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PREFACE Hydril makes no warranties of any kind, expressed or implied, including any warranty of mechanical fitness for any particular purpose, that the work performed pursuant to this manual will be free from defects in workmanship or material. Hydril retains for itself all proprietary rights in and to all designs, engineering details, data, and procedures set forth herein. This manual is intended for the sole use of Hydril customers, and they shall strictly control copying of same, as this manual and all copies thereof may be recalled by Hydril at any time. This manual makes recommendations recommendations only. The customer is at all times responsible for actual disas-

sembly, inspection, reassembly, and testing of the blowout preventer. The customer also is solely responsible for providing competent and qualified persons, equipment and facilities to perform such operations, and for workmanship and safety. If at any time the customer is unable to understand recommendations made in this manual or is unable to follow those recommendations, they should consult the nearest Hydril Authorized Repair Facility or Hydril Headquarters. The addresses, telephone numbers, numbers, FAX numbers of the repair facilities as well as Hydril Headquarters are listed in Section 10 of this manual.

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Ram BOPs

PREFACE Hydril makes no warranties of any kind, expressed or implied, including any warranty of mechanical fitness for any particular purpose, that the work performed pursuant to this manual will be free from defects in workmanship or material. Hydril retains for itself all proprietary rights in and to all designs, engineering details, data, and procedures set forth herein. This manual is intended for the sole use of Hydril customers, and they shall strictly control copying of same, as this manual and all copies thereof may be recalled by Hydril at any time. This manual makes recommendations recommendations only. The customer is at all times responsible for actual disas-

sembly, inspection, reassembly, and testing of the blowout preventer. The customer also is solely responsible for providing competent and qualified persons, equipment and facilities to perform such operations, and for workmanship and safety. If at any time the customer is unable to understand recommendations made in this manual or is unable to follow those recommendations, they should consult the nearest Hydril Authorized Repair Facility or Hydril Headquarters. The addresses, telephone numbers, numbers, FAX numbers of the repair facilities as well as Hydril Headquarters are listed in Section 10 of this manual.

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Ram BOPs

CONTENTS PAGE Prefac Preface e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

Revisio Revision n Record Record

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv

1. 0

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

2.0 2.0

INSP INSPEC ECTI TION ON SC SCHE HEDU DULE LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

3.0

VISUAL IN INSPE SPECTION

4.0

GAUGE INSPE SPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5.0 5.0

BOP BOP OPER OPERAT ATIN ING G TEST TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6.0 6.0

HYDR HY DRAU AUL LIC SYST SYSTEM EM TEST TEST

7.0 7.0

WELL WELLBO BORE RE PR PRES ESSU SURE RE TEST TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

8. 0

MPL LO LOCK TE TEST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

9.0

INSPECTION FORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

10.0 HYDRIL REPAIR FACILITIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Please contact Hydril Pressure Control Products for any assistance or questions concerning the information in this manual. All information contained in this manual is the exclusive property of Hydril Company LP .

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©2001 Hydril Company LP

HYDRIL COMPANY LP /P.O. BOX 60458/HOUSTON, TEXAS 77205 TELEPHONE: (281) 449-2000 FAX: (281) 985-2828

Printed In The U.S.A.

July 1994

Rev. A, A , April 2002

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REVISION RECORD SECTION

1.0

INTRODUCTION

2.0

INSPECTION SCHEDULE

3.0

VISUAL INSPECTION

4.0

GAUGE INSPECTION

5.0

BOP OPERATING TEST

6.0

HYDRAULIC SYSTEM TEST

7.0

WELLBORE PRESSURE TEST

8.0

MPL LOCK TEST

9.0

INSPECTION FORMS


DATE

REVISION

10-06-97

A

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PAGE 1-1

Ram BOPs  Introduction

1.0 INTRODUCTION

REV: PAGE

1.1

1.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Ram BOP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Initial Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Part Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. BOP Control System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J. Inspection Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Normal Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3

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1.1 General A. Purpose The purpose of this manual is to provide detailed instructions on how to perform scheduled inspections of Hydril ram blowout preventers when they are not in service. For in-service inspections, refer to the BOP operator's manual. B. Ram BOP Configuration Instructions in this manual are provided for single ram BOPs with one ram compartment . Therefore, if the BOP being inspected has more than one ram compartment, repeat the instructions as many times as necessary. C. Initial Safety Precautions WARNING: DO NOT OPEN THE BONNETS OF A RAM BOP UNLESS THE RAM BOP IS INSTALLED ON THE TEST STUMP OR SECURED TO THE FLOOR. THE WEIGHT OF AN OPEN BONNET CAN CAUSE AN UNSECURED BOP TO TURN OVER. D. Part Identification Parts referenced in this manual are identified by referring to Figures 4-2 through 4-5 in Section 4 of this manual. These figures contain exploded views and parts lists of typical ram blowout preventers, pipe rams, variable rams, and shear rams. However, these figures do not contain part numbers. For part numbers, refer to the part number stamped in the surface of the component. If the component does not have the part number stamped in its surface, refer to the parts list and assembly drawing in the BOP operator's manual. E. Required Equipment Adequate facilities and equipment are required to safely lift and move the assembled ram BOP and to pressure test the BOP. Hydril recommends the lifting configuration shown in Figure 1-1. F. BOP Control System Requirements Opening and closing of the BOP rams is accomplished by applying hydraulic pressure to the Open or Close port on the BOP. When pressure is applied to the Open port, the Close port must be piped in a manner that allows the free flow of operator fluid from the BOP as the pistons move to open the rams. This requirement is the same for the application of hydraulic pressure to the Close port.

Figure 1-1 Ram BOP Lifting Confinguration Use light weight hydraulic oil or a mixture of clean fresh water and a fluid concentrate composed of soluble oil and rust inhibitor. In freezing temperatures (below 0oC /32oF), add antifreeze (ethylene glycol) to any fluid concentrate and water mixtures. [CAUTION: Do not use synthetic fluids or fuel oil. Use of these will result in damage to the seals.] Use clean tap water as bore fluid. G. Cleaning Clean the ram BOP(s) as soon as possible after removing the BOP stack from the wellhead. Remove caked drilling mud and cuttings from the ram compartment(s) and exterior of the BOP with high pressure water or steam. H. Lubrication Lubricate all metal surfaces with light machine oil such as Gulf Harmony No. 46 or Exxon Coray 100 or equivalent. Use Never-Seez thread lubricant or equivalent with a coefficient of friction of .069. Coat all seals and nonextrusion rings with silicone grease or castor oil. CAUTION: Use of petroleum base oil or grease will reduce seal life. I. Part Replacement Only Hydril replacement parts should be used to insure expected performance and service life. Refer to the part number stamped on the part or to the parts lists in your BOP operator's manual.

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J. Inspection Records Inspection forms are provided in Section 9. These forms are designed to be used along with the inspection procedures. To make the recording of results easy, each form has step numbers that correspond to the steps used in the inspection procedure. Each form should be treated as a master for photocopying. Make as many copies as are needed.

1.2 How To Use This Manual A. Normal Use This manual is designed to be used in conjunction with the BOP operator's manual for disassembly and assembly instructions, operation specifications, bolt torques, and part numbers. If an operator's manual is not available, contact Hydril Headquarters in Houston, Texas for a copy (refer to Section 10 for address information). This manual is divided into sections for ease of use. The section headings are listed in the Table Of Contents at the front of this manual. To use this manual, turn first to the inspection schedule in Section 2. Find the desired inspection interval on the schedule. The procedure for each inspection on the schedule is found in Sections 3 through 8. Find the inspection form in Section 9, photocopy it, and use it as you follow the corresponding inspection procedure. If the BOP requires major repairs that cannot be made in the field, contact Hydril at one of the Hydril Repair Facilities listed in Section 10. B. Revision Occasionally, Sections 1 through 10 of this manual may be revised. Revisions are identified in two ways. First, by a letter of the alphabet (Rev. A, B, C, etc.) on page 1 of each section and in the Revision Record. The Revision Record follows the Table Of Contents in the front of this manual. Second, the revised portion will be indicated by an 8-pt. grey bar in the margin (see example in the left margin). This bar is intended to aid the user in finding the parts of the section that have been changed from the previous version. Furthermore, to make the updating of this manual easier when revisions are made, whole sections will be replaced rather than individual revised pages. NOTE: The revision letter indicated in the revision box on page 1 of each section should match with the letter shown in the Revision Record. If not, contact Hydril

Company Headquarters. Refer to Section 10 of this manual for the address, telephone, and FAX numbers.

PAGE 1-3

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PAGE 2-1

Ram BOPs  Inspection Schedule

2.0 INSPECTION SCHEDULE

REV: PAGE

2.1 2.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 2-2

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PAGE 2-2


2.1 General The inspection schedule provides the inspection interval and type of inspection required in tabular form. The procedures for performing the inspections are located in Sections 3 through 8 (see Table Of Contents for listing). To use the schedule, find the inspection interval on the schedule and the associated inspections. Next, photocopy the inspection form(s) from Section 9. Begin the inspections by turning to the section that contains the procedure for

performing the first inspection listed. Perform the inspection using the inspection form and the corresponding procedure. Continue to perform each inspection in the same manner until all inspections have been completed.

2.2 Inspection Schedule Refer to Table 2-1.

TABLE 2-1 INSPECTION SCHEDULE Inspection Interval AS REQUIRED

BETWEEN WELLS

YEARLY

FOUR YEARS

Description

Manual Section

1. Inspect Visually.

3

2. Perform BOP Operating Test.

5

3. Perform Hydraulic System Test.

6

4. Perform Wellbore Pressure Test.

7

1. Inspect Visually.

3


5


6


7

1. Disassemble BOP.

*

2. Inspect Visually. a. Replace All BOP Seals.** b. Replace Ram Packers And Seals.**

3

3. Assemble BOP.

*


5


6


7

1. Disassemble BOP.

*

2. Inspect By Gauge. a. Replace BOP Spare Parts.**

4

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PAGE 2-3


TABLE 2-1 CONTINUED Inspection Interval

Description

Manual Section

b. Replace Ram Spare Parts.** c. Replace parts as required.**

* **

3. Assemble BOP.

*


5


6


7

7. Perform MPL Lock Test (MPL Models Only).

8

Refer to operator's manual for disassembly and assembly instructions. Parts for a typical ram BOP are listed in Figures 4-2 through 4-5 in Section 4. Recommended spare parts, including seals, are also indicated. Refer to the ram BOP operator's manual for part numbers.

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PAGE 3-1

Ram BOPs  Visual Inspection

3.0 VISUAL INSPECTION

REV: PAGE

3.1

3.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Inspection Criteria for Nuts, Studs, Bolts, and Threaded Holes . . . . . . . . . . . . . Visual Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 3-2 3-2 3-2 3-2 3-2 3-3

Inspection Manual Ram BOPs  Visual Inspection

3.1 General The procedures in this section cover the visual inspection of the Hydril ram BOP. A. Inspection Records During the inspection of the ram BOP, keep records of the inspections and the actions taken. Use the inspection form(s) in Section 9. B. Repairs Minor repairs can be performed in the field. However, major repairs requiring welding must be performed at an approved Hydril Repair Facility. Refer to Section 10 for a list of facility locations. C. Cleaning Prior to inspection, clean caked drilling mud, loose rust, and scale from the exterior of the ram BOP with high pressure water or steam. D. Handling Lift the ram BOP using two slings of adequate strength in a basket configuration. Position the slings one on each side of the ram BOP from just inside the hinges, under the BOP body, and up the off hinge side (refer to Figure 3-1). CAUTION: To prevent damage, do not position slings under the multiple position locks or the manual locks when lifting the ram BOP. WARNING: USE EXTREME CAUTION WHEN LIFT-

ING THE RAM BOP. THIS IS VERY HEAVY AND BULKY EQUIPMENT. DO NOT PLACE HANDS OR OTHR BODY MEMBERS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DURING THE LIFTING OPERATION. E. Inspection Criteria for Nuts, Bolts, and Threaded Holes. Clean threads thoroughly because dirt and grit may account for symptoms that otherwise appear to be due to thread damage. Replace nuts and bolts if threads are damaged or if the hex surfaces are seriously rounded. A part with threaded holes with unacceptable threads may require replacement or repair of the part. Contact Hydril for advice. Refer to Section 10 for a list of Hydril Authorized Repair Facilities.

Figure 3-1. Ram BOP Lifting Arrangement

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3.2 Visual Inspection Procedure A. Tools and Materials Required 1. Emery cloth, 240 grit or finer 2. Light machine oil (Gulf Harmony No. 46 or Exxon Coray 100) 3. Never-Seez thread lubricant (coefficient of friction is .069) or equivalent 4. Inspection form(s) (refer to Section 9) B. Inspection Procedure Refer to Figure 3-2 while following this procedure. 1. Inspect the ring grooves and the mating faces of the top connection, bottom connection, and side outlets. a. Inspect the ring grooves for pitting, scratches, indentations, and washouts. Minor damage to the grooves may be repaired in the field by polishing with 240 grit or finer emery cloth. After polishing, wipe ring groove with a clean cloth soaked in light machine oil. Any damage requiring welding or machining must be repaired at a Hydril Authorized Repair Facility. Record findings on the inspection form.

b. Inspect the mating faces for upset metal and raised edges. Minor metal upset or raised edges can be repaired in the field by grinding until flush. Major metal upset or raised edges that require machining or welding must be repaired at a Hydril Authorized Repair Facility. Record findings on the inspection form. c. Inspect outlets for interior wall collapse. 2. Inspect nut and bolt heads for damage. Replace any nut or bolt that has hex corners on the head that are rounded off. If a nut or bolt requires replacement, apply Never-Seez thread lubricant to the threads of the new nut or bolt before installing. Refer to BOP operator's manual for torque specifications. 3. Clean the threads of any studs that are exposed and inspect the threads for cracks, galling, wear, and deformity. Replace as required. If a stud requires replacement, apply Never-Seez thread lubricant to the threads of the new stud before installing. Refer to BOP operator's manual for torque specifications. Ring Groove & Mating Surfaces (Top & Bottom)

TOP VIEW

Studs and Nuts Bolt Heads

Ring Grooves & Mating Surfaces (Side Outlets)

SIDE VIEW

Figure 3-2. Typical Ram BOP — Visual Inspection

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4. Open ram BOP bonnet and inspect the body as follows:. WARNING:

DO NOT OPEN A BONNET UNLESS THE RAM BOP IS INSTALLED ON A SECURED TEST STUMP OR SECURED TO THE FLOOR. THE WEIGHT OF AN OPEN BONNET CAN CAUSE AN UNSE- CURED RAM BOP TO TIP OVER. a. Inspect the area on the body where the bonnet seal contacts for pitting, scratches, and corrosion. Minor damage can be removed by polishing with 240 grit or finer emery cloth. After polishing, wipe surfaces with light machine oil. Any damage requiring welding or machining must be repaired at a Hydril Authorized Repair Facility. Record findings on the inspection form. b. Inspect bottom surface of ram bore for damage and wear. Minor damage can be removed by polishing with 240 grit or finer emery cloth. After polishing, wipe surfaces with light machine oil. Any damage requiring welding or machining must be repaired at a Hydril Authorized Repair Facility. Record findings on the inspection form. 5. Inspect the bonnet as follows: a. Remove the bonnet seal and Inspect the bonnet seal groove for pitting, scratches, indentations, and washouts. Minor damage can be removed by polishing with 240 grit or finer emery cloth. After polishing, wipe groove clean with light machine oil. Any damage requiring welding or machining must be repaired at a Hydril Authorized Repair Facility. Record findings on the inspection form. b. Inspect front and back of bonnet seal for cracks, cuts, hard skin, and deformity. Replace seal if necessary. Record finding on inspection form. c. Clean and inspect the threads of the bonnet bolts for cracks, galling, wear, and deformity. Replace any damaged bolt. Lubricate threads with Never-Seez thread lubricant. d. Clean and inspect the threads of the bonnet bolt holes in the body of the ram BOP for damage and wear. If threads are damaged or worn, contact a Hydril Authorized Repair Facility.

Bonnet

Sealing Area

Ram Bonnet Bolt Hole

Body

Bonnet Seal

Bonnet Bolt

Ram Bore Figure 3-3. Ram BOP With Bonnet Open.

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PAGE 3-5


6. Inspect Inspect the pipe ram, ram, shear shear ram, variable variable ram as follows: NOTE: If replacement of parts is required, refer to the disassembly and assembly procedures in the BOP operator's manual. manual. Refer to the operator's manual for part numbers. a. Pipe Ram and Variab Variable le R Ram: am: 1) Inspec Inspectt front front packer packer on ram ram asse assemmbly for wear, cracking, and hard skin. Check variable ram packers for insert separation. Replace if necessary. Record findings on the inspection form. 2) Inspec Inspectt top top seal seal groov groove e and and vertic vertical al packing slots for burrs. Remove burrs with 240-grit 240-grit emery cloth. Wipe clean with rag soaked in light machine oil. 3) Inspec Inspectt upper upper seal seal on pipe pipe ram assembly for wear, cracking, and hard skin. Replace if necessary. Record findings on the inspection form. 4) Inspec Inspectt botto bottom m surfa surface ce o off pipe pipe ram ram for wear and pitting. Minor damage damage can be removed removed by buffing. After buffing, wipe surfaces with light machine oil. Any damage requiring welding or machining must be repaired at a Hydril Authorized

Repair Facility. Record findings on the inspection form. b. Shear Ram: 1) Inspec Inspectt shear shear blades blades for wea wearr and and damage. Replace if necessary. Record findings on the inspection form. 2) Inspect Inspect lateral lateral T-Seal T-Seal for for wear, wear, crackcracking, and hard skin. Replace if necessary. Record findings on the inspection form. 3) Inspec Inspectt upper upper seal seal on shear shear ram ram assembly for wear, cracking, and hard skin. Replace if necessary. Record findings on the inspection form. 4) Inspec Inspectt botto bottom m surfa surface ce of of shear shear ram for wear and pitting. Minor damage can be removed by polishing with 240 grit or finer emery emery cloth. After polishing, wipe surfaces with light machine oil. Any damage requiring welding or machining must be repaired at a Hydril Authorized Repair Facility. Record findings on the inspection form. 5) Inspec Inspectt sealing sealing surfac surface e of lower lower carcarrier for scaring and pitting. pitting. Minor damage can be removed by polishing with Top Seal

Top Seal Packer

Pipe Ram

Variable Ram

Packer

Shear Ram Assemblies Top Seal

Lower Shear Blade

Upper Shear Blade

Lateral T-Seal

Figure 3-4. Hydril Pipe Ram, Variable Pipe Ram, And Shear Ram

Inspection Manual Ram BOPs  Visual Inspection

240 grit or finer emery cloth. After polishing, wipe surfaces clean with light machine oil. For major damage, contact a Hydril Authorized Repair Facility. Facility. Record findings on the inspection form. 7. Retract Retract ram assembly assembly and and close close the bonnet. bonnet. Torque the bonnet bolts as per Section 10. 8. Open, visually visually inspect, inspect, and close close the remainremaining bonnets as instructed above, beginning with Step 4.

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PAGE 4-1

Ram BOPs  Gauge Inspection

4.0 GAUGE INSPECTION

REV: PAGE

4.1 4.1

4.2 4.2

Gener General al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Insp Inspec ecti tion on Reco Record rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Repa Repair irs s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Clean Cleanin ing g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Hand Handlin ling g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Part Part Iden Identi tifi fica cati tion on and and Repla Replace ceme ment nt . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge Gauge Insp Inspec ecti tion on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Tool Tools s And And Ma Mate teri rials als Req Requi uire red d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Insp Inspec ecti tion on Proc Procedu edure re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Wear Wear Limit Limits s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-11 4-11 4-11 4-11 4-11 4-11 4-24 4-24

Inspection Manual Ram BOPs  Gauge Inspection

3.1 General The procedures in this section cover the gauge inspection of the Hydril ram BOP. To complete this inspection, the ram BOP operator's manual is required for disassembly, assembly, and part number identification. If a manual is not available, contact the nearest Hydril Repair Facility for a copy. Refer to Section 10 for a list of locations. A. Inspection Records During the inspection of the ram BOP, keep records of the inspections and the actions taken. Use the inspection form(s) in Section 9. B. Repairs Minor repairs can be performed in the field. However, major repairs requiring welding must be performed at an approved Hydril Repair Facility. Refer to Section 10 for a list of locations. C. Cleaning Prior to inspection, clean caked drilling mud, loose rust, and scale from the exterior of the ram BOP with high pressure water or steam. D. Handling Lift the ram BOP using two slings of adequate strength in a basket configuration. Position the slings one on each side of the ram BOP from just inside the hinges, under the BOP body, and up the off hinge side (refer to Figure 4-1). CAUTION: To prevent damage, do not position slings under the multiple position locks or the manual locks when lifting the ram BOP. WARNING: USE EXTREME CAUTION WHEN LIFT-

ING THE RAM BOP. THIS IS VERY HEAVY AND BULKY EQUIPMENT. DO NOT PLACE HANDS OR OTHER BODY MEMBERS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DURING THE LIFTING OPERATION. E. Part Identification and Replacement The parts of a typical Hydril ram BOP are illustrated in Figures 4-2 and 4-3 for the purpose of identifying the components that are discussed in the Gauge Inspection Procedure. Although the parts are identified by name, quantity, and recommended spares, no part numbers are provided. Refer to the illustrated parts lists in the ram BOP operator's manual for accurate representation and part numbers.


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Item No.

Part Name*

1 2 3 4 5 6 7 8 9 10 11 12

Body, Single Nameplate (not shown) Screw, Drive (not shown) Seat, upper Seal Ring, Lock O-Ring, Lower, Seat To Body Backup Ring, Lower, Seat To Body O-Ring, Upper, Seat To Body * Screw, Socket Head Set, Seal Seat*** Hydraulic Connection O-Ring, Hydraulic Connection Cap Screw, Socket Head ***

Qty. Rec. Spare Part Per 4 Year Cavity** 1 Year 1 1 4 1 1 1 1 1 4** 1 2 8

1 1 1

1 1 1 4**

2

2

Figure 4-2. Typical Hydril Ram BOP With Manual Lock.

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Item No. 13-20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41-50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75-80 117-120 121 122 123

Part Name*

Qty. Rec. Spare Part Per 4 Year Cavity** 1 Year

Reserved For Future Use Hinge, Load Pin, Locator Cap Screw, Socket Head *** Hinge, fluid Sub, Fluid Hinge O-Ring, Sub To Bonnet Hinge Sub, Energizer O-Ring, Sub To Energizer Back-Up Ring, Sub To Energizer O-Ring, Energizer To Fluid Hinge Back-Up Ring, Energizer To Fluid Hinge Spring Screw, Socket Head Set, Fluid Hinge *** Plug, Hex Head Pipe O-Ring, Fluid Hinge To Body Cap Screw, Hex Head *** Bearing, Hinge Pin Washer, Thrust Washer, Fluid Hinge O-Ring, Fluid Hinge To Bonnet Hinge Reserved For Future Us Ram Assembly Bonnet Bolt, Bonnet Retainer, Bonnet Bolt Seal, Bonnet Pin, Ram Guide Seal, Piston Rod Mud Ring, Spacer Ring, Retainer Seal, Bonnet To Piston Pin, Hinge O-Ring, Hinge Pin O-Ring, Pin Screw, Socket Head Set, Hinge Pin Ring, Plastic Packing w Ring, Plastic Energizing w Valve, Check w Packing, Plastic w Screw, Socket Head Set w Plug, Hex Head Pipe Hinge, Bonnet Hinge, Bonnet Cap Screw, Bonnet Hinge *** O-Ring, Bonnet Hinge Reserved For Future Use Reserved For Future Use Piston, Manual Lock Seal, Piston Lock, Mechanical

Figure 4-2 Continued

2 4 8 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 1 set 2 20 20 2 4 2 2 2 2 4 4 8 4 2 2 2 2 2 2 2 16 4

2 4 2

4

4

4 4 4 4

4 4 4 4

4

4

4 4

4 4

4

4

20 2

20 2

2 2 2 2

2 2 2 2

4 8

4 8

2 2 2 2

2 2 2 2 2

4

4

4

4

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PAGE 4-5


Item No.

124 125 126 127 128 129 130 131 132 133 134

Part Name*

Washer, Thrust O-Ring, Cylinder Liner To Bonnet Liner, Cylinder O-Ring, Cylinder To Bonnet Ring, Retaining Ring, Spacer Seal, Cylinder To Mechanical Lock Stud, Cylinder Nut, Heavy Hex Cylinder, Manual Lock Scraper

Qty. Rec. Spare Part Per 4 Year Cavity** 1 Year 2 2 2 2 2 2 2 12 12 2 2

2

2

2 2 2 2

2 2 2 2

2

2

Available on models used in surface applications only. * Item has been deleted on some BOPs. ** Quantities vary per BOP. Refer to ram BOP operator's manual. *** Use only Hydril replacement parts. Commercial grade fasteners will fail in service due to the loads experienced. w


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PAGE 4-6


52

Item No. 1 2 3 4 5 6 7 8 9 10 11 12

Part Name* Body, Single Nameplate (not shown) Screw, Drive (not shown) Seat, Upper Seal Ring, Lock O-Ring, Lower, Seat To Body Backup Ring, Lower, Seat To Body O-Ring, Upper, Seat To Body * Screw, Socket Head Set, Seal Seat *** Hydraulic Connection O-Ring, Hydraulic Connection Cap Screw, Socket Head ***

Qty. Rec. Spare Part Per 4 Year Cavity** 1 Year 1 1 4 1 1 1 1 1 4** 1 2 8

Figure 4-3. Typical Hydril Ram BOP With MPL

1 1 1

1 1 1 4**

2

2

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PAGE 4-7


Item No.

13-20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41-50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75-80 117-120 135 136

Part Name*

Reserved For Future Use Hinge, Load Pin, Locator Cap Screw, Socket Head *** Hinge, fluid Sub, Fluid Hinge O-Ring, Sub To Bonnet Hinge Sub, Energizer O-Ring, Sub To Energizer Back-Up Ring, Sub To Energizer O-Ring, Energizer To Fluid Hinge Back-Up Ring, Energizer To Fluid Hinge Spring Screw, Socket Head Set, Fluid Hinge *** Plug, Hex Head Pipe O-Ring, Fluid Hinge To Body Cap Screw, Hex Head *** Bearing, Hinge Pin Washer, Thrust Washer, Fluid Hinge O-Ring, Fluid Hinge To Bonnet Hinge Reserved For Future Us Ram Assembly Bonnet Bolt, Bonnet Retainer, Bonnet Bolt Seal, Bonnet Pin, Ram Guide Seal, Piston Rod Mud Ring, Spacer Ring, Retainer Seal, Bonnet To Piston Pin, Hinge O-Ring, Hinge Pin O-Ring, Pin Screw, Socket Head Set, Hinge Pin Ring, Plastic Packing w Ring, Plastic Energizing w Valve, Check w Packing, Plastic w Screw, Socket Head Set w Plug, Hex Head Pipe Hinge, Bonnet Hinge, Bonnet Cap Screw, Bonnet Hinge*** O-Ring, Bonnet Hinge Reserved For Future Use Reserved For Future Use Piston, MPL Seal, Piston


Qty. Rec. Spare Part Per 4 Year Cavity** 1 Year

2 4 8 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

8 4 4 4 4 4 4 4

4 4 4 4 4 4 4 4

4

4 4 4 4 4 4

20 2

20 2

2 2 2 2

2 2 2 2

4 8

4 8

2 2

2 2

2

2 2

2 2 16 4

4

4

2 4

4

4

1 set 2 20 20 2 4 2 2 2 2 4 4 8 4 2 2 2 2 2

4

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PAGE 4-8


Item No. 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164

Part Name*

Cylinder, MPL O-Ring, Cylinder To Bonnet Liner, Cylinder O-Ring, Cylinder Liner To Bonnet Stud, Cylinder Nut, Heavy Hex Nut, Lock Screw, Lock Plate, Retainer Plate, Front Clutch Capscrew, Sock. Hd. Front Clutch Plt.*** Plate, Rear Clutch Bearing, Lock Nut Spring, Clutch Key, Rear Clutch Plate O-Ring, Cylinder Head Dirt Seal Backup Ring, Cylinder Liner To Bonnet Head, Cylinder MPL O-Ring, Cylinder Head Cap Screw, Cylinder Head Pin, Locating, Bonnet (Not Shown) Pin, Locating, Retainer Plate Stem, Lockout Gland, Lockout Segment, Lockout O-Ring, Lockout Stem Backup Ring, Lockout Stem Ring, Transfer

Qty. Rec. Spare Part Per 4 Year Cavity** 1 Year 2 2 2 2 12 12 2 2 2 2 16 2 4 16 8 2 4 2 2 16 2 2 4 4 4 4 4 2

2

2

2

2

16 4

2 4

2 4

2

2

4 4

4 4

Available on models used in surface applications only. * Item has been deleted on some BOPs. ** Quantities vary per BOP. Refer to ram BOP operator's manual. *** Use only Hydril replacement parts. Commercial grade fasteners will fail in service due to the loads experienced. w


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4 1

2

3 PIPE RAM ASSEMBLY

4

2

1

3

VARIABLE RAM ASSEMBLY

Item No. 1 2 3 4

Part Name Ram Assembly Ram Block Front Packer Upper Seal

Qty. Per Cavity 2 2 2 2

Figure 4-4. Pipe Ram Assembly

Rec. Spare Part

1 Year

1 1

4 Year

1 1

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UPPER BLADE SHEAR RAM ASSEMBLY

LOWER BLADE SHEAR RAM ASSEMBLY

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

* **

Part Name

Qty. Per Cavity

Upper Blade Shear Ram Block Upper Shear Blade Upper Blade Cap Screw* Upper Blade Top Seal Alignment Pin Upper Blade Set Screw* Alignment Pin Set Screw* Lateral T-Seal Not Used Lower Blade Shear Ram Block Lower Shear Blade Lower Blade Cap Screw* Lower Blade Top Seal Anti-extrusion Block

1 1 4** 1 2 3 2 1 1 1 2 1 2

Rec. Spare Part

1 Year

4 Year

1

4 1

1

2 1

1

2 1

Use only Hydril replacement parts. Commercial grade fasteners will fail in service due to the loads experienced. Quantity varies per BOP. Refer to ram BOP operator's manual.

Figure 4-5. Shear Ram Assembly

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PAGE 4-11


4.2 Gauge Inspection A. Tools and Materials Required 1. Emery cloth 2. Light machine oil (Gulf Harmony No. 46 or Exxon Coray 100) 3. Never-Seez thread lubricant (coefficient of friction is .069) or equivalent 4. Inspection form(s) (refer to Section 9 ) 5. Spare parts (refer to Figures 4-2, 4-3, 4-4, and 4-5) B. Inspection Procedure Refer to Figures 4-2, 4-3, 4-4, and 4-5 while following this procedure. Refer to the figure that corresponds most closely to the ram BOP being inspected. Figure 4-2 has a manual ram lock and Figure 4-3 has a multiple position ram lock (MPL). 1. Disassemble the ram BOP completely following the procedure in the BOP operator's manual. Replace all parts indicated as spare parts (refer to Figures 4-2 and 4-3). 2. Clean remaining parts thoroughly and prepare them for inspection. 3. If the ram BOP is equipped with a MPL (multiple position lock), continue with the next step. If equipped with a manual lock, continue to step 7. 4. Inspect the MPL locknut assembly (items 143, 149, 158, 145, 150, 148, 146, and 147 of Figure 4-3). a. Inspect the lock nut (item 143 of Figure 43). Refer also to Figure 4-6 1) Inspect the two bearing surfaces. The bearing surface should be smooth with no gouges or scratches. 2) Measure the thickness of the shoulder. The thickness should not be less than minimum thickness listed in Table 4-1. 3) Inspect the threads in the thread holes for damage. Record the results on the inspection form. 4) Inspect the through bore threads for damage. Minor ridging of the threads due to wear is acceptable, but not heavy galling or wear. Install the lock nut onto the lock screw (item 144 of Figure 4-3) with timing marks aligned. The lock nut should fit easily on the lock screw and rotate down the length of the lock screw by hand. Record the condition on the

Bearing Surfaces

Rear

Minimum Thickness

Front

Figure 4-6. MPL Locknut (item 143, Figure 4-3)

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PAGE 4-12


inspection form. 5) Replace the lock nut if damaged or worn beyond the conditions stated in steps 1) through 4) above. Refer to the ram BOP operator's manual for the part number. b. Inspect the retainer plate (item 145 of Figure 4-3). Refer also to Figure 4-7. NOTE: Do not remove the retainer plate locating pin (item 158 of Figure 4-3). Inspect it for wear and straightness. 1) Inspect the bearing surface. It should be smooth and flat. Record condition on inspection form. 2) Inspect surface A and the key slots for burrs. It should be polished smooth with emery cloth. Record the condition on the inspection form. 3) Inspect Surface B for corrosion. Remove corrosion with emery cloth. Record condition on inspection form. c. Inspect front clutch plate (item 146 of Figure 4-3). Refer also to Figure 4-8. 1) Inspect all clutch teeth for dings and dents. CAUTION: Do not attempt repair if damage is present. Replace the clutch plate. Refer to BOP operator's manual for the part number. 2) Measure clutch teeth. If any tooth is worn below the minimum height shown in Table 41, replace the clutch plate. Refer to BOP operator's manual for the part number. 3) Record the condition of the front clutch plate on the inspection form. d. Inspect rear clutch plate (item 148 of Figure 4-3). Refer also to Figure 4-8. 1) Inspect all clutch teeth for dings and dents. CAUTION: Do not attempt repair if damage is present. Replace the clutch plate. Refer to BOP operator's manual for the part number. 2) Measure clutch teeth. If any tooth is worn below the minimum height shown in Table 41, replace the clutch plate. Refer to BOP operator's manual for the part number. 3) Record the condition of the rear clutch plate on the inspection form.

Retainer Locating Pin

Surface B

Surface A

Key Slot

Bearing Surface

Figure 4-7. Retainer Plate (Item 145 of Figure 4-3)

Minimum Teeth Height

Figure 4-8. MPL Clutch Plate (items 146 and 148 of Figure 4-3)


e.

Inspect retainer plate locating pin (item 158 of Figure 4-3). 1) Without removing the pin from the retainer plate (item 145), inspect the protruding end for rounded-off edges. Replace if necessary. Refer to BOP operator's manual for part number. 2) Record results on inspection form. 5. Inspect the MPL cylinder assembly (items 137, 142, 154, 156, 159, 160, 162, and 163 of Figure 4-3). a. Inspect the MPL cylinder (item 137 of Figure 4-3). Refer also to Figure 4-9. 1) Inspect the seal groove and the sealing surfaces for smoothness. Remove minor pits and scores up to a depth of .015 in (.38 mm) with emery cloth. If major pits and scores are present, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 2) Inspect the threaded holes for thread damage such as galling. If damage is present, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 3) Record results on the inspection form. b. Inspect the lockout stem (item 159 of Figure 4-3). 1) Inspect the internal threads for damage. 2) Inspect the seal groove for corrosion, nicks, and dings. 3) Inspect square end for damage. 4) Replace the lockout stem if any damage inspected for above is present. Refer to BOP operator's manual for part number. 5) Record the results on the inspection form. c. Inspect the lockout gland (item 160 of Figure 4-3). 1) Inspect the threads on the outside diameter of the gland for burrs. 2) Inspect the corners of the hex for roundedoff corners. 3) Replace gland if damage above is present.

Seal Groove Sealing Surfaces

Figure 4-9. MPL Cylinder (Item 137 of Figure 4-3)

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PAGE 4-13

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PAGE 4-14


4) Dress the center bore of the gland with emery cloth as required to remove nicks. 5) Record condition on inspection form. d. Inspect the cylinder head (item 154 of Figure 4-3). Refer also to Figure 4-10 . 1) Inspect the O-ring seal groove and dirt seal groove. Both grooves should be smooth and flat. Remove minor dings, gouges, and pitting up to a depth of .015 in (.38 mm) with emery cloth. For major damage, contact the nearest Hydril Repair Facility. Refer to Section 10 for a list of locations. 2) Smooth the bearing surface with emery cloth as necessary. Measure the depth of the bearing pocket. The depth should be less than shown in Table 4-1. If the depth is more, contact the nearest Hydril Repair Facility. Refer to Section 10 for a list of locations. 3) Record the condition of the cylinder head on the inspection form. 6. Inspect the piston and lock screw assembly (items 135, 136, 138, 139, 140, 144, 153, 161, and 164 of Figure 4-3). a. Inspect the cylinder liner (item 139 of Figure 4-3). Refer also to Figure 4-11. 1) Inspect the inside diameter for pits, dings, gouges, and wear. Repair minor damage up to a depth of .005 in (.13 mm) with emery cloth. Measure the inside diameter of the cylinder liner. The diameter should be less than the maximum inside diameter shown in Table 4-1. If the diameter is more, replace the cylinder liner. 2) Inspect the inside diameter of the piston entry bevels and the seal groove for pits, handling damage, and gouges. Repair minor damage up to a depth of .015 in (.38 mm) with emery cloth. 3) Inspect cylinder shoulder for burrs and flattened edges. Rework shoulder with a file to return it to its original contour if necessary. Also inspect for line scores and chips in the chrome. 4). Measure the outside diameter of the seal groove. The diameter should be greater than shown in Table 4-1. If less, replace the cylinder liner. 5) For major damage, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 6) Record condition of cylinder liner and any rework performed on the inspection form.

Dirt Seal Groove (152) O-Ring Seal Groove (155)

Bearing Pocket

Bearing Pocket Max. Depth Figure 4-10. Cylinder Head (Item 154 of Figure 4-3)

Cylinder Shoulder Seal Groove

Min. Seal Groove O.D.

Entry Bevels

Figure 4-11. Cylinder Liner (Item 139 of Figure 4-3)

Max. I.D.

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PAGE 4-15


b. Inspect the transfer ring (item 164 of Figure 4-3). Refer also to Figure 4-12. 1) Inspect transfer ring for corrosion and deformity. Remove minor corrosion with fine emery cloth. Replace if deformed. 2) Measure the thickness of the ring. Refer to Table 4-1 for minimum thickness. Replace if thickness is less. 3) Record condition and thickness on inspection form. c. Inspect lockout segment (item 161 of Figure 4-3). Refer also to Figure 4-13. 1) Inspect radius at the base of the threaded stem for cracks. 2) Inspect for damage to threads. 3) Inspect both sides for rounded-off edges. 4) Replace if any of the damage listed above is present. 5) Record condition on inspection form. d. Inspect piston (item 135) and lock screw (item 144 of Figure 4-3). Refer also to Figure 4-14. 1) Inspect surface A of the piston for pitting, dings, and gouges. Repair minor damage [less than .005 in (.13 mm) deep] with emery cloth. Replace piston if major damage is present. 2) Inspect piston rod for straitness. The rod must be perfectly straight. Verify that end of piston rod is perpendicular to shaft. Replace if necessary. Measure the outside diameter of the piston rod. If it is less than shown in Table 4-1, replace it. 3) Measure the large outside diameter of the piston on the center most land of the three lands. The diameter should not be less than the minimum piston diameter shown in Table 4-1 . Replace if less. 4) Inspect seal grooves for smoothness, pitting, and dings. Repair minor damage with emery cloth. Replace piston if major damage is present. 5) Gauge the screw for wobble or wear by measuring the side to side movement of the matching nut. More than .060 inch movement is cause for replacement. NOTE: Normally, it is nearly impossible to disassemble the lock screw from the piston without the proper tools. Contact a Hydril Repair Facility for instructions. Refer to Section 10 for a list of locations. 6) Inspect area around the lock screw shoulder for cracks. Replace if cracks are present.

Minimum Thickness Figure 4-12. Transfer Ring (Item 164 of Figure 4-3)

Inspect for Cracks

Inspect Both Sides For Roundedoff Edges Figure 4-13. Lockout Segment (Item 161 of Figure 4-3)

Lock Screw

Inspect For Cracks

Seal Grooves

Min. Piston O.D.

Min. Rod O.D. Piston Rod Surface A

Figure 4-14. Piston And Lock Screw (Items 135 and 144 of Figure 4-3)

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PAGE 4-16


7) Record results of inspections on the inspection form. 7. If the ram BOP is equipped with a manual lock assembly (items 121 through 134 of Figure 4-2), inspect it as follows. If the ram BOP is equipped with a MPL, skip this step and continue to step 8. a. Inspect the manual lock cylinder (item 133 of Figure 4-2). Refer also to Figure 4-15. 1) Inspect the seal groove for the cylinder to bonnet seal (item 127 of Figure 4-2) for pitting, dings, and gouges. Repair minor damage with emery cloth. If major damage is present, replace the cylinder. Refer to the ram BOP operator's manual for the part number. 2) Measure the inside diameter of the cylinder. The inside diameter should be less than the maximum bore shown in Table 4-1. If greater, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 3) Record condition on inspection form. b. Inspect the cylinder liner (item 126 of Figure 4-2). Refer also to Figure 4-16. 1) Inspect the seal groove for the cylinder liner to bonnet seal (item 125 of Figure 4-2) for pitting, dings, and gouges. Repair minor damage with emery cloth. If major damage is present, replace the cylinder liner. Refer to the ram BOP operator's manual for the part number. 2) Record condition on inspection form. c. Inspect the mechanical lock piston assembly (items 121 and 123 of Figure 4-2). Refer also to Figure 4-17. 1) Inspect the unthreaded surface of the mechanical lock for scars, dings, and gouges. Make minor repairs with emery cloth. Replace if major damage is present. NOTE: Normally, it is nearly impossible to disassemble the lock screw from the piston without the proper tools. Contact a Hydril Repair Facility for instructions. Refer to Section 10 for a list of locations. 2) Measure the diameter of the unthreaded rod of the mechanical lock screw. The diameter should be greater than the minimum rod outside diameter shown in Table 4-1. If the diameter is less, replace the mechanical lock screw. NOTE: Normally, it is nearly impossible to disassemble the lock screw from the piston without the proper tools. Contact a Hydril Repair Facility for instructions. Refer to Section 10 for a list of locations.

Seal Groove

Inside Diameter

Figure 4-15. Manual Lock Cylinder (item 133 of Figure 4-2)

Seal Groove

Figure 4-16. Manual Lock Cylinder Liner (item 126 of Figure 4-2)

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PAGE 4-17


d. Inspect piston (item 121) and lock screw (item 123 of Figure 4-2). Refer also to Figure 4-17. 1) Inspect surface A of the piston for pitting, dings, and gouges. Repair minor damage [less than .005 in (.13 mm) deep] with emery cloth. Replace piston if major damage is present. 2) Inspect piston rod for straitness. The rod must be perfectly straight. Verify that end of piston rod is perpendicular to shaft. Replace if necessary. Measure the outside diameter of the piston rod. If it is less than shown in Table 4-1, replace it. 3) Measure the large outside diameter of the piston on the center most land of the three lands. The diameter should not be less than the minimum piston diameter shown in Table 4-1 . Replace if less. 4) Inspect seal grooves for smoothness, pitting, and dings. Repair minor damage with emery cloth. Replace piston if major damage is present. 5) Gauge the screw for wobble or wear by measuring the side to side movement of the matching nut. More than .060 inch movement is cause for replacement. NOTE: Normally, it is nearly impossible to disassemble the lock screw from the piston without the proper tools. Contact a Hydril Repair Facility for instructions. Refer to Section 10 for a list of locations. 6) Inspect area around the lock screw shoulder for cracks. Replace if cracks are present. 7) Record results of inspections on the inspection form.

Lock Screw

Minimum Dia. Seal Grooves

Inspect for Cracks

Minimum Piston O.D. Piston Rod Surface A Min. Rod Dia.

Figure 4-17. Manual Lock Piston and Lock Screw Assembly (items 121 and 123 of Figure 4-2)

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PAGE 4-18


8. Inspect the bonnet hinge assembly (items 61, 62, 63, 71, 72, 74, and 75 of Figures 4-2 and 4-3). a. Inspect bonnet hinges (items 71 and 72 of Figures 4-2 and 4-3. Refer also to Figures 418 and 4-19. 1) Measure the distance between the bonnet hinges. The distance should be less than shown in Table 4-1. If the distance is more, replace the hinges. 2) Inspect all sealing surfaces for corrosion and damage. Repair minor damage up to a depth of .015 in (.38 mm) with emery cloth. Replace hinges if major damage is present. 3) Inspect hydraulic fluid passage for build up. Clean as required to assure full fluid flow. 4) Inspect threads for galling or tearing. Replace bonnet hinges that have damaged threads. 5) Inspect flatness of bonnet hinge mounting face. The face should be flat within .015 in (.38 mm) after cleaning. 6) Record inspection results on inspection form. b. Inspect hinge pin (item 61 of Figures 4-2 and 4-3). Refer also to Figure 4-20. 1) Inspect all seal grooves for corrosion. 2) Inspect the threads for galling and tears. 3) Inspect the hex head for rounded-off edges. 4) Replace the hinge pin if any of the conditions listed above are present. 5) Record the conditions on the inspection form.

Sealing Surface Bonnet Hinge Mounting Face

Sealing Surface Sealing Surface Figure 4-18. Bonnet Hinge (Items 71 and 72 of Figures 4-2 and 4-3)

Upper Bonnet Hinge

Distance Between Hinges Lower Bonnet Hinge Figure 4-19. Bonnet Hinge Measurement

Bearing Surfaces Figure 4-20. Hinge Pin (Item 61 of Figures 4-2 and 4-3)

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PAGE 4-19


9. Inspect the bonnet assembly (items 52, 53, 55, 56, 57, 58, 59, and 60 of Figures 4-2 and 4-3). a. Inspect bonnet (item 52 of Figures 4-2 and 43. Refer also to Figure 4-21. 1) Inspect the bonnet seal groove for corrosion, pitting, and dings. Repair minor damage with emery cloth. Measure the depth of the bonnet seal groove. The depth should not exceed the maximum depth shown in Table 4-1. 2) Inspect the piston rod bore for pitting, dings, and gouges. Repair minor damage of less than .015 in (.38 mm) in depth with emery cloth. 3) Measure the piston rod bore diameter with pitting and corrosion removed. The diameter should not exceed the maximum diameter shown in Table 4-1. 4) Measure the diameter of the cylinder liner bore. The diameter should not exceed the maximum diameter shown in Table 4-1. 5) Inspect the pilot surfaces for the cylinder (item 137 of Figure 4-3) and the cylinder liner (Item 126 of Figure 4-2 and item 139 of Figure 4-3) for pitting, dings, and gouges. Repair minor damage of less than .010 in (.25 mm) with emery cloth. 6) Smooth the seal surface with emery cloth where the bonnet hinge O-rings (item 74 of Figures 4-2 and 4-3) contact the bonnet. 7) Inspect all hydraulic fluid passages for any buildup. Clean as required to assure full flow. 8) Inspect the cylinder studs (item 131 of Figure 4-2 and item 141 of Figures 4-3) for damaged threads. Repair or replace as required. 9) Clean and inspect the threaded holes for thread damage. 10) If the bonnet cannot be repaired as directed above or wear exceeds specifications, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 11) Record conditions on the inspection form. b. Inspect the ram guide pin (item 56 of Figures 4-2 and 4-3). 1) Inspect the pins for wear and damage. Repair minor nicks, burrs, and gouges with a file. If the sides that support the rams are wearing flat, measure the diameter of the pin across the flat. The diameter should not be less than the minimum diameter shown in Table 4-1.

Bonnet Seal Groove

Pilot Surfaces

Maximum Piston Rod Dia.

Cylinder Liner Bore Dia.

Seal Surface HINGE SIDE Figure 4-21. Bonnet (Item 52 of Figures 4-2 and 4-3)

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PAGE 4-20


2) Inspect the straightness of the pins. The pins should be perpendicular to the bonnet face. If one is bent, lay a straightedge along the concave side of the bent pin and measure the standoff distance with a feeler gauge. Straighten or replace the pin if the standoff is greater than .060 in (1.52 mm). 3) Record condition on the inspection form. 10. Inspect the load hinge assembly (items 21, 23, 37, and 38 of Figures 4-2 and 4-3). a. Inspect the load hinge (item 21 of Figures 42 and 4-3). Refer also to Figure 4-22. 1) Inspect bearing and seal surfaces for corrosion. Remove corrosion with emery cloth. 2) Record condition on inspection form. 11. Inspect the remaining operator and bonnet components by repeating this procedure. Begin with Step 4 if the ram BOP is equipped with a MPL or with Step 7 if the ram BOP is equipped with a manual lock. If both sets of operator and bonnet components have been inspected, continue to the next step. 12. Inspect seal seat assembly (items 4, 5, 6, 7, 8, and 9 of Figures 4-2 and 4-3). a. Inspect seal seat (item 4 of Figures 4-2 and 4-3). Refer also to Figure 4-23. Repair if possible. Otherwise, replace it. 1) Inspect O-ring grooves for damage. Repair minor damage with emery cloth. NOTE: Some seats do not have an O-ring groove in the top edge. 2) Inspect lower surface finish for gouges, pitting, and dings. Repair damage less than .015 in (.38 mm) in depth with emery cloth. 3) Inspect the flatness of the seal seat upper surface. The upper surface should be flat within .005 in (.13 mm). 4) Inspect the set screw threaded holes for corrosion. 5) Measure the maximum thickness of the ram sealing flange. Refer to Table 4-1 for the dimension. 6) Inspect and clean the groove for the lock ring. 7) Record condition inspection form.

Seal Surface Bearing Surfaces

}

Figure 4-22 Load Hinge (Item 21 of Figures 4-2 and 4-3)

O-Ring Groove

Upper Surface

Lower Surface

Ram Sealing Flange

Figure 4-23. Seal Seat (Item 4 of Figures 4-2 and 4-3.

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PAGE 4-21


13. Inspect the body (item 1 of Figures 4-2 and 4-3). Refer also to Figures 4-24 through 4-26. a. Inspect the ring grooves on the top, bottom, and side connections for wear and damage. Minor damage (nicks and scratches not exceeding .015 in (.38 mm) to the grooves may be polished with emery cloth. After polishing, wipe ring groove with a clean cloth soaked in light machine oil. Nicks and scratches exceeding .015 in (.38 mm) must be repaired at a Hydril Repair Facility (refer to Section 10 for a list of locations). b. Inspect threaded stud and bolt holes for signs of wear and damage. If wear or damage is present, contact a Hydril Repair Facility for instructions. Refer to Section 10 for a list of locations. c. Inspect sealing surfaces where fluid hinges, bonnet hinges, and hydraulic connections mount. Surfaces should be clean and free of pits. Polish out any minor irregularities using emery cloth. If major damage is present, contact a Hydril Repair Facility for instructions. Refer to Section 10 for a list of locations. d. Inspect body where bonnet seal (item 55 of Figures 4-2 and 4-3) contacts for corrosion, pitting, and scratches (refer to Figure 4-25). Remove any corrosion, minor scratches, or minor pitting with emery cloth. Nicks and scratches exceeding .015 in (.38 mm) must be repaired at a Hydril Repair Facility (refer to Section 10 for a list of locations). Check flatness of areas with a straight edge and feeler gauges. Record findings on the inspection form. e. Inspect hydraulic operator fluid passages and flush out to ensure full flow.

Stud Holes Top View Ring Groove

Studded Top Connection Hydraulic Connections OPEN

CLOSE

SIDE VIEW

Fluid Hinge Sealing Area Ring Grooves

OPEN

CLOSE

Bolt Holes

Flanged Bottom Connection

Bolt Holes BOTTOM VIEW Ring Groove

Figure 4-24. BOP Body (Item 1 of Figures 4-2 and 4-3)

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PAGE 4-22


f.

Inspect the surface finish (refer to dimension F of Figure 4-26) of the seal seat sealing surfaces (item 4 of Figures 4-2 and 4-3) for flatness, pitting, dings, and gouges. Repair minor damage with emery cloth. The flatness should be within .010 in (.25 mm). If major damage is present, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. g. Measure the wellbore diameter (dimension C of Figure 4-26) of the ram BOP. The diameter should not exceed the maximum bore in Table 4-1. If it does, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. h. Measure the distance between the body rails and the seal seat pocket (refer to dimension A of Figure 4-26). This measurement should not exceed the maximum rails to seat pocket dimension in Table 4-1. If it does, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. i. Measure the distance between the body rails and the seal seat (refer to dimension B of Figure 4-26). This measurement should not exceed the maximum rails to seal seat dimension in Table 4-1. If it does, contact a Hydril Repair Facility. Refer to Section 10 for

a list of locations. Inspect the side walls of the body ram compartment for wear and damage. Repair minor damage with emery cloth. If major damage is present, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. k. Inspect side outlet bores (areas D and E of Figure 4-26) for erosion . Contact a Hydril Repair Facility if erosion is greater than .250 in (6.4 mm).

j.

Bonnet Seal Contact Areas

Figure 4-25 Ram BOP Body, Bonnet Side

C

LEGEND: A – Maximum Rails to Seat Pocket B – Maximum Rails to Seal Seat C – Maximum Bore D – Side Outlet Erosion E – Side Outlet Erosion F – Seal Seat Sealing Surfaces

F B

D

A

E

Rails Figure 4-26. Ram BOP Body

Inspection Manual

R

PAGE 4-23


14. Inspect the pipe ram, variable ram, and blind/ shear ram assemblies (item 51 of Figures 4-2 and 4-3). Refer also to Figures 4-4 and 4-5. a. Inspect pipe and variable ram blocks as follows: 1) Measure the overall height (refer to dimension A of Figure 4-27). If the height is less than the minimum height given in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 2) Measure the depth of the top seal groove (refer to dimensions B of Figure 4-27). If the depth is greater than the maximum depth given in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 3) Inspect the inlaid pipe hanging inserts for cracks. If cracks are present, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 4) Perform NDE and hardness tests on Area X of Figure 4-27. 5) Record the results on the inspection form. b. Inspect the shear ram assemblies as follows: 1) Measure the overall height of the upper and lower carrier assemblies (refer to dimension A of Figure 4-28). If it is less than the measurement given in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 2) Measure the depth of the top seal groove in the upper and lower carrier assemblies (refer to dimensions B of Figure 4-28). If it is greater than the measurement given in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 3) Measure the diameter of the guide pins (refer to dimension C of Figure 4-28) on the upper carrier assembly. If the diameter is less than the minimum diameter shown in Table 4-1, replace the guide pins. Part numbers are iocated in the Ram BOP Operator's Manual. 4) Measure the distance between the bottom of the upper carrier to the top of the guide pins (refer to dimension D of Figure 4-28). If the distance is less than the measurement shown in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 5) Measure the distance between the top of the upper carrier to the hard-faced surface

X

B

A

Figure 4-27. Pipe/Variable Ram Block Inspection

X

UPPER CARRIER

B

E A

X

C

D

B

G

LOWER CARRIER

A F

Figure 4-28. Shear Ram Inspection

H


(refer to dimension E of Figure 4-28). If the distance is less than the measurement shown in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 6) Measure the diameter of the guide pin holes (refer to dimension F of Figure 4-28) on the lower carrier assembly. If the diameter is greater than the maximum diameter shown in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 7) Measure the distance between the bottom of the lower carrier to the top of the guide pin holes (refer to dimension H of Figure 428). If the distance is greater than the measurement shown in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 8) Measure the distance between the top of the lower carrier to the hard-faced surface (refer to dimension G of Figure 4-28). If the distance is greater than the measurement shown in Table 4-1, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 9) Inspect the hard-faced sealing surface of the lower carrier for cracks, corrosion, erosion, and scratches. If cracks are found, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 10) Inspect threaded holes for damage. If damage is found, contact a Hydril Repair Facility. Refer to Section 10 for a list of locations. 11) Inspect the shear blades for nicks and cracks. Grind out any nicks that are present and dress the blade. Replace blades with cracks. Refer to the BOP operator's manual for the part number. 12) Perform NDE and hardness tests on Area X of Figure 4-28. 13) Record the results on the inspection form. C. Wear Limits The wear limits discussed in this section are listed in Table 4-1.

R

PAGE 4-24

Inspection Manual

R

PAGE 4-25

Ram BOPs  Gauge Inspection TABLE 4-1 RAM BOP WEAR LIMITS 7 1/16" – 3000 PSI Component

BOP Body

Bonnet

Seal Seat Piston Cylinder Cylinder Liner Cylinder Head Manual Lock Screw MPL Lock Nut MPL Clutch MPL Transfer Ring Bonnet Hinge Pipe Rams Variable Rams Shear Rams Upper Carrier

Lower Carrier

Description

Maximum Bore Maximum Rails to Seat Pocket Pipe Rams Maximum Rails to Seat Pocket Shear Rams Maximum Rails to Seat Pocket Variable Rams Maximum Rails to Seat Pipe Rams Maximum Rails to Seat Shear Rams Maximum Rails to Seat Variable Rams Maximum Bore Piston Rod Maximum Bore Cylinder Liner Maximum Depth Bonnet Seal Groove MinimumThickness of Ram Sealing Flange Minimum Piston O.D. Minimum Rod O.D. Maximum Bore, Manual Lock Maximum I.D. Minimum Seal O.D. Maximum Depth of Bearing Pocket Minimum Rod O.D. Minimum Shoulder Thickness Minimum Teeth Height Minimum Thickness Maximum Distance Between Hinges Minimum Height Maximum Depth of Top Seal Groove Minimum Height Maximum Depth of Top Seal Groove Minimum Height Maximum Depth of Top Seal Groove Minimum Diameter of Guide Pins Minimum Height from Bottom of Rams to Top of Guide Pins Minimum Height from Top of Rams to Hardface Surface Maximum Diameter of Guide Pin Holes Maxmum Height from Bottom of Rams to Top of Guide Pin Holes Maximum Height from Top of Rams to Hardface Surface

Wear Limit Standard Shear In MM In MM 7.126 6.246

181.00 158.65

5.583

141.81

2.386 6.512 0.344 0.625 5.464 2.368 1.769 5.511 6.484 1.538 1.742 1.247 0.045 1.423 3.530 4.479 0.655

60.60 165.40 8.74 15.88 138.79 60.15 44.93 139.98 164.69 39.07 44.25 31.67 1.14 36.14 89.66 113.77 16.64

Inspection Manual

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PAGE 4-26


BOP Body

Bonnet


Lower Carrier

Description



181.00 158.65

5.583

141.81

2.386 6.512 0.344 0.625 5.464 2.368 1.769 5.511 6.484 1.538 1.742 1.247 0.045 1.423 3.530 4.479 0.655

60.60 165.40 8.74 15.88 138.79 60.15 44.93 139.98 164.69 39.07 44.25 31.67 1.14 36.14 89.66 113.77 16.64

Inspection Manual

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PAGE 4-27

Ram BOPs  Gauge Inspection TABLE 4-1 RAM BOP WEAR LIMITS 7 1/16" – 10,000 PSI Component

BOP Body

Bonnet


Lower Carrier

Description



181.00 158.65

7.126 181.00 6.246 158.65 6.239 158.47

5.583

141.81

5.583 141.81 5.566 141.38

2.637 8.512 0.451 0.663 7.486 2.618 1.769 7.511 8.484 1.538 1.742 1.247 0.045 1.433 4.020 5.479 1.160

66.98 216.20 11.46 16.84 190.14 66.50 44.93 190.78 215.49 39.07 44.25 31.67 1.14 36.40 102.11 139.17 29.46

3.640 14.265 0.451 0.663 12.714 3.618 3.110 12.764 14.237 1.241 2.992 1.042 0.047 1.433 4.020 5.479 1.160

92.46 362.33 11.46 16.84 322.94 91.90 78.99 324.21 361.62 31.53 76.00 26.50 1.19 36.40 102.11 139.17 29.46

5.492 139.50 1.150 29.21

2.762

70.15

2.776

70.51

Inspection Manual

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PAGE 4-28


BOP Body

Bonnet


Lower Carrier

Description



181.00 158.65

7.126 181.00 6.246 158.65 6.239 158.47

5.583

141.81

5.583 141.81 5.566 141.38

3.637 11.015 0.451 0.663 9.987 3.618 2.521 10.016 10.983

92.38 279.78 11.46 16.84 253.67 66.50 64.03 254.41 278.97

2.493

63.32

5.046 5.479 1.160

128.17 139.17 29.46

3.637 14.265 0.451 0.663 12.714 3.618 3.019 12.764 14.237 1.241 2.992 1.042 .044 1.433 5.022 5.479 1.160

92.38 362.33 11.46 16.8 322.94 91.90 76.68 324.21 361.62 31.53 76.00 26.50 1.12 36.40 127.56 139.17 29.46

5.492 139.50 1.150 29.21

2.762

70.15

2.776

70.51

Inspection Manual

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PAGE 4-29

Ram BOPs  Gauge Inspection TABLE 4-1 RAM BOP WEAR LIMITS 9" – 3000 PSI Component

BOP Body

Bonnet


Lower Carrier

Description



230.23 163.32

5.835

148.21

3.262 8.512 0.451 0.610 7.486 3.243 3.019 7.515 8.484

82.85 216.20 11.46 15.49 190.14 82.37 76.78 190.88 215.49

2.992

76.00

4.020 5.729 0.785

102.11 145.52 19.94

Inspection Manual

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PAGE 4-30


BOP Body

Bonnet


Lower Carrier

Description



230.23 163.32

5.835

148.21

3.262 8.512 0.451 0.610 7.486 3.243 3.019 7.515 8.484

82.85 216.20 11.46 15.49 190.14 82.37 76.78 190.88 215.49

2.992

76.00

4.020 5.729 0.785

102.11 145.52 19.94

Inspection Manual

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PAGE 4-31


BOP Body

Bonnet


Lower Carrier

Description



281.03 185.55

11.064 281.03 7.305 185.55 7.298 185.37

6.676

169.57

6.676 169.57 6.664 169.27

3.262 9.512 0.451 0.605 8.486 3.243 3.019 8.515 9.484

82.85 241.60 11.46 15.37 215.54 82.37 76.78 216.28 240.89

2.992

76.00

5.022 6.604 1.035

127.56 167.74 26.29

4.387 12.014 0.151 0.605 10.714 4.367 3.019 10.758 11.986 1.241 2.992 1.042 0.047 1.433 5.022 6.604 1.035

111.43 305.16 3.84 15.37 272.14 110.92 76.78 273.25 304.44 31.52 76.00 26.47 1.19 36.40 127.56 167.74 26.29

6.611 167.92 1.025 26.04 1.248 31.70 2.762

70.15

3.303 1.260

83.90 32.00

2.766

70.26

3.336

84.73

Inspection Manual

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PAGE 4-32


BOP Body

Bonnet


Lower Carrier

Description



281.03 185.55

11.064 281.03 7.305 185.55 7.298 185.37

6.676

169.57

6.676 169.57 6.664 169.27

3.262 9.512 0.451 0.605 8.486 3.243 3.019 8.515 9.484

82.85 241.60 11.46 15.37 215.54 82.37 76.78 216.28 240.89

2.992

76.00

5.022 6.604 1.035

127.56 167.74 26.29

4.387 12.014 0.151 0.605 10.714 4.367 3.019 10.758 11.986 1.241 2.992 1.042 0.047 1.433 5.022 6.604 1.035

111.43 305.16 3.84 15.37 272.14 110.92 76.78 273.25 304.44 31.52 76.00 26.47 1.19 36.40 127.56 167.74 26.29

6.611 167.92 1.025 26.04 1.248 31.70 2.762

70.15

3.303 1.260

83.90 32.00

2.766

70.26

3.336

84.73

Inspection Manual

R

PAGE 4-33

Ram BOPs  Gauge Inspection TABLE 4-1 RAM BOP WEAR LIMITS 11" – 10,000 PSI Component

BOP Body

Bonnet


Lower Carrier

Description

Wear Limit Standard Shear In MM In MM

Maximum Bore 11.064 Maximum Rails to Seat Pocket Pipe Rams 7.614 Maximum Rails to Seat Pocket Shear Rams Maximum Rails to Seat Pocket Variable Rams Maximum Rails to Seat Pipe Rams 6.691 Maximum Rails to Seat Shear Rams Maximum Rails to Seat Variable Rams Maximum Bore Piston Rod 3.637 Maximum Bore Cylinder Liner 11.015 Maximum Depth Bonnet Seal Groove 0.451 MinimumThickness of Ram Sealing Flange 0.923 Minimum Piston O.D. 9.987 Minimum Rod O.D. 3.618 Maximum Bore, Manual Lock 3.019 Maximum I.D. 10.016 Minimum Seal O.D. 10.986 Maximum Depth of Bearing Pocket 1.241 Minimum Rod O.D. 2.992 Minimum Shoulder Thickness 1.042 Minimum Teeth Height 0.002 Minimum Thickness Maximum Distance Between Hinges 5.022 Minimum Height 6.597 Maximum Depth of Top Seal Groove 1.045 Minimum Height Maximum Depth of Top Seal Groove Minimum Height Maximum Depth of Top Seal Groove Minimum Diameter of Guide Pins Minimum Height from Bottom of Rams to Top of Guide Pins Minimum Height from Top of Rams to Hardface Surface Maximum Diameter of Guide Pin Holes Maxmum Height from Bottom of Rams to Top of Guide Pin Holes Maximum Height from Top of Rams to Hardface Surface

281.03 193.40

11.064 281.03 7.614 193.40 7.607 193.22

169.95

6.691 169.95 6.679 169.65

168.58 279.78 11.46 23.44 253.67 91.90 76.78 254.41 279.04 31.52 76.00 26.47 0.05 127.56 167.56 26.54

3.640 11.015 0.451 0.923 12.714 3.618 3.019 12.764 14.237 1.241 2.992 1.042 0.047 1.433 5.022 6.597 1.045

92.45 279.78 11.46 23.44 322.94 9.90 76.78 324.21 361.62 31.52 76.00 26.47 1.19 36.40 127.56 167.56 26.54

6.610 167.89 1.395 35.43 1.248 31.70 2.885

73.28

3.332 1.302

84.63 33.07

2.885

73.28

3.332

84.63

Inspection Manual

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PAGE 4-34


BOP Body

Bonnet


Lower Carrier

Description


Maximum Bore 13.689 Maximum Rails to Seat Pocket Pipe Rams 9.028 Maximum Rails to Seat Pocket Shear Rams Maximum Rails to Seat Pocket Variable Rams 9.025 Maximum Rails to Seat Pipe Rams 8.032 Maximum Rails to Seat Shear Rams Maximum Rails to Seat Variable Rams 8.028 Maximum Bore Piston Rod 4.387 Maximum Bore Cylinder Liner 11.015 Maximum Depth Bonnet Seal Groove 0.451 MinimumThickness of Ram Sealing Flange 0.996 Minimum Piston O.D. 9.987 Minimum Rod O.D. 4.367 Maximum Bore, Manual Lock 3.019 Maximum I.D. 10.016 Minimum Seal O.D. 10.983 Maximum Depth of Bearing Pocket 1.241 Minimum Rod O.D. 2.992 Minimum Shoulder Thickness 1.042 Minimum Teeth Height 0.047 Minimum Thickness Maximum Distance Between Hinges 6.034 Minimum Height 7.957 Maximum Depth of Top Seal Groove 1.040 Minimum Height 7.961 Maximum Depth of Top Seal Groove 1.035 Minimum Height Maximum Depth of Top Seal Groove Minimum Diameter of Guide Pins Minimum Height from Bottom of Rams to Top of Guide Pins Minimum Height from Top of Rams to Hardface Surface Maximum Diameter of Guide Pin Holes Maxmum Height from Bottom of Rams to Top of Guide Pin Holes Maximum Height from Top of Rams to Hardface Surface

347.70 229.31 229.24 204.01 203.91 111.43 279.78 11.46 25.30 253.67 110.92 76.78 254.41 278.97 31.52 76.00 26.47 1.19 153.26 202.11 26.42 202.21 26.29

13.689 9.028 9.021 9.025 8.032 8.023 8.028 4.387 15.762 0.451 0.996 14.237 4.367 3.019 14.264 15.734 1.241 2.992 1.042 0.047 1.433 6.034 7.957 1.040 7.961 1.035 7.964 1.030 1.248

347.70 229.31 229.13 229.24 204.01 203.78 203.91 111.43 400.35 11.46 25.30 361.62 110.92 76.78 362.31 399.64 31.52 76.00 26.47 1.19 36.40 153.26 202.11 26.42 202.21 26.29 202.29 26.16 31.70

3.410

86.61

3.983 101.17 1.260 32.00 3.408

86.56

4.016 102.01

Inspection Manual

R

PAGE 4-35


BOP Body

Bonnet


Lower Carrier

Description


Maximum Bore 13.689 Maximum Rails to Seat Pocket Pipe Rams 9.028 Maximum Rails to Seat Pocket Shear Rams Maximum Rails to Seat Pocket Variable Rams 9.025 Maximum Rails to Seat Pipe Rams 8.032 Maximum Rails to Seat Shear Rams Maximum Rails to Seat Variable Rams 8.028 Maximum Bore Piston Rod 4.387 Maximum Bore Cylinder Liner 11.015 Maximum Depth Bonnet Seal Groove 0.451 MinimumThickness of Ram Sealing Flange 0.996 Minimum Piston O.D. 9.987 Minimum Rod O.D. 4.367 Maximum Bore, Manual Lock 3.019 Maximum I.D. 10.016 Minimum Seal O.D. 10.983 Maximum Depth of Bearing Pocket 1.241 Minimum Rod O.D. 2.992 Minimum Shoulder Thickness 1.042 Minimum Teeth Height 0.047 Minimum Thickness Maximum Distance Between Hinges 6.034 Minimum Height 7.957 Maximum Depth of Top Seal Groove 1.040 Minimum Height 7.961 Maximum Depth of Top Seal Groove 1.035 Minimum Height Maximum Depth of Top Seal Groove Minimum Diameter of Guide Pins Minimum Height from Bottom of Rams to Top of Guide Pins Minimum Height from Top of Rams to Hardface Surface Maximum Diameter of Guide Pin Holes Maxmum Height from Bottom of Rams to Top of Guide Pin Holes Maximum Height from Top of Rams to Hardface Surface

347.70 229.31 229.24 204.01 203.91 111.43 279.78 11.46 25.30 253.67 110.92 76.78 254.41 278.97 31.52 76.00 26.47 1.19 153.26 202.11 26.42 202.21 26.29

13.689 9.028 9.021 9.025 8.032 8.023 8.028 4.387 15.762 0.451 0.996 14.237 4.367 3.019 14.264 15.734 1.241 2.992 1.042 0.047 1.433 6.034 7.957 1.040 7.961 1.035 7.964 1.030 1.248

347.70 229.31 229.13 229.24 204.01 203.78 203.91 111.43 400.35 11.46 25.30 361.62 110.92 76.78 362.31 399.64 31.52 76.00 26.47 1.19 36.40 153.26 202.11 26.42 202.21 26.29 202.29 26.16 31.70

3.410

86.61

3.983 101.17 1.260 32.00 3.408

86.56

4.016 102.01

Inspection Manual

R

PAGE 4-36


BOP Body

Bonnet


Lower Carrier

Description


Wear Limit Standard Shear In MM In MM 13.689 9.280 9.275 9.278 8.290 8.280 8.285 4.387 15.762 0.451 0.990 14.237 4.367 3.019 14.264 15.734 1.241 2.992 1.042 0.047 1.433 5.034 8.203 1.785 8.207 1.780 8.211 1.775 1.248

347.70 235.71 235.59 235.66 210.57 210.31 210.44 111.43 400.35 11.46 25.15 361.62 110.92 76.78 362.31 399.64 31.52 76.00 26.47 1.19 36.40 127.86 208.36 45.44 208.46 45.21 208.56 45.09 31.70

3.672

93.27

4.123 1.260

104.72 32.00

3.658

92.91

4.155

105.54

Inspection Manual

R

PAGE 4-37


BOP Body

Bonnet


Lower Carrier

Description


Wear Limit Standard Shear In MM In MM 13.689 10.765 10.760 10.763 9.567 9.557 9.562 5.137 15.762 0.638 1.198 14.227 5.117

347.70 273.43 273.30 273.38 243.00 242.75 242.87 130.48 400.35 16.21 30.43 361.37 129.98

14.264 15.734 1.241

362.31 399.64 31.52

1.042 0.047 1.433 5.034 9.476 2.030 9.480 2.025 9.484 2.275 1.248

26.47 1.19 36.40 127.86 240.69 51.56 240.79 51.44 240.89 57.79 31.70

4.434

112.62

4.628 1.266

117.55 32.16

4.420

112.27

4.670

118.62

Inspection Manual

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PAGE 4-38


BOP Body

Bonnet


Lower Carrier

Description


Maximum Bore 16.810 Maximum Rails to Seat Pocket Pipe Rams 10.515 Maximum Rails to Seat Pocket Shear Rams 10.510 Maximum Rails to Seat Pocket Variable Rams Maximum Rails to Seat Pipe Rams 9.540 Maximum Rails to Seat Shear Rams 9.530 Maximum Rails to Seat Variable Rams Maximum Bore Piston Rod 4.387 Maximum Bore Cylinder Liner 15.762 Maximum Depth Bonnet Seal Groove 0.451 MinimumThickness of Ram Sealing Flange 0.975 Minimum Piston O.D. 14.237 Minimum Rod O.D. 4.367 Maximum Bore, Manual Lock Maximum I.D. 14.264 Minimum Seal O.D. 15.734 Maximum Depth of Bearing Pocket 1.241 Minimum Rod O.D. Minimum Shoulder Thickness 1.042 Minimum Teeth Height 0.047 Minimum Thickness 1.433 Maximum Distance Between Hinges 5.034 Minimum Height 9.453 Maximum Depth of Top Seal Groove 2.035 Minimum Height Maximum Depth of Top Seal Groove Minimum Height 9.461 Maximum Depth of Top Seal Groove 2.025 Minimum Diameter of Guide Pins 1.248 Minimum Height from Bottom of Rams to Top of Guide Pins 4.223 Minimum Height from Top of Rams to Hardface Surface 4.736 Maximum Diameter of Guide Pin Holes 1.260 Maxmum Height from Bottom of Rams to Top of Guide Pin Holes 4.220 Maximum Height from Top of Rams to Hardface Surface 4.769

426.97 267.08 266.95 242.31 242.06 111.43 400.35 11.46 24.77 361.62 110.92 362.31 399.64 31.52 26.47 1.19 36.40 127.86 240.11 51.69

240.31 51.44 31.70 107.26 120.29 32.00 107.19 121.13

Inspection Manual

R

PAGE 4-39


BOP Body

Bonnet


Lower Carrier

Description



477.88 280.16 280.04 280.11 255.02 254.76 254.89 111.43 400.35 11.46 25.15 361.62 110.92

14.264 15.734 1.241

362.31 399.64 31.52

1.042 0.047 1.433 5.034 9.953 2.035 9.957 1.525 9.961 2.025 1.248

26.47 1.19 36.40 127.86 252.81 51.69 252.91 38.74 253.01 51.44 31.70

4.485

113.92

4.986 1.260

126.64 32.00

4.483

113.87

5.020

127.51

Inspection Manual

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PAGE 4-40 REV A


BOP Body

Bonnet


Lower Carrier

Description



477.88 299.80 299.42 299.49 274.65 274.40 274.52 146.38 400.35 16.21 25.15 393.12 145.85

15.514 17.234 1.241

394.06 437.74 31.52

1.042 0.047 3.751 5.034 10.726 2.030 10.730 2.025 10.740 2.025 1.248

26.47 1.19 95.28 127.86 272.44 51.56 272.54 51.44 272.80 51.44 31.70

4.485

113.92

5.236 1.294

132.99 32.87

4.495

114.17

5.252

133.40

Inspection Manual

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PAGE 4-41


BOP Body

Bonnet


Lower Carrier

Description


Maximum Bore 21.314 Maximum Rails to Seat Pocket Pipe Rams 8.305 Maximum Rails to Seat Pocket Shear Rams Maximum Rails to Seat Pocket Variable Rams 8.302 Maximum Rails to Seat Pipe Rams 7.311 Maximum Rails to Seat Shear Rams Maximum Rails to Seat Variable Rams 7.307 Maximum Bore Piston Rod 4.387 Maximum Bore Cylinder Liner 11.012 Maximum Depth Bonnet Seal Groove 0.451 MinimumThickness of Ram Sealing Flange 0.985 Minimum Piston O.D. 9.987 Minimum Rod O.D. 4.367 Maximum Bore, Manual Lock 3.019 Maximum I.D. 10.015 Minimum Seal O.D. 10.986 Maximum Depth of Bearing Pocket Minimum Rod O.D. 2.992 Minimum Shoulder Thickness Minimum Teeth Height Minimum Thickness Maximum Distance Between Hinges 5.025 Minimum Height 7.229 Maximum Depth of Top Seal Groove 1.025 Minimum Height 7.233 Maximum Depth of Top Seal Groove 1.020 Minimum Height Maximum Depth of Top Seal Groove Minimum Diameter of Guide Pins Minimum Height from Bottom of Rams to Top of Guide Pins Minimum Height from Top of Rams to Hardface Surface Maximum Diameter of Guide Pin Holes Maxmum Height from Bottom of Rams to Top of Guide Pin Holes Maximum Height from Top of Rams to Hardface Surface

541.38 210.95 210.87 185.70 185.60 111.43 279.70 11.46 25.02 253.67 110.92 76.68 254.38 279.05 76.00

127.64 183.62 26.04 183.72 25.91

21.314 8.305 8.298 8.302 7.311 7.302 7.307 4.387 15.760 0.451 0.985 14.227 4.367 3.019 14.264 15.734 1.241 2.992 1.042 0.047 1.433 5.020 7.229 1.025 7.233 1.020 7.234 1.015 1.248

541.38 210.95 210.77 210.87 185.70 185.47 185.60 111.43 400.30 11.46 25.02 361.37 110.92 76.68 362.31 399.64 31.52 76.00 26.47 1.19 36.40 127.51 183.62 26.04 183.72 25.91 183.74 25.78 31.70

3.143

79.83

3.628 1.260

92.15 32.00

3.120

79.25

3.670

93.22

Inspection Manual

R

PAGE 4-42


BOP Body

Bonnet


Lower Carrier

Description


Maximum Bore 21.314 Maximum Rails to Seat Pocket Pipe Rams 8.305 Maximum Rails to Seat Pocket Shear Rams Maximum Rails to Seat Pocket Variable Rams 8.302 Maximum Rails to Seat Pipe Rams 7.311 Maximum Rails to Seat Shear Rams Maximum Rails to Seat Variable Rams 7.307 Maximum Bore Piston Rod 4.387 Maximum Bore Cylinder Liner 11.012 Maximum Depth Bonnet Seal Groove 0.451 MinimumThickness of Ram Sealing Flange 0.985 Minimum Piston O.D. 9.987 Minimum Rod O.D. 4.367 Maximum Bore, Manual Lock 3.019 Maximum I.D. 10.015 Minimum Seal O.D. 10.986 Maximum Depth of Bearing Pocket Minimum Rod O.D. 2.992 Minimum Shoulder Thickness Minimum Teeth Height Minimum Thickness Maximum Distance Between Hinges 5.025 Minimum Height 7.229 Maximum Depth of Top Seal Groove 1.025 Minimum Height 7.233 Maximum Depth of Top Seal Groove 1.020 Minimum Height Maximum Depth of Top Seal Groove Minimum Diameter of Guide Pins Minimum Height from Bottom of Rams to Top of Guide Pins Minimum Height from Top of Rams to Hardface Surface Maximum Diameter of Guide Pin Holes Maxmum Height from Bottom of Rams to Top of Guide Pin Holes Maximum Height from Top of Rams to Hardface Surface

541.38 210.95 210.87 185.70 185.60 111.43 279.70 11.46 25.02 253.67 110.92 76.68 254.38 279.05 76.00

127.64 183.62 26.04 183.72 25.91

21.314 8.305 8.298 8.302 7.311 7.302 7.307 4.387 15.760 0.451 0.985 14.227 4.367 3.019 14.264 15.734 1.241 2.992 1.042 0.047 1.433 5.020 7.229 1.025 7.233 1.020 7.234 1.015 1.248

541.38 210.95 210.77 210.87 185.70 185.47 185.60 111.43 400.30 11.46 25.02 361.37 110.92 76.68 362.31 399.64 31.52 76.00 26.47 1.19 36.40 127.51 183.62 26.04 183.72 25.91 183.74 25.78 31.70

3.143

79.83

3.628 1.260

92.15 32.00

3.120

79.25

3.670

93.22

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PAGE 4-43


BOP Body

Bonnet


Lower Carrier

Description


Wear Limit Standard Shear In MM In MM 21.314 8.305 8.298 8.302 7.320 7.308 7.314 4.387 15.760 0.451 0.985 14.227 4.367 3.019 14.264 15.734 1.241 2.992 1.042 0.047 1.403 5.034 7.229 1.025 7.233 1.020 7.234 1.015 1.248

541.38 210.95 210.77 210.87 185.93 185.62 185.78 111.43 400.30 11.46 25.02 361.37 110.92 76.68 362.31 399.64 31.52 76.00 26.47 1.19 35.64 127.86 183.62 26.04 183.72 25.91 183.74 25.78 31.70

3.143

79.83

3.628 1.260

92.15 32.00

3.120

79.25

3.670

93.22

Inspection Manual

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PAGE 5-1

Ram BOPs  BOP Operating Test

5.0 BOP OPERATING TEST

REV: PAGE

5.1

5.2

General . . . . . . . . . . . . . . A. Purpose . . . . . . . . . . . . B. Inspection Records . . . . . . C. Control System Requirements BOP Operating Test Procedure .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 5-2 5-2 5-2 5-3

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tion 4-Way valve (Open, Block, Close) and a hydraulic regulator should be installed in the output line of the test pump. An opening and closing line is required to A. Purpose The procedures in this section cover the BOP operat- operate each set of rams. These control lines are ing test of the Hydril ram BOP. This test verifies that connected to the one-inch NPT ports on the hinge the Open and Close functions of the ram BOP operate side of the BOP. The regulated pressure source to operate the ram BOP should be from a regulator properly. separate from that used for the annular blowout preventer(s). B. Inspection Records Any clean, light petroleum hydraulic oil can serve During the BOP operating test of the ram BOP, records should be kept of the results. Use the Ram as a hydraulic fluid. Fresh water may be used if water soluble oil is added. Antifreeze must be added to BOP Inspection Form located in Section 9. water based operating fluids to prevent serious damage to the operators when used in freezing condiC. Control System Requirements The Hydril ram BOP may be tested with any oil field tions. CAUTION: Do not use synthetic fluids or fuel test pump of sufficient pressure capacity. A 3-posi- oils. Serious seal damage will result. 5.1 General

PAGE 5-2

Inspection Manual Ram BOPs  BOP Operating Test

5.2 BOP Operating Test Procedure A. Testing Precautions Take the following precautions to insure the safety of all personnel during blowout preventer testing. 1. Use safety barrier during test operations. 2. Verify that test stump, blind flanges, mandrels, blind hubs, piping, valves, gauges, and related equipment are rated for the test pressures. 3. Check resolution and accuracy of pressure indicating devices. A resolution of one percent of full range and an accuracy of two percent is required. 4. Do the following if a leak occurs, or an unacceptable pressure loss occurs: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-

SURE TO AVOID INJURY. c.

Make necessary repairs and perform the BOP Operating Test again.

B. Tools and Materials required: 1. New API metal ring gasket 2. Light machine oil ( Gulf Harmony No. 46 or Exxon Coray 100) 3. Never-Seez thread lubricant (.069 coefficient of friction) or equivalent 4. Ram BOP Inspection Form (refer to Section 9) C. BOP Operating Test 1. If the ram BOP is already installed on the test stump, continue to Step 2. Otherwise, install the BOP onto the test stump as follows: a. Wipe hubs/flanges, ring gasket, and ring grooves clean with a rag soaked in light machine oil. b. Install the BOP onto the test stump. Lift the BOP using the sling arrangement shown in Figure 5-1. WARNING:

THE RAM BOP IS VERY HEAVY AND BULKY EQUIPMENT. TAKE EXTREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DUR- ING LIFTING AND INSTALLATION OPERA- TIONS. BE SURE THAT THE LIFTING APPA- RATUS IS ADEQUATE TO HANDLE THE LOAD. 1) If a clamp is required to make up the


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PAGE 5-4


Ram Assy.

Seal Seat

Ring Groove Ram BOP Body

Bonnet Bolts

MPL

Side Outlets for Choke and Kill Piston & Piston Rod Assy.

Cylinder Liner

Piston Seals

Ram Compartment Bonnet Seal Piston Rod Mud Seal Weephole

Figure 5-2. Typical Ram BOP Cutaway View

c.

connection between the test stump and the ram BOP, clean the clamp thoroughly and coat the insides with light machine oil. Apply Never-Seez thread lubricant to clamp nut and bolt threads. Tighten clamp nuts and bolts alternately, side to side, during installation to bring the clamp haves together uniformly. Strike the clamp occasionally with a sledge hammer during tightening to ensure proper seating of the clamp on the hub. Contact clamp manufacturer for torque values. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, apply Never-Seez thread lubricant to the threads prior to installation. Refer to the ram BOP operator's manual for the torque value. Blind off all outlet connections with appropriate hardware. Outlet clamps (if required) are installed in the same manner as end connec-

tion clamps. d. Connect hydraulic test pump to ram BOP. Refer to Paragraph 5.1.C. 2. Open the ram BOP bonnets. CAUTION: Open and close bonnets with the rams fully retracted (Open position). Never apply operator closing pressure to open a bonnet with all bonnet bolts unscrewed. Otherwise, the ram will bind in the ram compartment and damage the BOP. 3. Cycle the rams Open and Closed three times, using 200 PSI (14 Bar) operator pressure. Observe for proper operation and hydraulic leaks. Record results on inspection form. Leave the rams in the Open position. If a visible leak occurs: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require

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PAGE 5-5


disassembly of the BOP, cycle the rams again as instructed by Step 3. 4. Close one bonnet and tighten one bolt on the off hinge side. CAUTION: Ensure that the ram is in the Open (retracted) position. 5. Slowly apply minimum operating pressure (less than 200 PSI (14 Bar) to the Close operator and observe the ram stroke under the seal seat. WARNING:

STAND CLEAR OF THE OPEN BON- NET ON THE OTHER SIDE OF THE CLOSED BON- NET. THE RAM IN THE OPEN SIDE WILL BE STROKING ALSO.

BOP Body Bonnet Ram

Record the results on the inspection form. If ram closes properly, continue to the next step. If any binding and/or interference occurs, stop the closing of the ram and find the cause of the problem. If disassembly is required: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-

SURE TO AVOID INJURY. Figure 5-3. Ram BOP With Bonnet Open c.

6. 7. 8. 9.

10.

Make necessary repairs. If repairs require disassembly of the BOP, repeat Steps 2 through 5 again. Open (retract) the rams. Open the closed bonnet. Repeat Steps 4 through 7. Then, continue to Step 9. Close the bonnets and tighten the bonnet bolts. Refer to the BOP operator's manual for the tightening torque and sequence. If further testing is required, leave the ram BOP on the test stump. Otherwise, remove the BOP from the test stump as follows: a. Install the lifting apparatus onto the ram BOP Lift the BOP using the sling arrangement shown in Figure 5-1. 1) If a clamp is required to make up the connection between the test stump and the ram BOP, remove the clamp. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, remove the studs and nuts. b. Remove blind hardware from outlet connections. Outlet clamps (if required) are removed in the same manner as the end connection clamp. c. Vent all pressure and disconnect the test

Inspection Manual Ram BOPs  BOP Operating Test

pump from the ram BOP. d. Lift and remove the ram BOP from the test stump. WARNING: THE RAM BOP IS VERY HEAVY

AND BULKY EQUIPMENT. TAKE EX- TREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS OR OTHER BODY MEM- BERS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DURING LIFTING AND INSTALLATION OP- ERATIONS. BE SURE THAT THE LIFTING APPARATUS IS ADEQUATE TO HANDLE THE LOAD. 11. Sign and date the inspection form.

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PAGE 6-1

Ram BOPs  Hydraulic System Test

6.0 HYDRAULIC SYSTEM TEST

REV: PAGE

6.1

6.2

General . . . . . . . . . . . . . . A. Purpose . . . . . . . . . . . . B. Inspection Records . . . . . . C. Control System Requirements Hydraulic System Test Procedure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 6-2 6-2 6-2 6-3

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test pump of sufficient pressure capacity. A 3-position 4-Way valve (Open, Block, Close) and a hydraulic regulator should be installed in the output line of the A. Purpose The procedures in this section cover the hydraulic test pump. An opening and closing line is required to system test of the Hydril ram BOP. This test verifies operate each set of rams. These control lines are connected to the one-inch NPT ports on the hinge the integrity of the hydraulic operator system. side of the BOP. Any clean, light petroleum hydraulic oil can serve B. Inspection Records During the hydraulic system test of the ram BOP, as a hydraulic fluid. Fresh water may be used if water records should be kept of the results. Use the Ram soluble oil is added. Antifreeze must be added to water based operating fluids to prevent serious damBOP Inspection Form located in Section 9. age to the operators when used in freezing conditions. CAUTION: Do not use synthetic fluids or fuel C. Control System Requirements The Hydril ram BOP may be tested with any oil field oils. Serious seal damage will result. 6.1 General

PAGE 6-2

Inspection Manual Ram BOPs  Hydraulic System Test

6.2 Hydraulic System Test Procedure A. Testing Precautions Take the following precautions to insure the safety of all personnel during blowout preventer testing. 1. Use safety barrier during test operations. 2. Verify that test stump, blind flanges, mandrels, blind hubs, piping, valves, gauges, and related equipment are rated for the test pressures. 3. Check resolution and accuracy of pressure indicating devices. A resolution of one percent of full range and an accuracy of two percent is required. 4. Do the following if a leak occurs of unacceptable pressure loss occurs: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require disassembly of the BOP, perform the Hydraulic System Test again.

B. Tools and Materials required: 1. One new API metal ring gasket 2. Light machine oil ( Gulf Harmony No. 46 or Exxon Coray 100) 3. Never-Seez thread lubricant (.069 coefficient of friction) or equivalent 4. Ram BOP Inspection Form (refer to Section 9) C. Hydraulic System Test 1. If the ram BOP is already installed on the test stump, continue to Step 2. Otherwise, install the BOP onto the test stump as follows: a. Wipe hubs/flanges, ring gasket, and ring grooves clean with a rag soaked in light machine oil. b. Install the BOP onto the test stump. Lift the BOP using the sling arrangement shown in Figure 6-1. WARNING:

THE RAM BOP IS VERY HEAVY AND BULKY EQUIPMENT. TAKE EXTREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DUR- ING LIFTING AND INSTALLATION OPERA- TIONS. BE SURE THAT THE LIFTING APPA- RATUS IS ADEQUATE TO HANDLE THE LOAD.


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PAGE 6-4


Ram Assy.

Seal Seat


Bonnet Bolts

MPL


Cylinder Liner

Piston Seals



c.

1) If a clamp is required to make up the connection between the test stump and the ram BOP, clean the clamp thoroughly and coat the insides with light machine oil. Apply Never-Seez thread lubricant to clamp nut and bolt threads. Tighten clamp nuts and bolts alternately, side to side, during installation to bring the clamp haves together uniformly. Strike the clamp occasionally with a sledge hammer during tightening to ensure proper seating of the clamp on the hub. Contact clamp manufacturer for torque values. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, apply Never-Seez thread lubricant to the threads prior to installation. Refer to the BOP operator's manual for the torque value. Blind off all outlet connections with appropriate hardware. Outlet clamps (if required) are

installed in the same manner as end connection clamps. d. Connect test pump to the ram BOP. Refer to Paragraph 6.1.C. 2. Open the ram BOP bonnets. Pressurize the Close side of the BOP operator system. Beginning at zero, increase the pressure to 3000 PSI(207 Bar) in increments of 500 PSI (34 Bar). Isolate (Block) the pump from the ram BOP. Observe the exterior of the BOP bonnets for leakage for three minutes minimum. If no leaks are present, continue to the next step. Do the following if a leak occurs or unacceptable pressure loss occurs: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require

Inspection Manual

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disassembly of the BOP, perform the Hydraulic System Test again beginning with Step 2. 3. Pressurize the Open side of the BOP operator system. Beginning at zero, increase the pressure to 3000 PSI (207 Bar) in increments of 500 PSI (34 Bar). Isolate (Block) the pump from the ram BOP. Observe the exterior of the BOP for leakage for three minutes minimum. If no leaks occur, continue to the next step. Do the following if a leak occurs of unacceptable pressure loss occurs: a. Stop the test. b. Vent pressure from the BOP.

shown in Figure 6-1. 1) If a clamp is required to make up the connection between the test stump and the ram BOP, remove the clamp. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, remove the studs and nuts. b. Remove blind hardware from outlet connections. Outlet clamps (if required) are removed in the same manner as the end connection clamp. c. Vent all pressure and disconnect the test pump from the ram BOP. d. Lift and remove the ram BOP from the test stump.

WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require disassembly of the BOP, perform the Hydraulic System Test again beginning with Step 2. 4. Determine if the operator systems still functions smoothly. With the bonnets open, cycle the rams closed and open using 200 PSI (14 Bar) pressure. Observe for binding and leakage. If the operator system functions smoothly with no leaks, continue to the next step. If binding and/or leakage is/are present, do the following: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require disassembly of the BOP, perform the Hydraulic System Test again beginning with Step 2. 5. Hand start all bonnet bolts and then screw them in all the way until they are snug against the face of the bonnet. Tighten the bolts using the torque value shown in the BOP operator's manual. Tighten the bolts in the sequence shown in the BOP operator's manual. CAUTION: To prevent damage to the BOP, be sure that rams are retracted (Open) before closing bonnets. 6. If further testing is required, leave the ram BOP installed on the test stump. If testing is complete, remove the BOP from the test stump as follows: a. Install the lifting apparatus onto the ram BOP Lift the BOP using the sling arrangement

WARNING:

THE RAM BOP IS VERY HEAVY AND BULKY EQUIPMENT. TAKE EXTREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS OR OTHER BODY MEMBERS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DURING LIFTING AND INSTALLATION OPERATIONS. BE SURE THAT THE LIFTING APPARATUS IS ADEQUATE TO HANDLE THE LOAD. 7. Sign and date the inspection form.

PAGE 6-5

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PAGE 7-1

Ram BOPs  Wellbore Pressure Test

7.0 WELLBORE PRESSURE TEST

REV: PAGE

7.1

7.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Inspection Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Control System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellbore Pressure Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2 7-2 7-2 7-2 7-3

Inspection Manual

R


test pump of sufficient pressure capacity. A 3-position 4-Way valve (Open, Block, Close) and a hydraulic regulator should be installed in the output line of the A. Purpose The procedures in this section cover the wellbore test pump. An opening and closing line is required to pressure test of the Hydril ram BOP. This test verifies operate each set of rams. These control lines are the ability of the ram BOP to seal against wellbore connected to the one-inch NPT ports on the hinge side of the BOP. pressure. Any clean, light petroleum hydraulic oil can serve as a hydraulic fluid. Fresh water may be used if water B. Inspection Records During the wellbore pressure test of the ram BOP, soluble oil is added. Antifreeze must be added to records should be kept of the results. Use the Ram water based operating fluids to prevent serious damage to the operators when used in freezing condiBOP Inspection Form located in Section 9. tions. CAUTION: Do not use synthetic fluids or fuel oils. Serious seal damage will result. C. Control System Requirements The Hydril ram BOP may be tested with any oil field 7.1 General

PAGE 7-2

Inspection Manual Ram BOPs  Wellbore Pressure Test

7.2 Wellbore Pressure Test Procedure A. Testing Precautions Take the following precautions to insure the safety of all personnel during blowout preventer testing. 1. Use safety barrier during test operations. 2. Verify that test stump, blind flanges, mandrels, blind hubs, piping, valves, gauges, and related equipment are rated for the test pressures. 3. Check resolution and accuracy of pressure indicating devices. A resolution of one percent of full range and an accuracy of two percent is required. 4. Do the following if a leak occurs of unacceptable pressure loss occurs: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require disassembly of the BOP, perform the Wellbore Pressure Test again.

B. Tools and Materials required: 1. One new API metal ring gaskets 2. Light machine oil ( Gulf Harmony No. 46 or Exxon Coray 100) 3. Never-Seez thread lubricant (.069 coefficient of friction) or equivalent 4. Ram BOP Inspection Form (refer to Section 9) C. Wellbore Pressure Test 1. If the ram BOP is already installed on the test stump, continue to Step 2. Otherwise, install the BOP onto the test stump as follows: a. Wipe hubs/flanges, ring gasket, and ring grooves clean with a rag soaked in light machine oil. b. Install the BOP onto the test stump. Lift the BOP using the sling arrangement shown in Figure 7-1. WARNING:

THE RAM BOP IS VERY HEAVY AND BULKY EQUIPMENT. TAKE EXTREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS OR OTHER BODY MEMBERS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DURING LIFTING AND INSTALLATION OPERATIONS. BE SURE THAT THE LIFTING APPARATUS IS ADEQUATE TO HANDLE THE LOAD.


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PAGE 7-4


Seal Seat

Ram Assy.


Bonnet Bolts

MPL


Cylinder Liner

Piston Seals



c.

1) If a clamp is required to make up the connection between the test stump and the ram BOP, clean the clamp thoroughly and coat the insides with light machine oil. Apply Never-Seez thread lubricant to clamp nut and bolt threads. Tighten clamp nuts and bolts alternately, side to side, during installation to bring the clamp haves together uniformly. Strike the clamp occasionally with a sledge hammer during tightening to ensure proper seating of the clamp on the hub. Contact clamp manufacturer for torque values. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, apply Never-Seez thread lubricant to the threads prior to installation. Refer to the BOP operator's manual for the torque value. Blind off all outlet connections with appropriate hardware. Outlet clamps (if required) are

2.

3.

4.

5. 6. 7. 8.

installed in the same manner as end connection clamps. d. Connect test pump to the ram BOP. Refer to Paragraph 7.1.C. Open the ram BOP bonnets and cycle the rams using 200 PSI (14 Bar) pressure. Leave the rams in the Open (retract) position. Close the bonnets and tighten the bolts using 100 percent of the torque value shown in the BOP operator's manual. Also refer to the operator's manual for the tightening sequence. If pipe rams are installed in the ram BOP, install a test mandrel into the bore of the ram BOP. Do not install a test mandrel if shear rams are installed. Fill the bore of the ram BOP with clean tap water to a level six inches above the rams. Close the rams using 1500 PSI (103 Bar) for pipe rams or 3000 PSI (207 Bar) for shear rams. Vent the operator system to zero. Remove the excess water from above the rams

Inspection Manual

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so that rams can be observed clearly. 9. Apply wellbore pressure of 200 - 300 PSI (14 - 21 Bar). Isolate (Block) test pump from ram BOP and allow pressure to stabilize. Hold pressure for three minutes minimum. Observe for dramatic pressure loss and leakage. Use a mirror or boroscope suspended over the bore of the BOP to observe for leakage between the ram packing and the mandrel.

b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-


11.

DO NOT EXTEND ANY PART OF BODY OVER THE BOP WHILE PRESSURE IS 12. IN THE WELLBORE. 13. 14. This low pressure test is satisfactory if no visable leaks occur. Record initial and final wellbore pressure on the inspection form. If no leaks occur, continue to the next step. Do the following if a leak occurs: a. Stop the test. b. Vent pressure from the BOP. WARNING:

WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require disassembly of the BOP, perform the Wellbore Pressure Test again beginning with Step 2. 10. Increase wellbore pressure to BOP rated working pressure (refer to operator's manual for working pressure of your particular ram BOP). Isolate (Block) test pump from ram BOP and allow pressure to stabilize. Hold pressure for three minutes minimum. Observe for dramatic pressure loss and leakage. Use a mirror or boroscope suspended over the bore of the BOP to observe for leakage between the ram packing and the mandrel. WARNING:

DO NOT EXTEND ANY PART OF BODY OVER THE BOP WHILE PRESSURE IS IN THE WELLBORE. This high pressure test is satisfactory if the well pressure does not drop more than 100 PSI (7 Bar) in three minutes and no visable leaks occur. Record initial and final wellbore pressure on the inspection form. If pressure loss is less than 100 PSI (7 Bar) and no leaks occur, continue to the next step. Do the following if a leak occurs or if an unacceptable pressure loss occurs: a. Stop the test.

Make necessary repairs. If repairs require disassembly of the BOP, perform the Wellbore Pressure Test again beginning with Step 2. Vent wellbore pressure to zero. Allow a few seconds to allow any residual pressure to bleed off. Open (retract) rams and remove mandrel. Drain water from wellbore. If further testing is required, leave the ram BOP installed on the test stump. If testing is complete, remove the BOP from the test stump as follows: a. Install the lifting apparatus onto the ram BOP Lift the BOP using the sling arrangement shown in Figure 7-1. 1) If a clamp is required to make up the connection between the test stump and the ram BOP, remove the clamp. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, remove the studs and nuts. b. Remove blind hardware from outlet connections. Outlet clamps (if required) are removed in the same manner as the end connection clamp. c. Vent all pressure and disconnect the test pump from the ram BOP. d. Lift and remove the ram BOP from the test stump. WARNING:

THE RAM BOP IS VERY HEAVY AND BULKY EQUIPMENT. TAKE EXTREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS OR OTHER BODY MEMBERS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DURING LIFTING AND INSTALLATION OPERATIONS. BE SURE THAT THE LIFTING APPARATUS IS ADEQUATE TO HANDLE THE LOAD. 15. Sign and date the inspection form.

PAGE 7-5

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PAGE 8-1

Ram BOPs  MPL Lock Test

8.0 MPL LOCK TEST

REV: PAGE

8.1

8.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Inspection Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Control System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPL Lock Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 8-2 8-2 8-2 8-3

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8.1 General A. Purpose The procedures in this section cover the MPL lock test of the Hydril ram BOP. This test verifies the operation of the multiple position lock. B. Inspection Records During the MPL lock test, records should be kept of the results. Use the Ram BOP Inspection Form located in Section 9. C. Control System Requirements The Hydril ram BOP may be tested with any oil field test pump of sufficient pressure capacity. A 3-position 4-Way valve (Open, Block, Close) and a hydraulic regulator should be installed in the output line of the

test pump. An opening and closing line is required to operate each set of rams. These control lines are connected to the one-inch NPT ports on the hinge side of the BOP. Any clean, light petroleum hydraulic oil can serve as a hydraulic fluid. Fresh water may be used if water soluble oil is added. Antifreeze must be added to water based operating fluids to prevent serious damage to the operators when used in freezing conditions. CAUTION: Do not use synthetic fluids or fuel oils. Serious seal damage will result. Closing time of the ram BOP is determined by the rate at which the hydraulic closing fluid can be delivered to the operating cylinders. Minimum closing time will result by short large-bore hydraulic control lines and large accumulator volume.

PAGE 8-2

Inspection Manual

PAGE 8-3


8.2 MPL Lock Test Procedure A. Testing Precautions Take the following precautions to insure the safety of all personnel during blowout preventer testing. 1. Use safety barrier during test operations. 2. Verify that test stump, blind flanges, mandrels, blind hubs, piping, valves, gauges, and related equipment are rated for the test pressures. 3. Check resolution and accuracy of pressure indicating devices. A resolution of one percent of full range and an accuracy of two percent is required. 4. Do the following if a leak occurs of unacceptable pressure loss occurs: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-


Make necessary repairs. If repairs require disassembly of the BOP, perform the MPL Lock Test again.

B. Tools and Materials required: 1. One new API metal ring gasket 2. Light machine oil ( Gulf Harmony No. 46 or Exxon Coray 100) 3. Never-Seez thread lubricant (.069 coefficient of friction) or equivalent 4. Ram BOP Inspection Form (refer to Section 9) C. MPL Lock Test 1. If the ram BOP is already installed on the test stump, continue to Step 2. Otherwise, install the BOP onto the test stump as follows: a. Wipe hubs/flanges, ring gasket, and ring grooves clean with a rag soaked in light machine oil. b. Install the BOP onto the test stump. Lift the BOP using the sling arrangement shown in Figure 8-1. WARNING:

THE RAM BOP IS VERY HEAVY AND BULKY EQUIPMENT. TAKE EXTREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS OR OTHER BODY MEMBERS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DURING LIFTING AND INSTALLATION OPERATIONS. BE SURE THAT THE LIFTING APPARATUS IS ADEQUATE TO HANDLE THE LOAD.

R


Inspection Manual

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PAGE 8-4


Ram Assy.

Seal Seat


Bonnet Bolts

MPL


Cylinder Liner

Piston Seals



c.

1) If a clamp is required to make up the connection between the test stump and the ram BOP, clean the clamp thoroughly and coat the insides with light machine oil. Apply Never-Seez thread lubricant to clamp nut and bolt threads. Tighten clamp nuts and bolts alternately, side to side, during installation to bring the clamp haves together uniformly. Strike the clamp occasionally with a sledge hammer during tightening to ensure proper seating of the clamp on the hub. Contact clamp manufacturer for torque values. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, apply Never-Seez thread lubricant to the threads prior to installation. Refer to the BOP operator's manual for the torque value. Blind off all outlet connections with appropriate hardware. Outlet clamps (if required) are installed in the same manner as end connec-

2.

3.

4.

5.

6.

tion clamps. d. Connect test pump to the ram BOP. Refer to Paragraph 8.1.C. Open the ram BOP bonnets and cycle the rams using 200 PSI (14 Bar) pressure. Leave the rams in the Open (retract) position. Close the bonnets and tighten the bolts using the torque value shown in the BOP operator's manual. Also refer to the operator's manual for the tightening sequence. If pipe rams are installed in the ram BOP, install a test mandrel into the bore of the ram BOP. Do not install a test mandrel if shear rams are installed. Close the rams using 1500 PSI (103 Bar) operating pressure, then reduce the closing pressure to 100 PSI (7 Bar). Inspect the MPL lockout devices (one on each side of the MPLs) for freedom of movement by turning the stems alternately clockwise and counter clockwise approximately 6 1/2 turns or until they stop turning.

Inspection Manual

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PAGE 8-5


7. Engage the lockout devices by rotating the stems clockwise approximately 6 1/2 turns or until they stop turning. Tighten the stems using 10 lb-ft (13 N•m) torque. 8. Bleed operator closing pressure to zero. 9. Slowly increase operator opening pressure to 1500 PSI (103 Bar) in increments of 500 PSI (34 Bar). Observe through the bore of the ram BOP to see if the rams retract. USE A MIRROR OR A BORE SCOPE TO OBSERVE THE OPERATION OF THE RAMS THROUGH THE BORE. WARNING:

CAUTION: Do not exceed 1500 PSI (103 Bar) or damage to the MPL may occur). If the rams remain closed, continue to the next step. If the rams open (retract), do the following: a. Stop the test. b. Vent pressure from the BOP. WARNING: STAND CLEAR OF VENTED PRES-

connection between the test stump and the ram BOP, remove the clamp. 2) If studs and nuts are required to make up the connection between the test stump and the ram BOP, remove the studs and nuts. b. Remove blind hardware from outlet connections. Outlet clamps (if required) are removed in the same manner as the end connection clamp. c. Vent all pressure and disconnect the test pump from the ram BOP. d. Lift and remove the ram BOP from the test stump. WARNING:

THE RAM BOP IS VERY HEAVY AND BULKY EQUIPMENT. TAKE EXTREME CARE WHEN LIFTING IT. DO NOT PLACE HANDS WHERE THEY CAN BE INJURED BY CONTACT WITH OTHER EQUIPMENT DUR- ING LIFTING AND INSTALLATION OPERA- TIONS. BE SURE THAT THE LIFTING APPA- RATUS IS ADEQUATE TO HANDLE THE LOAD.

SURE TO AVOID INJURY. 17. Sign and date the inspection form. c.

10.

11. 12.

13.

14 15. 16.

Make necessary repairs. If repairs require disassembly of the BOP, perform the MPL Lock Test again beginning with Step 2. Apply 200 PSI (14 Bar) wellbore pressure and hold for three minutes. NOTE: The application of higher wellbore pressures do not test the locking system because the ram blocks become well pressure energized; therefore, the locks become essentially passive. Vent wellbore pressure to zero. Apply 100 PSI (7 Bar) closing pressure to set the cylinder liner forward and away from the lockout segments. Disengage lockout devices by turning the stems 6 1/2 turns counterclockwise until they are fully retracted. Set normal operating pressure and open the rams. Vent the operating pressure to zero. If further testing is required, leave the ram BOP installed on the test stump. If testing is complete, remove the BOP from the test stump as follows: a. Install the lifting apparatus onto the ram BOP Lift the BOP using the sling arrangement shown in Figure 8-1. 1) If a clamp is required to make up the

Inspection Manual

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PAGE 9-1

Ram BOPs  Inspection Forms

9.0 INSPECTION FORMS

REV: PAGE

9.1

9.2

General . . . . . . . . . . . . . . . . . A. Purpose . . . . . . . . . . . . . . . B. How To Use Forms . . . . . . . . . Inspection Forms . . . . . . . . . . . . A. Ram BOP Inspection Form B. Pipe/Variable Ram Inspection Form C. Shear Ram Inspection Form

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9-2 9-2 9-2 9-2

Inspection Manual

R

Ram BOPs  Inspection Forms

9.1 General A. Purpose The purpose of the inspection forms is to provide a written record of the findings when scheduled inspections of Hydril ram blowout preventers are performed. B. How To Use Forms The inspection forms in this section are intended to be used as a master for photocopying. The Ram BOP Inspection Form is written for a single ram BOP containing two bonnets and one ram compartment. For models that have more than one ram compartment, photocopy this form as many times as there are ram compartments in use. Each form is designed to be used as you follow the corresponding inspection procedure outlined in the various sections of this manual. The section and paragraph where the procedure is located is given on the form. The numbered steps on the form correspond to the numbered steps in the procedure. The Ram BOP Inspection Form incorporates all of the scheduled inspections listed in Table 2-1 of Section 2. However, not all of the inspections and tests are necessary for a given inspection interval. To use the form correctly, check the box at the top of the form to select the desired inspection interval; fill out the descriptive sections; perform the necessary inspections and tests listed in Table 2-1; and skip the inspections and tests that do not apply. The inspections and tests on the form that do not apply can be crossed out or marked as being not applicable. NOTE: The Pipe/Variable Ram Form and the Shear Ram Form are separate forms due to the requirement for unscheduled gauge inspection of the rams that often occurs. However, the forms are used as part of the Ram BOP Form during scheduled gauge inspection.

9.2 Inspection Forms The inspection forms and the inspections contained on the forms are as follows: Ram BOP Inspection Form Visual Inspection BOP Operating Test Hydraulic System Test Wellbore Pressure Test MPL Lock Test Gauge Inspection Pipe/Variable Ram Inspection Form Gauge Inspection Shear Ram Inspection Form Gauge Inspection

PAGE 9-2

Inspection Form

R

PAGE 1

Ram BOP

As Required

Between Wells

Yearly

4-Year

RAM BOP IDENTIFICATION NOTE: This inspection form is written for a single ram BOP containing two bonnets and one ram compartment. For models that have more than one ram compartment, photocopy this form as many times as there are ram compartments in use. Owner:

User:

Ram BOP Size:

Pressure Rating (PSI):

Ram BOP Model:

[

]

Single

[

]

Dual

[

]

Triple

Top Connection:

[

]

Flange

[

]

Clamp Hub

[

]

Studded

[

]

Studded

[

]

Studded

Size: Bottom Connection:

[

]

Pressure Rating (PSI): Flange

[

Size: Side Outlets:

[

]

[

]

Clamp Hub

Pressure Rating (PSI): Flange

[

Size: Ram Lock:

]

]

Clamp Hub

Pressure Rating (PSI): Manual

[

]

MPL

MPL Size:

Hydril BOP Part No:

Hydril Serial No:

Owner ID No:

User ID No:

INSTALLATION & TYPE OF SERVICE [

]

Land Stack

[

]

Jackup

[

]

[

]

Drilling

[

]

Stripping

[

]

Subsea

SERVICE CONDITIONS OR ENVIRONMENT [

]

Water Base Mud:

[

]

Oil Base Mud/Chemically Agressive Drilling Fluid:

[

]

Ester Base Mud:

[

]

Carbon Dioxide (Stack Temperature):

[

}

Hydrogen Sulfide (Stack Temperature):

[

]

High Temperature Well (Stack Temperature):

[

]

Below Freezing Ambient Temperatures:

o

o

F o

C o

F

C

o

o

F

o

F

C

o

C

Inspection Form

R

PAGE 2

Ram BOP

VISUAL INSPECTI0N ( Section 3) Step

Paragraph 3.2.B

1

Top Connection: Bottom Connection: Side Outlets:

2

Nut/Bolt Heads:

3

Stud Threads:

4

Body:

5

Bonnets:

6

Pipe Ram/HVR: Shear Ram:

BOP OPERATING TEST (Section 5) Step 3

5

Paragraph 5.2.C Pressure: 200 PSI (14 Bar) — Both Bonnets Closed 1st Cycle:

Close:

Open:

Leaks:

2nd Cycle:

Close:

Open:

Leaks:

3rd Cycle:

Close:

Open:

Leaks:

Pressure: Less than 200 PSI (14 Bar) — Left Bonnet Open And Right Bonnet Closed Cycle Under Seal Seat:

Close:

Open:

Pressure: Less than 200 PSI (14 Bar) — Left Bonnet Closed And Right Bonnet Open Cycle Under Seal Seat:

Close:

Open:

HYDRAULIC SYSTEM TEST (Section 6) Step

Paragraph 6.2.C

2,3

Pressure: 0-3000 PSI (207 Bar) In 500 PSI (34 Bar) Increments – Bonnets Open Hold Close Pressure 3 Minutes:

Pressure Change:

Leaks:

Hold Open Pressure 3 Minutes:

Pressure Change

Leaks:

Inspection Form

R

PAGE 3

Ram BOP

HYDRAULIC SYSTEM TEST CONTINUED Step 4

Pres Pressu sure re:: 200 200 PSI PSI (14 (14 Bar) Bar) — Bon Bonne nets ts Ope Open n Cycle Rams:

Close:

Op en :

WELLBORE PRESSURE TEST (Section 7) Step Step 2

Para Paragr grap aph h 7.2 7.2.C .C Pres Pressu sure re:: 200 200 PSI PSI (14 (14 Bar) Bar) — Bot Both h Bonn Bonnet ets s Open Open Cycle Rams:

7

Close:

Leaks:

Wellbo Wellbore re Pres Pressur sure: e: 200 200 to to 300 300 PSI (14 - 21 Bar) Bar) Hold Wellbore Pressure 3 Minutes:

11

Ope n :

Operator Operator Pressure Pressure:: 1500 PSI (103 (103 Bar) Bar) — Both Both Bonnets Bonnets Closed Closed — Pipe Rams Rams or 3000 PSI PSI (207 (207 Bar) —Shear Rams Close Rams:

10

Close:

Pressure Change:

Leaks:

Pressure Change:

Leaks:

Wellbo Wellbore re Pressu Pressure: re: Workin Working g Pressu Pressure re Hold Wellbore Pressure 3 Minutes

MPL LOCK TEST (Section 8) Step Step 2

Para Paragr grap aph h 8.2 8.2.C .C Pres Pressu sure re:: 200 200 PSI PSI (14 (14 Bar Bar)) — Bon Bonne nets ts Open Open Cycle Rams:

5

Close:

O pe n :

Operator Operator Pressur Pressure: e: 1500 1500 PSI (103 (103 Bar) Bar) — Both Both Bonnets Bonnets Closed — Pipe Rams or or 3000 3000 PSI (207 (207 Bar) —Shear Rams; Reduce Pressure to 100 PSI (7 Bar). Close Rams:

Close:

Leaks:

6

MPL Lockout Device:

Movement:

Engagement:

9

Open Open Pressu Pressure: re: 0 - 1500 1500 PSI (104 (104 Bar) Bar) in 500 500 PSI (35 Bar) Bar) Incr Increme ements nts.. Ram Movement:

10

Close:

O pen :

Wellb Wellbor ore e Pre Press ssur ure: e: 200 200 PSI PSI (14 (14 Bar Bar)) Hold Wellbore Pressure 3 Minutes:

Pressure Change:

Leaks

Inspection Form

PAGE 4

Ram BOP

GAUGE INSPECTION (Section 4) Step Step 4

Para Paragr grap aph h 4.2 4.2.B .B MPL MPL Loc Lockn knut ut Asse Assemb mbly ly —L —Lef eftt Bon Bonne nett

MPL Locknut Assembly — Right Bonnet

a. Locknut

a. Locknut

1) Bear Bearin ing g Surf Surfac aces es::

1) Bear Bearin ing g Surf Surfac aces es::

2) Shou Should lder er Thic Thickn knes ess: s:

2) Shou Should lder er Thic Thickn knes ess: s:

3) Thre Thread aded ed Ho Hole les: s:


4) Thro Throug ugh h Bor Bore e Thr Threa eads ds::

4) Thro Throug ugh h Bore Bore Thr Threa eads ds::

b. Re Reta tain iner er Plat Plate e

`

1) Bear Bearin ing gS Sur urfa face ce::

2) Surf Surfac ace e A and and Key Key Slot Slot::

2) Surf Surfac ace e A and and Key Key Slot: Slot:

3) Surface B: B:

3) Surface B: B:

c. Fron Frontt Clut Clutch ch Plat Plate e

c. Fron Frontt Clut Clutch ch Plat Plate e

1) Clutch Teeth:

1) Clut Clutch ch Teet Teeth: h:

2) Clut Clutch ch Teet Teeth h Heigh Height: t:

2) Clutc Clutch h Teet Teeth h Heigh Height: t:

d. Re Rear ar Clut Clutch ch Plat Plate e

d. Re Rear ar Clut Clutch ch Plat Plate e

1) Clut Clutch ch Teet Teeth h:

1) Clut Clutch ch Teet Teeth: h:

2) Clut Clutch ch Teet Teeth h Heigh Height: t:

2) Clutc Clutch h Teet Teeth h Heigh Height: t:

1) Edges: 5

b. Re Rettaine ainerr Plat Plate e

1) Bear Bearin ing g Surf Surfac ace: e:

e. Reta Retain iner er Plat Plate e Loca Locati ting ng Pin Pin::

R

e.

Retainer Plate Locating Pin: 1) Edges:

MPL MPL Cyl Cylin inde derr Ass Assem embly bly — Lef Leftt Bon Bonne nett

MPL Cylinder Assembly — Right Bonnet

a. MPL C Cy ylinder

a. MPL C Cy ylinder

1) Seal Seal Gro Groov oves es/S /Sur urfa face ces: s:

1) Seal Seal Gro Groov oves es/S /Sur urfa face ces: s:



Inspection Form

PAGE 5

Ram BOP

GAUGE INSPECTION CONTINUED Step 5

b. Lockout Stem — Left Bonnet

c.

1) Inte Intern rnal al Thre Thread ads: s:

2) Seal Gro Groove:

2) Seal Gr Groove:

3) Square E En nd :

3) Square End: c.

Lockout Gl Gland

1) Outsi Outside de Diam Diamet eter er Thre Thread ads: s:

1) Outs Outsid ide e Diame Diamete terr Thre Thread ads: s:

2) He Hex x Co Corrners ners::

2) Hex Co Corners:

d. Cyli Cylind nder er He Head ad

6

b. Lock Lockou outt Stem Stem — Righ Rightt Bonn Bonnet et

1) Inte Intern rnal al Thr Threa eads ds::

Lockout Gl Gland

d. Cyli Cylind nder er He Head ad

1) Seal Seal Groo Groove ves: s:

1) Seal Seal Groo Groove ves: s:

2) Bear Bearin ing g Poc Pocke kett Dept Depth: h:

2) Bear Bearin ing g Poc Pocke kett Dep Depth th::

Pist Piston on & Lock Lock Scre Screw w —Le —Left ft Bonn Bonnet et

Piston & Lock Screw — Right Bonnet

a. Cyli Cylind nder er Lin Liner

a. Cyli Cylind nder er Line Linerr

1) Insi Inside de Diam Diamet eter er::

1) Insi Inside de Diam Diamet eter er::

2) Entr Entry y Beve Bevell and and Seal Seal Groo Groove ve::

2) Entr Entry y Beve Bevell and and Seal Seal Gro Groov ove: e:

3) Cyli Cylind nder er Shou Should lder er::

3) Cyli Cylind nder er Sho Shoul ulde der: r:

4) Seal Seal Groo Groove ve O.D: O.D:

4) Seal Seal Groo Groove ve O.D: O.D:

b. Tran Transf sfer er Ring Ring

b. Tran Transf sfer er Ring Ring

1) Surfaces:

1) Surfaces:

2) Ring Ring Thic Thickn knes ess: s:

2) Ring Ring Thic Thickn knes esst st::

c. Lock Lockou outt Seg Segme ment nt

R

c. Lock Lockou outt Seg Segme ment nt

1) Radius:

1) Radius:

2) Threads:

2) Threads:

3) Edges:

3) Edges:

Inspection Form

PAGE 6

Ram BOP


7

d. Piston — Left Bonnet

d. Piston — Right — Bonnet

1) Surface A:

1) Surface A:

2) Rod Straightness:

2) Rod Straightness:

Rod Diameter:

Rod Diameter:

3) Large Piston Diameter:


4) Seal Grooves:

4) Seal Grooves:

5) Threads (lockscrew):


6) Shoulder Cracks:

6) Shoulder Cracks:

Manual Lock — Left Bonnet

Manual Lock — Right Bonnet

a. Manual Lock Cylinder

a. Manual Lock Cylinder

1) Seal Groove:

1) Seal Groove:

2) Bore Diameter:

2) Bore Diameter:

b. Cylinder Liner

b. Cylinder Liner

1) Seal Groove c.

8

Mechanical Lock Piston Assembly

R

1) Seal Groove c.

Mechanical Lock Piston Assembly

1) Surface A:

1) Surface A:

2) Straightness:

2) Straightness:



4) Seal Grooves:

4) Seal Grooves:



Bonnet Hinge Assembly — Left Bonnet

Bonnet Hinge Assembly — Right Bonnet

a. Bonnet Hinges

a. Bonnet Hinges

1) Distance Between Hinges:

1) Distance Between Hinges:

2) Sealing Surfaces:

2) Sealing Surfaces:

Inspection Form

R

PAGE 7

Ram BOP


a. Bonnet Hinges

3) Fluid Passages:

4) Threads:

4) Threads:

5) Mounting Face:

5) Mounting Face: b.

Hinge Pins — Right Bonnet

1) Seal Grooves:

1) Seal Grooves:

2) Threads:

2) Threads:

3) Hex Head:

3) Hex Head:

Bonnet Assembly — Left a. Bonnet

Bonnet Assembly — Right a.

1) Seal Groove :

Bonnet 1) Seal Groove:

Seal Groove Depth:

Seal Groove Depth:

2) Piston Rod Bore Surface:

2) Piston Rod Bore Surface:

3) Piston Rod Bore Diameter:

3) Piston Rod Bore Diameter:

4) Cylinder Liner Bore Diameter:

4) Cylinder Liner Bore Diameter:

5) Pilot Surfaces:

5) Pilot Surfaces:

6) Seal Surface:

6) Seal Surface:

7) Fluid Passages:

7) Fluid Passages:

8) Studs:

8) Studs:

9) Threaded Holes:

9) Threaded Holes:

b. Ram Guide Pin

10

Bonnet Hinges

3) Fluid Passages:

b. Hinge Pins — Left Bonnet

9

a.

b.

Ram Guide Pin

1) Condition:

1) Condition:

2) Straightness:

2) Straightness:

Load Hinge Assemblies — Left Bonnet

Load Hinge Assemblies — Right Bonnet

Inspection Form

PAGE 8

Ram BOP


a. Load Hinges 1) Bearing and Seal Surfaces:

12

a.

Load Hinges 1) Bearing and Seal Surfaces:

Seal Seat Assembly a. Seal Seat 1) O-Ring Grooves: 2) Lower Surface: 3) Flatness: 4) Set Screw Holes: 5) Ram Sealing Flange Thickness: 6) Lock Ring Groove:

13

Body a. Ring Grooves: b. Threaded Holes: c.

Mounting Surfaces:

d. Sealing Surfaces: e. Fluid Passages: f.

Seal Seat Sealing Surface:

g. Wellbore Diameter: h. Distance Between Body Rails and Seal Seat Pocket:

14

i.

Distance Between Body Rails and Seal Seat:

j.

Ram Compartment Side Walls:

k.

Side Outlet Bores:

R

Ram Assemblies a. Pipe/Variable Ram: (Use Pipe/Variable Ram Inspection Form .)

Inspection Form Ram BOP


b. Shear Ram Assemblies (Use Shear Ram Inspection Form .)

COMMENTS

R

PAGE 9

Inspection Form Ram BOP

COMMENTS CONTINED

Inspector:

Date

R

PAGE 10

Inspection Form

R

PAGE 1

Pipe/Variable Ram

RAM IDENTIFICATION NOTE: This inspection form is written for a single pipe/variable ram assembly containing two ram blocks. Photocopy this form for as many ram assemblies that are to be inspected. Owner:

User:

Ram Size: Ram Model:

Pressure Rating (PSI): [

]

Pipe

[

]

Variable

Hydril BOP Part No:

Hydril Serial No:

Owner ID No:

User ID No:


]

Land Stack

[

]

Jackup

[

]

Subsea

[

]

Drilling

[

]

Stripping

[

]

Other


]

Water Base Mud:

[

]


[

]

Ester Base Mud:

[

]


[

}


[

]


[

]


o

o

F o

C o

F o

14

o

F

Paragraph 4.2.B a. Ram Block - Left 1) Overall Height:

o

F

GAUGE INSPECTION (SECTION 4) Step

C

a. Ram Block - Right 1) Overall Height:

C

o

C

Inspection Form

R

PAGE 2

Pipe/Variable Ram


Paragraph 4.2.B a. Ram Block - Left

a. Ram Block - Right

2) Top Seal Groove Depth:


3) Pipe Hanging Inserts:

3) Pipe Hanging Inserts:

4) Hardness Value:

4) Hardness Value:

5) NDE Results:

5) NDE Results:

X

B

A

LEGEND: A: Overall Height B: Top Seal Groove Depth X: Area For NDE & Hardness Tests

Pipe/Variable Ram Block

Inspection Form Pipe/Variable Ram

COMMENTS

Inspector:

Date:

R

PAGE 3

Inspection Form

R

PAGE 1

Shear Ram

RAM INDENTIFICATION NOTE: This inspection form is written for a single shear ram assembly containing an upper and lower carrier. Photocopy this form for as many shear ram assemblies that are to be inspected. Owner:

User:

Ram Size: Pressure Rating (PSI): Hydril BOP Part No:

Hydril Serial No:

Owner ID No:

User ID No:


]

Land Stack

[

]

Jackup

[

]

Subsea

[

]

Drilling

[

]

Stripping

[

]

Other


]

Water Base Mud:

[

]


[

]

Ester Base Mud:

[

]


[

}


[

]


[

]


o

o

F o

C o

F o

14

o

F

Paragraph 4.2.B b. Upper Carrier Ram Block 1) Overall Height:

o

F

GAUGE INSPECTION (SECTION 4) Step

C

b. Lower Carrier Ram Block 1) Overall Height:

C

o

C

Inspection Form

R

PAGE 2

Shear Ram


Paragraph 4.2.B b. Upper Carrier Ram Block

b. Lower Carrier Ram Block



3) Guide Pin Diameter

6) Guide Pin Hole Diameter

Left Pin:

Left Hole:

Right Pin:

Right Hole:

4) Distance Between the Bottom of the Ram Block and the Top of the Guide Pins

7) Distance Between the bottom of the Ram Block and the Top of the Guide Pin Holes

Left Pin:

Left Hole:

Right Pin:

Right Hole:

5) Distance Between the Top of the Ram Block to the Hard-Faced Surface:

8) Distance Between the Top of the Ram Block to the Hard-Faced Surface: 9) Hard-Faced Sealing Surface:

10) Threaded Holes:

10) Threaded Holes:

11) Shear Blade:

11) Shear Blade:

12) Hardness Value:

12) Hardness Value:

NDE Results:

NDE Results:

Inspection Form

R

PAGE 3

Shear Ram

GAUGE INSPECTION CONTINUED

X

UPPER CARRIER

B

E A

C D LEGEND: A: Overall Height B: Top Seal Groove Depth C: Guide Pin Diameter D: Distance Between Bottom of Ram Block To Top of Guide Pins E: Distance between Top of Ram Block to Hard-Faced Surface X: Area for NDE and Hardness Tests

X

LOWER CARRIER

B

G A

F LEGEND: H A: Overall Height B: Top Seal Groove Depth F: Guide Pin Hole Diameter G: Distance between Top of Ram Block to Hard-Faced Surface H: Distance Between Bottom of Ram Block To Top of Guide Pin Holes X: Area for NDE and Hardness Tests

Shear Ram Assembly

Inspection Form Shear Ram

COMMENTS

Inspector:

Date:

R

PAGE 4

Inspection Manual

R

PAGE 10-1

Ram BOPs  Hydril Repair Facilities


REV: PAGE

10.1 General . . . . . . . . . 10.2 Hydril Repair Facilities . A. United States . . . . B. Canada . . . . . . . C. Brazil . . . . . . . . D. Overseas . . . . . .

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