregnated timber, other rubber goods of different rubber compounds, sulfur, and copper napthenate. 5. When cleaning is necessary, rubber goods may be cleaned with soap and water or methyl alcohol. After cleaning, the rubber goods should be dried at room temperature. 6. Examine the part before installation. Important: Rubber goods taken from storage must ALWAYS be inspected before installation. Rubber goods should NOT be flexed at temperatures below 40°F (5°C). Rubber goods in storage should be inspected every 12 months to ensure that they are still serviceable.
a. Ensure that the part does not have a tacky surface or noticeable softening or hardening of the surface. b. Flex the part and inspect with a magnifying glass to ensure that there are no cracks. c. Replace items that show any of the aging signs mentioned above.
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