tc9009 op & maint man 13in 10k dl

8/17/2019 TC9009 Op & Maint Man 13in 10k DL

1/34

DL Blowout Preventer13-5/8" 10,000 psi WP

Operation and Maintenance Manual

TC9009

Cameron, P.O. Box 1212, Houston, Tx 77251-1212, Fax 713-939-2211, http://www.c-a-m.com


2/34

All the information contained in this manual is the exclusive property ofCameron International Corporation. Any reproduction or use of the cal-culations, drawings, photographs, procedures or instructions, either ex-pressed or implied, is forbidden without the written permission ofCameron or its authorized agent.

Initial Release 01February 2007

Copyright © 2007 all rights reservedby

Cameron International Corporation

TC9009 2


3/34

PREFACE

The procedures included in this book are to be performed in conjunctionwith the requirements and recommendations outlined in API Specifica-tions. Any repairs to the equipment covered by this book should be doneby an authorized Cameron service representative. Cameron will not beresponsible for loss or expense resulting from any failure of equipment orany damage to any property or death or injury to any person resulting inwhole or in part from repairs performed by other than authorizedCameron personnel. Such unauthorized repairs shall also serve to termi-nate any contractual or other warranty, if any, on the equipment andmay also result in equipment no longer meeting applicable require-

ments.

File copies of this manual are maintained. Revisions and/or additions willbe made as deemed necessary by Cameron. The drawings in this book arenot drawn to scale, but the dimensions shown are accurate.

This book covers Cameron products, which are products of Cameron In-ternational Corporation.

CameronP.O. Box 1212

Houston, Texas 77251-1212713-939-2211http://www.c-a-m.com

TC9009 3


4/34

TC9009 4


5/34

Table Of Contents

DL BOP, 13-5/8" 10,000 psi WP. . . . . . . . . . . . . . . . . . . . . . . 7P/N 699341-30-00-03(Illustration and Parts List)

Standard Spare Parts, 13-5/8" 10,000 psi WP DL BOP . . . . . . . . . . . 11P/N 046064-30-00-01(Parts List)

Seals, Bearings and Scrapers, 13-5/8" 10,000 psi WP DL BOP . . . . . . . 12

P/N 049742-12(Parts List)

I. Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

II. Applicable Operating Characteristics . . . . . . . . . . . . . . . . . . 15

III. Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 16

IV. Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

V. Operation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 25

VI. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . 28

VII. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

VIII. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

TC9009 5


6/34

TC9009 6


7/34

TC9009 7


8/34

TC9009


9/34

Parts List: DL BOP, 13-5/8" 10,000 psi WPP/N 699341-30-00-03Rev. 01

Item Part Number Qty Description

1 046088-30-00-03 1 Body

2 046054-30-00-04 1 Top

3 699333-06-00-03 1 Piston

4 699334-30-00-03 1 Inner Cylinder Head

5 699335-30-00-03 1 Outer Cylinder Head

6 699336-06-00-03 1 Pusher Plate

7 644856-07-00-01 1 Packing Element Subassembly

9 699337-30-01 1 Lock Ring, Split

10 699338-30-00-01 1 Actuator Ring11 049089-02 4 Actuator Screw Subassembly

12 699343-02 4 Insert, Actuator Screw

13 614350-01 3 Lock Segment, Outer Cylinder Head

14 049416-01 1 Ring, Outer Cylinder Head Locking Segment

15 2010341-06 1 Support Plate

16 046045-09 1 Top Trash Seal

17 644868-02 8 Bearing, Actuator Screw

18 2032175-02 1 Name Plate, Annular BOP, API 16A

19 049047-03 1 Name Plate, Type D BOP, 10,000# Pressure Rating

20 049052-01 4 Name Plate, Vent21 049051-01 2 Name Plate, Close Port

22 049050-01 2 Name Plate, Open Port

29 663311-13 4 Shackle, Anchor, Fits Body Lifting Lugs

30 046037-20 12 Stud, Double Ended, Inner Cylinder Head

31 049800-05 12 Nut, Modified Heavy Hex, Inner Cylinder Head

32 219065-17-10-71 20 Stud, Double Ended

33 2709000-17-01 20 Nut, Heavy Hex

34 235539-63 2 Plug, Hex Head, Special

35 005930-06-10 2 Pipe Plug, Hex Head

36 046052-09 24 Screw, Socket Head Cap

37 046052-02 4 Screw, Socket Head Cap, Special

38 11849 4 Lifting Eye

39 700649 4 Eyebolt

40 012185-01 2 Eyebolt

41 012185-03 4 Eyebolt

42 700446 2 Eyebolt

45 702514-25-20-08 4 Screw, Socket Head Set

46 700594 4 Fitting, Grease-Straight

TC9009 9


10/34


50 049122-06 1 Wear Ring

51 2010196-23 1 Bearing

52 2010196-11 1 Bearing

53 2010196-12 1 Bearing

54 2010196-24 1 Bearing

55 699345-03 1 Wear Ring

56 700319 1 Wiper Ring

57 700320 1 Wiper Ring

58 615850-32-01 1 Seal Ring

59 615850-33-01 1 Seal Ring

60 615847-40-01 1 Seal Ring

61 615850-30-01 1 Seal Ring

62 615846-22-01 1 Seal Ring

63 615850-31-01 1 Seal Ring

64 615846-23-01 1 Seal Ring

65 615846-24-01 1 Seal Ring

66 615850-34-01 1 Seal Ring

67 706258-10 1 Seal Ring

68 615851-28-01 1 Seal Ring

69 615846-25-01 1 Seal Ring

75 702645-33-01 2 O-Ring

76 230266-02-00-16 4 Screw, Hex

TC9009 10


11/34

Parts List: Standard Spare Parts, 13-5/8" 10,000 psi WP DL BOPP/N 046064-30-00-01Rev. A01


7 644856-07-00-01 1 Packing Element Subassembly


66 615850-34-01 1 Seal Ring

67 706258-10 2 Seal Ring

TC9009 11


12/34

Parts List: Seals, Bearings and Scrapers, 13-5/8" 10,000 psi WP DL BOPP/N 049742-12Rev. H20



17 644868-02 8 Bearing, Actuator Screw

50 049122-06 1 Wear Ring

51 2010196-23 1 Bearing

52 2010196-11 1 Bearing

53 2010196-12 1 Bearing

54 2010196-24 1 Bearing

55 699345-03 1 Wear Ring

56 700319 1 Wiper Ring57 700320 1 Wiper Ring

58 615850-32-01 1 Seal Ring

59 615850-33-01 1 Seal Ring

60 615846-25-01 1 Seal Ring

61 615850-30-01 1 Seal Ring

62 615846-22-01 1 Seal Ring

63 615850-31-01 1 Seal Ring

64 615846-23-01 1 Seal Ring

65 615846-24-01 1 Seal Ring

66 615850-34-01 1 Seal Ring67 706258-10 1 Seal Ring

68 615851-28-01 1 Seal Ring

69 615847-40-01 1 Seal Ring

TC9009 12


13/34

13-5/8" 10,000 PSI WP DL ANNULAR BLOWOUT PREVENTER

I. PHYSICAL DATA

A. Lubricants:

1. Thread lubricant - API-5A-Lub, Fel-Pro Paste #670, or SLECT-A-TORQPaste #503 (4 lb can P/N 705444).

2. Multi-purpose lubricant or grease.

3. Multi-purpose lubricant or grease for cold weather operation.

4. Hydraulic operating system:

a. Storage - P/N 718100 (Marston Bentley Preservation Fluid).

b. Standard Operation - use a fresh water lubricant that forms a truesolution rather than an emulsion when mixed with water and/orantifreeze.

B. Dimensional Drawings

1. SD-035687 13-5/8"-10,000 psi WP DL Annular BOP

C. Drawings with Bills of Material

1. SD-035682 13-5/8"-10,000 psi WP DL Annular BOP

D. Weights and external dimensions

1. Total estimated weight: 27,262 lb.

2. Lifting Lug capacity for each lug: 35 tons

3. Maximum capacity of all four lugs used together: 140 tons

E. Lifting and Handling

1. Lift BOP assemblies only with slings appropriately rated for the maxi-mum weight of the BOP.

2. Handle all other sub-assemblies using appropriately rated slings.

TC9009 13


14/34

F. External Thread Connections

NPT Fitting Size for Open and Close Ports: 1"-11-1/2 NPT

G. Hydraulic Operating System Requirements

US Gallons to Open 15.22

US Gallons to Close 17.10

1. Normal pressure for the hydraulic operating system is 1500 psi.

2. Maximum pressure for the hydraulic operating system is 3000 psi.

H. Torque Specifications

1. Inner Cylinder Nuts (Item #31): 2220 ft-lb.

2. Pusher Plate Screws (Item #36): 68 ft-lb.

I. API Drift:

1. API drift for 13-5/8"-10,000 psi is 13.595".

J. Service Tools and Equipment

Item No. Description Wrench Size

11 Actuator Screw Assembly 1-7/16" Socket

31 Inner Cylinder Nut 2" Socket

33 Flange Nut 2-15/16" Wrench

34 Lock Ring Access Port Plug 2" Wrench

35 Hydraulic Port Plug 1-7/16" Wrench

36 Pusher Plate Screw 5/8" Allen

37 Actuator Ring Stop Screw 1" Allen

45 Insert Retaining Screw 3/8' Allen

46 Oil Injection Fitting 7/16" Socket

K. Temperature Rating of Annular BOP Packers:

1. Continuous Service — 70 - 180 deg. F (21 - 82 deg. C)

2. Extreme Service — 30 - 200 deg. F (-1 - 93 deg. C)

Note: There is no industry accepted method of establishing BOP temperature rat-ings at this time. These are estimates based on lab testing and field perfor-mance. Temperature ratings for rubber components must take into account the environmental exposure history, the chemical environment while at tem-

perature, and other factors. Therefore, a single number rating can be mis-leading if all conditions are not understood.

TC9009 14


15/34

II. APPLICABLE OPERATING CHARACTERISTICS ANDPRINCIPLES OF OPERATION

A. Packer/Donut Assembly

1. The packer is a cylinder of molded rubber combined with sixteen steelreinforcing inserts.

2. The donut is made of homogeneous molded rubber that surroundsthe packer.

3. The packer inserts are flanged on the top and bottom.

4. The shape of the flanges have been designed to maintain an unbro-ken barrier of steel above and below the packer rubber as the packeris closed, regardless of the size or shape of the pipe or tool in thebore.

5. The uninterrupted barrier reduces rubber extrusion, even under highbore pressure.

6. The rubber on the ID of the packer forms a pressure tight seal againstthe pipe or the tool in the BOP bore.

B. Hydraulic Operating System

1. The annular BOP does not depend upon wellbore pressure to close thepacker.

2. Closing pressure must be maintained to the operating system to holdthe packer in the closed position.

3. This independence of wellbore pressure gives the operator control ofthe rubber pressure on the pipe, reduces packer extrusion, and cansignificantly increase packer life when the BOP is used for stripping.

C. Closing the Annular BOP

1. Hydraulic fluid is pumped into the closing chamber to force the pistonand the pusher plate upward against the donut.

2. The pusher plate squeezes the donut, forcing the donut to expand in-ward.

3. The inward displacement of the donut forces the packer inward to-ward the center of the bore.

TC9009 15


16/34

III. DISASSEMBLY PROCEDURE

A. Part Preparation Prior to Disassembly

The work area should be clean and well lighted.

B. BOP Disassembly

1. Clean the outside of the BOP body (1). Use high pressure water anddetergent to clean mud and debris from the outside of the BOP.

2. Make sure the BOP is fully open. Apply opening pressure and allowpressure to build up to the regulator pressure and make sure that thepacker is completely open.

3. Remove and bleed all operating pressure.

4. Vent the operating system. Remove the plugs from the unused openand close ports on the BOP body. This will eliminate the possibility ofaccidental operation of the BOP once the quick release Top is un-locked.

5. Inspect the Top trash seal (16). If the seal is damaged, it should be re-placed as soon as possible, to keep mud and debris out of the mecha-nism of the quick-release top (2).

6. Open the access flaps on the Top trash seal (16). Clean out the cavity

around the head of each actuator screw. Do not reuse the grease re-moved from these cavities.

7. Grease the Actuator Screws (11). Inject a molybdenum disulfide orgraphite-loaded grease fitting in the head of each actuator screw, un-til grease is forced up through the threads and comes out underneaththe head of the actuator screw.

Note: The actuator screws should be greased before unlocking the quick releasetop. This should be done EVERY time the top is unlocked. This will make the

screws turn more easily and reduce the possibility of thread galling.

8. To prepare for the removal of the quick-release top (2), install eyebolts in the tapped holes in the top.

9. Using two wrenches, operate the actuator screws (11) in pairs of twoadjacent (NOT OPPOSITE!) screws, alternately lifting first one side ofthe actuator ring and then the other. Turn each actuator screw coun-ter-clockwise, a few turns at a time, or until the screw starts to bind.A socket wrench with a 12-inch handle works well for turning thesescrews.

TC9009 16


17/34

Note: If only one wrench is used, the wrench should be moved from one screw tothe next, moving in the same direction around the ring.

10. When the actuator screws can no longer be turned using a wrenchwith a 12-inch handle, the actuator ring (10) has reached its upper-most position, and the quick release top should be fully unlocked.

11. Clean out the vent ports using a stiff wire or rod. Attach lifting chainsto the lifting eyes in the top and lift the quick-release top out of theBOP body. If the top is pulled at an angle instead of straight out, thetop may bind in the BOP body.

Danger: Dried mud or clogged vent ports may cause the quick release top to stick in the BOP body. When lifting force is applied, the top may break loose

suddenly. Use safe rigging and lifting procedures to avoid injury.

Danger: The donut may hang in the quick release top as it is lifted out of the BOP body, and then fall from the top.

Note: If the donut (7) hangs in the quick release top, lower the top to the floor,then insert a pry bar through the bore FROM ABOVE and pry the donut loose.

12. Set the quick release top (2) down on a flat, clean surface.

13. Remove and inspect the top trash seal (16), being careful not to dam-

age the seal.14. Remove the actuator ring stop screws (37).

15. To remove the actuator ring/lock ring assembly, install eye bolts in thetapped holes in the actuator ring (10), and lift the assembly off thequick release top.

16. Pull each actuator screw (11) from its slotted recess in the actuatorring (10). Remove the pair of actuator screw bearings (17) from eachactuator screw. DO NOT remove the grease fitting from the head ofthe actuator screw unless it is damaged.

17. Remove and inspect the Top ID (66) and Top OD (67) seal rings.

Warning: To remove seals, use a dull tool, such as a screwdriver blade with the sharp edges removed. Insert the tool under the seal at one point, and carefully stretch the seal out of the groove by pulling the tool around the entire circumference of the groove. A sharp tool may damage the

seal or the seal groove.

TC9009 17


18/34

18. Install eye bolts in the tapped holes in the top of the packer, attachlifting chains, and lift the packer out of the BOP body. If the donutdoes not come out with the packer, use a pry bar to lift the donut inorder to get a lifting strap around the donut.

19. Install eye bolts in the tapped holes in the support plate (15) and re-move it from the BOP.

20. Remove the outer cylinder lock ring (14).

Note: Older model BOPs may not be equipped with this lock ring. If this is the case,move on to step 22.

21. Remove the outer cylinder lock segments (13). Use a pry bar or a longflat head screwdriver to assist in the removal of the lock segments.

22. Use an air wrench to remove the inner cylinder nuts (31).

23. Remove the pusher plate screws (36).

24. Install lifting eyes into the pusher plate (6) and remove it from theBOP.

25. Apply low pressure hydraulic fluid (up to 300 psi) to the BOP closeport. Release the pressure as soon as the seal leaks.

26. Install lifting eyes into the tapped holes in the top of the inner cylin-

der (4). Attach lifting chains and lift the operating system out of theBOP body (1).

C. Disassembly of the Operating System Outside the BOP

Note: In order to disassemble the operating system after it has been removed fromthe BOP, low pressure hydraulic fluid (up to 300 psi) is used to pump the in-ner and outer cylinders off the piston. The ports in the outer cylinder and the ports in the piston must first be tapped with a pipe tap. All but one of the ports are then plugged with pipe plugs, and low pressure hydraulic fluid is applied to the remaining port to pump the assembly apart.

1. If the pusher plate has not been removed, remove the pusher platescrews (36) and then lift the pusher plate (6) off the piston (3).

2. Tap the ports in the outer cylinder so the outer cylinder may bepumped off the piston. It is not necessary to tap and plug the smallvent holes.

3. Plug all but one of the ports in the outer cylinder. Use NPT pipe plugs,and use TFE thread sealing tape on the threads.

TC9009 18


19/34

4. Slowly apply low pressure hydraulic fluid (up to 300 psi) to the remain-ing port. To prevent damage to the components, the assembly is sus-pended an inch or two above a sheet of plywood on the floor usinglifting eyes installed in the outer cylinder.

5. The piston/inner cylinder assembly will drop onto the wood withoutbeing damaged.

6. Remove all pipe plugs from the outer cylinder.

7. Tap the ports in the Piston.

8. Plug all but one of the ports in the piston.

9. Pump the assembly apart as in step 4.

10. Remove all pipe plugs from the piston.

11. Inspect the bearing rings, the seals, and the wiper rings.

IV. ASSEMBLY PROCEDURE

A. Part Preparation Prior to Assembly

The work area should be clean and well lighted.

1. Remove all dirt, grit, oil, and contaminants from the ID sealing sur-

faces of the Body and all fluid passageways. Clean detergent and freshwater should be used for cleaning. High pressure air may also be usedif it is dry air.

2. Clean the piston, the outer and inner cylinder, and the quick- releasetop using clean detergent and fresh water. Lubricate areas that willcome in contact with other parts.

3. Sealed elastomer containers should not be opened until they are re-quired for assembly. This is to prevent contamination and damage tothe seals.

B. Assembly of the Quick-Release Top Outside the BOP

1. Place the top (2) on a pallet with the flange stud holes looking up.

2. Apply anti-seize to the outside threads of the four actuator screw in-serts (12) and install them into the tapped holes of the quick-releasetop until the top of the insert is flush with the top of the hole. Thetop of each insert is slotted, to allow the insert to be turned with ascrewdriver blade.

TC9009 19


20/34

Note: The easiest way to install an insert is to first thread it onto an actuator screw and then use the actuator screw as an insertion tool.

3. Apply anti-seize to the threads of the four insert retaining screws (45).Install the retaining screws and tighten them securely with an Allenwrench.

4. Apply a light coat of grease to the outside surface (the teeth) of thelock ring (9) and apply a heavy coat of grease to the inside surface ofthe lock ring. Also, completely fill the axial grooves on the inside ofthe ring.

5. Position the actuator ring (10) inside the lock ring (9).

6. Install the actuator screws (11) into the actuator ring by first suspend-ing the actuator ring/lock ring assembly above the quick-release top.Apply grease to the threads of the actuator screws and to the actuatorscrew bearings (17). Install a bearing on the top side and another onthe bottom side of the actuator screw head. Slide each actuator screwinto its recess in the actuator ring.

7. Install the actuator ring/lock ring assembly on the quick release top.Slowly lower the actuator ring/lock ring assembly into place on thequick release top, until the actuator screws can be started in thethreads of the actuator screw inserts.

8. When all four actuator screws are started (at least two threads) in theactuator screw inserts without binding, remove the lifting chains.

9. Using two wrenches, operate the actuator screws in pairs of two adja-cent (NOT opposite!) screws, alternately lowering first one side of theactuator ring and then the other. Turn each screw clockwise, a fewturns at a time, or until the screw starts to bind. A socket wrench witha 12-inch handle works well for turning these screws.

10. If only one wrench is used, the wrench should be moved from onescrew to the next, moving in the same direction around the ring.

11. Using the actuator screws, lower the actuator ring approximately oneinch, so that the actuator ring stop screws (37) can be installed.

12. Apply anti-seize compound to the threads of the actuator stop screws(37) and seat all four screws fully before tightening any of them.

13. Install the quick-release top OD seal (67) with the sealing lips face up.

14. Using lifting chains, raise the entire top assembly and install the top IDseal ring (66). Do not lubricate this seal or seal groove with grease.

TC9009 20


21/34

C. Assembly of the Hydraulic Operating System Outside the BOP

1. Install the bearing rings, seal rings, and wiper rings on the piston.

a. Install the piston ID seal ring (61). The lip faces down.

b. Install the piston ID bearing ring (51).

c. Install the piston OD seal ring (62). The lip faces down.

d. Install the piston OD bearing ring (54).

2. Install the bearing rings, seal rings, and wiper rings on the outer cylin-der.

a. Install the outer cylinder ID wiper ring (56). The scraper end is up.

b. Install the outer cylinder ID bearing ring (53).

c. Install the outer cylinder ID seal ring (upper) (68). The lip faces up.

d. Install the outer cylinder ID seal ring (lower) (63). The lip facesdown.

e. Install the outer cylinder OD seal ring (upper) (64). The lip facesdown.

f. Install the outer cylinder OD seal ring (lower) (65). The lip facesdown.

3. Install the bearing rings, seal rings, and wiper rings on the inner cylin-der.

a. Install the inner cylinder ID seal ring (upper) (58). The lip faces up.

b. Install the inner cylinder ID seal ring (lower) (59). The lip facesdown.

c. Install the inner cylinder OD wiper ring (57). The scraper end is up.

d. Install the inner cylinder OD bearing ring (52).

e. Install the inner cylinder OD seal ring (upper) (69). The lip faces up.

f. Install the inner the cylinder OD seal ring (lower) (60). The lip facesdown.

TC9009 21


22/34

TC9009 22

D. Assembly of the Inner Cylinder onto the Piston.

1. Apply a light coat of light clean oil to the inner surface of the pistonand to the outer surface of the inner cylinder.

2. Place the piston on a flat, clean surface.

3. Lower the inner cylinder onto the piston.

4. Keep the inner cylinder level, and make sure the seals do not slip outof the grooves and become pinched or cut as the inner cylinder slidesinto the piston.

5. Lower the inner cylinder slowly, and inspect each seal as it engageswith the piston.

6. Seat the inner cylinder on the piston by placing a packer on the innercylinder and then set the BOP body on top of the packer. The weightof the BOP body should be sufficient to seat the inner cylinder on thepiston.

7. Remove the BOP body and the packer, then install lifting eyes in thepiston. Lift the assembly, and inspect the underside of the piston toensure that the piston ID seal ring and the piston ID bearing ring havenot extruded out of the groove.

E. Assembly of the Outer Cylinder onto the Piston

1. Apply a light coat of light clean oil to the outer surface of the piston.

2. Place the piston/inner cylinder assembly on a flat, clean surface.

3. Apply a light coat of light clean oil to the inner surface of the outercylinder.

4. Lower the outer cylinder onto the piston. Keep the outer cylinderlevel, and make sure the seals do not slip out of the grooves and be-come pinched or cut as the cylinder slides onto the piston.

5. Lower the outer cylinder slowly, and inspect each seal as it engageswith the piston.

6. Seat the outer cylinder on the piston by placing the quick-release topon the outer cylinder, then place the BOP body on the quick-releasetop. The combined weight should be sufficient to seat the outer cylin-der on the piston.

7. Remove the BOP body and the quick-release top, then install liftingeyes in the inner cylinder.


23/34

8. Lift the assembly, and inspect the bottom of the piston to ensure thatthe piston OD seal ring and the piston OD bearing ring have not ex-truded.

F. Assembly of the Pusher Plate to the Operating System

1. Clean the tapped holes in the top of the piston.

2. Lower the pusher plate onto the top of the piston.

3. Apply anti-seize compound to the pusher plate screws and installthem.

4. Fully seat all the pusher plate screws, then tighten them evenly to 68ft-lb.

G. Installation of the Operating System as a Unit into the BOP body.

1. Lubricate the interior of the body by applying a light coat of lightclean oil to the inside of the body below the locking grooves.

Note: Make certain that any plugs installed in the vents of the BOP body havebeen removed, and that all control system lines have been disconnected from the BOP. Otherwise, it may be impossible to seat the operating systemin the BOP body.

2. Install eye bolts in the tapped holes in the top of the inner cylinder.Do not attempt to lift the operating system using eye bolts installed inthe outer cylinder.

3. Attach lifting chains and suspend the operating system above the BOPbody.

4. Apply a light coat of light clean oil to the outer surface of the operat-ing system.

5. Line up the holes in the inner cylinder with the studs in the BOP body,then slowly lower the operating system into place.

6. Make certain the lip seals on the outside of the outer cylinder are notforced out of the seal grooves, and use care not to pinch or cut themduring the assembly process.

7. Remove the lifting eyes from the inner cylinder.

8. Apply anti-seize compound to the threads of the inner cylinder nuts(Not to the studs!).

9. Draw the inner cylinder into place with the inner cylinder nuts.

TC9009 23


24/34

TC9009 24

Note: If the inner cylinder is sitting so high in the BOP body that the inner cylinder nuts cannot be started onto the inner cylinder studs, place a few nuts on topof the inner cylinder between the stud holes. Then place a packer on top of the nuts and use the quick-release top as a weight to force the inner cylinder down into the body.

10. Install the inner cylinder nuts and tighten them evenly to 2220 ft-lb.

11. Make sure the outer cylinder is properly seated. The shoulder of theouter cylinder should be level with or slightly lower than the adjacentinner shoulder of the BOP body.

Note: If the outer cylinder is too high in the BOP body, place three heavy hex nutsof the same size on the outer shoulder of the outer cylinder. Stand the nutson edge, if necessary, and space the nuts evenly around the cylinder. Do not

allow the nuts to protrude beyond the outer edge of the outer cylinder. Theinner cylinder nuts are suitable for this application. Use the quick-release topas a weight to seat the outer cylinder. Lower the top into the BOP body, and

set it down on the nuts.

12. Install the outer cylinder lock segments in the groove on top of theouter cylinder.

13. Install the lock segment retaining ring next to the lock segments.

14. Lower the support plate into place inside the pusher plate. Make cer-tain the recesses in the underside of the support plate fit down over

the inner cylinder studs. The support plate should rest evenly on theinner cylinder nuts.

H. Final Assembly

1. Lubricate the inside of the BOP body by applying a light coat of lightclean oil.

2. Apply a light coat of grease or light machine oil to the teeth of thelock ring and the lower surface of the quick-release top.

3. Lubricate the OD and ID of the donut (7) with a light coat of grease.

Make certain the donut is installed top side up. The word “TOP” ismolded into the rubber and the top side of the donut has a long,smooth bevel on the OD. Use a fabric sling to lift the donut into theBOP.

4. Attach eye bolts to the top of the inserts on the packer. Attach liftingchains to the eye bolts. Lift the packer into the BOP and position thepacker inside the donut. Make sure the packer is installed top side up.

5. Lower the assembled quick-release top into the BOP body.


25/34

Note: The quick-release top is designed to rest on the shoulder within the BOP body which is just below the locking grooves. When the top is resting on the

shoulder, the upper surface of the top is flush with the upper surface of theBOP body. The top must be in this position before it can be locked.

6. Lock the quick-release top with the actuator screws. The quickest andeasiest way to lock the quick-release top is to use two wrenches.

7. Operate the actuator screws in pairs of two adjacent (Not opposite!)screws, alternately lowering first one side of the actuator ring andthen the other.

8. Turn each actuator screw clockwise, a few turns at a time, or until thescrew starts to bind. A socket wrench with a 12-inch handle works well

for turning these screws.

9. When the actuator screws can no longer be turned with the 12-inchwrench, the actuator ring should be in its lowermost position. Whenthe actuator ring is in this position, the teeth of the lock ring are fullyengaged in the locking grooves of the BOP body, and the upper sur-face of the top trash seal is approximately flush with the upper sur-face of the quick-release top. The quick-release top is now locked.

10. Grease the actuator screws with molybdenum disulfide or graph-ite-loaded grease in the grease fitting.

11. Pack the cavity around the head of each actuator screw with cleangrease.

12. Close the access flaps of the top trash seal.

13. Reinstall the pipe plugs which were removed to vent the operatingsystem. Use TFE thread-sealing tape on the plugs.

14. Verify operation of the BOP.

V. OPERATION PROCEDURES

A. Normal Operation

1. Operating Pressure — General Recommendations

a. A minimum closing pressure of 1500 psi is required to close andseal the BOP on pipe. Higher closing pressures (up to the ratedworking pressure of 3000 psi) may be necessary, depending uponpacker condition, pipe size, and ambient temperature. Neither theoperating system nor the packer will be damaged by application ofup to 3000 psi closing pressure.

TC9009 25


26/34

b. Closing pressure should never be reduced below 1500 psi, exceptwhen stripping. It is only during stripping that reduced closingpressure is beneficial in prolonging packer life.

c. A minimum opening pressure of 1500 psi is required for reliableoperation. The operating system will not be damaged by repeatedapplication of up to 3000 psi opening pressure.

2. Closing the BOP on pipe or tools

a. To close the BOP on pipe or tools, apply closing pressure whileventing the opening port.

b. If well fluid leaks past the packer, increase closing pressure as nec-essary until the leakage stops, but do not exceed 3000 psi.

c. Closing pressure must be continuously applied in order to hold thepacker in the closed position.

3. Closing the BOP on open hole

a. To close the BOP on open hole, apply the maximum available clos-ing pressure (not to exceed 3000 psi) while venting the openingport.

Note: Every annular packer (including replacement packers) has been tested onopen hole with a wellbore pressure of one half the rated working pressureof the BOP, according to API 16A, latest edition. As a packer wears, its ability to close and seal on open hole will decrease, even though it may continue tohold full rated working pressure when closing on pipe.

4. Opening the BOP

a. To open the BOP, apply opening pressure while venting the closingport. Opening pressure must never exceed 3000 psi.

Warning: Operating system control valves may develop internal leakage. This leak-age may cause either the opening or the closing line to be pressurized

when the valve handle is set to “Neutral” or “No Pressure”. This could result in unintended closing of the BOP. It is therefore recommended that the control valve handle be left in the “Open” position at all timeswhen the operator wishes the BOP to be open.

B. Stripping Pipe Through the Closed BOP

1. Before stripping pipe through the closed BOP, make certain the hy-draulic control system and the control piping conforms to the follow-ing requirements:

TC9009 26


27/34

a. A nitrogen-precharged surge bottle of 10 gallon capacity

b. A pneumatically-controlled or hydraulically-controlled self-reliev-

ing pressure regulator

c. A control valve of the non-check type.

Note: The purpose of these items is to reduce the pressure surge which occurs inthe BOP closing chamber each time a tool joint enters the closed packer.High pressure surges cause excessive and unnecessary packer wear.

2. Stripping Procedure

a. Check the surge bottle precharge pressure. A 10 gallon surge bot-tle, precharged to a pressure of 400 to 500 psi, will normally give

proper stripping performance with all annular sizes.

b. Open the valve between the surge bottle and the BOP closing line.

c. Vent the opening chamber by removing the pipe plug from the un-used opening port.

d. Keep the packer lubricated while stripping to prevent excessivewear. Do not move dry pipe through the packer, except in anemergency.

e. When stripping out of the hole, leakage of well fluid (if other than

dry gas) will provide adequate lubrication.

f. When stripping into the well, apply lubricant to the pipe, and es-pecially to the tool joints or couplings. Suitable lubricants, in orderof preference, are:

1) oil

2) oil-base drilling mud

3) water-base drilling mud

4) water with gel

5) plain water

g. Control the closing pressure by using the lowest practical closingpressure when stripping.

h. Reduce the closing pressure until well fluid leaks slightly betweenthe pipe and the packer while the pipe is in motion. This leakagelubricates the packer, thus reducing packer wear.

TC9009 27


28/34

TC9009 28

i. If the packer is closed tightly enough to eliminate all leakage,packer wear will be greatly increased. The graph below shows theapproximate closing pressure required to seal a given bore pres-sure when stripping.

j. As a new packer begins towear during stripping,sealing is improved, andthe closing pressure re-quired to seal on pipe willdecrease. For this reason,closing pressure should bereduced as often as is nec-essary to maintain slight

leakage for lubrication ofthe packer.

k. When the packer has be-come severely worn dur-ing stripping, leakage willbegin to increase. Whenleakage cannot be con-trolled by increasing theclosing pressure, thepacker is nearly worn out,

and arrangements shouldbe made to replace the packer.

l. Observe the pressure gauge on the BOP closing port as a tool jointapproaches and enters the packer. If the drill string is moved slowlyenough, the pressure surge in the BOP closing chamber during en-try of a tool joint should be 100 psi or less.

The faster the tool joint enters the packer, the greater will be thepressure surge. If the pressure surge as tool joint enters the packeris greater than 100 psi, packer wear will be excessive.

VI. MAINTENANCE PROCEDURES

A. Routine Maintenance

1. Preparation and Safeguards prior to maintenance

a. Use high-pressure water to clean mud and debris from the outsideof the BOP.

SD-10779-99

5000 psi BOP

10,000 PSI BOP

C L O S I N G P

R E S S U R E ( P S I )

WELL PRESSURE (PSI)

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

1 0 , 0

0 0

9 0 0 0

8 0 0 0

7 0 0 0

6 0 0 0

5 0 0 0

3 0 0 0

4 0 0 0

2 0 0 0

1 0 0 0


29/34

TC9009 29

b. Apply opening pressure and allow pressure to build up to the regu-lator pressure and make certain that the packer is completelyopen.

c. Make certain all pressure is bled from both the opening and theclosing lines.

d. Vent the operating system by removing the plugs from the unusedopening and closing ports on the BOP body.

e. Inspect the top trash seal for damage.

f. Clean out the cavity around the head of each actuator screw.

g. Grease the actuator screws.

Note: The actuator screws should be greased before unlocking the quick-releasetop. This should be done every time the top is unlocked. This will make the

screws turn more easily and will reduce the possibility of thread galling.

2. Inspection and changeout of the packer and donut

a. The packer should be inspected weekly, after every pressure test,between wells, after stripping, and in the event of a packer leak.

b. The packer should be replaced if there are vertical cracks or tearsacross the full height of the sealing surface. Also, if a large portion

of the sealing surface has been gouged away, or if the packer hasbeen exposed to hydrogen sulfide at temperatures in excess of 200deg. F., the packer should be replaced.

3. Between-well servicing

a. Between-well servicing consists of cleaning debris from the insideof the BOP body and inspecting the packer and donut, followed bya test of the packer. The quick-release top, the packer, and the do-nut must be removed for this cleaning and inspection.

b. Once the packer, the donut, and the quick-release top have been

reinstalled, the API Hydraulic Test (Packer Test) in accordance withAPI RP 53 is performed. It is not necessary to open or service theoperating system at this time, as long as the specified operatingfluids have been used.

4. Disassembly and cleaning:

a. Remove the quick-release top.


30/34

b. Clean the quick-release top by using high-pressure water. Makecertain the lower surface of the top, the lock ring, and the actuatorare clean.

c. Remove, clean, and inspect the top trash seal.

d. Reinstall the top trash seal.

e. Inspect the seals and the wiper rings on the quick-release top.

Note: The quick-release top ID lip seal should be replaced at each between-well servicing.

f. Remove, clean, and inspect the packer and donut.

g. Remove the support plate.

h. Clean out the inside of the BOP Body.

i. Clean out the vent ports with a stiff wire or rod.

5. Reassembly:

a. Check tightness of pusher plate screws.

b. Make certain the outer cylinder is fully seated.

c. Apply a light coat of grease or light machine oil to the inside of

the BOP body.

d. Lubricate the teeth of the lock ring and lower surface of thequick-release top.

e. Install the support plate.

f. Install the donut and packer.

g. Replace and install the top ID lip seal with the sealing lip facing up.

h. Install the quick-release top.

i. Verify operation of the BOP and test the packer according to APIRP 53.

B. Periodic Maintenance

1. Every two years, or as required by the appropriate regulatory agency,completely disassemble the preventer and:

a. Clean all parts. Do not use a wire brush on sealing areas.

TC9009 30


31/34

TC9009 31

b. Replace all rubber seals, gaskets, and O-rings.

c. Replace the packer and donut according to its physical condition.

d. Repair or replace damaged metal parts.

e. After reassembly, test the packer and operating system in accor-dance with this manual.

VII. TESTING

A. Function Test - With Pipe

1. Install the appropriate pipe mandrel into the test stump.

a. For 9" diameter bores or less use 3.5" diameter pipe mandrel.

b. For 11" diameter bore or greater use 5" diameter pipe mandrel.

2. Install the strip chart recorder and identify the device.

3. Apply 1500 psi +/- 200 psi to the close port as follows:

a. Pump up the accumulator pressure to at least 2500 psi.

b. Set the regulator to provide 1500 psi +/- 200 psi closing pressure.

c. Move the control valve to the close position. The closing pressureat the BOP must be up to 1500 psi +/- 200 psi within five minutesafter moving the control valve to the close position. Less than fiveminutes would be preferable.

4. Exercise the packer two times (open-close cycles).

5. Apply 200 psi wellbore test pressure.

6. After a minimum of 200 psi wellbore test pressure has been reachedand has stabilized, hold for a period of at least five minutes.

7. Increase the wellbore pressure to full rated working pressure.

8. After full rated working pressure is reached and has stabilized, holdfor a period of at least five minutes.

9. If the packer fails to hold pressure on the first test or develops a tear,discontinue the test. A new packer must be tested.

10. Bleed bore pressure to zero psi.


32/34

TC9009 32

11. Check the packer for 13.595" API drift within 30 minutes after open-ing the BOP.

a. The 30-minute time period starts when the operating piston is fully

open. This is the time period when opening pressure builds up andcan normally be determined by watching the BOP open hose.

12. If the packer fails to drift within 30 minutes:

a. Exercise the packer, (open-close cycles if required to achieve fulldrift). The exercise cycles should be performed immediately one af-ter the other and should not exceed more than a total of 15 exer-cise cycles, including exercises performed per Paragraph A, step 4.

b. The 30 minute drift time starts after the last packer exercise(open-close cycle).

B. Drift Test

Drift Diameter

Bore Size (Inch) Drift Diameter (Inch)

13-5/8 13.595

1. Open the BOP using 1500 psi hydraulic pressure.

2. Drift BOP through bore with a drift of 13.595" in diameter.

VIII. STORAGE

A. Preventer

1. If the BOP is to be stored for a period of a year or longer, the packerand donut should be removed from the BOP and stored separately,following the packaging and storage recommendations of section VIIIB.

2. Clean the outside of the BOP body.

3. Disconnect the hydraulic hose at the close port and drain the operat-ing fluid out of the BOP.

4. Attach a hydraulic line containing only preservation fluid to the closeport. Use Marston Bentley preservation fluid, P/N 718100.

5. Disconnect the bottom open hydraulic port to allow the operatingfluid to drain out of the BOP once closing pressure is applied to theclose port.


33/34

6. Apply pressure to the closing port, allowing the operating fluid todrain out of the bottom open port. Once the fluid has completelydrained, plug the open port.

7. Apply pressure to the opening port to fill the operating system withthe preservation fluid.

8. Release the pressure, disconnect the hydraulic lines, and install pipeplugs into the open and close connections.

B. Elastomers

1. Store rubber products inside a cool, dark, dry storage.

a. The preferred storage temperature range for rubber goods is from40 deg. F (5 deg. C) to 80 deg. F (25 deg. C)

b. Rubber goods should be wrapped or otherwise protected from di-rect exposure to sunlight or artificial light with a high ultravioletcontent (such as fluorescent lighting). Do not store in direct sun-light even if wrapped, as overheating will result.

c. Store rubber parts in a relaxed position. Do not stretch or hangO-rings and seals. Labels should not be attached to seals withstring, wire, or tape, as these items may deform the sealing sur-face.

2. Use airtight containers when possible to protect against circulatingair.

3. Ozone is extremely harmful to rubber. Ensure that there is no equip-ment in the storage area which may generate ozone, such as mercuryvapor lamps, high-voltage electrical equipment, electric motors, or anyelectric apparatus which produces arcing.

4. Keep the rubber products clean and free of solvents, oil greases, orany other semi-solid or liquid materials during storage. Rubber goodsshould specifically be protected against direct contact with: manga-

nese, copper, copper alloys (including brass), polyvinyl chloride (PVC),creosote-impregnated timber, other rubber goods of different rubbercompounds, sulphur, and copper napthenate.

5. When cleaning is necessary, rubber goods may be cleaned with eithersoap and water or methyl alcohol. After cleaning, the rubber goodsshould be dried at room temperature.

6. Examine the part before installation.

TC9009 33


34/34

Important: Rubber goods taken from storage must always be inspected before installation. Rubber goods should not be flexed at temperatures below 40 deg. F (5 deg. C). Rubber goods in storage should be inspected every 12 months to ensure that they are still serviceable.

a. Ensure that the part does not have a tacky surface or noticeablesoftening or hardening of the surface.

b. Flex the part and inspect with a magnifying glass to ensure thatthere are no cracks.

c. Replace items which show any of the aging signs mentionedabove.

tc9009 op & maint man 13in 10k dl

Documents